Badger Meter 2100 Manual de usuario

SCOPE OF MANUAL Keep the manual in a readily accessible location for

future reference.

Changes and additions to the original edition of this

manual will be covered by a "CHANGE NOTICE"

supplied with the manual. The change notice will identify

the sections in this manual where the changes have

occurred.

This manual contains information concerning the

installation, operation and maintenance of the Model

2100 flowmeter. To ensure proper performance of the

meter, the instructions given in this manual should be

thoroughly understood and followed.

Model 2100

TABLE OF CONTENTS

Page Page

Unpacking and Inspection................................. 1-1 OPERATION

General Specifications ...................................... 1-2 General Description .......................................... 3-1

System Diagram................................................ 1-3 Status Mode....................................................... 3-2

-- INSTALLATION PROCEDURE............. Calibration Mode .............................................. 3-3

Enclosure Mounting.......................................... 2-1 Option Screens.................................................. 3-8

Wiring Connections .......................................... 2-2 Hexadecimal Conversions................................. 3-10

Sensor Mounting............................................... 2-4 Illustrated Parts List .......................................... 4-1

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 following

any instructions that may be marked o the box. Remove

all cushioning material surrounding the product and

carefully lift the product from the container.

UNPACKING

INSPECTION

Retain the container and all packing material for

possible use in reshipment or storage.

b. Visually inspect the product and applicable

accessories for any physical damage such as scratches,

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.

941164

4/98

1-1

GENERAL SPECIFICATIONS

FULL SCALE

HEAD RISE RANGE 0-4 inches to 0-120 inches. Maximum total range including offset distance is

132 inches.

SENSOR OFFSET Minimum distance from maximum fluid level to face of sensor is 12 inches.

OUTPUT 4-20 mADC isolated into a maximum load of 1000 ohms when operating on

AC power. Maximum load when operating on DC power depends on size of

DC voltage powering 4-20 mA loop.

Four programmable relays; SPDT 1 amp at 24 VDC/0.5 amp at 120 VAC.

DISPLAY 2 line, 24 character per line LCD display. Indicates flow rate, flow total and

alarm trip status.

PROGRAMMING Front panel mounted 5 button keypad.

POWER 115/230 VAC, 50/60 HZ, 10 watts or 12-14 VDC.

ACCURACY +/- .1% of target distance or +/- .08 inches whichever is greater. +/- 0.5% H/Q

curve reproducibility. Resolution: 0.01 inches. Repeatability: +/- 0.25%.

SENSOR Maximum cable length 1000 feet.

Temperature range: -20° F to 160° F (-30° C to 65° C).

ELECTRONIC

ENCLOSURE NEMA 4X standard, temperature range: 32°F to 150°F (0° C to 65° C).

Optional NEMA 4X with heater and thermostat, temperatures down to -40° F

(-40° C).

1-2

2100 SYSTEM DIAGRAM

2100 ENCLOSURE

117/220 VAC/12VDC

OUTPUTS

1/2" SEALTITE CONDUIT

& FITTINGS

2100 SENSOR

MTG BRACKET METALLIC

CONDUIT

(PROVIDED BY

CUSTOMER)

J-BOX

(PROVIDED BY

CUSTOMER)

MAXIMUM CABLE LENGTH FROM SENSOR

TO ELECTRONICS IS 1000 FT.

SUNSHADE FOR SENSOR

(PROVIDED BY CUSTOMER)

2100

NOTE: 4-20 mA output must be in metallic conduit which does not contain any AC power,

controller/driver, or relay wiring.

1-3

BACK

HOUSING

GASKET

MOUNTING

SCREW AND

"O" RING

FRONT

HOUSING

HEX BOLT

INSTALLATION

ELECTRONIC ENCLOSURE

The Model 2100 electronics are housed in a rugged,

NEMA 4X rated 7.75" x 5.75" x 4" (W x H X D)

polycarbonate enclosure designed for wall mounting.

Supplied are two 1/4-20 x 3/4 inch mounting screws for

use with lead inserts, two 1/4-20 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.

