WA0001-MN000630TPC ELECTRIC COMPANY, INC.
6309 INDUSTRIAL DR.
SACHSE, TEXAS 75048
PROJECT:
CITY OF COPPELL, TEXAS
VILLAGE PARKWAY PUMP STATION ADDITIONS
O & M MANUALS FOR:
BADGER METER
ARCHITECTI.
300
FORT WORTH,
PROJECT
SHIMEK, JACOBS, & FINKLEA, CONSULTING ENGINEERS
8333 DOUGLAS AVE. #820
DALLAS, TEXAS 75225
Compu-$onic Flowmeter
Closed Pipe
Badger Meter
Instruction Manual
BadgerMeter~ Inc. Industrial Division
P.O. Box 581390, 6116 East 15th. Tulsa, OK 74158
918/836-8411
RCA 203605
941288
Badger Meter, inc., Industrial Products Division
4500-6 C0mpu-Sonic Data Sheet
1.04
Date
Entered By
Badger Order-Item Nbr
Customer PO Nbr
Customer Name
User Name
Consulting Engineer
Tag Information
Serial Number(s)
Existing Application
04-JAN-00
CWS
- 01 - ,-! :~, Z,4Y
TPCE-111-001
TPC ELECTRIC COMPANY
CITY OF COPPELL
36"
No
Fluid Selection Parameters
Application Type Wastewater/Water
Flow Media Water
Maximum Temp [°F] 68
Maximum Pressure [PSI] 150
Fluid Viscosity [Cp] 1.000
Fluid Specific Gravity 1.000
Fluid Sonic Velocity [Ft/Sec] 4800
Solids Concentration [% Vol] 0
[] Corrosive [] Aeration Present Fluid is Non-Corrosive
Other Customer Requirements
Customer Selected
Full Scale Flow Rate [ MGI)
[] Lab Calibration []:actory Mutual Approval
[] Remove Sensors w/o Process Interuption
Full pipe flow at all flow conditions
30
Pibe Info
One Way Cable Length [Ft]
Pipe Inside Diameter [Inches]
Pipe Wall Thickness [Inches]
Pipe Material
Liner Thickness [Inches]
Liner Material
Pipe Wall Condition
Sensor Installation Pipe Access
Hydraulics Info
Not Specified
36' STANDARD
100 [] Splice Allowed
35.250
0.375
Carbon Steel
0
None
[] Pipe Wall is Highly Corroded or Internal Mineral
Deposits or Sludge Build-up present
[] Internal [] External
[] Not Specified
Not Specified
Warning,.. Hydraulics data not specified. Accuracy and/or Performance of meter may be affected.
Badger Meter,
4500-6
Date
Entered By
Badger Order-Item Nbr
Customer PO Nbr
Customer Name
User Name
Consulting Engineer
Tag Information
Serial Number(s)
Existing Application
Meter Inf0
Frequency [KHz]
Flow Direction
Meter Config
Site No
Flow Rate Info
Flow Rate Units
Display Rate Multiplier
Full Scale Maximum
Full Scale Minimum
Selected Full Scale
Inc., Industrial Products Division
Corapu-S0nic Data Sheet
1.04
04-JAN-00
CWS
- 01 -
TPCE-111-001
TPC ELECTRIC COMPANY
CITY OF COPPELL
6II
No
640
Uni-Dir
Rate/Total
0001
MGD
.01
65.185
2,037
30
Totalizer Info
Totalizer Units
Totalizer Multiplier
GALS
1000
Calculated Parameters
Full Scale Velocity [ FPS ] 6.84
Reference Reynolds No. 994446
Fluid Transit Time [uS] 646.636
System Delay Time [uS] 11.143
Full Scale Phase [Deg] 152.33
Kfactor 1.048
Calibration Mode Info
Meter Rescale - Full Scale
Meter Factor
Totalizer Enabled/Disabled
Response Time
Failure Mode - Fail To
Contact Integrator
Integrator Pulse Width On For
Remote Tot Pulse Width On For
Voltaoe/Enclosure
3000
1.000
Enabled
0007
Zero
0001
0002 X 0.01 Sec
0005 X 0.01 Sec
117 AC Nema4X
Setpoint #1 On% Of P/o 00.0 00.0
Setpoint #2 On% Off % 00.0 00.0
Relay Assign 01 NONE
Relay Assign 02 NONE
Relay Assign 03 NONE
Relay Assign 04 NONE
Security ID 0000
Sensor Jumper Setting Low
Date
Entered By
Badger Order-Item Nbr
Customer PO Nbr
Customer Name
User Name
Consulting Engineer
Tag Information
Serial Number(s)
Existing Application
Sensor Style
Sensor Separation [IN]
Effective Diameter [IN]
Frequency [KHz]
Crossing Angle [Radians]
Badger Meter, Inc., Industrial Products Division
4500-6 Compu-Sonic Data Sheet
1.04
04-JAN-O0
CWS
- 01
TPCE-111-001
TPC ELECTRIC COMPANY
CITY OF COPPELL
No
Windowed Spool WD-1
13.15 Inside Diameter [IN]
35 EndF~'~j
640 Range Matedal
20* pi / 180 Pipe Wall Material
Length [1N]
Part Number
FLOW.>
35.250
AWWA CL D FF
Carbon Steel
Carbon Steel
36.00
542578-0028
Customer Approval
As an authorized representative of
I certify the accuracy and completeness of the flow meter application data contained
herein. I further understand that failure to provide accurate and complete application
data could affect the installation, oderation, and/or the accuracy of the flow meter
manufactured for this application.
Signed
Date
SCOPE OF MANUAL
This manual contains information concerning the
installation. operation and maintenance of the Series 4500
Compu-Sonic uhrasonic flowmeter. To ensure proper
performance of the meter, the instructions given in this
manual should be thoroughly understood and Ibllowed.
Keep the tnanual in a readily accessible location for
future reference.
Changes and additions to the original edition of this
manual will becovered by a "CHANGE NOTICE" supplied
with the manual.
SERIES 4500 COMPU-SONIC
TABLE OF CONTENTS
Page
Page
Unpacking and lnspeclion .......................... I- I
INSTALLATION PROCEDURE
Electronics
Enclosu~v Mounting and Wiring ............... 2-1
Outdoor Enclosure ................................ 2-6
450 )R+ (wilh Recorder) ......................... 2-6
Splice Procedure .................................. 2-7
Sensors
Sensor & Mounting Hardware ................. 3-2
V-Shot Strap-on ................................... 3*3
Z-Shot Strap-on ................................... 3-4
2 Inch Strap-on .................................... 3-10
Hi-Temp Sirup-on ................................. 3-1 I
Window Spool ..................................... 3-12
HS3 "Hotshot" Sensor ............................ 3-13
Instrcam RefractingSensor ...................... 3-16
Wetted Sensor with Hoop ........................ 3-17
OPERATION
Menu Funclions ...................................... 4-1
'Froublcshooting Guide ............................. 5-I
Illustrated Parts List ................................. 6-I
UNPACKING &
INSPECTION
To avoid damage in transit, Badger products are shipped
to the customer in special shipping containers. Upon receipt
of the product, perform the following unpacking and
inspection procedures:
NOTE: If damage to the shipping container is evident
upon receipt, request the carrier to be present when the
product is unpacked.
a. Carefully open the shipping container Mlowing any
instructions that may be marked on the box. Remove all
cushioning material surrounding the product and carefully
lift the product from the container.
Retain the container and all packing material for
possible use in reshipment or storage.
b. Visuallyinspecttheproductandapplicableaccessories
for any physical damage such as scralches, loose or broken
parts or any other sign of damage that may have occurred
during shipment.
NOTE: If damage is found, request an inspection by
the carrier's agent within 48 hours of delivery and file a
claim with the carrier. A claim for equipment damage in
transit is the sole responsibility of the customer.
01-00
1-1 941288
INSTALLATION
ELECTRONIC ENCLOSURE
The Series 4500 electronics is housed in a rugged, NEMA
4X rated, polycarbonate enclosure which can be wall
mounted. Supplied with each unit are two I/4-20 x 3/4 inch
mounting screws for use with lead inserts, two I/4-20 x 3/4
inch sheet metal screws for other wall materials, and two "O"
rings necessary to maintain the NEMA 4X rating of the
enclosure.
When mounting the Series 4500 electronics, select a
location that has good ventilation, temperature within the
meter's specification, not in direct sunlight, not subject to
flooding, protection from accidental shock, and provides
accessibility to operate and service the meter.
ENCLOSURE MOUNTING
To mount the enclosure, using the 5/32 inch Allen wrench
supplied in the mounting hardware package, loosen and
remove all four hex bolts in the front of the housing (see
Figure 2-1). Separate the fronl and back housings.
CAUTION: THERE ARE TWO SIGNAL WIRES ON
THE FRONT HOUSING AND A RIBBON CABLE ON
THE POWER SUPPLY BOARD THAT WILL NEED
TO BE DISCONNECTED WHEN REMOVING THE
FRONT HOUSING (SEE FIGURE 2-2). Place the front
housing in a protected area so it will not be damaged while
mounting the back housing.
To mount the back housing, drill two holes in the wall 4.5
inches apart (centerline to centerline, see Figure 2-3). The
size of the holes wi I1 depend on whether lead inserts are used
or the mounting screws are screwed directly in the wall.
Select the appropriate screws and place the "O" rings on the
screws. With a 3/8 inch hex head driver, secure the back
housing to the wall. Since the power supply board is in the
back housing, care should be taken to prevent damaging
any components on the board.
HOUSING /~
GASKET
(~ / MOUNTING
~ ~ / SCREW AND
'O" RING
FIGURE 2-1
FIGURE 2-2
RIBBON CABLE
SIGNAL
WIRE
POWER
SUPPLY
BOARD
'~~SCREW
4.5"
CL-CL
FIGURE 2-3
2-1
WIRING CONNECTIONS
The Series 4500 electronics enclosure is provided with
three holes for I/2 i nc h NPT condu it fi tti ngs. These holes are
on the bottom of the back housing of the enclosure and allow
entry for the 115 or 230 VAC power wires, sensor cables and
4-20 mADC signal output wires. The AC power lines as
well as the sensor cables must be in separate metallic
conduits or the operation of the meter could be affected.
The terminals on the power supply board will accept 14 to
22 gauge wire. A small common screw driver will be
required to loosen and tighten the screws. The connectors
snap off the board to facilitate the inserting of the wires
easier.
