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ModMAG M-Series M3000 User Manual

Electromagnetic flow meter, class 1, division 2 environments
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M-Series® M3000
Electromagnetic Flow Meter, Class 1, Division 2 Environments
User Manual
MAG-UM-00158-EN-07 (June 2018)

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James Campanella
January 25, 2025

I have a model 3000 mag meter and I need to get a new card and also have the meter calibrated. Can you tell me where to send the meter to get it calibrated?

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Summary of Contents for ModMAG M-Series M3000

  • Page 1 M-Series® M3000 Electromagnetic Flow Meter, Class 1, Division 2 Environments User Manual MAG-UM-00158-EN-07 (June 2018)
  • Page 2 M-Series® M3000 Electromagnetic Flow Meter, Class 1, Division 2 Environments Page ii MAG-UM-00158-EN-07 June 2018...

  • Page 3: Table Of Contents

    User Manual CONTENTS Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Unpacking and Inspection .
  • Page 4 M-Series® M3000 Electromagnetic Flow Meter, Class 1, Division 2 Environments Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Flow Tube and Electrode Cleaning .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions 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 .
  • Page 6 Safety Precautions and Instructions ® ® 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 .
  • Page 7 Safety Precautions and Instructions 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 IAB-182-01 . •...
  • Page 8 Safety Precautions and Instructions Additional Information Certification markings are noted on the product label . Markings include: M SERIES MAG METER M SERIES MAG METER Model #: 3000... Model #: 3000... APPROVED Serial #:....APPROVED Serial #:....Tag #:......Tag #:......®...

  • Page 9: System Description

    System Description SYSTEM DESCRIPTION The Badger Meter M-Series® model M3000 electromagnetic flow meters are FM approved for Class I, Div 2 hazardous locations . To achieve hazardous location ratings, electrodes in the flow tube are Intrinsically Safe, designed according to Factory Mutual (FM) standards .

  • Page 10: Meter/Amplifier Location, Orientation And Applications

    Meter/Amplifier Location, Orientation and Applications METER/AMPLIFIER LOCATION, ORIENTATION AND APPLICATIONS 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…122° F (–20…50° C) . •...

  • Page 11: Meter Orientation

    Meter/Amplifier Location, Orientation and Applications Meter Orientation Mag meters can operate accurately in any pipeline orientation and can measure volumetric flow in forward and reverse directions . OTEE: A Forward Flow direction arrow is printed on the detector label . Vertical Placement Mag meters attain optimal performance when placed vertically, with liquid flowing upward and meter electrodes in a closed, full pipe .

  • Page 12: Pipe Reducer Requirements

    Meter/Amplifier Location, Orientation and Applications Pipe Reducer Requirements With pipe reducers a smaller size 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 an approximate slope angle of 15 degrees to minimize flow disturbances and excessive loss of head .

  • Page 13: Meter Gaskets And Grounding

    Meter/Amplifier Location, Orientation and Applications Always position the ON/OFF valves on the downstream side of the meter . WRONG RIGHT Do not install in a vertical, downward position . Position On/Off valves on downstream side . Figure 17: 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 ensures the detector remains full of liquid at all times .
  • Page 14 Meter/Amplifier Location, Orientation and Applications Non-Conductive Pipe Grounding If the process pipeline material is not electrically conductive and your meter was not ordered with an optional grounding electrode, place a grounding ring (available from Badger Meter) between two gaskets on both ends of the meter . GROUNDING RING INSTALLATION KIT SUPPLIED HARDWARE INCLUDES: 2 GROUNDING RINGS...

  • Page 15: Meter Installation Plans And Execution

    Meter Installation Plans and Execution METER INSTALLATION PLANS AND EXECUTION Plan meter layout, location and installation . During installation, remember these important points: • Heed all safety notifications . • Select a detector location with room for installation and maintenance procedures . •...