FIGURE 2-1

RIBBON CABLE

CONN.

SIGNAL

WIRE

When mounting the Model 2100 electronics, select a

location that has good ventilation, temperature within the

meter's specification, not subject to flooding, protection

from accidental shock and provides for accessibility to

operate and service the meter.

FIGURE 2-2

ENCLOSURE MOUNTING

To mount the enclosure use the 5/32 inch Allen wrench

supplied in the mounting hardware package to loosen and

remove all four hex bolts in the front of the housing (see

Figure 2-1). Separate the front and back housings.

CAUTION: THERE IS A COAX SIGNAL WIRE

AND A RIBBON CABLE CONNECTED FROM

THE FRONT HOUSING TO THE POWER SUPPLY

BOARD THAT MUST BE DISCONNECTED WHEN

REMOVING THE FRONT HOUSING (SEE

FIGURE 2-2). Place the front housing in a protected area

so that it will not be damaged while mounting the back

housing.

4.5"

BACK HOUSING

POWER

SUPPLY

BOARD

"O" RING

MOUNTING

SCREW

CL-CL

To mount the back housing, two holes must be drilled

in the wall 4.5 inches apart (center line to centerline, see

Figure 2-3). The size of the holes will 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. FIGURE 2-3

2-1

WIRING CONNECTIONS

The Model 2100 electronics enclosure is provided with

four holes for 1/2 inch NPT conduit fittings. These holes

are on the bottom of the back housing of the enclosure

and allow entry for the 115 (230) VAC power wires,

sensor cable, 4-20 mADC signal output wires and the

relay output wires. Do not run the power wiring, sensor

cable or signal output wires in the same conduit as this

will affect the meter's operation.

The terminals on the power supply board will accept 14

to 22 gauge wire. A small flat blade screw driver will be

required to loosen and tighten the screws. Figure 2-5

identifies the terminals for proper wiring.

Power connections. TB1 is the terminal block for the

115 (230) 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.

TB2 Terminals 1 and 2 are the connections for the DC

power input if the meter is to be operated on battery

power Terminal 1 is the positive (+) connection and

Terminal 2 is the negative (-) connection. The DC input

voltage must be between 12 and 14 volts..

When operating the meter on DC power, an additional

DC power source may be required to power the 4-20

mADC output. Refer to the 4-20 mA signal output in the

following section for instructions.

Signal output connections. TB2 is the terminal block

for the 4-20 mADC output signal and the four relay

outputs.

4-20 mA OUTPUT - Terminals 3 and 6 are the con-

nections for the 4-20 mA output when the meter is

operated on AC power. Terminal 6 is the positive (+)

connection and Terminal 3 is the negative (-) connection.

A jumper wire is connected between Terminals 4 and

5 when shipped from the factory. This jumper must be

in place when operating the meter on AC power.

If the meter is operated on DC (battery) power and a 4-

20 mA output is required, an additional DC power source

may be required. To properly connect the power source

for the 4-20 mA output refer to Figure 2-5. Disconnect

the jumper wire between Terminals 4 and 5. Connect the

positive wire of the battery to Terminal 5, the negative

wire of the battery to the negative input of the load

(recorder) and connect the positive input of the load to

Terminal 6. The DC voltage required to power the 4-20

mA loop is 8 volts. The size of the DC voltage source

BACK HOUSING POWER SUPPLY BOARD

POWER OUTPUTS 4-20

MADC

TEST POINTS

SENSOR

FIGURE 2-4

BACK HOUSING

2-2

Battery+

Recorder

CENTER CONDUCTOR

MIDDLE SHIELD

OUTER SHIELD

SENSOR HEAD CABLE

FUSE

SW1 SW2 SW3 SW4 P2

H L G

VAC Bat 4-20 mA

Optional 4-20 mA Loop Power

Battery

Power Source

FIGURE 2-5

For External Battery Operation

RELAY OUTPUTS - TB2 is also the terminal block for the

relay output connections. Terminal connections 7 through 18

are used for the four relays which are marked SW1, SW2,

SW3 and SW4. These relays are single pole double throw with

a 1.0 amp 24 VDC or 0.5 amp 120 VAC current rating.

