Badger Meter ModMAG M2000 User manual

®
Badger Meter Europa GmbH
ModMAG M2000
INSTALLATION AND
OPERATION MANUAL
April 2010
MID_M2000_BA_02_1004

Contents Page
1.Basic safety precautions ..................................................................................................1
2.System description............................................................................................................2
3.Installation..........................................................................................................................3
3.1 General information ...................................................................................................3
3.1.1 Temperature ranges .......................................................................................3
3.1.2 Protection class .............................................................................................. 3
3.1.3 Transport ........................................................................................................4
3.2 Installation..................................................................................................................4
3.2.1 Meter orientation.............................................................................................4
3.2.2 Inlet and outlet pipe ........................................................................................4
3.2.3 Meter location .................................................................................................5
3.2.4 Pipe reducer requirements ............................................................................. 6
3.2.5 Separate version............................................................................................. 7
3.2.6 Grounding and potential equalization .............................................................7
3.2.7 Plastic or lined pipelines .................................................................................8
3.2.8 Pipelines with cathodic protection................................................................... 8
3.2.9 Electrically disturbed environment ..................................................................9
4.Power connections............................................................................................................9
4.1 Auxiliary power...........................................................................................................9
4.2 Separate version......................................................................................................10
4.2.1 Signal cable specification ............................................................................. 11
4.3Configuring input/output (I/O)...................................................................................12
5.Programming ...................................................................................................................13
5.1 Quick Setup………………………………………………………………………………...13
5.2 Main menu……………………………………………………………………………………15
5.2.1 Meter Setup…………………….………………………….....……………………….15
5.2.2 Measurement………………………………………………………….…………..16
5.2.3 Inputs and Outputs………………………………………………………………..19
5.2.4 Clear Totals………………………………………………………………………..24
5.2.5 Communications………………………………………………………………… .25
5.2.6 Advanced…………………………………………………………………………..27
5.2.7 Info/Help……………………………………………………………………………30
5.2.8 Language Select………………………………………………………………….31
6.Troubleshooting ..............................................................................................................32
6.1Replacing the fuse ...................................................................................................33
6.2Replace meter’s electronics.....................................................................................33
7.Technical data..................................................................................................................34
7.1 Detector type II.........................................................................................................34
7.2 Detector type Food ..................................................................................................36
7.3 Detector type III........................................................................................................38
7.4 Meter type M2000®..................................................................................................39
7.5 Error limits................................................................................................................40
7.6 Size selection...........................................................................................................41
8.Program structure ...........................................................................................................42
9.Return of goods for repair ..............................................................................................44

Basic safety precautions Page 1/44
MID_M2000_BA_02_1004
1. Basic safety precautions
The electromagnetic flow meter is only suitable for the measurement of conductive fluids.
The manufacturer is not liable for damages that result from inproper use or from use that
is not in accordance with the requirements.
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, putting into operation and maintenance of the meter is
to 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.
Basically you have to respect the regulations for the opening and repairing of electrical
equipment applicable in your country.
Repairs
Should you send back a flow meter, please take notice of the following points:
-Please enclose a description of the error 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.
RoHs
Our products are RoHs compliant.

System description Page 2/44
MID_M2000_BA_02_1004
2. System description
The electromagnetic flow meters are intended for the metering of all fluids with electric
conductivity of at least 5 μS/cm (20 μS/cm for demineralized water). These series of
meters is characterized by a high degree of accuracy. Measuring results depend on
density, temperature and pressure.
Measuring principle
In accordance with Faraday’s induction principle, electric voltage is induced in a conductor
moving through a magnetic field. In case of the electromagnetic flow measurement, the
moving conductor is replaced by the flowing fluid. Two opposite measuring electrodes
conduct the induced voltage which is proportional to flow velocity to the amplifier. Flow
volume is calculated based on pipe diameter.