Power supply connections (Figure 2-4). Terminal
connector TB 1 is for the I 15 VAC connections. Terminal 1
is the high side (black wire) connection. Terminal 2 is the
low or neutral side (white wire) connection. Terminal 3 is
the earth ground (green wire) connection.
Terminal connectorTB2 is for the 12VDC external battery
power connections and the 4-20 mA output. Terminal I is
the positive (+) connection and Terminal 2 is the negative (-)
connection for the battery (12 VDC) power input. The
voltage range for this input is 9VDC to 14VDC. This input
will operate the meter but not the 4-20 mA output. Terminals
3 and 4 of TB2 are for the 4-20 mA output. Terminal 3 is the
positive (+) connection and Terminal 4 is the negative (-)
connection. The maximem load resistance when bperating
the meter with AC power is 1000 ohms.
To power the 4-20 mA output when operating with DC
power, the DC power must be connected in series with the
load (recorder) as shown below.
4-20 mA
Output
-- +
VDC
+ Recorder or
_ Other device
DOT
FIGURE 2-4
BACK HOUSING POWER SUPPLY
2-2
The size of the DC supply will depend on the load
resistance the 4-20 mA is driving. It requires 8 VDC to
power the 4-20 mA circuitry. The equation to determine the
required voltage for a load is:
V = (R * .02) + 8
where:
V = Power supply in VDC
R = Resistance of load in ohms
For example, if the device connected to the 4-20 mA
output has a resistance of 250 ohms, then the required power
supply is 13 VDC.
V = (250 * .02) + 8
V= 13VDC.
The terminal strip TB3 has the connections for the four
relay outputs. These are labeled SWI through SW4 and
represent relays I through 4 respectively. These relays are
SPDP and are rated for I amp at 24 VDC or 0.5 amp at 120
VAC.
The output of these relays will depend on the assignment
gi yen to them in the Calibration Mode. Refer to Page 4-7 for
furtherdetails regarding the assignment of specific functions
to the relays.
There are two test point jacks on the bottom of the case
between the third and fourth conduit holes. These allow the
checking of the 4-20 mA output with a current meter. A load
must be connected to the 4-20 mA output terminals. Do not
use these jacks as a second 4-20 mA output or the normal
output will be affected.
1-3/4"
Remove
outer
cover
1-1/8"
1-3/8" ,_L_
Remove Remove
outer
shield
3/4" 1 . ~"
· ~ 1/4
li,.,
~ ~ /8"
,I,
Remove Remove Completed
middle ,.,- middle ,,, inner / cable
cover 3 shield 4 cover 5 6
FIGURE 2-5
SENSOR CABLE PREPARATION
Sensor cable connections. Before pulling the sensor
cables through the conduit, mark the ends of the cables to
indicate which is the upstream and downstream sensor
cable. Leave approximately 8 inches of cable extending
from the conduit in the enclosure. Refer to Figure 2-5 and
prepare the cable ends in the following manner.
I. Remove outer cable cover. Measure I-3/4" from the
end of the cable. With a cutting tool, carefully cut through
the outer covering completely around the cable making sure
not to cut into the outer shield. Make another cut from the
first cut to the end of the cable and remove the outer cover.
2. Remove outer shield, Measure I -3/8" from the end of
the cable. With a pair of small cutters, cut the shield around
the cable at the measured point and remove the cut off
shield.
3. Remove middle cover, Measure I - I/8" from the end
of the cable. With a cutting tool, carefully cut through the
middle covering completely around the cable making sure
not to cut into the middle shield. Make another cut from the
first cut to the end of the cable and remove the middle cover.
4. Remove middle shield. Measure 3/4" from theendof
the cable. With a pair of small cutters, cut the shield around
the cable at the measured point and remove the cut off
shield.
2-3
5. Removeinnercover. Measurel/2"ii'omtheendofthe
cable. With a cutting tool or pair of wire strippers, carefully
cut tbe inner covering completely around the cable, making
sure not to cut into thecenterconductorand remove the inner
cover.
After the ends of the cables have been prepared, loosen the
screws on Terminals 1 and 2 of TB4 on the back housing
power supply and remove the two pairs of c!amps below
TB4. Take the upstream cable and insert the center conductor
into Terminal I and tighten the screw. Slightly pull on the
cable to ensure the wire is secured to the terminal. Take the
downstream cable and insert the center conductor into
Terminal 2 and tighten the screw. Slightly pull on the cable
to ensure the wire is secured to the terminal.
Place the two pair of clamps over the middle and outer
shields and secure them into place. Verify that the clamps
are making good contact with the shields and that no wires
of the shields are extending beyond their own clamp down
area.
Front housing installation. After the wiring of the back
housing is completed, the front housing can be reinstailed.
The gasket is attached to the front housing to ensure proper
alignment for maintaining a good seal.
Refer to Figure 2-6. On the front housing there is a
protective cover for the electronic boards that also has the
drawing for the wiring connections of the unit. Connect the
ribbon cable plug S 1 com, ing from the front housing into the
socket connector PI on the power supply in the back
housing.
Insert the two signal wires coming from the power supply
board in the back housing into the connectors on the electronic
board in the front housing. One of the signal wires has a
white dot marked on it and should be inserted into the
connector next to the dot indicated on the protective cover
drawing. Secure the front housing to the back housing with
the four hex bolts.
Page 2-6 shows the wiring for the Series 4500 mounted in
the 3000+ recorder and in an outdoor enclosure with heater
and thermostat.
2-4
DOT
BACK HOUSING POWER SUPPLY BOARD7
=, ,~, ::~~ ~ -
~ Z' ~ . TP4 + 40VDC
~' Tea1I I II II I~ ? liP5+ 4-20mA
Test Poinls
FIGURE 2-6
117VAC FROM CUSTOMER TERMINAL TO 4500
AND RECORDER TERMINALS AND 4-20 MADC
SIGNAL FROM 4500 TO RECORDER ARE PRE-WIRED
AT THE FACTORY
RECORDER ACCESSORY OUTPUTS
SEE RECORDER MANUAL PG. 4
UPSTREAM & D TB5
DOWNSTREAM -
SENSOR TERMINATION ~ g '1'94 ~ ~ -
(SEE MANUAL PG. 2-3 D '1~
· 2-41
D 1/;
/
HI LO GND
117VAC
CUSTOMER INPUT
FIGURE 2-7
SERIES 4500 IN 3000+ RECORDER
WIRING DIAGRAM
OUTDOOR ENCL.
DIMENSIONS
A= 8.0O"
B= 10.75"
C= 12.75" '.,_.
D= 13.50" ~ ~
E= 5.62" E
-,~ UPSTREAM &
DOWNSTREAM
I
TERMINAL TO 4500
ARE PRE-WIRED
HI LO GND
117VAC
CUSTOMER INPUT
FIGURE 2-8
SERIES 4500 OUTDOOR ENCLOSURE
WIRING DIAGRAM
TRIAX CABLE SPLICE PROCEDURE
Materials Required
* 4 pigtail cap crimps (wire size 18-12)
* 2 center conductor cap crimps (wire size 22-14)
* 1 roll of electrical tape
* 2 epoxy resin envelopes
Crimp tool (customer supplied)
Knife (customer supplied)
Pointed tool (customer supplied)
Junction box (customer supplied)
A cable connection kit may be purchased through Badger
Meter that will include the * items above (Part # 541874).
Trim each of the four cables at the junction box to 9 inches
in length. Each of the four cables can now be prepared as
described in the sequence following:
7, B C D E F ~a
Using a knife, trim two inches of the outer jacket from
each cable, The wire braid beneath the outer jacket must not
be cut. See "A".
Using a pointed tool, carefully comb out the outer braid of
each cable as shown in "B". Form the combed braid into a
pigtail dressed to the side of the cable as shown in "C".
Trim I inch of the inner jacket from each of the cables as
shown in "D". Again, use care not to cut the inner braid
beneath the i n net jacket.
Using a pointed tool, carefully comb out the inner braid
"E" and form into a pigtail dressed to the same side of the
cable as outer pigtail in "F",
Remove I/2 inch of insulation from the innerconductor of
each cable. Cut the outer pigtail to the same length as the
inner pigtail on each cable. "G" depicts the completed
preparation.
FIG 1 FIG 2
Cable Termination
Pull cables approximately 18 inches outside of junction
box. Select one sen sot cable and one cable from the electron ic
enclosure and place them side by side as shown in Fig. 1.
Twist each cable's outer pigtails together, then the inner
pigtails together and finally the center conductors together
to form the cable splice. In similar fashion, connect the
remaining sensor cable and the cable from the electronic
enclosure.
Identification of upstream and downstream sensor cables
must now be made. Connect a short wire from the center
conductor splice to the inner shield pigtail splice on the
upstream sensor cable. Using a multimeter determine the
upstream sensor cable at the electronic enclosure end by
continuity measurement. Identify the upstream cable for
later termination.
Remove the shorting wire and using the cap crimps
supplied, crimp the larger caps on each spliced pigtail and
the small cap on the center conductor splice as shown in Fig.
2. Repeat this procedure for the second cable.
At this point turn power on at the electronics and verify
that an OK signal condition appears on the display.
Turn power "OFF".
Using Scotchlok Sealer
I. Read caution statement at bottom.
2. Remove guard bag, using caution not to damage
inner bag.
3. Grip both edges of bag at the center barrier (Fig. 3)
and wrinkle and flex the bag across the barrier. This
will weaken the barrier.
4. Squeeze the clear side of the resin, forcing the resin
through the center barrier.
5. Mix thoroughly to a uniform color by squeezing
contents back and forth 24-30 times.
6. Squeeze resin to one end of bag, and cut oft' the
other end (Fig. 4).
7. Slowly insert connection into sealing pack until it fits
snugly against the opposite end (Fig. 5).
8. Wrap open end of bag with vinyl electrical tape and
position the taped end up until resin jells (Fig. 6).
The finished splices should be coiled inside the junction
box. When properly placed, the spl ices should be clear of the
junction box cover area. Proper sealing of the junction box
is necessary for watertight integrity.
This completes the triax cable splice connection.
The sealer kit above is a 3M Scotchlok #3570 product
IRRITATING TO SKIN AND EYES ON DIRECT
CONTACT
May cause skin sensitization in susceptible individuals. May be
toxic by skin absorption.
Harmful if swallowed. Vinyl cyclohexene dioxide has caused
skin cancer in animal tests.
Contains epoxy resin and vinyl cyclohexene dioxide.
