Badger Meter M5000 User manual

Standard mount Remote mount
Description
These instructions explain how to convert a standard mount
M5000 meter to a remote mount using the Remote Junction
Box Kit, PN 63384-043. Contents of the kit are:
• Remote junction box, red aluminum, 122 × 120 × 80 mm
with 2 metal cable glands and 4 copper screws, qty. 1
• Remote junction box PCB, qty. 1
• Remote mounting bracket, qty. 1
• Socket head cap screws, M5 × 16, qty. 4
• Stat-O-Seal washers M5, qty. 4
• Gasket, rectangular, 75 × 45 mm, qty.1
CONTAINS PARTS AND ASSEMBLIES SUSCEPTIBLE
TO DAMAGE BY ELECTROSTATIC DISCHARGE (ESD).
BEFORE PICKING UP AN ESD-SENSITIVE ELECTRONIC
COMPONENT, DISCHARGE YOURSELF BY TOUCHING A
GROUNDED BARE METAL SURFACE OR APPROVED
ANTI-STATIC MAT.
TURN OFF POWER BEFORE PERFORMING ANY WORK ON
THE M5000 METER.
See "Wiring Reference for Remote Configuration" on page 4
for the wiring overview.
Tools Required
• Flathead screwdriver
• 4 mm or 5/32 in. bit
• Electric driver
• Torque screwdriver 4.7 Nm
• Torque wrench 5.2 Nm
Junction Box Assembly
1. Disconnect the electrode and coil terminal blocks in the
amplier housing.
Figure 1: M5000 junction box
2. Using the 4 mm or 5/32 in. bit and electric driver, remove
the bottom four bolts and washers from the amplier and
slide the detector away from the amplier making sure
the gasket is not lost. See Figure 1.
3. On each cable (one black, one white), inspect each wire
connection to verify that the ferrules at both cable ends
do not slide o the ends of the wire by gently pulling
on the ferrules. If any are lacking a proper electrical
connection, replace them.
Figure 2: M5000 cables
Electromagnetic Flow Meters
M5000 Converting a Standard Mount to a Remote Mount
MAG-UM-03188-EN-02 (January 2022) User Manual

4. Attach the PCB to the inside of the junction box with four
(4) copper screws. See Figure 3.
5. Thread two (2) metal cable glands into the junction box.
Torque the cable gland nuts to 5.2 Nm. See Figure 3.
CABLE GLANDS,
METAL
COPPER
SCREWS
(× 4)
Figure 3: M5000 junction box
6. Slide the white cable through the lower cable gland and
pull the cable forward until the exposed shielding is
covered by the grounding prongs on the gland.
Figure 4: M5000 junction box lower cable gland
7. Attach the white cable wires (the end with the shorter
exposed wires) to the 3-pin connector on the junction
box circuit board (see Figure 5 for wiring).
8. Slide the black cable through the upper cable gland and
pull the cable forward until the shielding is covered by
the grounding prongs on the gland (see Figure 4).
9. Attach the black cable wires (the end with the shorter
exposed wires) to the 6-pin connector on the junction
box circuit board (see Figure 5 for wiring).
SHIELD
RED (EP)
GREEN
BLACK (E2)
SHIELD
WHITE (E1)
WHITE (C2)
BROWN (C1)
Figure 5: M5000 connector cable wires
10. Slide the seal/grip and dome nut into position
(see Figure 4). Visually conrm the shielding is in contact
with the gland prongs, then tighten the dome nut to
5.2 Nm, securing the cable in place.
11. Using the 4 mm or 5/32 in. bit and electric driver, attach
the junction box to the detector with the gasket in
between. Use the same bolts that were removed when
the amplier and detector were disassembled. Torque the
bolts to 4.7 Nm.
12. Remove the electrode and coil terminal blocks from the
junction box circuit board.
13. Connect the electrode and coil connectors from the
detector to the junction box PCB.
14. Plug the detector’s electrode and coil terminal blocks
into the junction box circuit board (see Figure 5) and tuck
wires neatly inside. DO NOT ROUTE THE WIRES UNDER
THE JUNCTION BOX CIRCUIT BOARD!
Amplier Assembly
Using the components from junction box kit:
1. Place four (4) M5 Stat-O-Seal washers on four (4) M5 × 16
socket head cap screws.
2. Set the gasket on the amplier box. See Figure 6.
3. Lay the wall bracket on the gasket. See Figure 6.
4. Thread the four (4) screws with washers into the wall
bracket and torque to 4.7 Nm. See Figure 6.
Figure 6: M5000 gasket on amplifier
5. Remove the bottom two (2) cable glands on the amplier
and remove the plugs from the cable glands. See Figure 7.
Figure 7: M5000 amplifier housing
6. Replace the upper cable gland dome nut. See Figure 7.
7. Insert the black cable (the end with longer exposed wires)
through the upper cable gland. Tighten cable gland and
torque to 5.2 Nm.
8. Replace the lower cable gland dome nut. See Figure 7.
9. Insert the white cable (the end with longer exposed
wires) through the lower cable gland. Tighten cable gland
and torque to 5.2 Nm.
Amplier Assembly
Page ii January 2022MAG-UM-03188-EN-02

10. Using the electrode and coil terminal blocks removed
from the junction box circuit boards, connect the wires
per Figure 8, making sure all connections are secure.
Figure 8: M5000 electrode and coil terminal blocks
11. Route the wires of the electrode and coil terminal blocks
around the bottom of the amplier housing. See Figure 9.
Figure 9: M5000 wires routed around bottom of housing
12. Attach battery wire harness to amplier PCB.
Amplier Assembly
Page 3January 2022 MAG-UM-03188-EN-02

Wiring Reference for Remote Conguration
M5000 AMPLIFIER
RED
RED
Figure 10: Wiring for remote configuration
Remote style M5000 amplifier models can be ordered with standard cables measuring 15, 30, 50,100 and 150 feet.
Junction Box
Connection
No. Description Wire Color
11 Coil Brown
12 Coil White
13 Main Shield Not Used
40 Empty Pipe Red
44* Shield —
44* Empty Pipe Shield Shield Wire
45 Electrode White
46 Electrode Black
*Connections with the No. 44 are lying on the same potential.
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product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding
contractual obligation exists. © 2022 Badger Meter, Inc. All rights reserved.
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Electromagnetic Flow Meters, M5000 Converting a Standard Mount to a Remote Mount