User Manual: M5000 Flow Meter
Contents
1. The up arrow button allows scrolling through seven menu screens This button is also used to advance numerical digits to change values such as frequency period and EP level as well as toggle on off conditions and flow directions The right arrow button allows digit selection from left to right and allows selecting either the top row of the display or the bottom row the bottom row is active when flashing The EXIT SAVE button allows the saving of changed values and conditions toggling between the upper and lower display lines and returning to a previous menu Display The top row displays seven digits for specific values on each screen and the bottom row e piece ee eee ae displays meter and register condition icons and current screen descriptions 104 104 0 00 0 000 LYI LYI Dv i i i ich aaa BSJAO REE Icons a Battery status Mir Communication interface is activated RS232 IrDA M Bus 3 Meter is unlocked A Error message O Empty pipe detection Battery Levels The battery icon indicates three levels of capacity E Greater than 3 volts maximum 3 6V ae Greater than 2 volts less than 3 volts recommended battery replacement E Less than 2 volts measuring has stopped Page 18 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual M5000 MAIN MENU PROGRAMMING OPTIONS The following M5000 programming options are available from the Main Menu Meter Setup Measure In Out Com2. Flow Simulation LS Digital Input Q Flow Simulation provides output simulation based on a percentage of the full scale flow Simulation will not accumulate the totalizers The range of simulation includes 100 100 of the full scale flow The Flow Simulation Parameter lets you set the range of simulation in increments of 50 OFF O 50 100 50 100 The factory default is OFF Digital input lets you reset totalizers or interrupt flow measurement Input switching is provided by applying an external voltage of 3 35V DC Use a normally open contact for operating Digital Outputs continued on next page Pulse Unit 1 This parameter lets you set how many pulses per unit of measure will be transmitted to remote applications For example assuming the unit of measure is gallons Setting the Pulses Unit to 1 standard setting will transmit 1 pulse every gallon Setting the Pulses Unit to 0 01 will transmit 1 pulse every 100 gallons You must configure pulses unit if the function of the selected output is to be forward or reverse This parameter must be considered with the Pulse Width and Full Scale Flow parameters The maximum pulse frequency is 100 Hz The frequency is correlated with the flow rate Violation of output frequency limits will generate a PULSE_ OVERLOAD_WARNING Width E This parameter establishes the ON duration of the transmitted pulse The configurable range is 0 500 ms Th
3. The remote mount configuration places the amplifier at a location away from the fluid flow and detector This is necessary in situations where process fluid temperature or the environment exceeds amplifier ratings The detector and amplifier are connected by wires run through conduit between junction boxes on the detector and the amplifier The distance between the detector junction box and amplifier junction box can be up to 100 feet 30 meters A remote mounting bracket is supplied Submersible Option If you are installing the meter in a vault you should order the remote amplifier option You must not install the amplifier inside a vault We also recommend ordering the remote meter package with the submersible option NEMA 6P This will eliminate any potential problems resulting from humidity or temporary flooding in the vault NOTE NEMA 6P enclosures are constructed for indoor or outdoor use to provide protection against access to hazardous parts to provide a degree of protection against ingress of solid foreign objects and water hose directed water and the entry of water during prolonged submersion at a limited depth that provide an additional level of protection against corrosion and that will be undamaged by the external formation of ice on the enclosure WIRING Wiring Safety ATINSTALLATION BE SURE TO COMPLY WITH THE FOLLOWING REQUIREMENTS Disconnect power to the unit before attempting any connection or service to the unit
4. ooo 12 Meter Grounding s moria arar ara AA AERA A TOE OA A e 6 at dat 12 Conductive Pipe Grounding cacs ee a a e A a heuer ea a 12 Non Gonductiv Pipe Grounding se cod de eos oa daha SOR ORG SN Oe OH eA ee ae A 12 AMPLIFIER MOUNTING CONFIGURATION OPTIONS 13 Meter Mount Configuration vs cies 64 e Os Aw ea A OG AO ee A ee a ee ee 13 Remote Mount Configurationy 4 5 26 0k4 2p 408485 PRC RE EP ERE EE SE ERS ES ED EEE RS RESP E Ea ES 13 Submersible Option rea dare nea ta fer keee eh aed eGlaaie bak dee dee Maen aras 13 WIRING ss i s eee add ida e Take eke tada eee al eb ete hd ele ab Weg ee a ee ata ES 13 Wining Satety 4 s 0a ride der Le aoe epee il a a a te a eee hae eae a st 13 Opening the M5000 Covel circa a ie ahaa ee eee ee ERE ene oe RE a a 0 dv a A Aa 13 BATTERY sadn aot dar ake aoe Ade Pehle wee pa ee Er Ata a ale dos ahr e ee eA eae tes 14 Battery Life an e sete a ata A Te Aa ae a a ia 0008 a hE RE RED AE AED New dee RAS mee wR Aare a 14 Battery Replacement sio 4 acea a ca ea ma a ca E a aa c a a c a a d a daa a d n a a PA d 14 Remote Mount Installation y se cca e i ace ae e e a ca a e Dawe Re Eke he EAE Ie e ee ead y 15 September 2013 Page iii www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Mount Bracket to Ampli 40 aeania 24a a baad Pe ao al a PAG a bead ek al aa d wos 15 Wiring Configurationis 2 caiace cea agg Oe a ae ee ad C
5. Do not bundle or route signal lines with power lines e Keep all lines as short as possible Use twisted pair shielded wire for all output wiring Observe all applicable local electrical codes Opening the M5000 Cover The M5000 amplifier s design lets you open the cover without completely removing it Follow these steps 1 Completely remove the top two screws from the amplifier using a blade slotted screwdriver 2 Loosen both of the bottom screws so that the round head of each screw clears the top face of the cover 3 Pull the cover down to the open position Figure 17 Remove Two Screws Figure 18 Open the Cover September 2013 Page 13 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter BATTERY Use a two D cell battery pack 1 2 to 6 or a double two D cell battery pack 8 to 24 Battery Life Standard Pack Sampling Expected Life 0 25 3 months 4 4 years 8 8 years 15 10 years These calculations are for a standard battery pack with two D size batteries with communication and outputs OFF at a temperature of 77 F 250 C Battery Replacement 1 Goto Main Menu gt Misc gt Battery gt Change and select the capacity of the battery pack which should be installed see label on the battery pack 19 Ah 38 Ah or 70 Ah Press E to quit The display freezes no reaction by pressing any button Open the
