ModMAG M-Series User manual

Electromagnetic Flow Meter
M5000
MAG-UM-00219-EN-15 (April 2021) User Manual

CONTENTS
Safety Precautions and Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Basic Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rigging, Lifting and Moving Large Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Amplier Mounting Conguration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Meter Mounted Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remote Mount Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Submersible Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Meter Location, Orientation and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Protection Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pipelines and Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Meter Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Vertical Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Horizontal Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Straight Pipe Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pipe Reducer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chemical Injection Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Partially-Filled Pipe Situations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Meter Gaskets and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Meter/Pipeline Connection Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Meter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Conductive Pipe Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Non-Conductive Pipe Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pipelines with Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrically Disturbed Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Wiring Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Opening the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electromagnetic Flow Meter M5000
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Battery Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Remote Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Signal Cable Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conguring Input/Output (I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Function Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Access the Programming Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
M5000 Main Menu Programming Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Navigating the Initial Main Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Programming Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Meter Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Measure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inputs/Outputs Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Communication Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Battery Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Miscellaneous Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Setting a PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Activating the Security Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Logging Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
PIN Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cleaning the Flow Tube and Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacing Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Errors and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Connecting an ORION RTR® Endpoint to the M5000 Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
User Manual
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Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connecting an ORION Encoder Endpoint to the M5000 Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
M5000 Amplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
M5000 Amplier Dimensions in Inches (Millimeters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Detector Type VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Detector Weight and Flow Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Error Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
OIML Approved Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MID Approved Meter (MI-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electromagnetic Flow Meter M5000
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SAFETY PRECAUTIONS AND INSTRUCTIONS
Some procedures in this manual require special safety considerations. In such cases, the text is emphasized with the
following symbols:
Indicates a hazardous situation, which, if not avoided, will result in death or serious personal injury.
WARNING Indicates a hazardous situation, which, if not avoided, could result in death or serious personal injury.
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury or
damage to property.
Basic Safety Recommendations
Before installing or using this product, read this instruction manual thoroughly. Only qualified personnel should install and/or
repair this product. If a fault appears, contact your distributor.
The electromagnetic flow meter is only suitable for the measurement of conductive fluids. The manufacturer is not liable for
damages that result from improper 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.
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.
Setup and 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.
RoHs
Our products are RoHs compliant.
Battery Disposal
The batteries contained in our products need to be disposed of per your local legislation according to
EUdirective2006/66/EG.
Safety Precautions and Instructions
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UNPACKING AND INSPECTION
Follow these guidelines when unpacking the equipment.
• If a shipping container shows any sign of damage, have the shipper present when you unpack the meter.
• Follow all unpacking, lifting and moving instructions associated with the shipping container.
• Open the container and remove all packing materials. Store the shipping container and packing
materials in the event the unit needs to be shipped for service.
• Verify that the shipment matches the packing list and your order form.
• Inspect the meter for any signs of shipping damage, scratches, or loose or broken parts.
OTE:NIf the unit was damaged in transit, it is your responsibility to request an inspection report from the carrier within 48
hours. You must then file a claim with the carrier and contact Badger Meter for appropriate repairs or replacement.