  • Page 16: Remote Mount Amplifier/Detector Wiring

    Meter Installation Plans and Execution Remote Mount Amplifier/Detector Wiring Remote Mount Amplifier The remote mount amplifier has three chambers and five wire ports . The junction box and connections chambers and wiring ports provide amplifier openings for wire, conduit, tool and hand access to amplifier terminal blocks . Detector to amplifier wires connect in the junction box chamber .
  • Page 17 Meter Installation Plans and Execution Electrode and Coil Wiring from Detector Junction Box to Remote Mount Amplifier Junction Box A remote mount unit requires electrode and coil cables, from the detector junction box to the amplifier junction box, be enclosed in properly rated conduit . Use conduit fittings (not supplied) that are rated for Class I, Div 2 hazardous locations . FAILURE TO USE PROPER CONDUIT FITTINGS RATED FOR CLASS I, DIV 2 HAZARDOUS LOCATIONS INVALIDATES THE FM RATING AND ANY WARRANTIES, EXPRESSED OR IMPLIED, FOR THIS EQUIPMENT.
  • Page 18 Meter Installation Plans and Execution Figure 25: Remote mount wiring diagram Page 18 MAG-UM-00158-EN-07 June 2018...
  • Page 19 Meter Installation Plans and Execution Electrode Wiring in Amplifier Junction Box To connect the electrode wires in the amplifier junction box: 1 . Unscrew the amplifier junction box chamber cover . If necessary, use a strap wrench . 2 . Remove the protective plastic cover to access the terminal block screws . OTEE: Plastic cover must be reattached when wiring is complete .

  • Page 20: Output Wiring

    6 . Attach the amplifier junction box chamber cover . Output Wiring The M-Series M3000 meter converts liquid flow into electrical signals . With proper output wiring and amplifier programming, the signals are sent to, and used by, processing equipment used in operations or other procedures .
  • Page 21 Meter Installation Plans and Execution • If an NPT connection is not used, then a plug equipped with thread sealant that is approved for NEMA 6P (IP67) must be used to fill the hole . NOTE: All three NPT connections of the amplifier housing come equipped from the factory with hole plugs incorporating approved thread sealant •...

  • Page 22: Output Wire Connections

    Meter Installation Plans and Execution Output Wire Connections • PROPERLY TRAINED PERSONNEL MUST PERFORM ALL INSTALLATION AND/OR REPAIR PROCEDURES. • DISCONNECT POWER TO THE UNIT BEFORE ATTEMPTING ANY INSTALLATION OR MAINTENANCE. To connect control signal wires: 1 . Remove the connections chamber cover . If necessary, use a strap wrench . 2 .

  • Page 23: Auxiliary Input Wiring Diagram

    Meter Installation Plans and Execution Auxiliary Input Wiring Diagram Function: Reset Positive Zero Return +18VDC 1 Normally Open Contact Input 1 (+) Input 1 (+) 5-24VDC Common Figure 30: Auxiliary input wiring Auxiliary Output Wiring Diagram Function: 4-20mA • Analog Output (Loop voltage = 18VDC Sourced, 750 MAX) 0-20mA 0-10mA...

  • Page 24: External Disconnect

    Meter Installation Plans and Execution External Disconnect POSITION THIS DEVICE IN AN ACCESSIBLE LOCATION. • Position and identify the disconnect device so as to provide safe and easy operation . • Label the disconnect device as being for the Mag Meter . •...

  • Page 25: Adjustable Display/Control Card

    Meter Installation Plans and Execution Adjustable Display/Control Card Because meter positioning sometimes places the amplifier display/programming chamber in an awkward position, the display/control card is adjustable in 90-degree increments . DISCONNECT MAIN POWER TO THE UNIT BEFORE ATTEMPTING ANY DEVICE MAINTENANCE. To re-position or rotate the display/control card in the amplifier: 1 .
  • Page 26 Meter Installation Plans and Execution 7 . Push card in, between holding clips . Lower card back into position and attach card with screws and washers . 8 . Attach the chamber cover . Page 26 MAG-UM-00158-EN-07 June 2018...