6. Horizontal Placement the error message disappears and the meter will begin measuring When installing the meter on a horizontal pipe mount the detector to the pipe with the flow measuring electrode axis in a horizontal plane three and nine o clock This placement helps prevent solids build up sediment deposit and accumulation on the electrodes Straight Pipe Requirements Sufficient straight pipe runs are required at the detector inlet and outlet for optimum meter accuracy and performance An equivalent of three diameters of straight pipe is required on the inlet upstream side Two diameters are required on the outlet downstream side FLOWMETER D Pipe Size D Pipe Size FORWARD FLOW gt ELBOW TEE GATE VALVE 3xD FULLY OPEN MINIMUM STRAIGHT PIPE MI INIMUM STRAIGHT RIPE CHECK VALVE GLOBE VALVE BUTTERFLY VALVE 7xD STANDARD CONCENTRIC PA MINIMUM STRAIGHT PIPE REDUCERS NO DISTANCE REQUIRED ELBOW TEE ANY VALVE MINIMUM PIPING REQUIREMENT Figure 8 Straight Pipe Requirements September 2013 Page 9 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Pipe Reducer Requirements With pipe reducers a smaller meter can be mounted in larger pipelines This arrangement may increase low flow accuracy There are no special requirements for standard concentric pipe reducers Custom fabricated pipe reduce
7. Place straps between flanges Use lifting lugs with 10 inch or larger meters Figure 2 Rigging Large Units September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Use the sling rigged method to lift large detectors into a vertical position while they are still crated Use this method to position while they are still crated Use this method to position large detectors vertically into pipelines Figure 3 Sling Rigged Lifting Methods Do not lift a detector with a forklift by positioning the detector body on the forks with the flanges extending beyond the lift This could dent the housing or damage the internal coil assemblies Never place forklift forks rigging chains straps slings hooks or other lifting devices inside or through the detector s flow tube to hoist the unit This could damage the isolating liner O O Do not lift detector with forklift Do not lift or rig lifting devices through detector Figure 4 Lifting and Rigging Cautions September 2013 Page 7 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter METER LOCATION ORIENTATION AND APPLICATIONS The M5000 provides two amplifier mounting options an integral or meter mount option and a junction box remote option Meter mount amplifier Junction box with remote amplifier Figure 5 Amplifier
8. activated Flow rates above the threshold will LS activate the output alarm Out 1 Func This parameter provides configuration of the functional operation of the Out 2 Func associated output The following operations are supported eure Puel Function Dig1 Dig2 Dig3 Dig4 Out 4 Func Off X X X y Test X X X LS MinMax X X X Empty X X X ErAlarm X X X Forward X Reverse X Direct X ADE X Inactive Off means digital output is switched off It is recommended to switch off the outputs in the menu Output function if not used This increase the battery life time Test Test triggers the output Flow setpoint MinMax provides indication when flow rate exceeds thresholds defined by flow setpoints set min set max Empty pipe alarm Empty provides indication when pipe is empty Error alarm ErAlarm provides indication when meter has error condition Forward pulse Forward generates pulses during forward flow conditions Reverse pulse Reverse generates pulses during reverse flow conditions Flow direction Direct provides indication on current flow direction ADE ADE Absolute Digital Encoder for remote meter reading using ASCII communication protocol Out 1 Type This parameter lets you set the output switch to normally open or normally Out 2 Type closed If normally open is selected the output switch is open no current when Out 3 Type the output is inactive and closed current flows when the output is active Ou
9. cover Remove all connectors detector and outputs Remove all 4 screws of the main board remove the circuit board and disconnect the old battery Remove the old battery and wait about 2 minutes before replacing it with a new one LCD display should be off Plug the battery connector into the back of the main board and reinstall the circuit board Replace all the plugs Close the cover tight SO 00 FS Ove UT eM Check time and date Main Menu gt Misc gt Time and Main Menu gt Misc gt Date DMY o Check capacity of battery Main Menu gt Misc gt Battery AH The first value is the used capacity which should be 0 0 The second value is the capacity of the battery pack Battery AH is a read only parameter NOTE Totalizers and configuration remain unaffected during battery replacement 4 e of 73 TS TT Figure 19 Amplifier Housing Components Exploded View Page 14 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Remote Mount Installation If you are installing the M5000 amplifier in a remote location review the procedures in this section Mount Bracket to Amplifier 1 Align bracket mounting holes with amplifier mounting holes 2 Attach bracket to amplifier with supplied screws Torque the screws to 80 inch pounds Wiring Configuration Wiring between the detector and the M5000 amplifier comes complete from the factory If y