• All detectors with polytetrafluoroethylene (PTFE) liners are shipped with a liner protector on each end to maintain proper
form of the PTFE material during shipping and storage.
OTE:NDo not remove the liner protectors until you are ready to install.
• Storage: If the meter is to be stored, place it in its original container in a dry, sheltered location. Storage temperature
ranges are: –40…160° F (–40…70° C).
Rigging, Lifting and Moving Large Units
WHEN RIGGING, LIFTING OR MOVING LARGE UNITS, FOLLOW THESE GUIDELINES:
• DO NOT lift or move a meter by its amplifier, junction box or cables.
• Use a crane rigged with soft straps to lift and move meters with flow tubes that are between two inches and eight inches
(50 mm and 200 mm). Place the straps around the detector body, between the flanges, on each side of the detector.
• Use the lifting lugs when lifting meter flow tubes that are 10 inches (250 mm) in diameter or larger.
®
®
®
Place straps between flanges. Use lifting lugs with 10-inch or larger meters.
Figure 1: Rigging large units
Unpacking and Inspection
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• Use the sling-rigged method to lift large detectors into a vertical position while they are still crated. Use this method to
position while they are still crated. Use this method to position large detectors vertically into pipelines.
Figure 2: Sling-rigged lifting methods
• Do not lift a detector with a forklift by positioning the detector body on the forks, with the flanges extending beyond the
lift. This could dent the housing or damage the internal coil assemblies.
• Never place forklift forks, rigging chains, straps, slings, hooks or other lifting devices inside or through the detector's flow
tube to hoist the unit. This could damage the isolating liner.
Do not lift detector with forklift. Do not lift or rig lifting devices through detector.
Figure 3: Lifting and rigging cautions
Unpacking and Inspection
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SYSTEM DESCRIPTION
The Badger Meter model M5000 electromagnetic flow meter is intended for fluid metering in most industries including
potable water, reclaimed water, food and beverage, pharmaceutical and chemical. The meter can measure all fluids with
electric conductivity of at least 5 µS/cm (20 µS/cm for demineralized water) and is highly accurate. Measuring results depend
on density, temperature and pressure.
The basic components of an electromagnetic flow meter are:
• The detector, which includes the flow tube, isolating liner and measuring electrodes.
• The amplifier, which is the electronic device responsible for the signal processing, flow calculation, display and
outputsignals.
Figure 4: Amplifier and detector
The construction materials of the wetted parts (liner and electrodes) should be appropriate for the specifications on the
intended type of service. We recommend that you review all of the compatibilities consistent with the specifications.
Each meter is factory tested and calibrated. A calibration certificate is included with each meter.
OPERATING 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.
AMPLIFIER MOUNTING CONFIGURATION OPTIONS
Meter Mounted Conguration
The meter mount configuration has the amplifier mounted directly on the detector. This compact, self-contained
configuration minimizes installation wiring.
Remote Mount Conguration
The remote mount configuration places the amplifier at a location away from the fluid flow and detector. This is necessary in
situations where process fluid temperature or the environment exceeds amplifier ratings.
The detector and amplifier are connected by wires, run through conduit, between junction boxes on the detector and the
amplifier. The distance between the detector junction box and amplifier junction box can be up to 100 feet (30 meters). A
remote mounting bracket is supplied.
Submersible Option
If you are installing the meter in a vault, order the remote amplifier option. Do not install the amplifier inside a vault. We also
recommend ordering the remote meter package with the submersible option (NEMA 6P/IP68) to eliminate any potential
problems resulting from humidity or temporary flooding in the vault.
OTE:NNEMA 6P/IP68 enclosures are constructed for indoor or outdoor use to provide protection against access to
hazardous parts, and to provide a degree of protection against ingress of solid foreign objects and water (hose
directed water and the entry of water during prolonged submersion at a limited depth). They provide an additional
level of protection against corrosion and are not damaged by the external formation of ice on the enclosure.
System Description
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METER LOCATION, ORIENTATION AND APPLICATIONS
The M5000 provides two amplifier mounting options: a meter mounted option and a remote option.
Meter mounted option Remote option
Figure 5: Amplifier mounting options
Remote Option
Use a remote amplifier in the following situations:
• Detector protection class IP 68
• Detector to be mounted in a vault (see note on previous page)
• Fluid temperature is greater than 212° F (100° C)
• Strong vibrations at meter location
Remote Amplifier Outdoor Location
The amplifier can be installed and operated outdoors. However, it must be protected from the elements, as follows:
• The ambient environment/temperature rating for the unit is –4…140° F (–20…60° C).
• If an indoor location is within 100 feet (30 meters) of the detector, consider increasing the cable length (up to 100 ft)and
mounting the amplifier indoors.
• At minimum, fabricate a roof or shield over and/or around the amplifier to protect the LCD display screen from
directsunlight.
• Do not install the signal cable close to power cables, electric machines, and more.
• Secure the signal cables. Due to capacity changes, cable movements may result in incorrect measurements.
Temperature Ranges
• To prevent the meter from any damage, strictly observe the amplifier’s and detector’s maximum temperature ranges.
• In regions with extremely high ambient temperatures, it is recommended to protect the detector.
• In cases where fluid temperature exceeds 212° F (100° C), use the remote amplifier option.
Amplifier Ambient temperature –4…140° F (–20…60° C)
Detector Fluid temperature
PTFE / PFA –40…302° F (–40…150° C)
Hard rubber 32…176° F (0…80° C)
Soft rubber 32…176° F (0…80° C)
Meter Location, Orientation and Applications
MAG-UM-00219-EN-15 Page 9April 2021