Avoid skin and eye contact. Use only in well-vend lated areas with
sufficient air movement to maintain airborne vapor levels at
recognized health and safety levels. Wash thoroughly after using.
before eating, drinking or smoking.
EYE CONTACT: Immediately flush eyes with water for at least
ten minutes. Call physician.
SKIN CONTACT: Wash with soap and water. INHALATION:
Provide fresh air.
2-7
SECTION 3 - SENSOR INSTALLATION
This section includes installation for the various sensors Customer Data Sheet in the front of this manual to determine
used with the Series 4500 ultrasonic flowmeter. Refer to the
SENSOR TYPE PAGE
V-SHOT
STRAP-ON 3-3
the type of sensors that are supplied.
Z-SHOT
STRAP-ON
3-4 THRU 3-9
2" STRAP ON 3- I 0
HI-TEMP
STRAP ON 3- I I
WINDOWED SPOOL
HS3 "HOTSHOT"
SENSOR
3-12
3-13 THRU 3-15
FLOW
FLOW
INSTREAM
REFRACTING SENSOR
3-16
WETTED SENSOR
WITH HOOP
3-17 THRU 3-18
3-1
STRAP-ON SENSORS
The strap-on sensors for the Series 4500 are designed for
external mounting on pipes made of material, such as steel
or plastics, that will support ultrasonic signal transmissions.
The mounting hardware i s constructed of corrosion resistant
materials and designed for ease of installation.
It is important that the sensors are installed correctly on
the pipe to ensure good accuracy. A template is provided for
positioning the sensor holders on the pipe. The proper
configuration for your application is indicated on the data
sheet in the front of this manual. When properly installed,
the sensors will be located 180 degrees apart on opposite
sides of the pipe and be offset upstream and downstream by
the distance on the Data Sheet in the front of this manual. The
sensors may be mounted on horizontal or vertical pipe runs.
If the pipe is horizontal, the sensors must be located on
the sides and not on the top and bottom.
It is important that there be as much upstream straight run
as possible so there will be a well developed velocity profile
at the point of measurement. There should be 3 pipe diameters
of downstream straight run after the point of measurement.
WIDTH
7"
14"
21"
28"
35"
42"
56"
MOUNTING CONFIGURATION
CaseB&C
Case D
Case E
Case F
CaseG
Case H
Case I
Case J
3-2
SERIES 4000 V-SHOT SENSOR INSTALLATION
~f ~ ITEM DESCRIPTION QTY
I. SENSOR HOLDER 304 S/S I
2. SENSOR W/100 FT. CABLE 2
t ~ ~ ~ 3. SENSOR CLAMP & 7/16 HEX HEAD SCREW 4
4. SILICONE (FOR SENSORS) I
4. 5. WIRE ROPE I/8" DIA. (CUT PER ORDER) 2
2. a. (L~5~ 6. ALLEN WRENCH
C~ .......................... ~3 6.
s.
NOTE: Pipe preparation before installation. It may be necessary, particularly with Cast Iron or Ductile Iron pipe,
to sand pipe to a smooth and radial surface where the sensors are to be placed.
Place the probe holder ( I ) on the top of the pipe.
\ ~\ // PIPE //
\ /
WRAPPING THE CABLE
I. Placeoneendofthestainlesssteelcablethroughtheslotclosest
to the rail and opposite of the clamp side.
2. Pull cable over the groove in the tension holder (9).
3. Pull cable through the slot on the holder.
4. Wrap cable completely around the pipe.
5. Pull cable through the slot on the holder.
6. Pull cable over the groove in the tension holder (9).
7. Pull cable through the slot on the holder.
8. Loosen the cable clamp with the socket head screw. Slide the
cable betweeh the probe holder and the cable clamp. Pull the
excess cable through the clamp.
9. Tighten the socket head screw.
Repeat the above instructions for the otherend of the probe holder and
cable.
Slide the probe holder down to the side of the pipe.
10. Use the Allen wrench and turn the tension holder screw (10)
counterclockwise until the probe holder is tight against the pipe.
Place a single bead of siticone grease (4) longitudinally along the PVC face of the sensor. Slide sensor (2) into sensor holder
( I ), note that the sensor cable (yellow) will be pointing toward the other sensor (Fig. 3). Use sensor clamp (3) and place the
top over the sensor with hubs in sensor hole and place the bottom of the clamp on the bottom of the rail of the sensor holder.
(See A-A detail)
~ SILICONE GREASE (4.) A'A DETAIL
3. FIG. 2
SENSOR SEPARATION
IN INCHES*** (Inside edges of sensors)
FIG. 3
See Data Sheet in front of customer IOM manual. Locate on Page 2 of Data Sheet Sensor Style Section. The Sensor Offset
in inches will be displayed as "Offset #.#,~q4 Inches". The offset in inches is the separation to be used on the top ruler on the
probe holder. AIign Top right edge of the left hand sensor on the "0" on the top ruler on the sensor holder. Move the right hand
sensor to the sensor separation in inches using the upper left edge of the right hand sensor to the Offset distance. Tighten hex
head screws on the sensor clamp (3) snugly to the sensor holder with Hex wrench. See IOM manual for cable termination
at electronics.
3-3
SERIES 4000 Z STRAP-ON SENSOR INSTALLATION (CASE B)
7~ ~ ITEM DESCRIPTION QTY
/
" I. SENSOR HOLDER 304 S/S 2
2. SENSOR W/100 PT. CABLE 2
~ 3. SENSOR CLAMP & 7/16 HEX HEAD SCREW 4
l ~ D 4. SILICONE (FOR SENSORS) 1
· .~ ~:~', 4. 5, WIRE ROPE I/8" DIA. (CUT PER ORDER) 4
a. 3. ~ 6. ALLEN WRENCH I
~ ..........................~ ~. 7. MYLAR TEMPLATE I
NOTE: Pipe preparation before installation. It may be necessary, particularly with Cast Iron or Ductile Iron pipe,
to sand pipe to a smooth and radial surface where the sensors are to be placed. If pipe is Asbestos Cement place a coat
of shellac over the surface where the sensors are to be mounted.
Using tape, attach one end of the template (7) to the pipe and wrap the rest of the tomplate around the pipe. Pull the ternplate
straight and mark the point of overlap on the template. Cut off the excess.
Remove ternplate from pipe. Fold template exactly in half and crease in the middle. Wrap the template around the pipe so
that the crease is on one side of the pipe and the two ends of the template meet on the other. side of the pipe. Try to line up
the crease and ends with the horizontal center of the pipe. Tape the ends of the template together with masking tape to hold
in place on the pipe (Fig. I).
Fig. 2
' I HOL~LDER r()r
LEFT BLACK LINE
Fig. 3 (
RIGHT BLACK LINE
Place the probe holders ( I ) on the top of the pipe. The probe holder on the right hand side should have the ruler on the upper
right corner and should be lined up with the right black line in the middle of the ternplate (Fig. 2 & 3). The probe holder on
the left should be upside down and have the ruler on the lower left corner and should be lined up with the left black line in
the middle of the ternplate (Fig. 2 & 3).
WRAPPING THE CABLE
I. Placeoneendofthestainlesssteelcablethroughtheslotclosest
to the rail and opposite of the clamp side.
2. Pull cable over the groove in the tension holder (9).
3. Pull cable through the slot on the holder.
4. Wrap cable completely around the pipe.
5. Pull cable through the slot on the holder.
6. Pull cable over the groove in the tension holder (9).
7. Pull cable through the slot on the holder.
8. Loosen the cable clamp with the socket head screw. Slide the
cable between the probe holder and the cable clamp. Pull the
excess cable through the clamp.
9. Tighten the socket head screw.
Repeat the above instructions for the other end of the probe holder and
cable.
Slide the probe holder down to the side of the pipe. Align the
center of the holder to the template fold and the ends.
10. Use the Allen wrench and turn the tension holder screw (10)
counterclockwise until the probe holder is tight against the pipe.
3-4
; I'
Place a single bead ot' silicone grease (4) Iongiludinally along the PVC I'ace ol' the sensor. Slide sensor (2) into sensor holder
( I ), note Ihat the sensor cable (yel low) will be pointing loward the olhcr sensor (Fig. 4). Use sensor clamp (3) and place lhe
top over the sensor with hubs m sensor hole and place the bottom ol'lhc clamp on the boltore of the rail of the sensor holder.
(Scc A-A detail)
_] ,, SILICONE GREASE 4. A-A DETAIL
FIG. 4
-SENSOR SEPARATION '
IN INCHES***
FIG. 5
Scc Data Sheet in I'ront ot'custon~cr IOM manual, Locate on Page 2 of Data Sheet Sensor Style Seelion. The Sensor Offset
in inches will bc displayed as "Case B Ofl'sct #.### h~ches". The offer in inches is the separation to be used on the top ruler
on the probe holder, Align right edges {71' Ihc sensors on the "{}" on the rulers on both sensor holders. Either move one sensor
h~ the sensor ofl'sct using the right cdgc <71' the sensor, or divide OtiSset by 2 and move both sensors I/2 the Offset distance.
Tighten screw on Ihc sensor clamp (3) wiih the wrench. Scc IOM manual for cable tcnninalion at electronics.
UPSTREAM SENSOR
OF EACH SENSOR /
~DOWNSTEAM SENSOR
CUT OUT THE TEMPLATE
MATERIAL FROM INSIDE THE HOLDER
FLOW ~'
3-5
SERIES 4000 Z STRAP-ON SENSOR INSTALLATION (CASE C thru J)
DESCRIPTION QTY
I. SENSOR HOLDER 304 SIS 2
2. SENSOR W/100 FT. CABLE 2
3. SENSOR CLAMP & 7/16 HEX HEAD SCREW 4
4. SILICONE (FOR SENSORS) I
5. WERE ROPE I/8" DIA. (CUT PER ORDER) 4
6. ALLEN WRENCH I
7. MYLAR TEMPLATE I
NOTE: Pipe preparation before installation. It may be necessary, particularly with Cast Iron or Ductile Iron pipe,
to sand pipe to a smooth and radial surface where the sensors are to be placed. lfpipe is Asbestos Cement place a coat
of shellac over the surface where the sensors are to be mounted.
Using tape, attach one end of the template (7) to the pipe and wrap the rest or' the template around the pipe. Pull the ternplate
straight and mark the point of overlap on the template. Cut off the excess.
