ModMAG M-Series User manual

M-Series® M4000
Electromagnetic Flow Meter, Class 1, Division 1 Environments
MAG-UM-00159-EN-05 (June 2018) User Manual

Page ii
M-Series® M4000 Electromagnetic Flow Meter, Class 1, Division 1 Environments
MAG-UM-00159-EN-05 June 2018

CONTENTS
Safety Precautions and Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rigging, Lifting and Moving Large Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Empty Pipe Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Amplier Mounting Conguration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Meter/Amplier Location, Orientation and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Amplier Outdoor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pipelines and Fluid Flow Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Meter Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Straight Pipe Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pipe Reducer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chemical Injection Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Partially Filled Pipe Situations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Meter Gaskets and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Meter Installation Plans and Execution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remote Mount Amplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remote Mount Amplier/Detector Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Output Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Output Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Amplier Output Wire Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Auxiliary Input Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Analog Output Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
External Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC/DC Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustable Display/Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Programming the M4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
M4000 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Programming Practice—Understanding the Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Programming Practice—Navigating the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Programming the Required Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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User Manual
MAG-UM-00159-EN-05June 2018

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Flow Tube and Electrode Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Amplier Printed Circuit Board (PCB) Stack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Amplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Page iv
M-Series® M4000 Electromagnetic Flow Meter, Class 1, Division 1 Environments
MAG-UM-00159-EN-05 June 2018

SAFETY PRECAUTIONS AND INSTRUCTIONS
Safety considerations are emphasized by the placement of safety symbol icons on the product or next to important text,
pictures or drawings throughout this manual. The symbols are:
Symbol Explanation
When and where this symbol is attached to the product, it indicates a potential hazard. It means that
documentation must be consulted to determine the nature of the potential hazard and any actions
that need to be taken.
Warning indicates the potential for severe personal injury, death or substantial property damage.
Comply with the instructions and proceed with care.
Caution indicates the potential for minor personal injury or property damage. Comply with the
instructions and proceed with care.
Unpacking and Inspection
Follow these guidelines when unpacking the M-Series 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.
NOT: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 PTFE liners are shipped with a liner protector to maintain proper form of the PTFE material during
shipping and storage.
NOT: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: –4…158° F (–20…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.
Safety Precautions and Instructions
MAG-UM-00159-EN-05 Page 5June 2018

®
®
Place straps between flanges. Use lifting lugs with 10-inch or larger meters.
Figure 1: Rigging large units
• 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.
Safety Precautions and Instructions
MAG-UM-00159-EN-05Page 6 June 2018

Do not lift detector with forklift. Do not lift or rig lifting devices through detector.
Figure 3: Lifting and rigging cautions
Instructions Specific to Hazardous Area Installations
These instructions apply to equipment covered by FM Certificate Number 3015930.
• The temperature range for fluids passing through the detector is – 4…248° F (–20…120° C).
• The ambient temperature range surrounding the amplifier is – 4…122° F (–20…50° C).
• The ambient temperature range surrounding the junction box must not exceed 122° F (50° C).
• During any installation or repair, perform all procedures in accordance with the applicable code of practice.
• Suitably trained personnel shall perform all installation or repair procedures.
• If the equipment is likely to come into contact with aggressive substances, it is the responsibility of the user to take
suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection is not
compromised.
◊ Aggressive Substances such as acidic liquids or gases that may attack metals, or solvents that may affect
polymeric materials.
◊ Suitable Precautions are regular checks as part of routine inspections or establishing, from the material’s data sheet,
that it is resistant to specific chemicals.
Safety Precautions and Instructions
MAG-UM-00159-EN-05 Page 7June 2018

Additional Information
Certification markings are noted on the product label. Markings include:
FM
APPROVED
-20 C < Tamb < +50 C
Provides intrinsically safe electrode circuits
CLII Div1 GP EFG T4
CLI Div1 GP BCD T4
Type 4X/IP66
Power: 85-240 VAC/50-60 Hz/15VA
Tag #:........................
Serial #:....................
Model #: 4000...........
M SERIES MAG METER
®
Badger Meter Brno Czech Republic
!
Warning - Substitution of components may impair Intrinsic Safety
Exia
FM
APPROVED
FM CONTROL DWG Exia CSA CONTROL DWG
MAG-AS-00496-EN MAG-AS-00496-EN
-20 C < Tamb < +50 C
Provides intrinsically safe electrode circuits
CLII Div1 GP EFG T4
CLI Div1 GP BCD T4
Type 4X/IP66
Power: 85-240 VAC/50-60 Hz/15VA
Tag #:........................
Serial #:....................
Model #: 4000...........
M SERIES MAG METER
®
Badger Meter Brno Czech Republic
!
Warning - Substitution of components may impair Intrinsic Safety
Figure 4: Mounted amplifier 85…240V AC Figure 5: Remote mount 85…240V AC
FM
APPROVED
-20 C < Tamb < +50 C
Provides intrinsically safe electrode circuits
CLII Div1 GP EFG T4
CLI Div1 GP BCD T4
Type 4X/IP66
Power: 24 VDC/5W
Tag #:........................
Serial #:....................
Model #: 4000...........
M SERIES MAG METER
®
Badger Meter Brno Czech Republic
!
Warning - Substitution of components may impair Intrinsic Safety
Exia
FM
APPROVED
FM CONTROL DWG Exia CSA CONTROL DWG
MAG-AS-00496-EN MAG-AS-00496-EN
-20 C < Tamb < +50 C
Provides intrinsically safe electrode circuits
CLII Div1 GP EFG T4
CLI Div1 GP BCD T4
Type 4X/IP66
Power: 24 VDC/5W
Tag #:........................
Serial #:....................
Model #: 4000...........
M SERIES MAG METER
®
Badger Meter Brno Czech Republic
!
Warning - Substitution of components may impair Intrinsic Safety
Figure 6: Mounted amplifier 24V DC Figure 7: Remote mount 24V DC
NOT:NTable 1 below refers to the data plate codes per the configured meter order. The data plate code string follows the
model number on the data plate.
A = Mounting Type M Meter mount
R Remote mount
B = Liner Material R Hard rubber
T PTFE
C = Electrodes
H Alloy C
S 316 stainless steel
G Gold/platinum
T Tantalum
R Platinum/rhodium
D = End Flange D DIN flange
S SAE flange
E = Entry M Metric
N NPT
F = Number of Electrodes T Three
F Four
G = Detector Size (DN Size MM) 6, 8, 10, 15 and so on
H = Voltage H 110/220V AC
L 24V DC
Table 1: Data plate codes
Contact Badger Meter for information on the dimensions of the flameproof joints.
For additional information regarding importation, equipment installation, equipment repair, equipment return or renewal
parts, contact:
Badger Meter, Inc.
P.O. Box 245036
Milwaukee, WI 53222
Telephone: [phone] or [phone]
On the Web: www.badgermeter.com or contact your local Badger Meter representative.
Safety Precautions and Instructions
MAG-UM-00159-EN-05Page 8 June 2018