Protection Class
The device has protection class IP 67, optional IP 68. In order to fulfill requirements in respect of the protection class, follow
these guidelines:
• Body seals must be undamaged and in proper condition.
• All of the body screws must be firmly screwed.
• Outer diameters of the used wiring cables must correspond to cable inlets (for M20 Ø 7…12 mm). In cases where cable
inlet is not used, put on a dummy plug.
• Tighten cable inlets.
• If possible, lead the cable downwards to avoid humidity going into cable inlet.
• We normally deliver the meter in accordance with protection class IP 67. If you require a higher protection class, use the
remote version. If requested, we can also deliver the detector in IP 68.
Pipelines and Fluid Flow
Take the following precautions during installation:
• Do not install the meter on pipes with extreme pipe vibrations. If pipes are vibrating, secure the piping with
appropriate pipe supports in front of and behind the meter. If vibrations cannot be restrained, mount the amplifier in a
remotelocation.
• Do not install the detector close to pipeline valves, fittings or impediments that can cause flow disturbances.
• For detectors with PTFE liners, do not install the detector on suction sides of pumps.
• Do not install the detector on outlet sides of piston or diaphragm pumps. Pulsating flow can affect meter performance.
• Avoid installing the detector near equipment that produces electrical interference such as electric motors, transformers,
variable frequency and power cables.
• Verify that both ends of the signal cables are securely fastened.
• Place power cables and signal cables in separate conduits. Do not install the signal cable close to other sources of
electricity, such as power cables or electric machines.
• Place the meter where there is enough access for installation and maintenance tasks.
Meter Orientation
Mag meters can operate accurately in any pipeline orientation and can measure volumetric flow in forward and reverse
directions, as long as the pipe is completely full.
OTE:NA "Forward Flow" direction arrow is printed on the detector label.
Meter Location, Orientation and Applications
MAG-UM-00219-EN-15Page 10 April 2021

Vertical Placement
Mag meters perform best when placed vertically, with liquid flowing upward and meter electrodes in a closed, full pipe.
Figure 6: Vertical placement
Vertical placement allows the pipe to remain completely full, even in low flow, low pressure applications, and it prevents
solids build-up, sediment deposit and accumulation on the liner and electrodes.
OTE:NCarefully observe the“Forward Flow” label on the meter body and install the meter accordingly. When installed
vertically, rotate amplifier so that cable glands are facing down.
Horizontal Placement
M5000 meters are equipped with an Empty Pipe
Detection feature. If an empty pipe electrode mounted
in the pipe is not covered by fluid for five seconds, the
meter displays an Empty Pipe Detection condition. The
meter sends out an error message and stops measuring
flow. When the electrode is again covered with fluid,
the error message disappears and the meter resumes
measuring.
Electrode
Plane
RIGHT
Electrode
Plane
WRONG
Figure 7: Horizontal placement
When installing the meter on a horizontal pipe, mount the detector to the pipe with the flow-measuring electrode axis in a
horizontal plane (three and nine o’clock). This placement helps prevent solids build-up, sediment deposit and 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 3…7 diameters of
straight pipe is required on the inlet (upstream) side to
provide a stable flow profile. Two diameters are required
on the outlet (downstream) side.
FORWARD FLOW
MINIMUM STRAIGHT PIPE MINIMUM STRAIGHT PIPE
ELBOW
TEE
GATE VA LVE
(FULLY OPEN)
MINIMUM STRAIGHT PIPE
CHECK VALVE
GLOBE VALVE
BUTTERFL
Y VALVE
PUMP
ELBOW
TEE
ANY VAL
VE
FLOWMETER
3 x D
7 x D
2 x D
D (Pipe Size)D (Pipe Size)
MINIMUM PIPING REQUIREMENT
STANDARD CONCENTRIC
REDUCERS
(NO DISTANCE REQUIRED)
Figure 8: Straight pipe requirements
Meter Location, Orientation and Applications
MAG-UM-00219-EN-15 Page 11April 2021

