Badger Meter ModMAG M1000 User manual

Electromagnetic Flow Meters
M1000, M2000 and M5000 Field Verication Device
MAG-UM-00368-EN-03 (August 2021) User Manual

CONTENTS
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Questions or Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About the Field Verication Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Field Verication Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Field Verication Device Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cable Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
M1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
M5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Alpha/Numeric Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Field Verication Device Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flow Meter Modbus Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Field Verication Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manual Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Amplier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Detector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main Test Fails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Meter Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation of the PC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Download of the Verication Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Print Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Export Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electromagnetic Flow Meters, M1000, M2000 and M5000 Field Verication Device
Page ii August 2021MAG-UM-00368-EN-03

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, Inc. assume any liability
arising out of the application and use of the equipment.
Should the equipment be used in a manner not specified by Badger Meter, Inc., the protection provided by the equipment
may be impaired.
QUESTIONS OR SERVICE ASSISTANCE
If you have questions regarding the product or this document, please visit us on the web at www.badgermeter.com or call your
local Badger Meter representative.
ABOUT THE FIELD VERIFICATION DEVICE
The Field Verification Device is a portable test device for the Badger Meter electromagnetic flow meters. The M1000, M2000
and the M5000 meters can be tested using this device.
With the Field Verification Device, accurate verification of meter functionality is assured without taking the meter out of the
pipeline and interrupting the process. The complete verification test takes approximately 20 minutes and results can be
downloaded to a Microsoft® Windows® 8, 7, XP or Vista®, personal computer.
Disclaimer
Page 3August 2021 MAG-UM-00368-EN-03

FIELD VERIFICATION DEVICE FUNCTIONS
• Determines if the meter amplifier is within one percent of the original factory calibration.
• Verifies the functionality of all the meter’s inputs and outputs.
• Measures electrode resistance and integrity.
• Measures coil resistance and integrity.
• Measures coil insulation resistance.
• Measures current and frequency output.
• Evaluates the signal processing functionality.
• Provides pass/fail results to aid in troubleshooting.
FIELD VERIFICATION DEVICE KIT COMPONENTS
The Field Verification Device is packaged in a foam-lined, durable plastic case and includes the following components.
1. One (1) Field Verication Device +5V AC, 3.0A power adapter
2. Four (4) AC power conversion connectors
3. One (1) USB PC data cable
4. One (1) DC power adapter
5. Two (3) Verication cable harnesses: one each for the M1000, M200 and M5000
1
2
3
4
5
Figure 1: Kit components
Field Verication Device Functions
Page 4 August 2021MAG-UM-00368-EN-03

CABLE CONNECTIONS
Cable Harness
The cable harnesses are tagged with M1000, M2000 or M5000 on the outer harness wire cover so the user can differentiate
between the two.
Connect the 25-pin connector of the corresponding cable harness to the top of the Field Verification Device and secure it with
the two screws on the left and right.
Figure 2: 25-pin connection
Power Connector
The Field Verification Device is a battery powered unit. Before using the Field Verification Device, make sure it is fully charged
by connecting it to either the AC or DC power adapter.
AC Power Adapter Car Charger (DC Power) USB to PC (DC Power)
Figure 3: Power and PC connections
OTE:N The USB connector is used for either the DC power adapter or for downloading the test information to a PC.
Cable Connections
Page 5August 2021 MAG-UM-00368-EN-03

M1000
Communication Settings
M1000 port adjustment
Navigate to Main Menu > Communication and adjust as follows:
• Interface: Modbus RTU
• Port address: 1
• Mode: RS232
• Baud rate: 9600
• Parity: Even
Check that the hardware DIP switches are adjusted for an RS232 interface.
Figure 4: M1000 dip switches
Disconnect the power to the amplifier before connecting the cable harness to the Field Verification Device.
Opening the Cover
1. Using a 1/4 inch slotted screwdriver, remove the two right-hand screws from the front of the amplier.
2. Loosen the two left-hand screws until the screw heads protrude above the surface of the amplier door.
3. Open the amplier door from right side to left.
Connecting the Cable Harness
The individual connector wires are labeled as to where each connector is to be connected onto the internal circuit board of
the amplifier. A connection instruction label has been placed inside the amplifier for reference. Existing connections should
also be disconnected before the Field Verification Device cable harness is installed.
OTE:N Disregard any meter screen errors.
Cable Connections
Page 6 August 2021MAG-UM-00368-EN-03

