Badger Meter ModMAG M1000 User manual

®
Badger Meter Europa GmbH
Field Verification Device
for ModMAG®M1000, M2000 and
B-MAGI M5000
USER MANUAL
July 2016
MID_VD_BA_02_1607

Contents Page
MID_VD_BA_02_1607
1. Basic safety recommendations.......................................................................................... 1
2. Verification Device............................................................................................................. 2
2.1 Disclaimer ............................................................................................................... 2
2.2 Product identification information............................................................................. 2
2.3 Product description.................................................................................................. 2
2.4 Functions ................................................................................................................ 2
2.5 Components............................................................................................................ 3
3. Cable connections............................................................................................................. 4
3.1 Verification Device................................................................................................... 4
3.2 ModMAG®M1000 ................................................................................................... 5
3.3 ModMAG®M2000 ................................................................................................... 7
3.4 B-MAG I M5000 ...................................................................................................... 9
4. Display and keypad..........................................................................................................11
5. Menu structure .................................................................................................................12
6. Settings............................................................................................................................13
7. Tests ................................................................................................................................15
7.1 Main test ................................................................................................................15
7.2 Manual tests...........................................................................................................16
7.2 Amplifier test ..........................................................................................................16
7.3 Detector test...........................................................................................................16
7.5 Main test fails.........................................................................................................17
7.6 Meter identification.................................................................................................17
7.7 About .....................................................................................................................17
8. PC software......................................................................................................................18
8.1 Installation of the PC software................................................................................18
8.2 Download of the verification tests...........................................................................19
8.3 Print reports............................................................................................................20
8.4 Export reports.........................................................................................................21
8.5 Language selection................................................................................................21
9. Technical data..................................................................................................................22
9.1 Features.................................................................................................................22
9.2 Accessories...........................................................................................................22
9.3 Accuracy................................................................................................................22
9.3.1 Amplifier..........................................................................................................22
9.3.2 Detector ..........................................................................................................22
10. Return of goods for repair / Harmlessness declaration ...................................................23

Basic safety recommendations Page 1 / 23
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1. Basic safety recommendations
Before installing or using this product, please read this instruction manual thoroughly.
Only qualified personnel should install and/or repair this product. If a fault appears,
contact your distributor.
Installation
Do not place any unit on an unstable surface that may allow it to fall.
Never place the units above a radiator or heating unit.
Route all cabling away from potential hazards.
Isolate from the mains before removing any covers.
Power connection
Use only the type of power source suitable for electronic equipment. If in doubt, contact
your distributor. Ensure that any power cables are of a sufficiently high current rating.
All units must be earthed to eliminate risk of electric shock.
Failure to properly earth a unit may cause damage to that unit or data stored within it.
Protection class
The device has protection class IP 46 and needs to be protected against dripping water,
water, oils, etc.
Setup & operation
Adjust only those controls that are covered by the operating instructions. Improper
adjustment of other controls may result in damage, incorrect operation or loss of data.
Cleaning
Switch off all units and isolate from mains before cleaning.
Clean using a damp cloth. Do not use liquid or aerosol cleaners.
Repair of faults
Disconnect all units from power supply and have it repaired by a qualified service person if
any of the following occurs:
•If any power cord or plug is damaged or frayed
•If a unit does not operate normally when operating instructions are followed
•If a unit exposed to rain/water or if any liquid has been spilled into it
•If a unit has been dropped or damaged
•If a unit shows a change in performance, indicating a need for service.
RoHs
Our products are RoHs compliant.
Battery disposal
The batteries contained in our products need to be disposed of as per your
local legislation acc. to EU directive 2006/66/EG.
Failure to adhere to these safety instructions
may result in damage to the product or serious
bodily injury.