Installation Page 3/44
MID_M2000_BA_02_1004
3. Installation
Warning: •Installation instructions given in the following are to be observed in order
to guarantee a perfect functioning and a safe operation of the meter.
3.1 General information
3.1.1 Temperature ranges
Caution: •In order to prevent a damaging of the meter, you are requested to
strictly observe amplifier’s and detector’s maximum temperature
ranges.
•In regions with extremely high ambient temperatures, foresee a
protection from direct sun radiation.
•In cases where fluid temperature exceeds 100°C, foresee separate
amplifier and detector (separate version).
Amplifier Ambient temp. -20 to + 60 °C
Detector Fluid temp. PTFE / PFA -40 to +150 °C
Hard rubber 0 to +80 °C
Soft rubber 0 to +80 °C
3.1.2 Protection class
In order to fulfill requirements in respect of the protection class, please follow the
following guidelines:
Caution: •Body seals need to be undamaged and in proper condition.
•All of the body screws need to be firmly screwed.
•Outer diameters of the used wiring cables must correspond to cable
inlets (for M20 Ø 5....10 mm). In cases where cable inlet is not used,
put on a dummy plug.
•Tighten cable inlets.
•If possible, lead cable away downwards. Thus humidity cannot get into
cable inlet.
We normally deliver the meter in accordance with protection class IP 67. If you
however require a higher protection class, the amplifier is to be installed separately
from the detector. If requested, we can also deliver the detector in IP 68.

Installation Page 4/44
MID_M2000_BA_02_1004
> 3-5 x DN > 2 x DN
BA2000-10-MID
3.1.3 Transport
Caution: •Use lifting lugs when lifting meter flow tubes that are 150 in diameter or
larger.
•Do not lift meter on measuring amplifier or on detector’s neck.
•Do not lift meter with a fork lift on the jacket sheet. This could damage
the body.
•Never place rigging chains, forklift forks, etc inside or through the
meter’s flow pipe for hoisting the meter. This could damage the
isolating liner.
3.2 Installation
In order to provide a perfect functioning and to prevent the meter from eventual
damages, please follow the following installation instructions.
Caution: •Carefully observe the forward flow label on the meter body and install
the meter accordingly.
•As for detectors with PTFE liner, remove protective cap on the flange
or on the threaded pipes of milk pipe screws as per DIN 11851 not until
shortly before installation.
3.2.1 Meter orientation
Meters can operate accurately in any pipeline orientation. Meters can be installed in
horizontal as well as in vertical pipelines.
Meters perform best when placed vertically with liquid flowing upward as it prevents
solids build-up.
When installing the meter on a horizontal pipe, mount the meter to the pipe with the
flow-measuring electrode axis in a horizontal plane as it prevents that gas bubbles
result in a temporary isolation of the flow-measuring electrodes.
Carefully observe the forward flow label on the meter body and install the meter
accordingly.
3.2.2 Inlet and outlet pipe
Always install the detectors in front of fittings producing turbulences. If this is simply
not possible, foresee distances of > 3 x DN. Distance ought to be > 2 x DN.

Installation Page 5/44
MID_M2000_BA_02_1004
BA2000-11-MID
h > 2 x DN
BA2000-12-MID
>3-5xDN>2xDN
BA2000-13-MID
BA2000-14-MID
3.2.3 Meter location
Caution: •Do not install the detector on the suction sides of pumps. This could
damage the liner (in particular PTFE liners).
•Verify that the pipeline is always filled on the measuring point, if not - a
correct or accurate measurement is not possible.
•Do not install the detector on the highest point of a pipeline system.
Gas accumulation may follow.
•Do not install the detector in downcomer pipes with free outlet.
•Do not install the detector on pipes with vibrations. If pipes are strongly
vibrating, make sure that detector and amplifier are separated
(separate version).