The wiring connections are marked on the printed circuit

board below the terminal block. Each relay terminal is marked

NC (normally closed), C (common) and NO (normally open).

The normally open and normally closed positions are with the

relay de-energized. The relays are energized when they are

tripped by the assigned level or alarm. The relays can be

assigned for different functions which are explained in the

Operation Section of this manual.

needed will depend on the amount of resistance of the

load connected to the 4-20 mA loop. To determine the

size of the DC power source, use the following equation:

DC volts = (Max load/50) + 8

Two test points are provided on the bottom of the back

housing to allow adjustment of the 4-20 mADC signal. A

load must be connected to the 4-20 mADC output

terminals for these test points to work. Refer to the

Operation Section when adjusting Zero and span.

2-3

FB-1 (FULL FACE)

SENSOR INSTALLATION

GENERAL DESCRIPTION

The Model 2100 FB-1 sensor has a PVC plastic

housing. The sensor is back filled with an epoxy resin.

The sensor head has a 3/4 inch NPTmounting nipple to

secure the sensor to the mounting bracket and attaching a

conduit fitting for routing the sensor cable back to the

elecontric enclosure. Metallic conduit must be used to

run the sensor cable back to the electronics. The sensor

must be mounted level. An ‘L’ mounting bracket is

supplied with the sensor.

The sensor is supplied with 50, 100, 300 or 500 feet of

continuous cable, or additional cable (up to 1000 feet

total) may be spliced onto the cable from the sensor. Only

Belden 9222 cable should be used.

A component change in the electronics may be required

if the sensor cable length is changed from that shipped by

the factory. The critical lengths of the cable for the

component change are 150 feet and 500 feet. The

following shows the component value for C11 according

to the sensor cable length (see Figure 2-7, page 2-11 for

location):

0 to 150 feet — C11 = 6800PF

151 to 500 feet — C11 = no component

501 to 1000 feet — C11 = 470 uH

3 - 1/8 "

4 "

INSTALLATION

The meter is normally programmed at the factory to a

specific application. The sensor must be installed to the

proper mounting dimensions to ensure the accuracy of the

flowmeter. Refer to the data sheet in the front of this

manual for these dimensions.

MOUNTING BRACKET

4 - 1/8 "

1/8 "

3/8 "

DIA. 1 -1/4 " 3 "

6 - 1/8 "

Mounting Hole

The dimension that is used when mounting the sensor is the

vertical calibrated (Vcal) mounting distance. This is the

distance from the surface of the fluid at no (zero) flow, to

the face (bottom) of the sensor. There are two regions that

make up the Vcal distance. These are the sensor offset

and the customer selected full scale headrise.

2-4

Sensor

Offset

Customer

Selected

Full scale

Headrise

Vcal

Sensor

Mounting

Dimension

Level of fluid at no flow 6° Beam Angle

NOTE:

If sensor is exposed to sunlight, a sun shield should be used. Refer to System Diagram, Page 1-3.

The sensor offset is the distance from the maximum level

of the fluid to the face of the sensor. The minimum offset is

12 inches.

The full scale headrise is the level of the fluid at the

customer’s selected full scale flow for the flume or weir.

The minimum full scale headrise is 4 inches and the

maximum is 132 inches.

Therefore,

Sensor vertical mounting distance (Vcal) =

Customer full scale headrise + Sensor offset

When the Model 2100 is programmed at the factory, the

Vcal is determined by taking the full scale head rise of the

maximum capacity of the flume or weir plus 12 inches for

the offset. This is done so that the flowmeter can be rescaled

to a higher full scale flow in the future without having to

move the sensor. This is reflected on the Mounting and

Calibration Data Sheet in the front of the manual by the

Max. Capacity (Element) and Customer Maximum

Headrise. When the Customer Max. Flow is less that the

Max. Flow (Element) then the sensor offset will be 12

inches plus the difference between Max. Flow (Element)

and the Customer Max Headrise.