Verification Device Page 2 / 23
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2. Verification Device
2.1 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 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, the
protection provided by the equipment may be impaired.
2.2 Product identification information
Record the product identification numbers from the nameplate.
Modular Mag Meter
Model number M5000________________________________
Serial number ______________________________________
Tag number (if applicable)
2.3 Product description
Field Verification Device is a portable test device for the electromagnetic flow meters
type ModMAG®M1000, M2000 and B-MAG I M5000.
With the Field Verification Device, accurate verification of meter functionality is assured
without taking the meter out of the pipeline ("wet" test) and interrupting functionality.
Meter diagnosis and calibration can be performed on-site. A "dry" test (removing the
meter and benchtesting) can also be performed. The complete verification test
consumes approximately 20 minutes and results can be downloaded to a Microsoft
Windows®personal computer.
2.4 Functions
The Verification Device also:
• determines if the meter is within one percent of the original factory
calibration.
• verifies the functionality of all of the meter's inputs and outputs.
• measures electrode resistance and integrity.
• measures coil resistance and integrity.
• measures coil insulation resistance.
• measures current and frequency at previously selected flow rate.
• evaluates the signal processing functionality.
• verifies that there is no high-voltage noise disturbing the coil circuit.

Verification Device Page 3 / 23
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2.5 Components
The Field Verification Device is packaged in a foam-lined, durable, plastic case and
includes the following components:
1 3 pcs. verification cable harnesses: For the ModMAG®M1000,
ModMAG®M2000 and one for the B-MAG I M5000 meters.
2 4 pcs. AC power conversion connectors
3 1 pc. DC power adapter
4 1 pc. amplifier AC power cord
5 1 pc. Verification Device +5 VAC, 3.0A power supply

Cable connections Page 4 / 23
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3. Cable connections
3.1 Verification Device
Connecting the cable harness:
The cable harnesses are tagged with either ModMAG®M1000,
M2000 or B-MAG I M5000 on the outer harness wire cover so that
the user can differentiate between the two.
Connect the 25 pin connector of the corresponding cable harness
to the top of the Verification Device and fix it by the two screws on
the left and right.
Power connector:
AC power supply Car charger via USB cable (DC power)
USB connector:

Cable connections Page 5 / 23
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M1000-23
3.2 ModMAG®M1000
Communication settings
ModMAG®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 if the hardware DIP switches adjusted for a RS232 interface.
Switch off the amplifier before connecting the cable harness of the Verification Device.
Opening the cover:
1. Using a 1/4" slotted screwdriver, remove the two upper screws from front of the
amplifier.
2. Loosen the two lower screws until the screw heads protrude above the surface of
the amplifier door.
3. Open the amplifier (lift up the door).
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 of the amplifier for connection reference.
On ModMAG®M2000 cable harness are following connectors:
1. Output 1 & 2 / Input (6 pins)
2. RS232 (5 pins)
3. Analog output (3 pins)
4. Detector electrode (5 pins)
5. Detector coil (3 pins)
6. Amplifier electrode (5 pins)
7. Amplifier coil (3 pins)
8. Detector ground (alligator clip)

Cable connections Page 6 / 23
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M1000-23
M1000-24
Harness connections
1. Clip the alligator clip labeled "Detector Ground" to either of the hex nuts mounted
on top of the meter flanges.
2. Plug the connector labeled "Amplifier Electrode" into the circuit board connector
labeled "E1, ES, E2, ES, EP".
3. Plug the "Amplifier 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.
Amplifier coil
Amplifier electrode
Output 1 & 2 / Input
Analogue output
RS232
Detector electrode
Detector coil
Detector ground

Cable connections Page 7 / 23
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3.3 ModMAG®M2000
Communication settings
ModMAG®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
Switch off the amplifier before connecting the cable harness of the Verification Device.
Opening the cover:
1. Using a 1/4" slotted screwdriver, remove the two right-hand screws from front of the
amplifier.
2. Loosen the two left-hand screws until the screw heads protrude above the surface
of the amplifier door.
3. Open the amplifier 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 of the amplifier for connection reference.
On ModMAG®M2000 cable harness are following connectors:
9. Output 1 & 2 / RS232 (7 pins)
10. Output 3 & 4 / Input (7 pins)
11. Analog output (2 pins)
12. Detector electrode (6 pins)
13. Detector coil (3 pins)
14. Amplifier electrode (6 pins)
15. Amplifier coil (3 pins)
16. Detector ground (alligator clip)
Harness connections
1. Clip the alligator clip labeled "Detector Ground" to either of the hex nuts mounted
on top of the meter flanges.
2. Plug the connector labeled "Amplifier Electrode" into the circuit board connector
labeled "E1, ES, E2, RS, EP, ES".
3. Plug the "Amplifier 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 "1 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.