10. A ee oe 23 Inputs Outputs Meniu sois duara OE RAS RE aE LER a HS Ree ui RE A OR REA RS ee ae Redes 25 Communication Menu s soi eis ina oars Bacal ea ee oe i a a We ae a ae dale ee Saal ae ee ie Ae ed a a we a a 27 Miscellaneous Menu escorias ve Whee cea eee eae e te a Ra a Habe pute 28 Information MENU ss eenst at ends oAe Hee Hd Oe GD D Ade du Soe la 8 SAE AAO TES Saad ae 28 PIN Men Ussa twa ot aed ap Gade w ent each es GR eas ERED RSE ERD EN RRR RE ERE RS eee aes 29 Faults Men sude ors Pee dena da E Ses ee Se ge a ca en EA sl di tt 29 MAINTENANCE Sa cts cria Aa ieee asada teas hage aoe Gees beeen eas 30 Cleaning the Flow Tube and Electrode 2 1 ne nett eee 30 TROUBLESHOOTING ice coed oe eh caw he ie ee Ree Oe ER Oe ead a Rane 2 RAO a a BAe a 31 Errors Sc Waring S sci eaten yea ade Grea ed nade bad sen be Ge eu Deke ode aa ee a 32 Page iv September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual SAFETY PRECAUTIONS AND INSTRUCTIONS Some procedures in this manual require special safety considerations In such cases the text is emphasized with the following symbols Symbol Explanation Warning indicates the potential for severe personal injury death or substantial property damage Comply with the instructions and proceed with care ACAUTION Caution indicates the potential for minor personal injury or property damage Comply with the instructions and proceed with car
11. ASTE Ad GEOR Se Bade ad ees 15 Wiring for Remote Configuration ceea 15 CONFIGURING INPUT OUTPUT WO sco as xsara a PAR AAA wacbe bg aha Peet pacha ee an 16 Circuit Board Diagram 4 50 406 act hae eae A One eee eae ene hae ee a i 16 Digital Output Wiring Diagrams caddies caw do ks eRe RS OS SER E ERTS AA A 17 Digital OUTPUESEIECHIONS enea a eek ea E OW i ta de a a OW A bea ae Ra ae eer da 17 PROGRAMMING THE M5000 ccoo oe abe he tad ewe tha de he ted ea KE CEECEE noes KEENE KEER 18 FUNCTION BUTTONS Wes 2 face Pace Be a ae de 0 ui a 8 a ac ae 8 mit ata eae Ree a ees we ee Pe d 3 le a 18 Display sist e arie ao i aaa pe hale Re Pa aci a e pe bale ae Res 18 Oe oa oie eee Ra eee ee a Eee Dae A eee aes earn Ad ae Oe 18 Battery Level caian ara oh a a wa ES A AER Gaede BAe SERA Awe ee Rho Rene 18 M5000 MAIN MENU PROGRAMMING OPTIONS 0 0 0 ee eee 19 USING THE M5000 MAIN MENU PROGRAMMING OPTIONS 0 000 eee ee te eee eee 20 Display Menu Screen Hierarchy Structure cena 20 SECURITY y i pacii ai ve arte Bes wei g ae e daa Gy i ta e spus e Ged d aci e a i ac a Ged dati a e wack 21 Setting a PIN sees saaan A a p ae gs be c ea si AAA A E RA a AA p d 21 LOGGING Mi a sas ade o FRR ODC 21 Logging QU o ta a ete p tach aoa ae uta SER 0 vata A dh Bee ad Bas ala ee ae ee a A 21 Meter Setup Menus 2 acts tix ceacte dw tp a e sc AA wae 22 Measure MEN sasana ce a aCe eee hha a ACOH s eee RO RA ed Oe eee ed
12. Distributed By MC M Series M5000 Meter Valve amp Control Badger Meter Electromagnetic Flow Meter 877 566 3837 MAG UM 00219 EN 02 September 2013 User Manual www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Page ii September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual CONTENTS SAFETY PRECAUTIONS AND INSTRUCTIONS 4 25 2 40 4 850 44 4 85464 e 84004038454 G4 G5 A Ra G4 3 5 SYSTEM DESCRIPTION crer ear e a ec e 0 ca i AAA a Doe e av ae eeav E e A 5 UNPACKING ANDIINSPECTION oca daa A A a Pewee os 6 Rigging Lifting and Moving Large Units ae 6 METER LOCATION ORIENTATION AND APPLICATIONS 8 Remote Amplifier Outdoor Location asariar meane EE a aa n E E OD ROE KE n R nee eee 8 Pipelines and Fluid Fl Wiss metea ana aaae eee pat au a a 2a a A cea a O da a d st 8 Meter Orientation vasca a a RA AR RR AA A A AAA AA ESE 9 Vertical ace MEN Ex AR A AA a ORS Oe Ca a ee oe A 9 Horizontal Place metes irradia RA AAA A A A AA 9 Straight Pipe Requirements ose sica ra rs las ae d a sa sa Bad 9 Pipe Reducer Requirements ssid a ica a RR ORE RARE A ARA HE ERTS EROS 10 Chemical Injection Applications ceea 10 Partially Filed Pipe Situations i cas e ee a ee ea A A A E A Ree 0 11 METER GASKETS AND GROUNDING s s krse e e ate da ti A Aa a ES 12 Meter Pipeline Connection Gaskets ooo
13. H Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Czech Republic Badger Meter Czech Republic s r o Maf kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 04 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 Legacy Document Number IOM 832 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903
14. Mounting Options Remote Amplifier Outdoor Location The amplifier can be installed and operated outdoors However it must be protected from the elements as follows The ambient environment temperature rating for the unit is 4 140 F 20 60 C If an indoor location is within 100 feet 30 meters of the detector consider increasing the cable length up to 100 ft and mounting the amplifier indoors At minimum fabricate a roof or shield over and or around the amplifier to protect the LCD display screen from direct sunlight Pipelines and Fluid Flow Take the following precautions during installation Do not install the meter on pipes with extreme pipe vibrations If pipes are vibrating secure the piping with appropriate pipe supports in front of and behind the meter If vibrations cannot be restrained mount the amplifier in a remote location Do not install the detector close to pipeline valves fittings or impediments that can cause flow disturbances For detectors with PTFE liners do not install the detector on suction sides of pumps Do not install the detector on outlet sides of piston or diaphragm pumps Pulsating flow can affect meter performance Avoid installing the detector near equipment that produces electrical interference such as electric motors transformers variable frequency and power cables Verify that both ends of the signal cables are securely fastened Place power cables and signal cables in separate
15. Only NOTE A new battery should be at or near a 0 38 reading Language This parameter allows changing the current language English is the default setting The following languages are supported German Deutsch Czech Cestina Spanish Espanol French Francais Russian Poccun Italian Italiano Day Month Year A real time calendar The day month and year must be reprogrammed after the battery is replaced A real time clock The hour minute and second must be reprogrammed after the battery is replaced EEPROM Format the EEPROM to erase all log files Totalizers and configuration remain unaffected during a Dy format Battery Saves Totalizers to nonvolatile memory in preparation for battery replacement Restart Provides the ability to reset the meter electronics Indicates the amount of free flash memory space Polarity Measured electrode polarizing voltage just for service purposes Datalogger The logging period can be adjusted to the following values 1 min 15 min 1h 6h 12h 24h See the Datalogging User Manual for more information Information Menu Info Serial Number Serial number of the electronic board Version Software version of the device Compilation Date Date of the software version OPT CRC Checksum of the software update APP CRC Checksum of the application Page 28 September 2013 www mvandc com sales mvandc c
