Badger Meter M-series User manual

IMPORTANT !!!! Read this manual before attempting any handling
or installation of the meter.
BME-M3000-09-07

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Disclaimer
The user/purchaser is expected to read and understand the information provided in this manual, follow any listed Safety
Precautions and Instructions and keep this manual with the equipment for future reference.
The information in this manual has been carefully checked and is believed to be entirely reliable and consistent with the product
described. However, no responsibility is assumed for inaccuracies, nor does Badger Meter Europe assume any liability arising out
of the application and use of the equipment described.
Should the equipment be used in a manner not specified by Badger Meter Europe, the protection provided by the equipment may
be impaired.
Questions or Service Assistance
If you have questions regarding the product or this document contact:
Badger Meter Europa GmbH
Nürtinger Str. 76
72639 Neuffen (Germany)
Telephone: [phone]
Fax: [phone]
On the Web: www.badgermeter.de
or call your local Badger Meter representative.
Product Identification Information
Record the product identification numbers from the
nameplate.
Modular Mag Meter
Model Number _M3000______
Serial Number _____________
Tag Number _______________(if applicable)

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Basic safety advices
The electromagnetic flow meter is only suitable for the measurement of conductive fluids. The manufacturer is not liable for
damages that result from improper or nor not in accordance with the requirements use.
The meters are constructed according to state-of-the-art technology and tested operationally reliable. They have left the factory in a
faultless condition concerning safety regulations.
The mounting, electric installation, taking into operation and maintenance of the meter may only be carried out by suitable
technicians. Furthermore the operating personnel has to be trained by the operating authority and the instructions of this manual
have to be followed.
Principally the regulations for the opening and repairing of electrical equipment in your country have to be payed attention.
Repairs
Should you send back a flow meter in operation, please take notice of the following points:
-Please enclose a description of the fault as well as a precise statement of the measured medium (if necessary a safety
specification sheet).
-The meter has to be in a cleaned condition (outside and inside). Especially with harmful measuring mediums you have to pay
attention that there are no impurities in the pipe or at the connections.
-If it is not possible to clean the meter completely, particularly with harmful materials, do not send back the meter.
We reserve the right to repair only cleaned meters. Costs, which result from insufficient cleaning, will be charged to you.
CE mark
The electromagnetic flow meter complies with the European regulation ATEX 94/9/EC,
EMC regulation 2004/108/EC and PED regulation 97/23/EC.
The device is so designed and manufactured that it cause no danger by direct or indirect contact.
Badger Meter Europe confirm the conformity with the European regulations by printing the CE sign on the meter.

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TABLE OF CONTENTS
Disclaimer 2
Questions or Service Assistance 2
Product Identification Information 2
Basic saftey and repair advise 3
CE mark 3
SAFETY PRECAUTIONS and INSTRUCTIONS
Equipment Unpacking, Inspection, Moving and Return Policies 6
Rigging, Lifting, Moving Large Units 6
Instructions Specific to Hazardous Area Installations 7
METER DESCRIPTION 9
Empty Pipe Detection 9
Amplifier Mounting Options 9
Meter Mount 9
Remote Mount 9
METER/AMPLIFIER LOCATION, ORIENTATION and APPLICATIONS 9
Remote Amplifier Outdoor Location 9
Temperature 9
Pipelines and Fluid Flow 10
Meter Orientation 10
Vertical Placement . 10
Horizontal Placement 10
Straight Pipe Requirements .. 10
Pipe Reducer Requirements . 10
Chemical Injection Applications 11
Partially Filled Pipe Situations . 11
Meter Gaskets and Grounding 12
METER INSTALLATION 12
Remote Mount Amplifier 13
Remote Mount Amplifer/Detector Wiring 13
Detector Junction Box 13
Remote Mount Wiring Diagram 14
Electrode and Coil Wiring from Detector Junction Box to Remote Mount Amplifier Junction Box 15
Electrode Wiring 15
Coil Wiring 15
Output Wiring 17
External Disconnect 18
AC Power Wiring 18
Adjustable Display/Control Card . 19
AMPLIFIER CONTROLS, CONTROL METHODS AND DATA DISPLAY PROGRAMMING 20
Card Display and Controls 20
Two Programming Methods 20
Main Screen(s) 20
Password 21
Amplifier Access Switches/Buttons 22
How to Program 22
What to Program 26
PROGRAMMING REQUIRED PARAMETERS 26
Input a Password 26
Set Flow Units 27
Set Full Scale Flow 27
Set Flow Direction 28
Set Damping Factor 28
Empty Pipe Calibration . 28
Pulse Output 29
Analog Output 31

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ADDENDUM A 34
Detector Specifications 34
Amplifier Specifications 35
ADDENDUM B 36
Maintenance 36
Flow Tube and Electrode Cleaning 36
Fuse Replacement 36
Amplifier PCB Stack Replacement 37
ADDENDUM C 40
Menu Structure Flow Chart
ADDENDUM D 42
ATEX Certificate 42