On the M1000 cable harness, the following connectors are tagged:
• Output 1 & 2 / Input (6-pin connector)
• RS232 (5-pin connector)
• Analog output (3-pin connector)
• Detector electrode (5-pin connector)
• Detector coil (3-pin connector)
• Amplifier electrode (5-pin connector)
• Amplifier coil (3-pin connector)
• Detector ground (alligator clip)
M1000 Harness Connections
1. Clip the alligator clip labeled Detector Ground to either of the hex nuts mounted on top of the meter anges.
2. Plug the connector labeled Amplier Electrode into the circuit board connector labeled E1, ES, E2, ES, EP.
3. Plug the Amplier Coil Output into the circuit board connector labeled CS, C2, C1.
4. Plug the Output 1 & 2/ Input into the board output connector labeled 1 to 6.
5. Plug the Analog Output into the board output connector labeled 9 to 8.
6. Plug the RS232 connector into the board connector labeled ABZYG.
7. Connect the harness wire connector labeled Detector Electrode to the 5-wire connector from the detector.
8. Connect the harness wire connector labeled Detector Coil to the 3-wire connector from the detector
M1000-23
Amplier coil
Output 1 &2 / Input
Analogue output
RS232
M1000-24
Amplier electrode
Detector electrode
Detector coil
Detector ground
Cable Connections
Page 7August 2021 MAG-UM-00368-EN-03

M2000
Communication Settings
M2000 port A adjustment
Navigate to Main Menu > Communication > Port A and adjust as follows:
• Interface: Modbus RTU
• Port address: 1
• Baud rate: 9600
• Data bits: 8
• Parity: Even
• Stop bits: 1
Disconnect the power to the amplifier before connecting the cable harness to the Field Verification Device.
Opening the Cover
1. Using a 1/4 inch slotted screwdriver, remove the two right-hand screws from the front of the amplier.
2. Loosen the two left-hand screws until the screw heads protrude above the surface of the amplier door.
3. Open the amplier door from right side to left.
Connecting the Cable Harness
The individual connector wires are labeled as to where each connector is to be connected onto the internal circuit board of
the amplifier. A connection instruction label has been placed inside the amplifier for reference. Existing connections should
also be disconnected before the Field Verification Device cable harness is installed.
OTE:N Disregard any meter screen errors.
On the M2000 cable harness, the following connectors are tagged:
• Out 1 and 2 RS232 (7-pin connector)
• Output 3 and 4 Input (7-pin connector)
• Analog Output (2-pin connector)
• Detector Electrode (6-pin connector)
• Detector Coil (3-pin connector)
• Amplifier Electrode (6-pin connector)
• Amplifier Coil (3-pin connector)
• Detector Ground (alligator clip)
Cable Connections
Page 8 August 2021MAG-UM-00368-EN-03

M2000 Harness Connections
1. Clip the alligator clip labeled Detector Ground to either of the hex nuts mounted on top of the meter anges.
2. Plug the connector labeled Amplier Electrode into the circuit board connector labeled E1, ES, E2, RS, EP, ES.
3. Plug the Amplier Coil Output into the circuit board connector labeled CS, C2, C1.
4. Plug the Output 1 & 2/ RS232 into the board output connector labeled 1 to 7.
5. Plug the Output 3 & 4 / Input into the board output connector labeled 8 to 14.
6. Plug the Analog Output connector into the board connector labeled 15 and 16 in connector row of COMMUNICATION /
Analog Out on the right side.
7. Connect the harness wire connector labeled Detector Electrode to the 6-wire connector from the detector.
8. Connect the harness wire connector labeled Detector Coil to the 3-wire connector from the detector.
BA2000-22MID
L N PE
JP1
JP2
COMMUNICATION
DISPLAY
CS C2 C1
E1
ES
E2
RS
EP
ES
15 16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Output 1 & 2 / RS232
Output 3 & 4 / Input
Analog Output
Amplier Coil
Amplier Electrode
Figure 5: M2000 wire harness circuit board connectors
Detector Electrode
Detector Coil
Detector Ground
Figure 6: M2000 detector connections
Cable Connections
Page 9August 2021 MAG-UM-00368-EN-03