Cable connections Page 8 / 23
MID_VD_BA_02_1607
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
Analogue output
Amplifier coil
Amplifier electrode
Detector electrode
Detector coil
Detector ground
13 Shield
12 C2
11 C1
45 E1
44 Shield
46 E2
44 Shield
40 EP
44 Shield
From
detector

Cable connections Page 9 / 23
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3.4 B-MAG I M5000
Communication settings
B-MAG I M5000 port adjustment
Navigate to "Main Menu" / "Communication" and adjust the port as follows:
•Interface: Serial
•Baud rate: 9600
•Parity: Even
•Address: 1
Note : A permanent enabled interface decreases considerably the battery life-time. We
therefore recommend to disable the interface after use.
Opening the cover:
1. Using a 1/4" slotted screwdriver, remove the two top screws from front of the
amplifier.
2. Loosen the two bottom screws until the screw heads protrude above the surface of
the amplifier door.
3. Open the amplifier 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. A connection instruction label
has been placed inside the amplifier for connection reference.
On B-MAG I M5000 cable harness are following connectors:
1. RS232 (4 pins)
2. Output 1 (2 pins)
3. Output 2 (2 pins)
4. Output 3 (2 pins)
5. Output 4 (2 pins)
6. Detector electrode (5 pins)
7. Detector coil (2 pins)
8. Amplifier electrode (5 pins)
9. Amplifier coil (2 pins)
10. Detector ground (alligator clip)
Harness connections:
1. Clip the alligator clip labeled "Detector Ground" to either of the hex nuts mounted
on top of the meter flanges.
2. Plug the connector labeled "Amplifier Electrode" into the circuit board connector
labeled "E1, ┴, E2, ┴, EP".
3. Plug the "Amplifier 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".

Cable connections Page 10 / 23
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7. Plug the "Output 4" into the board output connector labeled "Out4".
8. Plug the “RS232" into the board output connector labeled "RS232".
9. Connect the harness wire connector labeled "Detector Electrode" to the 5-wire
connector from the detector.
10. Connect the harness wire connector labeled "Detector Coil" to the 2-wire connector
from the detector.
OUT 1
OUT 2
OUT 3
OUT 4
+
-
+
-
+
-
+
-
Rx
Tx
GND
Amplifier electrode
Amplifier coil
Output 4
Output 3
Output 2
Output 1
RS232
Detector electrode
Detector coil
Detector ground
From
detector
COIL
ELECTRODE

Display and keypad Page 11 / 23
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4. Display and keypad
Display:
The display is a backlit LCD and 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.
Power key:
The power key on the lower right applies or remove power to the Verification Device.
Function keys:
The 2 top “soft” keys on the left and right sides of the up arrow key provide menu access,
wet or dry detector selection.
The up, down, left and right keys allow menu navigation.
The “OK” key confirms a menu selection.
The left arrow is the “Back key” (you can return back to the previous menu) and the “Delete
key”.
Alphanumeric keys:
The primary purpose of these keys is for entering the serial number of a meter if not
automatically recognized by the internal firmware or external software. Other functions
include Test ID entry.
D-25 harness connector
Display
Function keys
Numeric keys
Power key
AC Power connector
USB
connector

Menu structure Page 12 / 23
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5. Menu structure
Refer to the following when navigating the Verification Device menus:
Start Menu Main Test Test ID Detector Dry
Wet
Flow Meter Flow Meter Ident
Amplifier Detector Current
Analog Input
Analog Output
Inputs/Outputs
Empty Pipe
Detector Coil Resistance
Electrode Impedance
Isolation
Main Test fail
Settings Miscellaneous Language English
Czech
Contrast Rusian
German
Date Spanish
Time
Modbus Adress
About
Russian
Analogue Input
Analogue Output