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SAFETY PRECAUTIONS and
INSTRUCTIONS
Safety considerations are emphasized by the placement of
safety symbol icons on the product or next to important text,
pictures or drawings throughout this manual. The symbols
are:
When and where this symbol is attached to the product
it indicates a potential hazard. It means that
documentation must be consulted to determine the
nature of the potential hazard and any actions that need to
be taken.
Warning indicates an action or procedure, which, if not
performed correctly, can result in sever personal injury,
death, or substantial property damage. Comply with the
instruction and proceed with care.
Caution indicates an action or procedure, which if not
performed correctly, will or can cause minor personal
injury or property damage. Comply with the instruction
and proceed with care.
Equipment Unpacking, Inspection, Moving and
Return Policies
1. If shipping container damage is evident at delivery, have
a responsible person present when the meter is unpacked.
2. Inspect the shipping container for unpacking, lifting or
moving instructions.
3. As the unit is opened and unpacked, verify the shipment
packing list and your order form match the items in the
shipment.
4. Open the container and remove all cushioning materials.
Keep the shipping container and packing materials should
the meter need to be returned or put in storage.
5. Remove the meter from the container. For meter flow
tube diameters between 2” and 8” (50 and 200mm) use a
crane or lifting device with soft straps placed around the
detector body, at the flanges. For meter flow tube diameter
sizes 10” (250mm) and larger, lift the unit via the lifting lugs
with a crane, cables and hooks.
6. Inspect the meter for signs of shipping damage;
scratches, loose or broken parts.
NOTE: If damage is found, a formal claim for damage in
transit is the responsibility of the customer. Within 48 hours
of delivery request an inspection report from the carrier. File
a claim with the carrier. Contact the Badger Meter factory to
facilitate repair or replacement, [phone].
7. All detectors with PTFE liners are shipped with a liner
protector to maintain proper form of the PTFE material
during shipping and storage.
NOTE: Do not remove the liner protector until installation.
8. Storage: If the meter is to be stored, place it in its original
container in a dry, sheltered location. Storage
temperature ranges are: -4°F to 158°F (-20°C to 70°C).
Rigging, Lifting, Moving Large Units
DO NOT lift or move a meter via its amplifier, junction box
or cables.
Lift and move meters with flow tubes between 2" and 8" (50
and 200mm) with a crane rigged with soft straps. Place a
strap around the detector body, between the flanges, on
each side of the detector.
Lift meter flow tube diameter sizes 10" (250mm) and larger
via its lifting lugs. Use the proper size crane, cables and
hooks. DO NOT lift the meter by the amplifier or, on remote
style meter, by the junction box.

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Use the sling-rigged method to lift large detectors into a
vertical position while still crated. Use this method to position
large detectors vertically into pipelines.
Do not lift a detector with a forklift via the detector body
between the flanges. The housing could be dented and/or
damage caused to internal coil assemblies.
NEVER place forklift forks or rigging chains, straps, slings,
hooks or other objects inside or through the detector flow
tube for lifting or handling purposes. The isolating liner could
be damaged, rendering the unit inoperable.
Instructions Specific to Hazardous Area Installations
These instructions apply to equipment covered by ATEX
Certificate Number FM08ATEX0051X issued by FM.
1. During any installation or repair, perform all
procedures in accordance with the applicable code
of practice.
2. Suitably trained personnel shall perform all
installation or repair procedures.
3. If the equipment is likely to come into contact with
aggressive substances, it is the responsibility of the
user to take suitable precautions that prevent it
from being adversely affected, thus ensuring that
the type of protection is not compromised.
Aggressive Substances – e.g. acidic liquids or gases
that may attack metals or solvents that may affect polymeric
materials.
Suitable Precautions – e.g. regular checks as part of
routine inspections or establishing, from the material’s data
sheet, that it is resistant to specific chemicals.

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Additional Information
Certification markings are noted on the product label.
For additional information regarding importation, equipment
installation, equipment repair, equipment return or renewal
parts, please contact Badger Meter Europe or your local
Badger Meter representative.
Meter mounted 85-240 VAC
Remote mounted 85-240 VAC - Amplifier
Remote mounted 85-240 VAC - Detector
Meter mounted 24 VDC
Remote mounted 24 VDC - Amplifier
Remote mounted 24 VDC - Detector