Remove ternplate from pipe. Fold template exactly in half and crease in the middle. Wrap the template around the pipe so
that the crease is on one side of the pipe and the two ends of the template meet on the other side of the pipe. Try to line up
the crease and ends with the horizontal center of the pipe. Tape the ends of the ternplate together with masking tape to hold
in place on the pipe (Fig. 1).
LEFT EDGE RIGHT EDGE
PI ace the probe holders ( I ) on the lop of the pipe. The probe holder on the right hand side should have the ruler on the upper
right corner and should be lined up with the right edge of the ternplate (Fig. 2 & 3). The probe holder on the left should be
upside down and have the ruler on the lower left corner and should be lined up with the left edge of the ternplate (Fig. 2 &
3).
\ ~\ // PIPE //
\
WRAPPING THE CABLE
1. Placeoneendofthestainlesssteelcablethroughtheslotcloscst
to the rail and opposite of the clamp side.
2. Pull cable over the groove in the tension holder (9).
3. Pull cable Ihrough the slot on the holder.
4. Wrap cable completely around the pipe.
5. Pull cable through the slot on the holder.
6. Pull cable over the groove in the tension holder (9).
7, Pull cable through the slot on the holder.
8, Loosen the cable clamp with the socket head screw. Slide the
cable between the probe holder and the cable clamp. Pull the
excess cable through the clamp.
9. Tighten the socket head screw.
Repeat the above instructions for the other end of the probe holder and
cable.
Slide the probe holder down to the side of the pipe. Align the
center of the holder to the ternplate fold and the ends.
10.Use the Allen wrench and turn the tension holder screw (10)
counterclockwise until the probe holder is tight against the pipe.
3-6
Place a single bead of silicone grease (4) longitudinally along the PVC face of the sensor. Slide sensor (2) into sensor holder
( 1 ), note that the sensor cable (yellow) will be pointing toward the other sensor (Fig. 4). Use sensor clamp (3) and place the
top over the sensor with nubs in sensor holes and place the bottom of the clamp on the bottom of the rail of the sensor holder.
(See A-A detail )
SILlCONE GREASE 4. A-A DETAIL
FIG. 4
,SENSOR SEPARATION '
IN INCHES***
FIG. 5
See Data Sheet in front of customer IOM manual. Locate on Page 2 of Data Sheet Sensor Stvle Section. The Sensor Offset in
inches will be displayed as "Case C-J Offset ##.### Inches". The offset in inches is the separation to be used on the rulers
on the probe holders. AIign the right edges of sensors on the "0" on the rulers on both sensor holders. Either move one sensor
to the sensor offset using the right edge of the sensor, or divide Offset by 2 and move both sensors I/2 the Offset distance.
Tighten screw on sensor clamp (3) with wrench. See IOM manual for cable termination at electronics.
UPSTREAM SENSOR
".:"- [~7~.~ OF SENSOR CABLE
PUTABEADOFSILICONE f~ '/'~~ FLOW
CUT OUT THE TEMPLATE ~~ ~ ~
DOWNSTREAM SENSOR
MATERIAL FROM INSIDE THE HOLDER
3-7
I'
SERIES 4000 2 INCH SENSOR INSTALLATION
]~s ~ ) Z l~ U ITEM DESCRIPTION
3J I. SENSOR 2"
2. U BOLT
1. 2. ~ 3, WRENCH 7/16 X I/2
~"" 4. SPRING
5. FLAT WASHER
Tz/ 6. NUTHEX 112-13SIS
O I~ 7. SILICONE (FOR SENSORS)
4 5. 6. 7.
QTY
2
4
4
4
NOTE: Pipe preparation before installation. It may be necessary to sand pipe to a smooth and radial surface where
the sensors are to be placed.
Place a single bead of silicone grease (7) longitudinally along the PVC face of the sensor. Locate the flow direction arrow
on the sensor plate. Place sensor ( I ) onto the side of the pipe with the flow direction arrow pointing with the forward flow
direction. Put one U-bolt (2) around the pipe through the holes on the sensor plate (Fig. I ). Place a flat washer (5), spring (4),
and flat washer (5) over the two threaded ends of the U-bolt. Screw the nut (6) down snugly m the top flat washer. Place the
other U-boh around the pipe and through the olhcr end of the sensor. Place washers, spring and nut as above.
['~']..~~ FIG. 1
UPSTREAM SENSOR TAG
Tape the end of the upstream sensor cable before running both cables through conduit. This will case the termination of the
cables at thc electronics enclosure. The taped end is the upstream connection and Ihe untaped end is the downstream
connection. Tighten nuts (6) to compress the springs to approximately 0.75 inches with the wrench (3). See IOM manual for
cable termination at electronics.
3-8
SERIES 4000 HI TEMP SENSOR INSTALLATION
NOTE: FOLLOW SENSOR INSTALLATION INSTRUCTIONS FOR STYLE OF STRAP-ON SENSORS
INDICATED ON DATA SHEET.
UPSTREAM SENSOR
JUNCTION BOX PUT A BEAD OF SILICONE
MIDDLE
OF EACH SENSOR
TO ELECTRONICS
ENCLOSURE
DOWNSTEAM SENSOR
HI TEMP JUNCTION BOX
WITH PCB CONNECTION BOARD
JUNCTION BOX WIRING
J1 TO HI TEMP SENSOR
J3 TO HI TEMP SENSOR
J2 TO 100FT CABLE/ELECTRONICS
J4 TO 100FT CABLE/ELECTRONICS
FLOW
TO SENSORS
I. Place ,junction box on the top of the pipe orienting the two conduit hole side towards the mounted sensors.
2. Wrap stainless steel strap around the underneath side of the pipe and run each end through the snap lock screw on each
end of the straps on the j unction box. Lock one end of the snaplock onto the strap and pull the other end as tight as possible
through the other snaplock before snapping onto the strap. Use a fiat head screw driver and tighten the screw on the snap
lock, This will tighten the strap around the pipe.
3. P~accth~c~nduitfitdngsfrm~th~]cxib~c~nduitfr~mthes~ns~rsint~th~tw~h~spr~vid~dinth~juncti~nb~x.Tighten
the nuts onto the conduit Fillings.
4. The BNC connectors from the sensors will be connected to the BNC connectors ofJ I and J3 connections.
5. The customer supplied conduit should be installed in the one hole side of the junction box.
6. The BNC connectors are factory installed on two 100 ft. cables. The BNC connectors from the triax cables should be
connected to J2 and J4 connections.
7. Marktheend~f~n~cab~ewithapi~ce~f~apedesignating~itherth~ups~ream~rth~d~wnstrcamsens~r.
8. Terminate the sensor cables per wiring in the 4500 IOM manual.
3-9
SERIES 4000 WINDOWED SPOOL INSTALLATION
I. SPOOL
2. ROLL PIN (USED AS A GUIDE FOR #4)
3. O RING
4. SENSOR WINDOW
5. SENSOR HOLDER
6. WASHER (4 PLACES)
7. SCREW (4 PLACES)
8. SILICONE GREASE
9. RUBBER PAD
10. SENSOR & CABLE
I 1. SPRING
12. CAUTION TAG
13, SENSOR RETAINER
WARNING:
FIG.1
DO NOT REMOVE ASSEMBLY #3 THROUGH #7
.at.,/LIFTING LUGS TO TOP OF PIPE
FLOW ~[~"i~r°"~
INSTALL WITH ARROW POINTING WITH FLOW
SPOOL PIECES MAY BE INSTALLED EITHER IN THE HORIZONTAL PLANE OR IN
THE VERTICAL PLANE (WITH FLOW IN THE UP DIRECTION)
L = LAYING LENGTH IN INCHES
PLAIN ENO
REFER TO CUSTOMER DATA SHEET
SENSOR REMOVALPROCEDURE
I. Remove conduit from the sensor retainer (12).
2. Unscrew the sensor retainer (12).
3. Gently pull on the sensor cable. The sensor spring ( I 0) and the sensor (9). should "pop" out of the sensor holder (5).
4. Be~br~reinsta~lingth~sens~r~car~fu~lycl~anthes~ns~rgreasefr~mth~sens~rwind~wlens(4)~
NOTE: A long 6" cotton swab available at most electronic, or audio. stores works well for cleaning the window.
5. Wipe the end and sides of the sensor clean, removing any grease and grit.
6. Spread a thin 1/32" layerofsensorgrease(DowCorning I I I* valvelubricant&sealant)ontheendsurfaceofthescnsor.
7. Carefully reinsen the sensor into the sensor holder and gently push the sensor all the way in.
NOTE: If the sensor will not push in, try to loosen the holder screws (7) slightly (without removing the safety wire seal)
and shift the holder until the sensor will slide all the way in. Rctighten the holder screws.
8. Screw the sensor retainer down firm (hand tight) and reconnect the conduit.
* Type 29 silicone heat sink compound may be used (available at most electronic stores).
3-10
SERIES 4000 HS3 SENSOR INSTALLATION
ITEM DESCRIPTION QTY
PARTS LIST
I. RETAINER BRZ 2
2. SPLIT COLLAR 2
3. BRASS COLLAR 2
4. O-RING 1,287 X 2.7 2
6. 2" RETAINING RiNG 2
7. BEARING SEAL 2
8. BRASS TAIL PIECE 2
9. BRZ BALL VALVE 2
10. 1-1/2" NIPPLE 2
I I. SENSOR W/100* CABLE 2
12. SAFETY PLATE 4
13. SAFETY CABLE 4
14. TEMPLATE
15. TEFLON TAPE
TEMPLATE INSTALLATION
Using tape, attach one end of the template to the pipe and wrap the rest of the template around the pipe.
Pull the template straight and mark the point of overlap on the ternplate. Cut off the excess.
Reinore template from pipe. Fold template.
Wrap the template around the pipe so that the crease is on one side of the pipe and the two ends of the template meet on the
other side of the pipe.
Try to l i ne up the crease and ends with the horizontal center of the pipe. Tape the ends of the template together with maski ng
tape to hold in place on the pipe.
1. CREASE 2.
Use a center punch and a hammer. Punch a mark where the template ends meet and the right edge of the ternplate. Repeat
step on the other side of the pipe where the crease in the template and the right edge of the template meet (Fig. 4). The center
punch marks will become the center line for the I-I/2" nipples.
FLOW
SIDE VIEW
1-1/2' FEMALE NIPPLES ~I
?
TOP VIEW
TAPPING PROCEDURE
I. Install template and nipples per 3-1.
2. Usetefion tape, wraptheend ofmale
nipple (10) and screw into female
nipple of tapping saddle.