Pipe Reducer Requirements
With pipe reducers, a smaller 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 maximum slope angle of 8 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 required amount of
straight pipe.
Forward Flow
Flow Meter
D (Pipe Size)
Standard Concentric
Reducers
(No Distance Required)
Custom Fabricated
Reducers
(8 Degree Slope Angle)
D (Pipe Size)
Diameter ratiod/D
Diameter Ratio d/D
Pressure Drop in mbar
Figure 9: Pipe reducer requirements
Figure 10: Pressure loss chart
Chemical Injection Applications
For water line applications with a chemical injection point, install the meter upstream of the injection point. This eliminates
any meter performance issues.
Figure 11: Chemical injection point downstream of meter
If a meter must be installed downstream of a chemical injection connection, the distance between the flange and the
injection point should be between 50 and 100 feet (15 and 30 meters). The distance must be long enough to allow the water
or chemical solution to reach the meter in a complete, homogeneous mixture.
Meter Location, Orientation and Applications
MAG-UM-00219-EN-15Page 12 April 2021

Figure 12: Chemical injection point upstream of meter
If the injection point is too close, the meter senses the two different conductivities for each liquid. This can cause inaccurate
measurements. The injection method—spaced bursts, continuous stream of drips, liquid or gas—can also affect downstream
readings by the meter.
Partially-Filled Pipe Situations
In some locations, the process pipe may be momentarily only partially filled. Examples include: lack of back pressure,
insufficient line pressure and gravity flow applications.
To eliminate these situations:
• Do not install the meter at the highest point of the pipeline.
• Do not install the meter in a vertical, downward flow section of pipe.
• Always position the ON/OFF valves on the downstream side of the meter.
• Turn ON Empty Pipe for applications or installations where the pipe is sometimes empty.
• Do not install the detector on the suction side of pumps. This could damage the liner (in particular PTFE liners).
• Do not install the detector on pipes with vibrations. If pipes are strongly vibrating, use a remote version.
WRONG RIGHT
FLOW
FLOW
FLOW
FLOW
Figure 13: Incorrect meter placement
FLOW
FLOW
WRONG
FLOW
FLOW
RIGHT
Do not install in a vertical, downward position. Position "On/Off" valves on downstream side.
Figure 14: Position valves on downstream side
To minimize the possibility of partially-full pipe flows in horizontal, gravity or low pressure applications, create a pipe
arrangement that allows the detector to remain full of liquid at all times.
Figure 15: Pipe positioned to keep water in detector
Meter Location, Orientation and Applications
MAG-UM-00219-EN-15 Page 13April 2021