M5000
Communication Settings
M5000 port adjustment
Navigate to Main Menu > Communication and adjust the port as follows:
• Interface: Serial
• Baud rate: 9600
• Parity: Even
• Address: 1
OTE:N A permanent enabled interface decreases considerably the battery life-time. We therefore recommend to disable the
interface after use.
Disconnect the power to the amplifier before connecting the cable harness to the Field Verification Device.
Opening the Cover
1. Using a 1/4 inch slotted screwdriver, remove the two top screws from the front of the amplier.
2. Loosen the two bottom screws until the screw heads protrude above the surface of the amplier door.
3. Open the amplier door from top to bottom.
Connecting the Cable Harness
The individual connector wires are labeled as to where each connector is to be connected onto the internal circuit board of
the amplifier. Existing connections should also be disconnected before the Field Verification Device cable harness is installed.
OTE:N Disregard any meter screen errors.
On an M5000 cable harness, the following connectors are tagged:
• RS232 (4-pin connector)
• Input (2-pin connector)
• Output 1 (2-pin connector)
• Output 2 (2-pin connector)
• Output 3 (2-pin connector)
• Output 4 (2-pin connector)
• Detector Electrode (5-pin connector)
• Detector Coil (2-pin connector)
• Amplifier Electrode (5-pin connector)
• Amplifier Coil Output (2-pin connector)
• Detector Ground (alligator clip)
M5000 Harness Connections
1. Clip the alligator clip labeled Detector Ground to either of the hex nuts mounted on top of the meter anges.
2. Plug the connector labeled Amplier Electrode into the circuit board connector labeled E1, ┴, E2, ┴, EP.
3. Plug the Amplier Coil Output into the circuit board connector labeled C1, C2.
4. Plug the Output 1 into the board output connector labeled Out1.
5. Plug the Output 2 into the board output connector labeled Out2.
6. Plug the Output 3 into the board output connector labeled Out3.
7. Plug the Output 4 into the board output connector labeled Out4.
8. Plug the input into the board output connector labeled input.
OTE:N Phase 1 boards do not have an input connector. If you are performing a verification check on a phase 1 board, do not
connect the input connector.
9. Plug the RS232 into the board output connector labeled RS232.
Cable Connections
Page 10 August 2021MAG-UM-00368-EN-03

10. Connect the harness wire connector labeled Detector Electrode to the 5-wire connector from the detector.
11. Connect the harness wire connector labeled Detector Coil to the 2-wire connector from the detector.
OTE:N The M5000 communication must be set to Serial: Main Menu > Communication > Interface_Serial. Turn the Interface to
Off when testing is complete.
Amplier electrode
Amplier coil
RS232
Input
Output 4
Output 3
Output 2
Output 1
Figure 7: M5000 wire harness circuit board connectors
Detector Electrode
Detector Coil
Detector Ground
Figure 8: M5000 detector connections
Cable Connections
Page 11August 2021 MAG-UM-00368-EN-03

DISPLAY AND KEYPAD
Display
The display is a backlit LCD that displays the current date and time, percent of battery charge and menu indications.
Keypad
The keypad consists of 9 function keys, 12 numeric keys and the On/Off key.
D-25 Harness Connector
Display
Function Keys
Alpha/Numeric Keys
AC Power Connector
Power Key
USB Connector
Left Select Right Select
Figure 9: Field Verification Device functions
Power Key
The On/Off power key on the lower right applies or removes power to the Field Verification Device.
Function Keys
The two top soft keys on the left and right side of ▲are the Left Select and Right Select keys. These are option selection
keys and provide menu access.
The ▲, ▼, ◄, and ►keys provide menu navigation.
The OK key confirms a menu selection.
The Alt key provides no function.
The left arrow is the Back/Delete key.
Alpha/Numeric Keys
The primary purpose of the alpha-numeric keys is for entering the serial number of a meter PCB if it is not automatically
recognized by the internal firmware or external software. The alpha/numeric keys are also used for Test ID entry.
Display and Keypad
Page 12 August 2021MAG-UM-00368-EN-03

MENU STRUCTURE
Refer to the following chart when navigating the Field Verification Device menus.
Menu Structure
Page 13August 2021 MAG-UM-00368-EN-03

FIELD VERIFICATION DEVICE SETTINGS
Press On/Off on the Field Verification Device and wait for the SelfTest to complete. This takes a few seconds.
After the SelfTest, the display shows date, time, battery capacity and firmware version. Check to make sure the date and time
are correct because the test reports are stored and printed with this data.
When the Start Menu appears, press Left Select.
Language
1. Select StartMenu > Menu User > Settings > Misc > Language using Right Select.
2. Select the appropriate language. (The default language is English.)
Date
1. Select StartMenu > Settings > Misc > Date.
2. Edit the day, month and year in the edit box by using the numeric keypad. Use ►to move the cursor.
3. Press Right Select to conrm the new date.
Field Verication Device Settings
Page 14 August 2021MAG-UM-00368-EN-03