Installation Page 6/44
MID_M2000_BA_02_1004
max.8°
BA2000-15-MID
3.2.4 Pipe reducer requirements
With pipe reducers as per DIN 28545 detectors can be mounted in larger pipelines.
You can determine the occurring pressure drop by using the shown nomogram (only
applicable to liquids with similar viscosity like water).
Note: •In cases where flow velocities are very low, you can increment them by
reducing the size on the measuring point and hence obtain a better
measuring accuracy.
Define pressure loss:
1. Calculate diameter ratio d/D.
2. Read pressure loss depending on d/D ratio and flow velocity.
Diameter ratio d/D
D = pipeline
d = detector
Pressure loss in mbar
Diameter relation d/D

Installation Page 7/44
MID_M2000_BA_02_1004
BA2000-16-MID
3.2.5 Separate version
Provide a separate version in the following cases:
Note: •Detector protection class IP 68
•Fluid temperature > 100 °C
•Strong vibrations
Caution: •Do not install the signal cable close to power cables, electric machines,
etc.
•Fix signal cables. Due to capacity changes, cable movements may
result in incorrect measurements.
3.2.6 Grounding and potential equalization
In order to obtain an accurate measurement, detector and fluid need to be on the
same electric potential.
If flange or intermediate flange versions with additional grounding electrode are used,
grounding is provided by the connected pipeline.
Caution: •In case of a type with flange a connection cable (min. 4 mm²) between
grounding screw on the meter’s flange to the counterflange is to be
used in addition to the fixing screws. Verify that a perfect electric
connection is provided.
•Color or corrosion on the counterflange may have a negative effect on
the electric connection.
•In case of types with intermediate flanges, the electric connection to
the detector is done via two ¼ AMP plugs installed on detector’s neck.

Installation Page 8/44
MID_M2000_BA_02_1004
"X"
BA2000-17MID
"X" M4:1
BA2000-18-MID
6 mm² Cu
6 mm² Cu
BA2000-19-MID
3.2.7 Plastic or lined pipelines
If non-conductive pipelines or pipelines lined with non-conductive material are used,
install an additional grounding electrode or grounding rings between the flanges.
Grounding rings are installed like gaskets between the flanges and are connected
with a grounding cable to the meter.
Caution: •When grounding rings are used, please make sure that the material is
resistant to corrosion. If aggressive fluids are measured, use grounding
electrodes.
3.2.8 Pipelines with cathodic protection
As for pipelines with cathodic protection, install meter potential-free. No electric
connection from the meter to the pipeline system may exist and power supply is to be
provided via isolating transformer.
Caution: •Use grounding electrodes (grounding rings also need to be installed
isolated from the pipeline system).
•Observe national rules in respect of a potential-free installation
electricall
y
isolatedelectricall
y
isolated

Power connections Page 9/44
MID_M2000_BA_02_1004
6 mm² Cu
BA2000-20-MID
PE
BA2000-21-MID
3.2.9 Electrically disturbed environment
If the pipe material is in an electrically disturbed environment or if metallic pipelines
that are not grounded are used, we recommend a grounding as shown in the
following picture in order to assure that measurement is not influenced.
4. Power connections
Caution: •For the 3 x M20 cable inlets only use flexible electric cables.
•Use separate cable inlets for auxiliary power, signal and input/output
cables.
4.1 Auxiliary power
Warning: •Do not connect meter under impressed mains voltage.
•Take national applicable rules into account.
•Observe type plate (mains voltage and frequency).
1. Slightly loosen both of the left cover screws and loosen the two right
cover screws completely. Open cover to the left side.
2. Push auxiliary power cable through the upper cable inlet.
3. Connection as shown in the picture.
4. In the following close connection cover again firmly.
85 – 265 VAC
L
N
F1 2AT
BA14MID