16. RROR Configuration file is missing Replace the board CONFIG_ERROR Configuration file is corrupted Replace the board PREAMPLIFIER_OVERLOAD Input voltage exceeded the limits Maximum polarization is 227 mV maximum power line noise is 10 6 mV maximum useful signal is 10 7 mV Empty detector Dirty electrodes Switch Empty Pipe detection ON Clean the electrodes COIL ERROR Coil sensor is not connected Coil shorted Issue with coil current Make sure wiring is properly connected to the amplifier If that does not clear the alarm contact Badger Meter Technical Support M Series and ORION are registered trademarks of Badger Meter Inc Other trademarks appearing in this document are the property of their respective entities Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists 2013 Badger Meter Inc All rights reserved www badgermeter com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina N 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa Gmb
17. and packing materials in the event the unit needs to be shipped for service Verify that the shipment matches the packing list and your order form Inspect the meter for any signs of shipping damage scratches or loose or broken parts If the unit was damaged in transit it is your responsibility to request an inspection report from the carrier within 48 hours You must then file a claim with the carrier and contact Badger Meter for appropriate repairs or replacement All detectors with polytetrafluoroethylene PTFE liners are shipped with a liner protector on each end to maintain proper form of the PTFE material during shipping and storage Do not remove the liner protectors until you are ready to install Storage If the meter is to be stored place it in its original container in a dry sheltered location Storage temperature ranges are 40 160 F 40 70 C Rigging Lifting and Moving Large Units WHEN RIGGING LIFTING OR MOVING LARGE UNITS FOLLOW THESE GUIDELINES Page 6 DO NOT lift or move a meter by its amplifier junction box or cables Use a crane rigged with soft straps to lift and move meters with flow tubes that are between two inches and eight inches 50 mm and 200 mm Place the straps around the detector body between the flanges on each side of the detector Use the lifting lugs when lifting meter flow tubes that are 10 inches 250 mm in diameter or larger 3 B A A
18. conduits Place the meter where there is enough access for installation and maintenance tasks Page 8 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Meter Orientation Mag meters can operate accurately in any pipeline orientation and can measure volumetric flow in forward and reverse directions NOTE A Forward Flow direction arrow is printed on the detector label Vertical Placement Mag meters perform best when placed vertically with liquid flowing upward and meter electrodes in a closed full pipe D ct Figure 6 Vertical Placement Vertical placement allows the pipe to remain completely full even in low flow low pressure applications and it prevents solids build up sediment deposit and accumulation on the liner and electrodes NOTE Carefully observe the Forward Flow label on the meter body and install the meter accordingly When installed vertically rotate amplifier so that cable glands are facing down Horizontal Placement M5000 meters are equipped with an Empty Pipe Electrode Detection feature If an electrode mounted in the pipe is not covered by fluid for five seconds the meter will Pe rade O display an Empty Pipe Detection condition The meter will send out an error message and stop measuring RIGHT WRONG flow When the electrode is again covered with fluid Figure 7
19. e SYSTEM DESCRIPTION The Badger Meter M Series model M5000 electromagnetic flow meter is intended for fluid metering in most industries including water wastewater food and beverage pharmaceutical and chemical The basic components of an electromagnetic flow meter are The detector which includes the flow tube isolating liner and measuring electrodes The amplifier which is the electronic device responsible for the signal processing flow calculation display and output signals lt Amplifier 3 lt Detector Figure 1 Amplifier and Detector The construction materials of the wetted parts liner and electrodes should be appropriate for the specifications on the intended type of service We recommend that you review all of the compatibilities consistent with the specifications Each meter is factory tested and calibrated A calibration certificate is included with each meter September 2013 Page 5 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter UNPACKING AND INSPECTION Follow these guidelines when unpacking the M Series equipment NOTE NOTE If a shipping container shows any sign of damage have the shipper present when you unpack the meter Follow all unpacking lifting and moving instructions associated with the shipping container Open the container and remove all packing materials Store the shipping container
20. e after proper installation However some occurrences may require personnel to perform the following Flow tube and electrode cleaning Circuit board replacement DO NOT CLEAN COMPONENTS INSIDE THE AMPLIFIER OR JUNCTION BOX Cleaning the Flow Tube and Electrode At times flow tube electrodes amplifier junction box housings and the amplifier window may need periodic cleaning depending on process fluid properties fluid flow rate and surrounding environment Clean the flow tube and electrodes by following the material handling and cleaning procedures documented in Material Safety Data Sheet MSDS guidelines for the products s that were in contact with the flow tube and electrodes Should flow tube and or electrode cleaning become necessary 1 Disconnect detector from pipeline 2 Clean electrodes according to MSDS guidelines 3 Reconnect detector to pipeline Page 30 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 TROUBLESHOOTING The M5000 mag meter is designed for many years of optimal performance However should it malfunction there are certain things that we recommend you check before contacting our Technical Support department or your local Badger Meter Representative User Manual NOTE If the fluid measured has a high concentration of conductive solids deposits may accumulate on the internal liner walls and electrodes These deposits will cause a reduction of the measuri