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METER DESCRIPTION
Badger Model M3000 electromagnetic meters are ATEX
approved for Zone 2 hazardous locations. To achieve
hazardous location ratings electrodes in the flow tube are
Intrinsically Safe, designed according to ATEX standards.
Those standards limit the amount of energy that can be sent
to electrodes to prevent a spark from occurring.
Empty Pipe Detection
Badger Magnetoflow Mag meters are equipped with an
Empty Pipe Detection feature. Empty Pipe Detection is
accomplished by positioning a third electrode between 12
o’clock and 1 o’clock. Any time this electrode is not covered
by fluid, for a minimum of five seconds, the meter displays
an Empty Pipe Detection condition, sends out an error
message if desired, and stops measuring to maintain
accuracy. When the electrode is again covered with fluid, the
error message disappears and the meter continues
measuring.
Amplifier Mounting Configuration Options
Two amplifier-mounting configuration options are available to
meet a variety of meter placement and environmental
conditions.
Meter Mount Configuration
The Meter Mount configuration has the amplifier mounted
directly on the detector. This compact, self-contained
configuration minimizes installation wiring.
Meter Mount
Remote Mount Configuration
Remote Mount configuration places the amplifier and its
functions at a location separate from the fluid flow and
detector. This configuration is necessary in situations where
process fluid temperature or environment exceeds amplifier
ratings. A remote mounting bracket is supplied.
Detector and amplifier are connected by wires, run through
conduit, between junction boxes on the detector and remote
mounted amplifier. The distance between the detector
junction box and amplifier junction box can be up to 100 feet
(30m).
This configuration can also provide a more convenient
amplifier programming and display placement for monitoring
meter readings.
METER/AMPLIFIER LOCATION, ORIENTATION and
APPLICATIONS
Remote Amplifier Outdoor Location
The amplifier can be installed and operated outdoors.
However, protection from the elements must be considered:
1. Be aware of the ambient environment and temperature
ratings for the unit -4°F to 122°F (-20°C to 50°C).
2. If an indoor location is within 100 feet (30m) of the
detector installation, consider increasing the cable length
and mounting the amplifier indoors.
3. Consider mounting the amplifier in a IP 67 outdoor
enclosure.
4. At a minimum, fabricate a roof or shield over and/or
around the amplifier to protect the LCD display screen from
sunlight and to keep the possibility of rain or moisture
problems to a minimum.
Temperature
To prevent meter damage in any environment, minimum and
maximum temperature ranges must be observed.
1. For remote amplifier applications, the fluid temperature
range is -4°F to 221°F (-20°C to 105°C) at a maximum
ambient temperature of 122°F (50°C) for the following liner
materials: PTFE.
2. For remote amplifier applications, the fluid temperature
range is 32°F to 178°F (0°C to 80°C) at a maximum ambient
temperature of 122°F (50°C) for the following liner materials:
Hard rubber.
3. For meter mounted amplifier applications, the fluid
temperature range is -4°F to 212° (-20°C to 100°C) at a
maximum ambient temperature of 122°F (50°C) for the
following liner materials: PTFE.

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4. For meter mounted amplifier applications, the fluid
temperature range is 32°F to 178°F (0°C to 80°C) at a
maximum ambient temperature of 122°F (50°C) for the
following liner materials: Hard rubber.
5. The ambient temperature range surrounding the amplifier
is -4°F to 122°F (-20°C to 50°C.)
6. The ambient temperature range surrounding a remote
junction box mounted to the detector is -4°F to 122°F (-20°C
to 50°C.)
Pipelines and Fluid Flow
Although the Model M3000 is rugged, there are some
pipeline and fluid flow conditions that should be avoided:
1. Do not install the meter where extreme pipe vibrations
exist. If vibrations are present, secure piping before and after
the meter with appropriate pipe supports. If vibrations can’t
be restrained, consider mounting the amplifier remotely.
2. Avoid installing the detector close to pipeline valves,
fittings or impediments that can cause flow disturbances.
3. For detectors with PTFE liners, avoid installing the
detector on suction sides of pumps.
4. Avoid installing the detector on outlet sides of piston or
diaphragm pumps. Pulsating flow can affect meter
performance.
5. Avoid locations near equipment producing electrical
interference such as electric motors, transformers, variable
frequency, power cables, etc.
6. Verify both ends of the signal cables are securely
fastened.
7. Place power and signal cables in separate conduit.
8. Place the meter where there is enough access for
installation/maintenance purposes.
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 attain optimal performance when placed
vertically, with liquid flowing upward and meter electrodes in
a closed, full pipe.
Vertical placement allows the pipe to remain completely full,
even in low flow, low pressure applications and it prevents
any solids build-up or sediment deposit or accumulation on
the liner and/or electrodes.
NOTE: Carefully observe the “Forward Flow” label on the
meter body and install the meter accordingly.
Horizontal Placement
In a horizontal piping orientation, mount the detector to
piping with the flow measuring electrode axis in a horizontal
plane (3 and 9 o’clock).
This arrangement prevents solids build-up or sediment
deposit or 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 (3) diameters of straight pipe is required
on the inlet (upstream) side. Two (2) diameters are required
on the outlet (downstream) side.
Pipe Reducer Requirements
With pipe reducers a smaller size 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 reducers must have a minimum
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
amount of straight pipe stated previously.