Power connections Page 10/44
MID_M2000_BA_02_1004
4.2 Separate version
Caution: •Connect or separate signal connection cable only when the unit has
been switched off.
Connection in the measuring amplifier
1. Loosen both fixing screws of the connection cover
and remove cover.
2. Loosen upper and lower cover screw and open cover
to the left side.
3. Push signal cable on the upper side of the device
through cable inlet.
4. Connection as shown in the picture.
5. Close device and connection cover again firmly.
Connection on the detector
1. Loosen fixing screws of the connection cover
and remove cover.
2. Push signal cable through cable inlet.
3. Connection as shown in the picture.
4. Close device and connection cover again
firmly.
Terminal box – Terminal M2000 Description Wire color
Standard Stainless steel
11 5 C1 Coil 1 Green
12 4 C2 Coil 2 Yellow
13 PE CS Main shield Yellow/Green
45 1 E1 Electrode 1 White
44* PE ES Electrode shield Black
46 2 E2 Electrode 2 Brown
40 3 EP Empty pipe Pink
44* PE ES Empty pipe shield Black
*) Anschlüsse mit der Nr. 44 liegen auf gleichem Potential
5
MID
13 Shield
12 C2
11 C1
44 Shield
40 EP
44 Shield
46 E2
44 Shield
45 E1
Display
Calibrator
TP2
TP21
BA16MID
R
Badger Meter
JBOX - PRIMO
REMOTE - REV1
From
Detector To Amplifier
11 COIL
12 COIL
13 SHIELD
COIL 11
COIL 12
Shield 13
Shield 44
Shield 44
SHIELD 44
ELECTRODE 45
ELECTRODE 46
EMPTY PIPE 40
44 SHIELD
44 Shield
44 Shield
40 EMPTY PIPE
46 ELECTRODE
45 ELECTRODE

Power connections Page 11/44
MID_M2000_BA_02_1004
BA17MID
weiß (45)
braun (46)
pink (40)
schwarz (44)
schwarz (44)
gelb/grün (13)
gelb (12)
grün (11)
5 bis 300 m
grün (11)
gelb (12)
pink (40)
weiß (45)
braun (46)
schwarz (44)
schwarz (44)
gelb/grün (13)
5 to 300 m
pink
4.2.1 Signal cable specification
Note: •Only use signal cables delivered by Badger Meter or corresponding
cable in accordance with the following specification.
•Take max. signal cable length between detector and amplifier into
account (keep distance as low as possible).
Distance With electrode idle Loop resistance
0 – 75 m 3 x (2 x 0,25 mm²) =< 160 Ω/km
> 75 – 150 m 3 x (2 x 0,50 mm²) =< 80 Ω/km
> 150 – 300 m 3 x (2 x 0,75 mm²) =< 40 Ω/km
PVC cable with pair and total shield
Capacity: wire/wire < 120 nF/km, wire/shield < 160 nF/km
Temperature range –30 to +70 °C
Maximum cable length at different fluid temperatures
0
25
50
75
100
125
150
175
200
225
250
275
300
0 25 50 75 100 125 150 175
Temperature [°C]
Cable length [m]
0
,
25 mm²
0
,
5 mm²
0
,
75 mm²
BA17MID
white white
brown
brown
black black
black black
yellow/green (13) yellow/green (13)
yellow (12) yellow (12)
green (11) green (11)

Power connections Page 12/44
MID_M2000_BA_02_1004
BA2000-22MID
LNPE
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
Communication
4.3 Configuring input/output (I/O)
Displ
Input/Output Description Terminal
Analog output 0 - 20 mA
4 - 20 mA RL < 800 Ohm
0 - 10 mA
16 (+)
15 (-)
Digital output
1 Open collector max. 10 kHz
* Passive max. 30 VDC, 100 mA
* Active 24 VDC, 50 mA (Jumper JP1 placed)
1 (+) and 2 (-)
2 Open collector max. 10 kHz
* Passive max. 30 VDC, 100 mA
* Active 24 VDC, 50 mA (Jumper JP2 placed)
3 (+) and 4 (-)
3 Open collector passive max. 30 VDC, 100 mA, max. 10 kHz
or Solid State Relais max. 48 VAC, 500 mA, max 1 kHz
10 (+) and 11 (-)
4 Open collector passive max. 30 VDC, 100 mA, max. 10 kHz
or Solid State Relais max. 48 VAC, 500 mA, max 1 kHz
13 (+) and 14 (-)
Digital input 5 - 30 VDC 8 (+) and 9 (-)
RS 232 Remote display information or
Modbus RTU
7 GND
6 RxD
5 TxD
Communication Optional communication ports like
HART, Profibus DP, Modbus
Communication
A
uxiliary powe
r
Fuse
Display
Coil detector
Electrodes
detector
Jumper JP1
Jumper JP2
Memory token