The other mounting dimension that is important is the

Horizontal (H) dimension. This is the horizontal distance

from a reference point on the flume or weir to the sensor.

Pages 2-6 through 2-9 show this dimension for the

commonly used flumes and weirs.

Another aspect that must be considered when mounting

the sensor is the distance of the sensor from the walls of the

structure in which the fluid is flowing. If the sensor is too

close to the wall, reflections may occur which could cause

inaccuracies in the level measurement. The beam angle of

the transmitted signal from the sensor face is a maximum of

6 degrees. To determine the distance the sensor must be

mounted from the wall, multiply the Vcal distance times

0.0524. This will give the distance required from the wall to

the sensor housing.

The exit hole for the sensor cable on the top of the

housing is a 3/4" NPT nipple which is used to mount the

sensor to the mounting bracket and connecting the conduit

for the cable. The cable must be run in metallic conduit to

prevent any stray noise interference from affecting the

meter’s operation.

The mounting bracket provided with the sensor can be

mounted directly to the wall for Vcal distances of 60 inches

or less. An extension, or mounting brace, to the mounting

bracket will be required for Vcal distances greater than 60

inches.

When installing the sensor, it is imperative that it be level.

A level should be placed on top of the sensor and

adjustments made to the mounting bracket to ensure the

sensor face is level to the fluid.

This completes the FB-1 sensor installation procedure.

Refer to the electronic wiring section for connecting the

sensor cable to the electronics.

2-5

PARSHALL FLUME INSTALLATION

Vcal

FLOW

Size H Dim. Vcal Full Scale (GPM) Full Scale Head Rise

(in.) (in.) (in.) Min. Max. Max (in.)

2 11.00 21.46 60 210 9.46

3 12.00 30.21 85 850 18.21

6 16.00 30.29 180 1800 18.29

9 22.50 38.01 280 4500 26.01

12 35.25 42.70 375 7500 30.70

18 37.25 43.70 550 12000 31.70

24 39.25 43.47 700 16000 31.47

36 43.25 43.98 1100 25000 31.98

48 47.00 44.75 1350 35000 32.75

The H dimension is straight back from the entrance of the throat and not along the flume wall.

MANHOLE FLUME INSTALLATION

Vcal

FLOW

Size H Dim. Vcal Full Scale (GPM) Full Scale Head Rise

(in.) (in.) (in.) Min. Max. Max (in.)

4 5.75 17.86 45 90 5.86

6 7.75 20.94 60 250 8.94

8 9.75 24.32 75 550 12.32

10 11.75 27.58 80 1000 15.58

12 13.75 29.99 100 1500 17.99

2-6

OPEN FLOW NOZZLE INSTALLATION

Vcal

FLOW

Size H Dim. Vcal Full Scale (GPM) Full Scale Head Rise

(in.) (in.) (in.) Min. Max. Max (in.)

6 21.00 16.79 125 180 4.79

8 23.00 18.66 150 400 6.66

10 25.00 20.77 165 800 8.77

12 29.00 21.55 145 1100 9.55

14 31.00 24.75 85 1600 12.75

16 35.00 25.87 100 2100 13.87

18 38.00 28.16 85 2600 16.16

20 40.00 30.78 90 3700 18.78

24 46.00 35.07 95 7000 23.07

PALMER-BOWLUS FLUME INSTALLATION

Vcal FLOW

Size H Dim. Vcal Full Scale (GPM) Full Scale Head Rise

(in.) (in.) (in.) Min. Max. Max (in.)

6 3.00 17.16 130 200 5.16

8 4.00 18.77 145 400 6.77

10 5.00 20.46 175 700 8.46

12 6.00 22.15 200 1100 10.15

15 7.50 24.96 220 2000 12.96

18 9.00 27.13 270 3000 15.13

21 10.50 29.85 300 4500 17.85

24 12.00 32.77 325 6500 20.77

2-7

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