21. e factory default is 0 ms Non zero pulse width configuration the OFF duration of the transmitted pulse is dependent on flow rate The OFF duration is to be at least the configured ON duration At full scale flow the ON duration equals the Off duration The maximum configurable output frequency is limited to 100 Hz The duty cycle of the transmitted pulse is at 50 of the output frequencies greater than 1 Hz This parameter must be considered with the Pulses Unit and Full Scale Flow parameters The maximum pulse frequency is 100 Hz The frequency is correlated with the flow rate Violation of output frequency limits will generate a PULSE_ OVERLOAD_WARNING Power Line Frequency Q This parameter provides measuring immunity to industrial noise from a power supply feed This parameter should be set to your nominal line frequency typically 50 Hz September 2013 Page 25 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Inputs Outputs Digital Outputs Set Min This parameter establishes as a percentage of full scale flow the threshold at continued which the output alarm will be activated Flow rates below the threshold will LS activate the output alarm Set Max This parameter establishes as a percentage of full scale flow the threshold at a which the output alarm will be
22. es M5000 Electromagnetic Flow Meter CONFIGURING INPUT OUTPUT 1 0 This section describes wiring the following M5000 outputs Digital outputs Communication When the sensor and the amplifier have been wired wire any outputs to the M5000 amplifier Follow all of the safety precautions and local code to prevent electrical shock and damage to the electronic components Circuit Board Diagram Measure electrode RED ADE_CLOCK VS DOO Input GREEN ADE_DATA ol OS 3 BLACK ADE_GROUND Ze S 3 le cal O ll cal 2 O l all SHE Figure 21 Configuring Input Output Input Output Description Terminal Output 1 Passive max 30V DC 20 mA OUT1 and Max Frequency 100 Hz Output 2 Passive max 30V DC 20 mA OUT2 and Max Frequency 100 Hz Output 3 Passive Max 30V DC 20 mA OUT3 and Output 4 Passive Max 30V DC 20 mA OUT4 and Can be used with digital input as an ADE interface RS232 Modbus RTU RxD TxD GND IN Digital input 3 35V DC IN and M BUS M Bus interface No polarity Page 16 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Digital Output Wiring Diagrams Positive Pulse Logic Negative Pulse Logic Yo V SEL va x I lt 20mA V lt 30V gt Signal R Figure 22 Digita
23. etector zero Detector Zero This parameter is set at the factory A This parameter compensates for accuracy error as a result of the installed detector In the event the amplifier is replaced this parameter must be reprogrammed with the original detector factor Amplifier Factor This parameter is set at the factory and is Read Only This factor compensates for accuracy error as a result of the installed amplifier Coil Current This parameter is set at the factory and is Read Only This factor compensates for accuracy error as a result of the installed amplifier Scale Factor LS Power Line Frequency LS Changing the scale factor lets you adjust the meter s accuracy without disturbing parameters set by the factory You can tune the meter to meet changing application requirements This parameter is set at the factory This parameter provides measuring immunity to industrial noise from a power supply feed Period This parameter configures the frequency 1 4 1 99 seconds of sampled measurements In other T a words if set to 15 then every 15 seconds it will sample for 208 micro seconds A NOTE Parameters indicated by the battery icon if changed will affect battery performance Standard sampling period is 15 seconds Empty Pipe Detection Empty Pipe ON OFF When set to ON an Empty Pipe condition indicates to the outputs 2 that the meter is not completely filled When set to OFF empty pipe ES condition
24. inistrator can set up a single PIN for each of the three different levels of access Administration allows access to all M5000 menu configuration screens Service allows access to service level and user level menu configuration screens User allows access only to user level menu configuration screens NOTE For a lost PIN Contact Badger Meter Technical Support at 800 456 5023 for a replacement PIN Not all levels of access need to be set If no PINs are set up any M5000 user will have access to all functions NOTE The security settings will also apply to remote access All remote writes via Modbus to the meter will be blocked unless the user is remotely logged in Setting a PIN 1 From the Main Menu press the right arrow button From the Meter Setup menu press the up arrow button until the Pin menu is displayed Press the right arrow button to display the PINS Control menu Press the right arrow button to flash ON or OFF With either ON or OFF flashing press the up arrow button to display ON Press the EXIT SAVE button to save the ON setting A Oou oe oo wo ON With the Control menu flashing press the up arrow button to display the desired security level user service or admin go With the desired security level flashing press the right arrow button to display the upper row of six zeros digits 9 Press the up arrow button to change the first digit followed by pressing the right arrow button to select the
25. l Output Wiring Diagram Digital Output Selections Output 1 Output 2 Output 3 Output 4 Flow direction Forward Pulse Output Reverse Pulse Output Forward vs Reverso Flow Setpoint Flow Setpoint 0 100 of full scale resolution 1 0 100 of full scale resolution 1 Empty pipe alarm Empty pipe alarm ADE Error alarm Error alarm off Test Can be used with AMR when the pulse width is set to _ 50 milliseconds Outputs are configurable for Pulses Unit PPU and Pulse Width PW The PW is configurable from 5 500 milliseconds with a frequency limit is 100 Hz The PPU is displayed using an automatically selected resolution The high low flow alarm functionality is configurable for maximum and minimum setpoints as a percentage of full scale flow Configurable values are settable from 0 100 in 1 increments September 2013 Page 17 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter PROGRAMMING THE M5000 The M5000 amplifier is pre programmed from the factory No additional programming is necessary however for special features the meter can be programmed for specific requirements Function Buttons All M5000 programming is accomplished using the three function buttons located on the front of the amplifier Screen navigation and digit and parameter selection is performed by a A kb VE combination of these three buttons