SYSTEM DESCRIPTION
The Badger Meter M-Series® model M4000 electromagnetic flow meters are FM approved for Class I, Div 1 hazardous
locations. To achieve hazardous location ratings electrodes in the flow tube are Intrinsically Safe, designed according to
Factory Mutual (FM) standards. Those standards limit the amount of energy that can be sent to electrodes to prevent a spark
from occurring.
Empty Pipe Detection
Badger Model M4000 meters are equipped with an Empty Pipe Detection feature. Empty Pipe Detection is accomplished by
positioning a third electrode close to the 12 o’clock position. Any time this electrode is not covered by fluid, for a minimum
of five seconds, the meter displays an Empty Pipe Detection condition, sends out an error message if desired, and stops
measuring to maintain accuracy. When the electrode is again covered with fluid, the error message disappears and the meter
continues measuring.
Amplier Mounting Conguration Options
Two amplifier-mounting configuration options are available to meet a variety of meter placement and
environmental conditions.
Meter Mount Configuration
The Meter Mount configuration has the amplifier mounted directly on the detector. This compact, self-contained
configuration minimizes installation wiring.
Figure 8: Meter mount
Remote Mount Configuration
• Remote Mount configuration places the amplifier and its functions at a location separate from the fluid flow and detector.
This configuration is necessary in situations where process fluid temperature or environment exceeds amplifier ratings. A
remote mounting bracket is supplied.
• The detector and amplifier are connected by wires, run through conduit, between junction boxes on the detector and
remote mounted amplifier. The distance between the detector junction box and amplifier junction box can be up to 100
feet (30 m).
• This configuration can also provide a more convenient amplifier programming and display placement for monitoring
meter readings.
Figure 9: Remote mount
System Description
MAG-UM-00159-EN-05 Page 9June 2018

METER/AMPLIFIER LOCATION, ORIENTATION AND APPLICATIONS
Remote Amplier 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…122° F (–20…50° C).
• If an indoor location is within 100 feet (30 meters) of the detector, consider increasing the cable length 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.
Temperatures
To prevent meter damage in any environment, minimum and maximum temperature ranges must be observed.
• The ambient temperature range surrounding the amplifier is – 4…122° F (–20…50° C).
• The ambient temperature range surrounding a remote junction box mounted to the detector is – 4…248° F
(–20…120° C).
Application Fluid Temperature Range Max. Ambient Temperature Liner Materials
Remote amplifier – 4…248° F (–20…120° C) 122° F (50° C) PFA and PTFE
Remote amplifier 32…178° F (0…80° C) 122° F (50° C) Hard rubber
Meter mounted amplifier – 4…212° F (–20…100° C) 122° F (50° C) PFA and PTFE
Meter mounted amplifier 32…178° F (0…80° C) 122° F (50° C) Hard rubber
Pipelines and Fluid Flow Conditions
Pipeline and fluid flow conditions that should be avoided:
• Do not install the meter where extreme pipe vibrations exist. If vibrations are present, secure piping before and
after the meter with appropriate pipe supports. If vibrations cannot be restrained, consider mounting the amplifier
remotely.
• Avoid installing the detector close to pipeline valves, fittings or impediments that can cause flow disturbances.
• For detectors with PTFE liners, avoid installing the detector on suction sides of pumps.
• Avoid installing the detector on outlet sides of piston or diaphragm pumps. Pulsating flow can affect meter
performance.
• Avoid locations near equipment producing electrical interference such as electric motors, transformers, variable
frequency, and power cables.
• Verify both ends of the signal cables are securely fastened.
• Place power and signal cables in separate conduit.
• Place the meter where there is enough access for installation/maintenance purposes.
Meter/Amplier Location, Orientation and Applications
MAG-UM-00159-EN-05Page 10 June 2018