3. Slidesafetyplate(12)overouterend
of nipple.
4. Screw ball valve (9) onto nipple.
Adjust valve to the "open" position.
5. Connecttappingmachineintoendof
ball valve, I-1/2".
6. Use 1.38" minimum tapping bit and
tap through pipe wall.
7. Back the tapping bit out past the
valve assembly and move the valve
handle to the "off" position.
3-11
SERIES 4000 HS3 SENSOR INSTALLATION
PREPARATION TO INSTALL SENSORS:
FIG. 1
TAIL PIECE ASSEMBLY
(ASSEMBLED AT FACTORY)
FIG. 2
SENSOR & COLLAR ASSEMBLY
"S"= Length of saddle or threadolet nipple
"T"= Length from i.d. of pipe to outside
edge of item 8
· 8.15"
· "T' MEASURED BY INSTALLER
"T"+0.82" OR 8,g7"+"S"+WALL THICKNESS
FIG. 3
NOTE h USE ABOVE FORMULAS TO DETERMINE THE PLACEMENT OF ITEM 2, ONCE COLLAR IS
PLACED AT CORRECT DIMENSION TIGHTEN BOTH SOCKET HEAD SCREWS.
I. Screw tail piece assembly (Fig. I, 5, 6, 7 and 8) into ball valve (9).
2. Slide 12 and I onto sensor (I I); use Fig. 2.
3. P~siti~nc~llar(2)~nt~sens~randuseab~vef~rmulat~calculatcc~rrectdimensi~n~P~easen~tethatthec~l~arsh~u~d
already be installed by the factory on new orders, the collar dimension will have to be changed only if pipe dimensions
are other than given.
4. Slide brass collar and O-ring assembly (3 & 4) onto end of sensor and butt up against the split collar (2).
NOTE: USE SOAPY WATER, PETROLEUM JELLY OR SOME TYPE OF LUBRICANT TO SLIDE BRASS
COLLAR AND O-RING ONTO SENSOR.
5. Note scribe mark run ni ng near the end of the sensor. This scribe mark, when the sensor is installed, should be fact ng toward
the opposite sensor (Fig. 4).
6. Placetip~fsens~rthr~ughbearingseal(7)andcarefullypushuntilthesens~rst~psattheballva~ve~Fastensafetycable
clip (long length) to opposite safety plate.
7. Turn valve handle to the "on" position and insert the sensor until the brass collar (3) seats on the O-ring on the tail piece
(5 & 8).
8. Tightenretainer(I)ontothetailpiece(8)usinga 1/16" squarescrewdrivershaftinthenotchontheendoftheretainer.
9. Fasten short length of safety cable to opposite safety plate.
3-12
SERIES 4000 HS3 SENSOR INSTALLATION
FIG.
UPSTREAM SENSOR
FLOW
4
SCRIBE MARK
NOTE: TIPS OF SENSORS WILL
BE FAC;~G EACH OTHER
SCRIBE MARK
DOWNSTREAM SENSOR
SYSTEM DIAGRAM
METALLIC CONDUIT
(CUSTOMER SUPPLIED)
JUNCTION BOX
(CUSTOMER SUPPLIED) ,
FLEX CONDUIT
SUPPLIED)
117/230VAC ~
OR 12VDC I
OUTPUTS
3-13
SERIES 4000 INSTREAM REFRACTING SENSOR INSTALLATION
DESCRIPTION
The instream refracting sensors were designed for rectangular or
circular concrete channels flowing full at all times. These sensors
have a wedge shape to minimize possibilities of catching debris.
The sensor is made of PVC materials with 50 ft. of Belden triax
cable.
INSTALLATION
Refer to customer Data Sheet in front of this manual. Sensor
separation=__ __ inches. This dimension is from center
line of the upstream sensor to the center line of the downstream
sensor. Make sure that the arrow on the downstream sensor is
pointing upslream and the arrow on the upstream sensor is
pointing downstream. Mark holes on concrete conduit and use
lead inserts. Place sensor over lead inserts and attach with screws
(customer supplied). Route the sensor cables to the top of the
condu it and use custmner su ppl ied cable clamps to fasten cable to
the pipe at one foot intervals. Route the cables downstream and
out the pipe outlel. Secure with cable clamps.
Terminate sensor cables to the 4500 electronics.
( 0.5
· 6.5
3/8" HO2~S//~IJ~~
15/16" COUNTER BORE
SENSOR CABLE
t
NOTE: ARROWS ON TOP OF SENSORS
SHOULD BE POINTING TOWARDS
EACH OTHER AFTER INSTALLATION
UPSTREAM SENSOR
DOWNSTREAM SENSOR
--;**--.
'**SENSOR SEPARATION
(THIS DIMENSION IS CRITICAL
TO METER ACCURACY)
I
I
,
180°
(CUSTOMER SUPPLIED)
** 2-5 pipe dia.
3-14
! f
SERIES 4000 WETTED SENSORS WITH HOOP INSTALLATION
DESCRIPTION
The underwater sensors for the Series 4500 flowmeter are 4.
premounted on a stainless steel plate at the factory (see Fig.
2). The sensor cables are secured to the plate with clamps.
This plate is then formed into a hoop and inserted into the pipe
just upstream of the 2-inch conduit opening in the top of the 5.
pipe or upstream of the manhole entrance. The sensor cables
are then pulled though the conduit and attached to the sensor
connections on the Model 4500 electronic enclosure.
PROCEDURE
I. Inspectthesensormountingplateforevidenceofdamage
from shipping or handling.
Refer to Fig. 1. Form the plate into a hoop. Insert the four
8-32 studs on one end of the plate into the slots on the other
end. Loosely attach the holding strap to the four studs with
the flat washer, Bellville washer and nut. Compress the
hoop to its smallest diameter and tighten the nuts on the
holding strap.
Lower the sensor mounting assembly into the discharge
box at the end of the pipe, positioning it so the sensor
cables exit downstream. Insert it into the pipe 3 inches
upstream of the 2 inch conduit pipe opening in the top of
the pipe or 2 to 5 pipe diameters upstream of the manhole.
Position the hoop so the sensors are at 90 and 270 degrees
in the pipe.
Loosen the nuts to the holding strap. Expand the hoop to
the wall of the pipe and loosely tighten the nuts on the
holding strap.
Use large "C" ring pliers to secure the mounting plate to
the pipe. Starting at the upstream side of the mounting
plate, place the "C." ring pliers between the second slot and
the holding strap. Slowly spread the mounting plate with
the pliers forcing the mounting plate against the pipe.
Using a rubber head mallet, tap the plate starting at the
bottom and up the sides. Tighten the nut of the holding
strap on the end you have been spreading. Place the "C"
ring pliers on the downstream side of the plate and repeat
the same process. Go back to the upstream end and loosen
the end nut and use the "C" ring pliers to conti hue to force
the plate against the pipe wall. Repeat this process until
the mounting plate is secured against the pipe wall and
there are no gaps between the plate and wall.
Refer to Fig. 3. Route the sensor cables downstream to
exit.
This completes the sensor installation. See the electronic
assembly installation section for connecting and securing
the cables.
HOLDING STRAP
FLATLWL
SENSOR MOUNTING PLATE
3-15
SERIES 4000 WETTED SENSORS WITH HOOP INSTALLATION
FIG. 2
SENSOR MOUNTING
PLATE
~'~"'SENSORS
CABLE CLAMP
RRR
HOLDING STRAP
R R~,,,~
FLOW
FIG.3
3/4" METALLIC CONDUIT
CUSTOMER SUPPLIED
CABLE CLAMPS
FOOT iNTERVALS) ~
I
· * 2-5 PIPE DIAMETERS
3-16
T ! [
OPERATION
Badger Meter
Compu-Sonic
GENERAL DESCRIPTION
The Series 4500 is an ultrasonic transit-time flowmeter
designed to measure fluid flows in full pipes. The meter is
equipped with a 2-line, 24 character per line LCD display, 4-
20 m ADC signal output, 4 program mable tel ays and an RS232
serial communications port.
The Series 4500 is microprocessor based and provides a
number of menu functions from the front panel which al lows
the user to modify or interrogate meter operations to suit the
user's needs. These keys are the UP arrow, DOWN arrow,
RIGHT arrow, MENU and ENTER.
The MENU key allows access to the Status Mode or
Calibration Mode of the meter. It also can be used to roturn to
normal operation any time you am in the Status or Calibration
Mode. If you press the MENU key while in the Calibration
Mode, the processor will store any changes made up to that
point, but will retain the previous programming after that point
and return to the normal operating screen.
The ENTER key is used to store any data changes that am
made in the Calibration Mode and step through the screens of
the Status or Calibration Modes. The ENTER key must be
pressed to store the change made. Pressing the MENU key
before the ENTER key will not store the change.
The UP, DOWN, and RIGHT arrow keys are used for
selecting or making changes in the various screens of the meter
in the Status or Calibration Mode.
To prevent unauthorized entry into the Calibration Mode of
the meter, them is a Security screen that requires the correct
security code to be entered in order to gain access. The sec uri ty
code when shipped from the factory is 0000.
When power is first applied, the display will show squares
across the top line for a second and then the display will show
the normal operating screen, typically flow and total. The flow
rate value will have 3 X's for 3 to 5 seconds while the meter is
going through its set up procedure. The meter will then begin
to indicate the flow rate if an OK is di splayed in the right corner
of the top line as shown below.
FLOW 3480 GPM X 10 OK )
TOTAL 458932 GAL X 1000
If your meter has been programmed at the factory for bi-
directional flow, there will be a letter that follows the FLOW
word and a letter at the right end of the second line that will
indicate the direction of the flow. The letter will be F for
forward flow and R for reverse flow. The screen below shows
this feature.
FLOW F 3480 GPM X 10 OK )
TOTAL 458932 GAL X 1000 F
Them are two totalizer registers in the meter. One for
forward flow and the other for reverse flow. While in the
normal operating screen, the UP or DOWN arrow keys can be
used to view the totalizer that is not displayed.
The following pages in this section cover the Status and
Calibration Modes' menus. They will be listed in the order of
the sequence of screens.
The MENU key can be used to exit from any function in the
Status or Cal ibration Modes and go directly back to the normal
operating screen. The DOWN arrow key can be used to step
backwards in the main function screens.
4-1
STATUS MODE
The Status Mode al lows the user to determine the opemtional
status of the Series 4500 as well as perform a self diagnostic
and a flow simulation. Normal meter operation will still be
performed while in the Status Mode except when in the flow
simulation function.