Time
1. Select StartMenu > Settings > Misc > Time.
2. Edit the hour and minutes in the edit box by using the numeric keypad. Use ►to move the cursor.
3. Press Right Select to conrm the new time.
Contrast
Adjust the contrast of the display using ◄►▲and ▼and press Right Select to confirm the new setting.
Flow Meter Modbus Address
1. Select StartMenu > Settings > FM Modbus Address.
2. Edit the Address in the edit box by using the numeric keypad. Use Back/Delete to remove the last number position.
3. Press Right Select to conrm the new address.
4. Be sure that the ow meter is programmed with the same modbus address or communication will fail. The default address
is 1.
Field Verication Device Settings
Page 15August 2021 MAG-UM-00368-EN-03

FIELD VERIFICATION DEVICE TESTS
Main Test
The main test is the standard process for meter testing. The result of this test is automatically stored in the memory of the
Field Verification Device and can be uploaded to the PC program.
Perform the following steps:
1. Switch o the ow meter and connect the specic wire harness to the amplier circuit board.
2. Connect the male D-25 connector of the harness to the corresponding female connector on the Field Verication Device.
3. Switch on the owmeter to be sure that the meter is not in programming mode when the test is started.
4. Press On/O on the Field Verication Device and wait for the SelfTest to complete.
5. When the Start Menu appears in the display, press the upper left function key.
6. When the Main Test option is highlighted, press OK.
7. Press the appropriate numbers on the numeric keypad for the Test ID and press OK. The Test ID is a value which can be
used as a customer tag.
8. Select Dry or Wet using Left Select or Right Select based on the inside condition of the detector tube. This selection has
inuence on the test results of the electrode measurement.
9. The testing is completed automatically in 10 steps. During the test the ow meter shows Testing in progress on the display.
The result is Passed or Failed.
OTE:N Follow the onscreen prompts when necessary.
Field Verication Device Tests
Page 16 August 2021MAG-UM-00368-EN-03

10. If the test Failed, press Left Select to see the results. See the example below.
MANUAL TESTS
The result of the manual tests are not stored in the memory of the Field Verification Device and cannot be uploaded to the
PC program.
1. Switch o the ow meter and connect the specic wire harness to the amplier circuit board.
2. Connect the male D-25 connector of the harness to the corresponding female connector on the Field Verication Device.
3. Switch on the owmeter and be sure that the meter is not in programing mode when the test is started.
4. Press On/O on the Field Verication Device and wait for the SelfTest to complete.
5. When the Start Menu appears in the display, press the upper left function key.
6. Select the menu Flow Meter and press OK.
Amplier Test
• Detector current—The current [A] and excitation frequency [Hz] are measured
• Analog input—Amplification and linearity is measured [div/V]
• Analog output—Offset and linearity is measured [mA]
• Inputs/outputs—The Input and output function are tested as well as output frequency [Hz]
• Empty pipe
Detector Test
• Coil resistance—Measures the resistance of the coils [Ohm]
Manual Tests
Page 17August 2021 MAG-UM-00368-EN-03

• Electrode impedance—Measures the impedance of the 3 electrodes (measuring and empty pipe) in [Ohm]
• Isolation—Measures the resistance of the coils against ground [Ohm]
Main Test Fails
Shows the test result of the last Main Test.
Meter Identication
The menu displays information about the connected flow meter.
• Product name
• Serial number
• Firmware name and version
• Compilation date
• Otp Boot Checksum
• Flash Os Checksum
About
Information about the Field Verification Device
• Serial number
• Version
• Compilation date
• Flash Os Checksum
• MCU revision
• Date of last detector current calibration
• Date of last coils resistance calibration
• Date of last analog output calibration
• Date of last analog input calibration
Manual Tests
Page 18 August 2021MAG-UM-00368-EN-03

PC SOFTWARE
Installation of the PC Software
The software is downloaded from www.badgermeter.com. Follow the onscreen prompts for downloading and installing the
software. After the download is complete, an icon is installed on the Desktop named Verification Device.
Download of the Verication Tests
1. Start the PC program by clicking the Field Verication Device icon on your desktop.
2. Connect the Field Verication Device via the USB cable to the PC and switch the Field Verication Device on. The display
on the Field Verication Device shows USB Mass Storage.
3. The following PC window will be opened automatically. Select the Badger Meter Verication Device and click OK. If the
window will not open click FILE and OPEN (Ctrl+O) in the upper task bar.
4. The measurements automatically download to the PC. You will be asked if the measurements, which are on the Field
Verication Device, should be deleted or not.
Yes No
PC Software
Page 19August 2021 MAG-UM-00368-EN-03

The downloaded measurements are displayed on the left side of the window.
5. Select the new measurements and enter the following information for each test. Customer tag is already given by entering
the Test ID during the testing with the Field Verication Device. Click Save changes to save the entries.
PC Software
Page 20 August 2021MAG-UM-00368-EN-03