METER GASKETS AND GROUNDING
Consider gasket and grounding requirements when determining the meter location, orientation and application. Ground all
units to eliminate risk of electric shock.
FAILURE TO PROPERLY GROUND A UNIT MAY CAUSE DAMAGE TO THAT UNIT OR DATA STORED WITHIN IT.
Meter/Pipeline Connection Gaskets
Install gaskets (not provided) between the detector's isolating liner and the
pipeline flange to ensure a proper and secure hydraulic seal. Use gaskets that
are compatible with the fluid. Center each gasket on the flange to avoid flow
restrictions or turbulence in the line.
During installation, do not use graphite or any electrically conductive sealing
compound to hold the gaskets. This could compromise the accuracy of the
measuring signal.
If you are using a grounding ring (as Badger Meter recommends) in the detector/
pipeline connection, place the ring between two gaskets. (See "Non-Conductive
Pipe Grounding" on page15.)
GASKETS RECOMMENDED
Figure 16: Meter/pipeline connection gaskets
Meter Grounding
Process pipeline material can be either electrically conductive (metal) or not electrically conductive (made of or lined with
PVC, fiberglass or concrete).
IMPORTANT
It is essential that the mag meter amplifier’s input ground (zero voltage reference) be electrically connected to the liquid media and
to a good, solid earth ground reference.
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.
• If a type of meter with a flange connection cable (min. 4 mm²) between the grounding screw on the meter’s flange and
the counter flange is to be used in addition to the fixing screws, verify that the electric connection is complete.
• Color or corrosion on the counter flange may have a negative effect on the electric connection.
Conductive Pipe Grounding
To achieve an adequate ground, the meter body MUST be electrically connected to the liquid media. The mag meter flanges
are provided with grounding bolts for this purpose.
If the pipe material is electrically conductive, simply install grounding straps between these grounding bolts and the
mating flanges.
These grounding straps must be copper wire, at least 12 AWG size. They must be connected on both sides (inlet and outlet) of
the detector and to a local, earth ground.
To provide a good electrical connection at the mating flanges, Badger Meter recommends that you drill and tap the flanges
and install a grounding screw (not provided).
Meter Gaskets and Grounding
MAG-UM-00219-EN-15Page 14 April 2021

Non-Conductive Pipe Grounding
IMPORTANT
If the process pipe is not electrically conductive (PVC, fiberglass, cement-lined pipes or any other non-conductive material) and the
meter was not originally ordered with an optional grounding electrode, you must install a pair of grounding rings between the
mating flanges at both ends of the meter. See the following illustration.
In this case, connect the grounding straps to both of the grounding rings and
to a good, solid earth ground. Grounding rings are available in stainless steel.
If your fluid is too aggressive for stainless steel, order a meter with the optional
grounding electrode in a material compatible with the fluid.
GASKETS RECOMMENDED
GROUNDING RING
GROUNDING RING
Figure 17: Non-conductive pipe grounding
Pipelines with Cathodic Protection
For pipelines with cathodic protection, install the meter potential-
free. No electric connection from the meter to the pipeline
system may exist and the power supply is to be provided via
isolating transformer.
USE GROUNDING ELECTRODES. INSTALL GROUNDING RINGS
ISOLATED FROM THE PIPELINE.
OBSERVE NATIONAL RULES REGARDING
POTENTIAL‑FREEINSTALLATIONS. Figure 18: Potential-free installation
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 make sure
that measurement is not influenced.
6 mm² Cu
BA5000-20-MID
PE
Figure 19: Grounding for electrically disturbed environment
Meter Gaskets and Grounding
MAG-UM-00219-EN-15 Page 15April 2021

WIRING
Wiring Safety
WARNING
• Disconnect power to the unit before attempting any connection or service.
• Do not bundle or route signal lines with power lines.
• Use twisted pair shielded wire for all output wiring.
• For the 4 × M20 cable inlets, only use flexible electric cables.
• Observe all applicable, local electrical codes.
Opening the Cover
The M5000 amplifier's design lets you open the cover
without completely removing it.
Follow these steps:
1. Completely remove the top two screws from the
amplier using a blade/slotted screwdriver.
2. Loosen both of the bottom screws so that the round
head of each screw clears the top face of the cover.
3. Pull the cover down to the open position.
Figure 20: Remove two screws Figure 21: Open the cover
Wiring
MAG-UM-00219-EN-15Page 16 April 2021