To enter into the Status Mode, press the MENU key and the
following screen will appear:
PRESS UP FOR CALIBRATION )
PRESS DOWN FOR STATUS
This screen allows entry into the Calibration Mode or the
Status Mode. Press the DOWN arrow key and the following
screen will appear:
Measurement Data )
Press UP to Activate
This screen allows entry into the measurement data of the
meter. This is normally used in troubleshooting to detect
signal strength and error codes.
Press the UP arrow key and the following screen will
appear:
00, NoR- BE,8)
= A9C2 TI2 = 02C4
This screen of the measurement data gives the values of the
captured zero offset (ZOF), the normalized flow rate (NOR),
the phase shift (DEL) and the signal crossing time (TI 2). These
will be discussed in more detail in the troubleshooting section
of this manual.
Press the ENTER key and the following screen will appear:
This screen shows the error codes and the AGC (automatic
gain control) value on the first line and the signal strength
indication on the second line.
The various error codes are listed in the Troubleshooting
section of this manual. The first two hexadecimal digits of the
AGC value indicate the relative strength of the received signal
with a value of 9F lbr a minimum signal and 10 the maxi mum
signal.
You may switch between the two screens by pressing the UP
arrow key.
Press the ENTER key and the following screen will appear:
Self Test )
Press UP to Activate
Thisscreenallowsentryintotheselftestdiagnosticsroutine.
Press the UP arrow key and the following screen will appear:
SELF TEST )
TRANSMIT: <<PASSED>>
The self diagnostic first tests the transmitter section of the
electronics. A brief message will be displayed indicating that
testing is in process and then a PASSED or FAILED message
will appear. The self test automatically steps through each test
segment.
The following screen will appear next:
SELF TEST )
RECEIVER: <<PASSED>>
Again a brief message will be displayed indicating that
testing is in'process and then g PASSED or FAILED message
will appear. This test checks that the receiver section of the
electronics is functioning properly. The self test then checks
for the presence of a signal. Ifa received signal is present and
within the timing limits, the self test will step to the EEPROM
test. If there is no signal, this will be indicated on the display.
If there is a signal arriving at a time shorter than expected, then
'TI 2 Short' will be displayed. If there is a signal arriving at a
time longer than expected, then 'T12 Long' will be displayed.
The following screen will appear next:
SELF TEST )
EEPROM: <<PASSED>>
Th is screen indicates that the EEPROM of the m icroprocessor
is being tested. After a few seconds the "TESTING" message
will change to either "PASSED" or "FAILED". The fol Iowi ng
screen will appear:
SELF TEST )
* * * * * Completed * * * * *
This screen indicates that the self test function of the Status
Mode is completed. The following screen will appear:
Flow Simulation )
Press UP to Activate
This screen allows theentry into the flow simulation function.
This function can be used to simulate the flow from zero to full
scale. It will drive the 4-20 mADC output and the relays if
assigned to either of the flow set points.
4-2
When in this function the normal flow measurement of
the meter is discontinued. No totalization of flow will take
place, but any totalization in Flow Simulation will record
on the normal totalizer.
Press the UP arrow key and the fol lowi ng screen will appear:
CFLOW _0000 GPM X l0 SM )
Badger Meter Inc.
This screen is the flow simulation screen. In the top, right
corner of the display am the letters SM. These letters are to
prevent confusion with the normal flow screen. The meter
will stay in this mode until the MENU key is pressed.
To adjust the flow simulation to a specific flow rate, use the
RIGHT arrow key to move the cursor under the digit to be
adjusted and use the UP or DOWN arrow keys to adjust the
digit to the desired value. For example, if you wanted to
simulate a flow rate of 2500 GPM, move the cursor under the
second digit from the left with the RlGHT arrow key and press
the UP arrow key twice for a value of two (2). Then move the
c upsor under the third digit from the left with the RIGHT arrow
key and press the LIP arrow key five times for a value of five
(5). The display will now show 0250 which is 2500 GPM with
the X10 multiplier.
To exit from the flow simulation press the MENU key. The
screen will return to'the normal operating screen.
To exit from any screen and go back directly to the normal
operating screen press the MENU key.
This completes the Status Mode operation instructions.
CALIBRATION MODE
The Calibmtion Mode allows the user to calibrate and adjust
various functions related to the operation of the Series 4500. A
brief description of each follows.
4-20 mA Calibration - Adjusts the zero and span
(4-20 mA) output.
Meter Rescale - Changes the full scale range of the
meter.
Meter Factor - Adjusts meter factor for field calibration.
Zero Offset - Performs zero offset capture at no flow
condition,
Totalizer - Enables or disables totalizer or clears
totalizer.
Response Time - Adjust the response time of the meter.
Failure Mode - Selects default output of meter when loss
of signal occurs.
Integrator Configuration - Sets contact oulput in
multiples of the totalizer multiplier.
Remote Tot Configuration - Sets closure time of relay
for remote totalizer.
Set Point Configuration - Adjusts two set points for high
or low flow alarms.
Relay Configuration - Assigns alarms or set points to the
four relays.
Security ID - Changes the security cede.
To enter into the Cal ibration Mode, press the MENU key
while the display is in the normal operating screen. The
following screen will appear:
PRESS UP FOR CALIBRATION )
, PRESS DOWN FOR STATUS
Press the UP arrow key and the following screen will appear:
SECURITY ID )
Input 4 Digit Id ....
This screen is the Security screen which requires the correct
4 digit number to allow entry into the Calibration Mode of the
Model 4500. To change the value of each digit, move the line
under the digit to be changed with the RIGHT arrow key and
then use the UP or DOWN arrow keys to change the value of
the digit. When the 4 digit number is correct, press the ENTER
key. If the number is incorrect the meter will go back to the
normal operating screen. If the number is correct the followi ng
screen will appear:
4-20 mA Calibration )
Press UP to Activate
This screen allows entry into the Calibration screens for
the 4-20 mA current output. Press the UP arrow key and the
following screen will appear:
4-20 mA Calibration )
ZERO WORD = 2300
4-3
This screen allows adjustment of the zero output to 4 mA.
The 4-20 mA output can be monitored on the test jacks on the
bottom of the back half of the housing, red jack positive, black
jack negative. The 4-20 mA output must be connected to a
load for the test points to work. Use the RIGHT arrow key to
position the cursor under the digit to be adjusted. Fine adjustment
is made on the far right digit with the adjustment becoming
more coarse with each digit to the left. Use the UP or DOWN
arrow keys to adjust for the correct output. The display Zero
Word is lbr reference only. Press the ENTER key to store the
value. The following screen will appear:
4-20 mA Calibration )
SPAN WORD = AD00
This screen allows adjustment of span to 20 mA. The 4-20
mA output can be monitored on the test jacks on the bottom of
the back half of the housing. Use the RIGHT arrow key to
position thecursorunderthedigittobeadjusted. Fineadjustment
is made on the far right digit with the adjustment becoming
more coarse with each digit to the left. Use the UP or DOWN
arrow keys to adjust for the correct output. The display Span
Word is for reference only. Press the ENTER key to store the
value. The following screen will then appear:
Meter Rescale )
Press UP to Activate
This screen allows entry into the meter rescale screen which
increases or decreases the full scale of the meter. Press the UP
arrow key and the following screen will appear:
Meter Rescale )
Full Scale0900 x 10
The full scale value shown on this screen is the present full
scale (20 mA output). To change the full scale of the meter, use
the RIGHT arrow key to move the cursor under the digit to be
adjusted and use the UP or DOWN arrow keys to adjust the
digit to the desired value. For example, if you wanted to change
the full scale from 9000 to 10000, move the cursor under the
first digit from the left with the RIGHT arrow key and press the
UP arrow key once for a value of one ( I ). Then move the cursor
under the second digit from the left with the RIGHT arrow key
and press the DOWN arrow key nine times for a value of zero
(0). The display will now show 1000 which is 10000 with the
X 10 multiplier.
There is a maximum and minimum full scale limit. When the
fullscalevaluereacheseitherlimit, thedigitswillstopchanging.
Remember: Changing the full s~ale of the meter will
cause the 4-20 mADC output to change to re~t the new
full s~ale value.
Press the ENTER key to store the value. The following
screen will appear:
Meter Factor )
Press UP to Activate
This screen allows the user to calibrate the Model 4500 to
reproduce actual flow conditions. The user can modify the
meter factor lbr cal ibration of the meter to a known standard.
Press the UP arrow key and the foilowl ng screen will appear:
Meter Factor )
Meter Factor = I_.000
The user can modify the meter factor from a value of 0.800
to 1.200. The meter factor is the relation between the indicated
flow rate of the meter and the actual flow rate as proven by
calibration tanks orother means. If, forexample, the meter was
installedonapipeandduetouncertaintyinthepipedimensions,
the meter was determined to be indicating a flow rate 5.6%
higher than the actual flow, the flow meter is indicating 1.056
times the true value. The initial meter factor will be 1.000 as set
at the factory.
To correct for the 5.6% high error, the meter factor must be
changed to 0.947 ( I / 1.056). To change the meter factor, press
the RIGHT arrow key to move the cursor under the first digit
to the right of the decimal point and press the DOWN arrow
key to change the value to 9. Press the RIGHT arrow key to
move the cursor under the second digit to the right of the
decimal point and press the UP arrow key to change the value
to 4. Press the RIGHT arrow key to move the cursor under the
third digit to the right of the decimal point and press the UP
arrow key to change the value to 7. Pressing the MENU or
ENTER key will store the new value.
After pressing the ENTER key the following screen will
appear:
Zero Offset )
Press UP to Activate
This screen allows the user to capture and correct for zero
offsets that may be present in the metering system. It is
4-4
l'
intended to be used for periodic maintenance to correct for
small zero drifts. TIlE FLOW IN THE PIPE MUST BE
ZERO TO USE THIS FUNCTION. IF FLOW EXISTS IN
THE PIPE, USE OF THIS FUNCTION WILL CREATE
LARGE ERRORS IN THE METER. Therefore, the user
must prepare for use of this function. Appropriate valving must
be done to ensure that no flow exists; allow at least I 0 minutes
lbr the fluid motion to settle out. To start the Zero Offset
function press the UP arrow key and the fo110wi ng screen will
appear:
Zero Offset )
STAT: Evaluating >
The zero offset function is now activated and the display
will indicate that it is evaluating for any offsets in the system.
Alter a period of approximately 20 seconds, the screen will
display: 'ERROR: Failed' or 'CAPTURED: Press UP to
Say'.