  • Page 27: Programming The M3000

    Programming the M3000 PROGRAMMING THE M3000 The M3000 amplifier is pre-programmed from the factory, based on information available at the time the unit was ordered . In most instances, it will not require any changes . The M3000 can be programmed to meter many flow situations and serve a variety of purposes during a production process . To meet diverse needs, there are a wide variety of programming options and parameters .
  • Page 28 Programming the M3000 How to Use the Controls for Programming All M3000 programming is accomplished using the three control switches or the three control push buttons located on the front of the amplifier in conjunction with an on-screen locator arrow . Use these controls to access menus, move from screen to screen, select parameters and settings, and enter values .

  • Page 29: M3000 Menu Structure

    Programming the M3000 M3000 Menu Structure The flowchart on these two pages shows each menu and its submenus: • Each separate screen is inside a box . • If a screen “branches”, each screen of the branch is in a box to the right . •...
  • Page 30 Programming the M3000 Digital Out . #3 Preset Amount Set batch amount for Preset output. Solid-state relay Setpoint Min . Set for Flow Setpoint output. Setpoint Max . Set for Flow Setpoint output. Output Type Select N.O. or N.C. for any output function. Select Function None Preset Output...

  • Page 31: Programming Practice-Understanding The Main Screen

    Programming the M3000 Programming Practice—Understanding the Main Screen The Main screen always displays when programming functions are not occurring . OTEE: If no contact is made with the control switches or buttons for 2 minutes, the display automatically returns to the Main screen .

  • Page 32: Programming Practice-Navigating The Menus

    Programming the M3000 However, if the wrong password was entered, the INVALID PSWD 02 screen opens . 1 . Tap +, – or E to return to the Main screen . 2 . Tap E again . The PASSWORD??? 01 screen returns . Enter the correct password as described above .
  • Page 33 Programming the M3000 Pipe Dia. 5 . On the PIPE DIA . 11 screen, move the arrow to the appropriate pipe size . PIPE DIA. 6 . Tap E . --------------- Exit this Menu A status screen, with the statement [(xx mm [xx"] ) 6mm [1/4"] **SELECTED** displays for about 2 seconds .
  • Page 34 Programming the M3000 Empty Pipe Empty Pipe is a branch list screen from the MAIN MENU 00 screen . From here, you can set Calibrate ON or OFF . 1 . Tap E to return to the MAIN MENU 00 . 2 .

  • Page 35: Programming The Required Parameters

    Programming the M3000 Programming the Required Parameters As you program parameters, see the “M3000 Menu Structure” on page 29. All meters have required parameters that must be programmed . They include a Password (if desired), the Main screen for Uni-Directional or Bi-Directional Flow, Empty Pipe, Pulse Output and Analog Output, among others .
  • Page 36 Programming the M3000 Set Flow Rate Unit of Measure and Totalizer Unit of Measure 1 . With the Main screen displayed, tap E to open the MAIN MENU 00 screen . 2 . Move the arrow to Measurements . 3 . Tap E to open the MEASUREMENTS 20 screen . 4 .
  • Page 37 Programming the M3000 Set Full Scale Flow Rate Value 1 . On the MEASUREMENTS 20 screen, move the arrow to FullScaleFlow . 2 . Tap E to open the FullScaleFlow 23 screen . 3 . Tap + or – to increase or decrease the underscored number to the desired digit . 4 .
  • Page 38 Programming the M3000 Set Damping Factor 1 . On the MEASUREMENTS 20 screen, move the arrow to Damping Factor . 2 . Tap E to open the DampingFactor 26 screen . 3 . Move the arrow to No Damping or to one of the time frames . A status screen displays for two seconds, then the display goes back to the MEASUREMENTS 20 screen .
  • Page 39 Programming the M3000 Empty Pipe Calibration 1 . On the Main screen, tap E to display the MAIN MENU 00 screen . 2 . Move the arrow to Meter Setup . 3 . Tap E to open the METER SETUP 10 screen . 4 .
  • Page 40 Programming the M3000 Full Pipe Calibration 1 . On the EMPTY PIPE 1E screen, move the arrow to Cal. full pipe . 2 . Tap E to open the FULL PIPE CAL 1F screen . 3 . Move the arrow to Cal[OFF] E=ON . 4 .
  • Page 41 Programming the M3000 Pulse Output 1 . With the Main screen displaying, press E once to open the MAIN MENU 00 . 2 . Move the cursor to Inputs/Outputs . 3 . Tap E to open the IN/OUTPUTS 30 screen . 4 .
  • Page 42 Programming the M3000 Setpoint OTEE: This is only for Flow Setpoint . See “Digital Out. #1” on page 33 . 1 . On the DIG OUTPUT 1 33 screen, move the arrow to Set point min . 2 . Tap E to open the SET PT MIN 3F screen . 3 .
  • Page 43 Programming the M3000 Output Type 1 . On the DIG OUTPUT 1 33 screen, move the arrow to Output Type . 2 . Tap E to open the OUTPUT TYPE 3H screen . 3 . Move the arrow to Normally Open or Normally Closed . 4 .
  • Page 44 Programming the M3000 Analog Output 1 . With the Main screen displaying, press E once to open the MAIN MENU 00 screen . 2 . Move the cursor to Inputs/Outputs . 3 . Tap E to the IN/OUTPUTS 30 screen . 4 .
  • Page 45 Programming the M3000 16 . Move the arrow to FS Calibrate . 17 . Tap E to open the ANALOG FS CAL 3C screen . 18 . Based on the amp meter reading, move the arrow to Decrease AO or Increase AO . 19 .