26. lso affect downstream readings by the meter Page 10 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Partially Filled Pipe Situations In some locations the process pipe may be momentarily only partially filled Examples include lack of back pressure insufficient line pressure and gravity flow applications To eliminate these situations Do not install the meter at the highest point of the pipeline Do not install the meter in a vertical downward flow section of pipe Always position the ON OFF valves on the downstream side of the meter WRONG RIGHT WRONG RIGHT i L Do not install in a vertical downward position Position On Off valves on downstream side Figure 12 Incorrect Meter Placement Figure 13 Position Valves on Downstream Side To minimize the possibility of partially full pipe flows in horizontal gravity or low pressure applications create a pipe arrangement that ensures the detector remains full of liquid at all times HEN A Figure 14 Pipe Positioned to Keep Water in Detector September 2013 Page 11 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter METER GASKETS AND GROUNDING Gasket and grounding requirements must be considered when determining the meter location o
27. munication Miscellaneous Information Pin Faults The applicable security level for each menu option is indicated as follows A 3 uv Administrative Service User Parameters indicated by the battery icon if changed will affect battery performance September 2013 Page 19 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter USING THE M5000 MAIN MENU PROGRAMMING OPTIONS Display Menu Screen Hierarchy Structure Main_Menu gt Page 20 Meter Setup gt Measure gt In Out gt Communication gt Miscellaneous gt Info gt PINs gt Faults gt www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 Calibration Scale Factor Frequency Period Empty Pipe Flow Unit Totalizer Unit Full Scale Flow Low Flow Cutoff Flow Direction Totalizer1 Reset Median Filter Display Simulation Digital Input Outputs Interface RS 232 MODBUS M Bus ADE Battery Voltage Battery Capacity Language Date DMY Time EEPROM Battery Restart HDD Free Polar V Datalogger Serial Number Version Compilation Date OtpCrc AppCrc Control User Service Admin Random Emergency Preamp Coil Empty Pipe Measure Time Voltage Overflow September 2013 User Manual SECURITY The M5000 security feature allows the option to restrict access to the meter by way of a 6 digit Personal Identification Number PIN The system adm
28. next digit 10 Press the EXIT SAVE button to save the PIN number for that security level The saved PIN number will be the same PIN number used to log in to the amplifier NOTE Be sure to log off when you have completed work with the M5000 Otherwise a five minute time delay occurs between the most recent activity and the time when the M5000 automatically logs off Logging In To change any parameter in the mag meter the PIN entered must provide the proper security privilege required by the parameter To enter a PIN go to the Login menu and enter the PIN for the required security level Once you are properly logged in the unlocked icon appears on the meter display NOTE A PIN Error message displays if the incorrect PIN is entered Logging Out To log out follow steps 1 through 8 under Setting a PIN At step 9 enter an unknown PIN then press EXIT SAVE September 2013 Page 21 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Meter Setup Menu Meter Setup Calibration Diameter This parameter is set at the factory In the event the amplifier is replaced a verify that the pipe diameter matches the installed pipe size Detector Factor This parameter is set at the factory This factor compensates for accuracy a error as a result ofthe installed detector A In the event the amplifier is replaced this parameter must be reprogrammed with the original d
29. ng output Thus Badger Meter recommends that you remove the meter and inspect the liner and electrodes after six months If deposits are found remove them with a soft brush Repeat inspection process every six months or until an appropriate inspection cycle can be established for the specific application Other general conditions include Description Possible Cause Recommended Action Flow is present but Disconnected signal cable Check signal cable display is 0 Detector mounted opposite of the main Flow Turn detector 180 or switch terminal E1 and E2 direction see arrow on the nameplate or reprogram to bidirectional mode Coil or electrode cables exchanged Check cable connections for cross wiring Improper low flow cutoff or full scale flow Replace configuration defaults Inaccurate Improper calibration measuring Check the parameters detector factor and size according to supplied data sheet Wrong calibration parameter Pipe not fully filled or air in pipe Check if meter is completely filled with fluid Invalid fluid conductivity aes Purge line to eliminate air bubbles Invalid fluid mixture Blank display Dead battery Replace battery Flow rate value known to be wrong Detector factor Check value on label Deposits on electrodes and or liner Check and remove deposits Incorrect pipe size programmed Check size if necessary Flow rate indication unstable Cable iss
30. om Phone 877 566 3837 Fax 925 407 2903 User Manual PIN Menu PIN Control Two options are available A ON requires PIN configuration OFF User Users logged in with this PIN have access to all user levels Users at this level do not have access to U Service or Admin functions Service Users logged in with this PIN have access to both service and user level procedures Users at this level a do not have access to Admin functions Admin Users logged in with this PIN have access to all procedures Users at this level have full access to the A meter Random This function generates a random number which is used when a PIN is lost This number will be needed for Badger Meter Tech Support to provide a Master PIN Emergency Enter the Master PIN received from Badger Meter Technical Support to unlock the meter in case the Faults Menu Admin PIN has been lost Faults Preamp The Faults menu displays the errors and the number of time they have occurred each hour For an Coil explanation of the error that has occurred or how to fix it see Errors amp Warnings on page 32 Empty Pipe Measure Time Volume Overflow September 2013 Page 29 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter MAINTENANCE Mandatory routine or scheduled maintenance should not be required for the M5000 Mag Meter electronics or flow tub