I1' an error is indicated, it means Ihat an offset was
measured greater than is expected under normal conditions.
The pipe needs 1o be rechec ked to veri fy that them is no llow.
Press the ENTER key to step out of the error screen. The
display will step to the Totalizer Function screen. If you
desire to try the zero offset function again, press the DOWN
arrow key and the display will step back to the zero offset
screen. Repeat the above procedure.
If the screen indicates that an offset is captured, press the
UP arrow key to store this value. After the UP arrow is
pressed the following screen will appear:
C Totalizer )
Press UP to Activate
This screen allows the totalizer to be enabled, disabled, or
reset m zero. Press the UP arrow key and the following
screen will appear:
Totalizer )
ENABLED
This screen allows the total izer to be enabled or disabled. If
the totalizer is enabled, the totalizer will be displayed on the
second line of the normal operating screen with its appropriate
multiplierand unitsofmeasumment. lfthetotalizerisdisabled
then the second line of the normal operating screen will have
Badger Meter, Inc. displayed. Use the UP or DOWN arrow
keys to make your selection and press the ENTER key.
lfyou selected DISABLED, the next screen displayed will
be the Response Time function. If you selected ENABLED the
following screen will appear:
C TOTALIZER CLEAR )
Press UP to Activate
This screen allows the user to clear the value in the totalizer
registers of both forward and reverse totalizers if applicable.
Press the UP arrow and the following screen will appear:
C TOTALIZER CLEAR )
' Press UP to Reset
This screen actually resets the totalizer(s) to zero. Press the
UP arrow to clear the totalizer(s) or ENTER to not clear the
totalizer(s). The following screen will appear:
C Response Time )
Press UP to Activate
This screen allows setting of the response time of the meter
to changes in the flow rate. Press the UP arrow key and the
following screen will appear:
Response Time )
. Response Const: 007
This screen sets the response ti me of the meter. The select ions
are from I to 7. The response time for each of the selections is:
1 = 2 seconds; 2 = 4 seconds; 3 = 8 seconds; 4 = 16 seconds;
5 = 32 seconds; 6 = 64 seconds; 7 = 128 seconds. Use the UP
or DOWN arrow keys to change to the desired response time.
Press the ENTER key to save. The following screen trill
appear:
Failure Mode )
Press UP to Activate
This screen allows setting of the default output of the meter
in the event there is a loss of signal failure. There are three
available selections: Zero, Full Scale or Hold Last Reading.
The selection of zero wi I1 drive the meter output to 4 mA. The
selection of full scale will drive the meteroutput to 20 mA. The
selection of hold last will retain the last flow value before loss
of signal.
Press the UP arrow key and the following screen will appear:
Failum Mode )
FAlL TO: ZERO _
This screen allows selection of the failure mode to zero, full
scale, or hold last reading. Use the UP or DOWN arrow key to
make the desired selection. Press the ENTER key to store the
selection. The following screen will appear:
4-5
Integrator Configuration )
Press UP to Activate
This screen al lows entry into the contact integrator function.
This lbature can be used Ibr activating a sampler or pacing a
chemical feed device if assigned to one of the relay outputs.
Theratcofcontact is in muhiplesofthetotalizermuhiplier. The
pulse width or contacl time can aIso be set fbr the required ti me
lilt the external device.
Press the UP arrow key and the li~l Iowi ng scmeu wi II appear:
C Contact Integrator )
O001 x 10A)0 GAL
This screen allows setting of the contact output based on
spccilic volume o1' measured llow. This can be selected on
muhiplcs of the totalizer muhiplicr. The above screen shows a
totalizer muhiplicr of' 1000 gallons. To have a contact every
10,(X X) gallons, move Ihc cursor with the RIGHT arrow key
umler Ih¢ third digit from the left and use the UP arrow key to
change it to I. Move the cursor with the RIGtlT arrow key
under the lasl digil and use the DOWN arrow key to change it
to O.
Press Ihc ENTER key to smm tile new setling and the
li/llowing screen will appear:
Integrator Pulse Width )
ON FOR (_~)02 X 0.010 SEC
This screen allows setting of the pulse widlh or c,,mlact
closure time for the contact integrator output. For example, if
the external contacl oulput device is going Io require a closure
time of50 milliseconds, then the on lime must be changed to
(X X)5. That is, 0.050 / 0.010 = 5. To change the on ti me, use the
RIGHT arrow key Io move the cursor under the lasl digil and
the UP arrow key to change it to 5.
Press tile ENIIER key to store tile new setting aud tile
li~llowing screen will appcar:
Remote Tot Configuration )
Press UP to Activate
This screen allows the entry into Ihe remole totalizcr
conliguration setup. lfa relay has been assigned to the remote
totalizer, then the relay will close evci~< increment of the
display tolalizcr. The configuratkm screen sets the closure
time of the relay. Press the UP arrow kcy and the li~llowiag
screen will appear:
Remote Tot Pulse Width )
ONFOR0005 X 0.010SEC
This semen allows the setting of the pulse width or contact
closure time for the remote totalizcr output. For example. if the
external totalizer device requires a closure ti me of at leasl 80
milliseconds, then the on time must be changed to 00)8. ~Hmt
is, 0.080 / 0.010 = 8. To change the on time, use the RIGHT
arrow key to move the cursor under the last digit and the UP
arrow key Io change it to 8.
Press the ENTER key to st,,~re the new selling and tile
li~llowing screen wilI appear:
Set Point Conllguration )
Press UP to Activate
This screen allows cnlry into the configuration screens
the two set points. The set points can be set up I~r either high
or low alarms with desired dead band. Press Ihc UP arrow key
and Ihe lilllowing screen will appear:
SE'FPOINT = 01 )
ON AT_00.0% OFF AT 00.0qc
This semen allows the adjustment of the number I sol poiut
as a high or low alaHn as well as Ihe dead band. For a low
alarm, the ON value must be a lower value than the OFF
value. For a high alarm, the ON value must be a higher
value than the OFF value. For example, to nmkc tile set pot nl
a high alarm at 90% of full scale Ilow with a 10~ dead baud,
press the UP arrow key to change the ON value to 90.0. The
RIGHT arrow key is used to move the cursor under the digit to
be changed. Press tile ENIER key to move Ihc cursor under
OFF digits. Press the UP arrow key Io char~gc the OFF value
Io 80.0. Pms~, the ENTER key Io store these settings. Thc
following screen will appear:
SETPOINT = 02 )
ON AT (_R).O~ OFF AT (}O.01~
This screcn is for setting Ihe number 2 set point. Use the
stone procedure as described for the number I set poiut. Allot
pressing the ENTER key to store the settings. the following
screen will appear:
C RELAY CONFIGURATION )
Press UP to Activate
This semen al lows entry into the relay con figuration screens
where the four relays m'e assigned to desired functions. Press
~hc UP arrow key and the following screen will appear:
4-6
T i
RELAY ASSIGNMENT )
RELAY01 => NONE
This screen allows the selection of the desired assignment to
the number 1 relay. The following functions are available:
NONE - Relay not used
DIR - Direction output for forward and reverse flow
TX - Transmitter failure in the electronlcs
LOS - Loss of signal
EEPRM - EEPROM failure
TOTL - Remote totalizer output
CINT - Contact integrator output
PNT#1 - Set point #1
PNT#2- Setpoint#2
Use the UP Or DOWN an-ow keys to make the desired
selection. Press the ENTER key to store the selection. The next
sc teen s will be for relay s 2, 3 and 4. The same procedure is used
as for the number I relay. After the selection is made for the
number 4 relay, the following screen will appear:
C SECURITY [D )
Press UP to Activate
This screen allows entry into the Security Identification
where the security code may be changed. Press the UP arrow
key and the following screen will appear:
SECURITY ID )
Input 4 Digit Id (~000
This screen will show the present security code in the meter.
To change the secudiy code move the cursor with the RIGHT
arrow key under the digit to be changed. Use the LIP or DOWN
arrow keys to change the value. The value can be I through 9
and A through F. After the new code has been entered, press
the ENTER key to store the new values. The display will then
return to the normal operating screen.
NOTE: At any time after a change has been entered in the
Calibration Mode, the MENU key can be pressed and the
display will return to the normal operating screen. Also the
DOWN arrow key can be used to step backwards through the
main function screens of the Calibration Mode.
The following pages diagram the menu screens for the
Status and Calibration Modes.
4-7
4500 STATUS MODE
Press UP for Calibration"'~
~Press Down for Status
FLOWF 1234 GPM X 10 OK)
TOTAL 123456 GAL X 100 F
I
l MENu 1
·
·
Measurement Data Z~.__~D :)F = 0000 NOR = (~{~_[ MENU
Press UP to Activate EL = 0000 T12 =
I
Press UP to Activate : << >>
~ ~ (EEp.o~EL:F~ZssED>>)
I
Flow Simulation~]· /~LOW 0000Mj~..~ MENU
Press uP ,o Ac,iva,e' ~, , ~r~c?°S
4-8
4500 CALIBRATION MODE
FLOW F 1234 GPM X 10 O~)
TOTAL 123456 GAL X 100
Press UP for Calibration
Press Down for Status
SECURITY ID
Input 4 Digit Id ....
L ENTER I
+
4-20 mA Calibration
Press UP to Activate
I ENTER I
Meter Rescale ~F Meter Rescale ~
·Press UP to Activate ull Scale _3500 x 1
EN~TE~ II"l4 IENTE" I ~"
Meter Factor
Press UP to Activate
Zero Offset
Press UP to Activate
I E.TE. I
4-9
Totalizer ~ Totalizer
Press UP to Activate ENABLED
--[ MENU
--{MENU
4k ( TOTALIZER CLEAR
Press UP to Activate
"' q I ENTER I "'
· [~ TOTALIZER CLEAR ~ ~
'J · Press UP to Reset MENU
---~MENU F'~ Failure Mode ~ Failure Mode ~'4 MENU
Press UP to Activate FAiL TO: ZERO
I
i
IZERO LAST
~ [~ S AN
H(~LD
Response Time ~ Response Time ~--[ MENU
Press UP to Activate Response Const: '0001
MENU ~ integrator Configuration Press UP to Activate
I
I ENTER I
Integrator Configuration
0000 x 1000 GAL MENU
'
L ENTER J
;r
4-10
T
Press UP to Activate
Set Point Configuration
Press UP to Activate
Relay Configuration
Press UP to Activate
RELAY ASSIGNMENT
RELAY 01 +> NONE
NONE
DIR
TX
LOS
EEPRM
TOTL
CINT
PNT#1
PNT#2
4-11
alk V
RELAY ASSIGNMENT
RELAY 02 => NONE
NONE
DIR
TX
LOS
EEPRM
"Ir TOTL
CINT
PNT#1
PNT#2
SECURITY ID
Press UP to Change
RELAY ASSIGNMENT
RELAY 03 => NONE
RELAY ASSIGNMENT
RELAY 04 => NONE
NONE
DIR
TX
LOS
EEPRM
TOTL
CINT
PNT#1
PNT#2
SECURITY ID
Input 4 Digit Id ~2000
4-12
TROUBLE SHOOTING
GENERAL
The Series 4500 is equipped with self test features which
allow the user to identify the operation status of the unit and
with the help of this section of the 1OM manual to determine
proper action to be taken. This section details the meaning
of the operational codes which appear in the main menu, the
meaning of the self test features, and provides a step by step
troubleshooting chart for determining the fault and the
necessary action.