  • Page 46: Maintenance

    Maintenance MAINTENANCE Mandatory, routine or scheduled maintenance should not be required for the Badger Meter M3000 Mag Meter electronics or flow tube, after proper installation . However, some occurrences may require personnel to perform the following: • Flow Tube and Electrode Cleaning •...
  • Page 47 Maintenance 1 . Remove the display chamber cover . Turn the cover counterclockwise to remove it from the amplifier . If necessary, use a strap wrench . 2 . Remove the two display card screws and washers . 3 . Tilt the card up and out approximately 45 degrees at the holding clips . 4 .

  • Page 48: Amplifier Printed Circuit Board (Pcb) Stack Replacement

    Maintenance Amplifier Printed Circuit Board (PCB) Stack Replacement All M3000 mag meters operate through printed circuit boards (PCBs) housed in the amplifier . The PCBs are grouped in a stack located behind the display/control card in the display/programming chamber . Because PCBs are complex circuits, with all meter functions enabled through multiple links and layers, determining the exact board and circuit that is causing a system problem is difficult and usually requires...
  • Page 49 Maintenance 6 . Disconnect the power, coil, electrode and I/O plugs and harnesses from the PCB interconnect card . 7 . Remove the 4 screws holding the PCB stack in the amplifier housing . Place in storage for reuse . 8 .

  • Page 50: Specifications

    Specifications SPECIFICATIONS M3000 Meter Flow Range 0 .1…39 .4 ft/s (0 .03…12 m/s) Flow Direction Uni-directional or Bi-directional Sizes 1/4…24" (6…600 mm) Conductivity Min . 5 micromhos/cm Accuracy ± 0 .25% of rate for velocities greater than 1 .64 ft/s (0 .50 m/s) ±...

  • Page 51: Amplifier

    Specifications Amplifier Junction Box on Detector Figure 44: Detector mount amplifier Figure 45: Remote mount amplifier Power Supply Excitation AC or optional 24V DC Programmable; 3 .75 Hz, 7 .5 Hz or 15 Hz Frequency (3 .125, 6 .25, 12 .5) AC Power Supply: 85…265V AC 45…65 Hz Auxiliary Input Max .
  • Page 52 M-Series® M3000, Electromagnetic Flow Meter, Class 1, Division 2 Environments Control. Manage. Optimize. M-Series is registered trademark of Badger Meter, Inc . Other trademarks appearing in this document are the property of their respective entities . Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specifications without notice, except to the extent an outstanding contractual obligation exists .

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