Programming Page 13/44
MID_M2000_BA_02_1004
5. Programming
Programming is accomplished by using the three functional buttons ▲,►and E.
You can move from the measuring mode to the programming mode by pressing twice the
button E. While first pressing this button, you activate the backlight and while pressing it for a
second time, you get into the programming menu.
The cursor →on the left side of the display is moved upward and downward with the buttons
▲/ ►. The menu manager or selection from a list is marked with the cursor and
acknowledged by pressing the button E.
To enter a parameter, the first number is marked with an underline 0.By pressing the buttons
+ /-, you can increment or decrement them. As soon as the requested number has been
selected, you can acknowledge it by pressing the button E. After having entered the last
number, the value is stored by pressing the button Eor press the button + in order to edit the
value again.
You get access to the individual menus through three programmable access levels:
Administrator, service and user level.
Access rights of the individual menu items is shown in the following with three symbols:
Administrator Service User
For programming the access levels, see the chapter “passwords”.
No passwords were set at the factory.
5.1 Quick setup
The M2000 amplifier provides you with a quick setup utility that allows you to quickly
set most of the important parameters like flow units, totalizer units, full scale flow and
low flow cutoff settings.
Quick Setup
Flow Units
Flow units let you select among the flow units mentioned below. Flow
units are automatically converted into the selected unit.
Unit Unit
LPS Liter/Second GPM Gallons/Min.
LPM Liter/Minute GPH Gallons/Hour
LPH Liter/Hour MGD MegaGallon/Da
M3S Cubic meters/Sec. IGS UKG/Sec.
M3M Cubic meters/Min. IGM UKG/Min.
M3H Cubic IGH UKG/Hour
F3S Cubic Feet/Sec. LbM Pound/Min.
F3M Cubic Feet/Min. OPM Ounce/Min.
F3H Cubic Feet/Hour. BPM Barrel/Min.
GPS Gallons/Sec. -- --

Programming Page 14/44
MID_M2000_BA_02_1004
Quick Setup
Totalizer Unit
This parameter establishes the units of measure for the totalizers:
Full Scale Flow
This parameter sets the maximum flow the system is expected to
measure. This parameter has influence on other system parameters.
These parameters include: Frequency output and current output.
In terms of flow velocity, the meter’s limit are from 0.1 to 12 m/sec.
Moreover the values for Low Flow Cut-off and limits monitoring depend
on Full Scale Flow.
The full scale flow is valid for both flow directions.
Note: If the flow rate exceeds the full scale setting, an error message
indicates that the configured full scale range has been exceeded.
Low Flow Cut-off
Low Flow Cut-off defines the threshold at which flow measurement will
be forced to zero. The cutoff value can be from 0 % to 9.9 % of the full
scale flow. Increasing the threshold will help prevent false reading
during “no flow” conditions possible caused by vibrations or liquid
fluctuations.
Unit Unit
LLiters UKG Imperial Gallons
HL HectoLiters Lb Pounds
M³ Cubic Meters Oz Fluid Ounces
CFt Cubic Feet Aft Acre Feet
USG U.S. Gallons BBL Barrel
MG MegaGallons

Programming Page 15/44
MID_M2000_BA_02_1004
5.2 Main menu
The following menu items are available to you in the main menu:
•Meter setup
•Measuring
•Inputs and outputs
•Reset of the totalizer
•Setting of communication port
•Specific counter settings
•Counter information
•Language selection
5.2.1 Meter Setup
Scale Factor
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.
Empty Pipe
Detection
Fluid monitoring shows if measuring pipe has only partly been
filled with liquid. Monitoring can be switched on or off.
Note: On request, fluid monitoring can be adjusted to fluid’s
conductivity or to cable length.
Power Line
Frequency
For an optimum operation of the meter, set Power Line Frequency in
this menu at operating location.
Excitation
Frequency
This value shows in which frequency the meter’s coils are operated.
Supported frequencies are dependent on the configured power line
frequency and meter’s size.
Note: When selecting excitation frequency, make sure to always
observe that the ratio in respect of power frequency is integer.
50 Hz 60 Hz
1 Hz 1 Hz
3.125 Hz 3.75 Hz
6.25 Hz 7.5 Hz
12.5 Hz 15 Hz