Operational Codes. The main menu of the Model 4500
indicates flow rate and flow total. In the upper right hand
side of the display appears an operational code which
indicates the operating condition of the meter. When the
meter is first powered up, the flow rate will display XXXX
and there will not be an operational code. The microprocessor
is initializing the meter constants and performing a self test
to ensure that all areas of the electronics are operating
properly. This may take several seconds.
After initialization, the X's in the flow rate will change to
O's. The operational code wi II display an OK which indicates
the meter is operati ng properly. The meter may recycle a few
times before locking onto a good signal. Should an OK not
bedisplayed, referto the troubleshooting chartforappropriate
action.
The following is a list of the operational codes and their
meanings.
OK
NS
XM
TL
TS
TM
OF
UF
GE
CM
Nominal Operation
No Signal Detected
Transmit Confirm Failure
Signal Transit Time Out of Bounds (too long)
Signal Transit Time Out of Bounds (too short)
FIFO Error (missing or misaligned timing mark)
Amplitude Overflow
Amplitude Underflow
Gain Error
Communications Mode Enabled
Measurement Data Screen in Status Mode: The
Measurement Data screen of the Status Mode displays
several measurement parameters that can be used to determ i ne
the operational status of the flowmeter. These screens are
intended to help facilitate troubleshooti ng should a problem
exist, especially when communicating with the factory
Service Department. The following is an explanation of the
data:
ZOF -
NOR -
DEL -
T12 -
ERR -
AGC -
Value of the capture zero offset.
Hexadecimal flow rate in percent of full scale.
Hexadecimal measured phase in percent of full
scale.
Hexadecimal measured average transit-time of
the signals in microseconds.
Error codes.
First two hexadecimal digits represent relative
signal strength with 9F being minimum signal
strength and l 0 being maximum signal strength.
REPLACEMENT OF PARTS
While the Series 4500 has been designed and built for
maximum reliability, there can be instances where
replacement of parts may be necessary. In those cases where
the troubleshooting procedure calls for replacement of a
part, the factory should be contacted for authorization to
send in a defective part for repair or replacement.
The Series 4500 has been designed so that the front
housing contains the major electronic hardware and can be
easily removed and installed. It also allows the replacement
unit to be preprogrammed with no ad.~ustments required
when installing the new unit. For this reason, we must know
the serial number of the defective unit when the usercontacts
the factory for repl acemen t or repair. Refer to the lnstal lati on
Section of this manual for disassembly instructions.
The back housing con tai ns the power supply circuit board.
This replacement will require a little more effort. Refer to
Figure 5-1. Disconnect the power wires, sensor cables, 4-20
mADC wires and conduit connections. Remove the two "O"
Ring back housing mounting screws.
5-1
®
DOT
BACK HOUSING POWER SUPPLY BOARD7
'l{""'-*'-"",-;"""'~-'-;::~::"[_~ ""'::x"~:::":~:::::,~,.,¢.~:~''':' ~,~ ................
::::::::::::::::::::::::::::::::: .
~:.:':::C{{{,Z~:u----~:;r{~{,Z~Z:Z:..' ~~.~; ~
Test Points
FIGURE 5-1
TROUBLESHOOTING CHART
On the following two pages is the troubleshooting chart
for the Series 4500 flowmeter. This chart will help you in
isolating possible causes for problems you may encounter
and give suggested corrective actions.
In the troubleshooting chart, there will be areas that
req u ire certain tests to be performed, The fol lowi ng describes
these tests.
Sensor cable connection continuity test. This test will
require the use of an ohmmeter. Connect the test leads of the
ohmmeter to points I and 3 of the sensor cable connections
on the power supply as shown in Figure 5-2. If the signal
wires on the power supply board are still connected to the
front housing electronics, the ohmmeter should read 5000
I
2
3 SENSOR CABLE CONNECTIONS
4 ON POWER SUPPLY BOARD
A
UPSTRS M DOWNSTREAM
SENSOR SENSOR
FIGURE 5-2
ohms +/- 5%. If the signal wires are not connected, the
reading should be 10,000 ohms +/- 5%. Repeat this test at
Points 2 and 3.
Connect the test leads to Points 3 and 4. The reading
should indicate infinity (or an open).
Connect the test leads to Points I and 4, then 2 and 4. The
reading should indicate infinity (or an open).
Power supply voltage test. This test will require the use of
a voltmeter. NOTE: With the front housing removed, a
magnet will be required to close the magnetic switch on the
back housing in order to perform this test. Refer to Figure 5-
I.
+14VDC - Connect the test leads to test points I and 2 on
the power supply board. The voltage should read 14 VDC
+/- 2 volts.
+40VDC - Connect the test leads to the test points 2 and
3 on the power supply board. The voltage should read 40
VDC +/- I volt.
-40VDC - Connect the test leads to the test points 2 and
4 on the power supply board.
4-20 loop power - Connect the test leads to the test points
5 and 6 on the power supply board. The voltage should read
45 to 50 VDC when operating the meter on AC power.
5-2
TROUBLESHOOTINGCHART
START
FUSE
NO NO
NO YES YES YES
i s N~ ~ F ~,~
, NO
REPLACE
POWER
SUPPLY
DISPLAY RECYCLE I NO REPLACE
READABLE ' POWER '~ ELECTRONICS
,7 UNIT
YES
CONTINUED
ON NEXT PAGE
REPLACE
ELECTRONICS
UNIT
CODE S T S
UNIT
CHECK SENSOR
ERROR YES CONNECTION OR YES MAKE SENSOR
REPLACE CABLE CONTINUITY
CODE ELECTRONIC TEST
NO . UNIT
CHECK SENSOR
MOUNTING & YES
PIPE SURFACE
SEE MOUNTING
INSTRUCTIONS
CHECK FOR LOOSE
SIGNAL WIRE
CHECK SENSOR CONNECTION
MOUNTING BAD CONNECTIONS
DIMENSIONS AT SENSOR CABLE
CONNECTIONS OR
SHORTED WIRES
POSSIBLE AERATION
OR CORRISON ON
INSIDE OF PIPE
5-3
TROUBLESHOOTING CHART
CONTINUED
CONTINUED
DO
MENUS
WORK
4-20mA
<~UTPUT
THERE
OUTPUT
YES
4-20 mA
CORRECT
UNIT IS
OPERATING
PROPERLY
LOOP I
NS~ REPLACE
ELECTRONICS
UNIT
YE
ACTIVATE
ZERO & SPAN
MODES
CHECK RECEIVING
INSTRUMENT
CHECKINSTRUMENT
RECEIVING 4~20 mA
NOI ~
~ ZE AN
CHECK VOLTAGE AT
THE 4-20 OUTPUT
, TERMINALS. FRONT . .
HOUSING MUST BE
CONNECTED
YES
RECAL MENU
~ R U
5-4
I
ILLUSTRATED PARTS LIST
SERIES 4500 ENCLOSURE
ITEM #
I
2
3
4
OF
5
6
7
PART #
541563-9999
543563-0001
543563-0002
543563-000~
400003-0048
501153-0001
501101-0001
400001-0025
400029-0002
400022-0016
490004
151944-0001
151944-0002
160978-0004
512310
DESCRIPTION
FRONT HOUSING W/EI,ECTRONICS
MODEL 4500-12
MODEL 4500-6
MODEl. 4500-3
SCREW SCHCAP I 0-32X2- I/2LG SS
CAP SEALING
CONNECTOR RECP 8CKTS W/SO-FLG
SCREW PNH-S 4040X3/8 SS
SCREW HEXWSHRH 1/3-ABX.75 STL
SCREW HEXWHRH 1/4-20 (ROLOK) ZN
O-RING
AC POWER SUPPLY I 17VAC
AC POWER SUPPLY 240VAC
FUSE 3AG I/4A 250V
GASKET
QUANTITY
1
6-1
WARRANTY
Badger warrants meters and parts manufactured by it and supplied
hereunder to be free from defects in materials and workmanship for a
period of 18 months from date of shipment or 12 months from date of
installation, whichever period shall be shorter. If within such period any
meters or parts shall be proved to Seller's satisfaction to be defective,
such meters or parts shall be repaired or replaced at Seller's option,
Seller's obligation hereunder shall be limited to such repair and
replacement and shall be conditioned upon Sellers receiving written
notice of any alleged defect within 10 days after its discovery and, at
Seller's option, return of such meters or parts f.o.b. to Seller's factory.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OFALL
OTHER EXPRESS OR IMPLIED WARRANTIES WHATSOEVER
INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EX-
CEPT OF TITLE) OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. Badger shall not be liable for any defects
attributable to acts or omissions of others after shipment, nor any
consequential, incidental or contingent damage whatsoever.
NUCLEAR DISCLAIMER
Equipment sold by Badger Meter, inc. is not intended for use in
connection with any nuclear facility or activity unless covered by a
specific quotation where the conditions of such usage will be detailed.
If equipment is used in a nuclear facility or activity without a supporting
quotation, Badger Meter disclaims at~ liability for any damage, injury or
contamination, and the buyer shall indemnify and hold Badger Meter,
its officers, agents, employees, successors, assigns and customers,
whether direct or indirect, harmless from and against any and all losses,
damages or expenses of whatever form or nature (including attorneys'
fees and other costs of defending any action) which they, or any of
them, may sustain or incur, whether as a result of breach of contract,
warranty, tort (including negligence), strict liability or other theSries of
law, by reason of such use.
All rights reserved, All data subject to change without notice.
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