31. ood electrical connection at the mating flanges we recommend that you drill and tap the flanges and install a grounding screw not provided These grounding straps must be copper wire at least 12 AWG size They must be connected on both sides inlet and outlet of the detector and to a local earth ground Non Conductive Pipe Grounding IMPORTANT If the process pipe is not electrically conductive PVC fiberglass cement lined pipes or any other non conductive material and the meter was not originally ordered with an optional grounding electrode you must install a pair of grounding rings between the mating flanges at both ends of the meter See the following illustration In this case the grounding straps should be connected to both of the zu ia grounding rings and to a good solid earth ground Grounding rings are available in stainless steel If your fluid is too aggressive for stainless steel order a meter with the optional grounding electrode in a material compatible with the fluid GROUNDING RING GASKETS RECOMMENDED Figure 16 Non Conductive Pipe Grounding Page 12 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual AMPLIFIER MOUNTING CONFIGURATION OPTIONS Meter Mount Configuration The meter mount configuration has the amplifier mounted directly on the detector This compact self contained configuration minimizes installation wiring Remote Mount Configuration
32. our installation requires the use of conduit we recommend that you follow these steps when wiring the detector to the amplifier 1 Carefully remove the wires connected to the terminal blocks that run to the M5000 amplifier or to the junction box See the chart below for a reference of wire color to terminal connection 2 Run cable through the conduit while retaining the wiring of the cable to the amplifier or the junction box as supplied 3 Complete conduit assembly on both ends and rewire the cable as it was previously wired Wiring for Remote Configuration Remote style M5000 amplifier models can be ordered with standard cables measuring 15 30 50 and 100 feet Junction Box eee Description Wire Color 11 Coil Red Brown 12 Coil Blue White 13 Main Shield Not Used 40 Empty Pipe Pink 44 Shield Green 44 Empty Pipe Shield Shield Wire 45 Electrode White 46 Electrode Black Connections with the No 44 are lying on the same potential M5000 AMPLIFIER RED BROWN BLUE WHITE ELECTRODE J 5 k M5000 JUNCTION BOX 44 SHIELD EMPTY PIPE 40 40 EMPTY PIPE O SHIELD 44 44 SHIELD ELECTRODE 46 46 ELECTRODE SHIELD 44 44 SHIELD ELECTRODE 45 45 ELECTRODE FROM DETECTOR TO AMPLIFIER EIB N Figure 20 Wiring for Remote Configuration September 2013 Page 15 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Seri
33. rientation and application Meter Pipeline Connection Gaskets You must install gaskets not provided between the detector s isolating liner and the pipeline flange to ensure a proper and secure hydraulic seal Use gaskets that are compatible with the fluid Center each gasket on the flange to avoid flow restrictions or turbulence in the line During installation do not use graphite or any electrically conductive sealing compound to hold the gaskets This could compromise the accuracy of the measuring signal GASKETS RECOMMENDED Figure 15 Meter Pipeline Connection Gaskets If you are using a grounding ring in the detector pipeline connection place the ring between two gaskets See Non Conductive Pipe Grounding on page 12 Meter Grounding Process pipeline material can be either electrically conductive metal or not electrically conductive made of or lined with PVC fiberglass or concrete IMPORTANT It is essential that the mag meter amplifier s input ground zero voltage reference be electrically connected to the liquid media and to a good solid earth ground reference Conductive Pipe Grounding To achieve an adequate ground the meter body MUST be electrically connected to the liquid media The mag meter flanges are provided with grounding bolts for this purpose If the pipe material is electrically conductive simply install grounding straps between these grounding bolts and the mating flanges To ensure a g
34. rs must have an approximate slope angle of 15 degrees to minimize flow disturbances and excessive loss of head If this is not possible install the custom pipe reducers as if they were fittings and install the required amount of straight pipe Flow Meter D Pipe Size D Pipe Size Forward Flow Custom Fabricated Reducers 15 Degree Slope Angle i Standard Concentric Reducers No Distance Required Figure 9 Pipe Reducer Requirements Chemical Injection Applications For water line applications with a chemical injection point install the meter upstream of the injection point This eliminates any meter performance issues CHEMICAL Flow Meter INJECTION HERE y al UPSTREAM DOWNSTREAM Figure 10 Chemical Injection Point Upstream of Meter If a meter must be installed downstream of a chemical injection connection the distance between the meter and the injection point should be between 50 and 100 feet 15 and 30 meters The distance must be long enough to allow the water or chemical solution to reach the meter in a complete homogeneous mixture CHEMICAL Flow Meter INJECTION UPSTREAM i DOWNSTREAM Figure 11 Chemical Injection Point Upstream of Meter If the injection point is too close the meter senses the two different conductivities for each liquid This will likely result in inaccurate measurements The injection method spaced bursts continuous stream of drips or liquid or gas can a