Programming Page 16/44
MID_M2000_BA_02_1004
Meter Setup
Pipe Diameter
This figure is used for setting pipe’s diameter (size). Several sizes DN
6 to DN 2000 as well as specific sizes in [mm] can be set.
Note: Pipe diameter is set at the factory. Changes of size have an
impact on meter’s accuracy.
Detector Factor
This parameter is set at the factory. This factor compensates for
accuracy error as a result of the installed detector. If accuracy
adjustment of the meter is required, please refer to the scale factor.
In the event the amplifier is replaced, this parameter must be
reprogrammed with the original detector factor.
Detector Offset
This parameter is set at the factory. This factor compensates for
accuracy error as a result of the installed detector. If accuracy
adjustment of the meter is required, please refer to the scale factor.
5.2.2 Measurement
Flow Units
Flow Units let you select among the Flow Units mentioned below. Flow
units are automatically converted into the selected unit.
Unit Unit
LPS Liter/Second GPM Gallons/Min.
LPM Liter/Minute GPH Gallons/Hour
LPH Litre/Hour MGD MegaGallon/Da
M3S Cubic meters/Sec. IGS UKG/Sec.
M3M Cubic meters/Min. IGM UKG/Min.
M3H Cubic IGH UKG/Hour
F3S Cubic Feet/Sec. LbM Pound/Min.
F3M Cubic Feet/Min. OPM Ounce/Min
F3H Cubic Feet/Hour. BPM Barrel/Min
GPS Gallons/Sec. -- --

Programming Page 17/44
MID_M2000_BA_02_1004
Measurement
Totalizer Unit
This parameter establishes the units of measure for the totalizers:
Full Scale Flow
This parameter sets the maximum flow the system is expected to
measure. This parameter has influence on other system parameters.
These parametes include: Frequency output and current output.
In terms of flow velocity, the meter’s limit are from 0.1 to 12 m/sec.
Moreover the values for Low Flow Cutoff and meter’s limits monitoring
depend on Full Scale Flow.
The full scale flow is valid for both flow directions.
Note: If the flow rate exceeds the full scale setting, an error message
indicates that the configured full scale range has been exceeded.
Low Flow Cut-off
Low Flow Cut-off defines the threshold at which flow measurement will
be forced to zero. The cutoff value can be from 0 % to 9.9 % of the full
scale flow. Increasing the threshold will help prevent false reading
during “no flow” conditions possible caused by vibrations or liquid
fluctuations.
Unit Unit
LLiters UKG Imperial Gallons
HL HectoLiter Lb Pounds
M³ Cubic Meters Oz Fluid Ounces
CFt Cubic Feet Aft Acre Feet
USG U.S. Gallons BBL Barrel
MG MegaGallons

Programming Page 18/44
MID_M2000_BA_02_1004
Measurement
Flow Direction
Flow direction lets you set the meter to measure forward flow only (uni-
directional) or both forward and reverse flow (bidirectional).
Unidirectional means that the flow is totalized in only one direction.
The flow direction is indicated by the arrow printed on the detector
label. In this mode, the two totalizers T1/T2 can be used as totalizers
and resettable day counters.
Bidirectional means the flow is totalized in both directions. The totalizer
T+ registers forward flow and the totalizer T-totalizes in reverse flow
direction. The net totalizer TN registers total flow and shows the
difference between T+ and T-.
A change of the flow direction can be signalized by the digital outputs.
Damping Factor
The damping factor establishes the stability of the measured flow
rate.Time constant can be set from “none” up to a max. of 30 seconds.
Note: Damping has no influence on the totalizers.