Settings Page 13 / 23
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6. Settings
Press the “On/Off” button on the Verification Device and wait for the “SelfTest” to complete,
which lasts a couple of seconds.
After that, following display appears and shows date, time, battery capacity and firmware
version. Check if date and time are correct because the test reports are stored and printed
with those data.
When the Start Menu appears on the display, press the upper left function key.
Language
1. Select a menu item from the StartMenu > Menu User > Settings > MISC > Language
with the upper right function key.
2. Select the appropriate language (the default language is English).
Date
1. Select a menu item from the StartMenu > Settings > Misc > Date.
2. Edit the day, month and year in the editbox by using the numeric keypad. Use the right
arrow key to move the cursor.
3. Confirm the new date with the upper right function key.
Time
1. Select a menu item from the StartMenu > Settings > Misc > Time.
2. Edit the hour and minutes in the editbox by using the numeric keypad. Use the right
arrow key to move the cursor.
3. Confirm the new date with the upper right function key.
Contrast

Settings Page 14 / 23
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Adjust the contrast of the display via the function keys (arrows) and save the adjustment
with “Yes”
Flow meter Modbus®address
1. Select a menu item from the StartMenu > Settings > FM Modbus®address.
2. Edit the address in the editbox by using the numeric keypad. Use the “Delete” arrow
key to remove the last number position.
3. Press the upper right function key to confirm the new address.
4. Be sure that the flow meter is programmed with the same Modbus®address otherwise
communication fail. Default address is 1.

Tests Page 15 / 23
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7. Tests
7.1 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 Verification Device and can be downloaded
from the PC program.
The procedure is the following one:
1. Switch off the flow meter and connect the specific wire harness to the amplifier
circuit board.
2. Connect the male D-25 connector of the harness to the corresponding female
connector on the Verification Device.
3. Switch on the flow meter and be sure that the meter is not in the programming
mode when the test starts.
4. Press the “On/Off” button on the Verification Device and wait for the “SelfTest” to
complete.
5. When the Start Menu appears on the display, press the upper left function key.
6. When the Main Test option is highlighted, press the “OK” button.
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 if the detector tube is inside dry or wet. This selection has influence on the
test results of the electrode measurement.
9. The tests are now automatically carried out in 10 steps. During the test, the flow
meter shows “Testing in progress” on the display.
10. The result will be “passed” or “failed”.
11. If the test failed, press the function key on the upper left “View Report” to see the
results. See example below.

Tests Page 16 / 23
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7.2 Manual tests
The result of the manual tests are not stored in the memory of the Veriification Device
and cannot be downloaded from the PC program.
1. Switch off the flow meter and connect the specificwire harness to the amplifier circuit
board.
2. Connect the male D-25 connector of the harness to the corresponding female
connector on the Verification Device.
3. Switch on the flow meter and be sure that the meter is not in the programming mode
when the test starts.
4. Press the “On/Off” button on the Verification Device and wait for the “SelfTest” to
complete.
5. When the Start Menu appears on the display, press the upper left function key.
6. Select the menu “Flow Meter” and press the “OK” button
7.2 Amplifier 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 in- and ouput function are tested as well as output frequency [Hz]
•Empty pipe
7.3 Detector test
•Coil resistance
Measures the resistance of the coils [Ohm]
•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]

Tests Page 17 / 23
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7.5 Main test fails
Shows the test result of the last main test.
7.6 Meter identification
The menu display information about the connected flow meter.
•Product name
•Serial number
•Firmware name and version
•Compilation date
•Otp Boot Checksum
•Flash Os Checksum
7.7 About
Information about your Verification Device
•Serial number
•Version
•Compilation date
•FlashOsChecksum
•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

PC software Page 18 / 23
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8. PC software
8.1 Installation of the PC software
Insert the delivered CD, open “setup.exe” and follow the instructions. An icon on
the desktop will be installed named “Verification Device”.