35. s are not detected Threshold This parameter is set at the factory and adjusted to the conductivity of a normal water Measure Measures the real empty pipe value This parameter is Read Only Page 22 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 Measure Menu User Manual Measure Flow Unit U This parameter establishes the unit of measure for the flow rate and full scale flow Changing this parameter readjusts the full scale flow parameter For example changing from GPM to GPS would change the full scale flow from 60 gal min to 1 gal s Display Flow Unit Display Flow Unit L s Liters Second gal s Gallons Sec L min Liters Minute gal min Gallons Min L h Liters Hour gal h Gallons Hour m s Cubic Meters Sec MG d MillionGallons Day m min Cubic Meters Min IG s ImperialGallons Sec m h Cubic Meters Hour IG min ImperialGallons Min ft3 s Cubic Feet Sec IG h ImperialGallons Hour ft m Cubic Feet Min oz min Ounce Min fte h Cubic Feet Hour bbl min Barrel Min U Totalizer Unit This parameter establishes the units of measure for the totalizers Display Totalizer Unit L Liters hL Hectoliter m Cubic Meters ft Cubic Feet gal U S Gallons MG Million Gallons IG Imperial Gallons bbl Barrel oz Fluid Ounces ac ft Acre per foot Full Scale Flow This parameter set
36. s the maximum flow that the system is expected to measure This parameter has influence on other system parameters which include Low Flow Cutoff Changes to full scale flow affect the measuring cut off threshold of the meter Alarm Outputs Changes to full scale flow adjusts the thresholds for generating setpoint alarms Pulse Outputs Changes to full scale flow adjusts the pulse frequency and duty cycle Change the full scale flow based on the meter size and the application s requirements Verify that the full scale flow falls within the meter s suggested flow range limits Flow Range 0 1 32 8 ft s 0 03 10 m s The full scale flow is valid for both flow directions NOTE If the flow rate exceeds the full scale setting of more than 100 a FLOW_OVERLOAD_ WARNING message indicates that the configured full scale range has been exceeded However the meter will continue to measure This will affect the latency of the pulse outputs and possibly cause overflow September 2013 Page 23 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Measure Low Flow Cutoff U Low flow cutoff defines the threshold at which flow measurement will be forced to zero The cutoff value can be set from 0 to 10 of the full scale flow Increasing this threshold will help prevent false readings during no flow conditions possibly caused by pipe vibration or inherent sy
37. stem noise Flow Direction Ss This parameter allows setting the meter to measure forward flow only unidirectional or both forward and reverse flow bidirectional Unidirectional Flow is totalized in only one direction The flow direction is indicated by the arrow printed on the detector label Unidirectional measurements on the main display screen include T1 Registers forward flow resettable by menu or Modbus RTU T2 Registers forward flow non resettable Bidirectional Flow is totalized in both directions Bidirectional measurements on the main display screen include T1 Registers forward flow resettable by menu or Modbus RTU T1 Registers reverse flow resettable by menu or Modbus RTU TIN Registers total flow T T resettable by menu or Modbus RTU T2 Registers forward flow non resettable T2 Registers reverse flow non resettable T2N Registers total flow T T non resettable T1 Reset This parameter allows the reset of totalizer T1 Median This parameter can be set to ON or OFF When set to ON the median display filters out the flow rate fluctuations displayed on the LCD Filter Display This parameter can be set from 0 99 seconds The display will update less frequently depending on how high the filter display is set Page 24 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 Inputs Outputs Menu User Manual Inputs Outputs
38. t 4 Type If normally closed is selected the output switch is closed current flows when gt the output is inactive and open no current when the output is active Page 26 September 2013 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 User Manual Communication Menu Communication Port Settings Interface This parameter provides communication port configuration D El IrDA Modbus RTU zi Serial Modbus RTU M Bus OFF turns off the serial interfaces Serial Baud Rate This parameter sets the baud rate a E The following baud rates are supported SE 9600 1200 2400 Parity This parameter sets the parity Q RI The following parities are supported E Even Odd Mark Modbus Address This parameter configures the Modbus address in the range from 1 247 LS M Bus Address MeterBus protocol mainly used in the European market Please direct Q questions to Badger Meter Technical Support ADE Control ON OFF Protocol V1 standard messages V2 extended messages Dial 4 9 Resolution 0 0001 10000 September 2013 Page 27 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 M Series M5000 Electromagnetic Flow Meter Miscellaneous Menu U Misc Battery Voltage Displays the current battery voltage This parameter is Read Only Battery Ah Displays the current battery capacity For example 0 38Ah to 38 38Ah This parameter is Read
39. ue Make sure cable is shielded and not vibrating Grounding issue Partially full pipe Make sure meter is properly grounded to a good earth ground Make sure pipe is full of fluid Air in pipe Make sure fluid does not contain air bubbles Invalid fluid conductivity Make sure amplifier is not too close to sources of electrical interference September 2013 Page 31 www mvandc com sales mvandc com Phone 877 566 3837 Fax 925 407 2903 Errors 8 Warnings What You See MEASURE_TIMEOUT Why It Happened The board may be damaged How to Fix It Contact Badger Meter Technical Support COMMON_MODE_VOLTAGE_ OVERLOAD Common mode voltage is smaller than 2 0V or larger than 4 1V Make sure the meter is properly grounded Empty detector Switch Empty Pipe detection ON Dirty electrodes Clean the electrodes EMPTY_PIPE_WARNING Measured impedance between the Empty Pipe electrode and the Ground exceeded the set value Empty detector Make sure the pipe is filled Check Empty Pipe threshold It should be 60000 Q corresponds with 20 uS cm PULSE_OVERLOAD_WARNING Overflow occurred on the flow output Lower the pulse number FLOW_OVERLOAD_WARNING LOW_POWER_WARNING Flow exceeded the Full Scale of more than 100 Battery voltage is smaller than 3 0V Set the flow range properly Consider replacing the battery EEPROM_E
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