POWER
The M5000 can be powered with:
• Battery only (2 D-cells or 4 D-cells)
• 100…240V AC (with battery back-up)
• 9…36V DC (with battery back-up)
Battery
Use a two D-cell battery pack for sizes 1/2…6 in. (DN 15…150) or a double two D-cell battery pack for sizes 8…24 in. (DN
200…600). For backup battery options, see "Battery Backup" on page18.
The meter is delivered with the battery unplugged. It must be plugged in before using the meter. The connection jack is
located by the symbol "BAT“ on the board.
Figure 22: Battery connection Figure 23: Battery plugged in
Battery Life
OTE:NThe battery life strongly depends on ambient temperature, sampling rate and the number of outputs used.
Standard Battery Pack
Sampling Expected Life
1 s 8 months
4 s 2.7 years
8 s 5.3 years
15 s 10 years
These calculations are for a standard battery pack, with two D-size batteries, with communication and outputs OFF, at a
temperature of 77º F (25º C). See "Battery Level Indicators" on page25.
Battery Replacement
1. Go to Main Menu > Misc > Battery > Change and select the capacity of the battery pack to be installed (see label on the
battery pack 19 Ah, 38 Ah or 70 Ah). Press Eto quit. The display freezes (no reaction by pressing any button).
2. Open the cover.
3. Remove all connectors (detector and outputs).
4. Remove all 4 screws of the main board, remove the circuit board and disconnect the old battery.
5. Remove the old battery and wait about 2 minutes before replacing it with a new one (LCD display should be o).
6. Plug the battery connector into the back of the main board and reinstall the circuit board.
7. Replace all the plugs.
8. Close the cover tight.
9. Check time and date (Main Menu > Misc > Time and Main Menu > Misc > Date DMY).
10. Check capacity of battery (Main Menu > Misc > Battery AH). The rst value is the used capacity, which should be 0.0. The
second value is the capacity of the battery pack. Battery AH is a read-only parameter.
OTE:NTotalizers and configuration remain unaffected during battery replacement.
Power
MAG-UM-00219-EN-15 Page 17April 2021

Figure 24: Amplifier housing components – exploded view
Battery Backup
The backup battery option allows the meter to run using the backup battery power in case of power loss. The meter ships
with an unplugged backup battery. Make sure that any power cables are of a sufficiently high current rating. If in doubt,
contact your distributor.
DO NOT INSTALL THE METER UNDER VOLTAGE
1. Connect the power supply according to the terminal marking.
L+ PE N- L+ PE N-
90…264V AC (50/60Hz) 9…36V DC
OTE:NThe safety fuse is soldered on the electronic board (1.6 A slow).
Figure 25: Power supply terminals Figure 26: Backup battery location
2. Connect the battery to the connection socket on the power supply board. See Figure 26.
Power
MAG-UM-00219-EN-15Page 18 April 2021

INSTALLATION
For detectors with PTFE liner, do not remove protective cap on the flange until shortly before installation.
Remote Mount Installation
Mount Bracket to Amplifier
1. Align bracket-mounting holes with amplier mounting holes.
2. Attach bracket to amplier with supplied screws. Torque the screws to 80 inch-pounds.
Wiring Configuration
Connection on the amplifier
1. Open the cover of the amplier.
2. Push both cables through two dierent cable glands as shown in Figure 27.
Figure 27: Cables in cable glands
3. The cable entry should be done as shown in Figure 28.
Figure 28: Cable entry
4. Connect the cables to the corresponding plugs on the left side of the board as
shown in Figure 29.
5. Close cover tight.
Figure 29: Cables to plugs
Connection on the detector
1. Loosen xing screws of the connection cover and remove cover.
2. Push both cables through two dierent cable glands.
3. The cable entry should be done as shown in Figure 30.
Figure 30: Cable entry
Installation
MAG-UM-00219-EN-15 Page 19April 2021

4. Connect the cables to the corresponding plugs on the left side of the board as
shown in Figure 31.
5. Close junction box cover again rmly.
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
Figure 31: Cables to plugs
Wiring for Remote Configuration
Remote style M5000 amplifier models can be ordered with standard cables measuring 15, 30, 50 and 100 feet (5, 10, 15, and
30 m).
Junction Box
Terminal Description Wire Color
11 C1 Coil C1 Brown
12 C2 Coil C2 White
13 N/A Not Used
40 EP Empty pipe detection Red
44* ⏚Shielding electrode —
44* ⏚Shielding electrode Green
45 E1 Electrode E1 White
46 E2 Electrode E2 Black
*Connections with number 44 are on the same potential.
M5000 AMPLIFIER
RED
RED
Figure 32: Wiring for remote configuration
Installation
MAG-UM-00219-EN-15Page 20 April 2021