Badger Meter AR/e User manual

IOM-034-12
PartNo.53400-034
7-01
Installation &
Operation Manual
BadgerMeter,Inc.
®
Model AR/e – AR/t
& RTR
Service Information (File manual for future reference and service.)
Serial Number DateInstalled / /
Service Line Operator
IMPORTANT !!!! Read this manual before
attempting any installation, wiring or operation.
Water Treatment Control System

2
■ TABLE OF CONTENTS
Page
UnpackingandInspection .................................................. 2
INSTALLATION
Surface Mounting or Pipe Mounting .................................. 3
Panel Mount ......................................................................... 3
Wiring Precautions & Procedures ...................................... 3
BatteryInstallation ............................................................. 3
AC Power Connections ........................................................ 3
Transmitter Connections (AR/t & RTR).............................. 4
Lockout Signal Connections ............................................... 4
Remote Start & Stop Connections ..................................... 4
Connecting to Other Equipment ........................................ 5
OPERATION
Forced Regeneration ........................................................... 6
Aborting Regeneration cycle .............................................. 6
Overriding Preset Batch Value ........................................... 6
PROGRAMMING
General Programming Procedures ..................................... 5
Setting For Manual/Auto Operation ................................... 5
Setting AR/e to Type & Size of Meter ................................ 5
Batch Size ............................................................................ 6
Output Signal Duration ....................................................... 6
Start-up Check List ............................................................. 6
TROUBLESHOOTING
Self-test Procedure .............................................................. 6
ReplacementParts ............................................................... 6
Troubleshooting Chart ........................................................ 7
Toavoiddamageintransit,Badgerprod-
uctsareshippedtothecustomer inspe-
cialshippingcontainers.Uponreceiptof
the product, perform the following un-
packing and inspection procedures.
Note: If damage to the shipping con-
tainer is evident upon receipt, request the carrier to be
present when the product is unpacked.
a. Carefully open the shipping container following any in-
structionsthatmaybemarkedonthebox.Removeallcushion-
ing material surrounding the product and carefully lift the
product from the container.
Retain carton and packing material for use in re-shipment
orstorageof unit.
b. Visuallyinspecttheproductandapplicableaccessoriesfor
anyphysicaldamagesuchasscratches,looseorbrokenparts
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 damaged in transit
is the sole responsibility of the customer.
■ UNPACKING & INSPECTION ■ SCOPE OF THE MANUAL
Thismanualcontainsinformationconcerningtheinstallation,
operationandmaintenanceoftheAR/ewithAR/torRTRWater
Conditioning Control System. To ensure proper performance
ofthe system,theinstructionsgiveninthismanualshouldbe
thoroughly understood and followed.
Keepthemanualinareadily,accessiblelocationforfuture
reference.
Changesandadditionstotheoriginaleditionofthismanualwill
becoveredbya"ChangeNotice"suppliedwiththemanual.The
changenoticewillexplainanydifferencesbetweentheproduct
received and the product described in this manual.
■ INSTALLATION
TheARSystemconsistsofaBadgerDisc
or Turbo meter with the AR/t or RTR
pulse transmitter and the AR/e Condi-
tioning Controller. Normally, the trans-
mitter will be mounted on the meter. It
does not require any additional mount-
ing procedure. All transmitters use a
simplebayonetmountandasealscrewto
attach to the meter.
Note: Alwaysbesuretomatchthetransmittertotheproper
meter. A red dot on the AR/t transmitter dial indicates the
metermodelandsizeforwhich thetransmitteris intended.
The RTR dial face has the model designation of the appro-
priatemeter.

3
MOUNTING
TheAR/econtrollercomesinarugged,watertightpolycarbon-
ate enclosure intended for wall, pipe or panel mounting. The
package contains two sets of mounting screws and "O" rings
which must be used to maintain the NEMA 4X rating of the
enclosure.
Whenmountingtheunitselectalocationwhichhasadequate
ventilation,protectionagainstmechanicalshockandaccessi-
bility for operation and service.
OperatingTemperature: 32° to 130° F (0° to 55° C)
Operating Humidity: Up to 85% non-condensing
Usinga5/32'' Allenwrench,removethe four cornerscrewsin
the housing.
Separate the front and rear halves of the housing. Keep the
screws and housing gasket in an accessible location.
WIRINGPROCEDURE
Three plug-in terminal block assemblies are provided for
connecting 28 to 14 gauge insulated wire. Solid or stranded
wire can be used.
It is recommended that wiring be carefully planned and laid
outbeforeinstallation.Thiswillhelpdeterminetheamountof
spaceneededforwiringaswellasthefinallocationoftheunit.
Detaildiagramsinthissectionillustrateproperwiringproce-
dures for all standard and optional functions.
Besure tocomplywiththewiringrequirementsandallappli-
cable electrical codes.
Note:Terminalblockassemblyunplugsfromprintedcircuit
board for ease in connecting field wiring.
Disconnectall powerto theunitbeforeconnectingwires to
any of the terminals. Do not use machine power service. A
dedicated or lightning circuit is recommended.
Wall or Pipe Mount
1. Usingtheappropriatemountinghardwareattachtheback
part of the housing to the mounting surface.
2. Wire the unit (see wiring procedures on this page).
3. Carefully place the housing gasket in place and bolt the
front part of the housing to the back part.
Panel Mount
1. Use the housing gasket to mark and drill the panel.
2. Drill a 3/4" hole in the panel for the fuse holder.
3. Wire the unit (see wiring procedures on this page).
4. With the housing gasket properly placed on the front
housing, mount the unit to the panel.
POWERINPUT
TheAR/eisdesignedtoworkwitha110VACpowersupply.In
case of power failure, the unit will retain all programmed
valuesandcontinuetocountdown(withoutdisplayoroutput)
forseveralhours.Whenpowerisrestored,theunitwillsendan
outputsignalifenoughpulseshaveaccumulatedduringpower
outage.Ifthepowerdownperiodexceedsthebatterycapacity,
thelastknownbatchcountandotherprogrammedvalueswill
be stored until the power comes back on. (Battery requires a
minimum of 24 hours to recharge from a fully discharged
condition.)
INSTALL BATTERY ON CIRCUIT BOARD ONLY
AFTERWIRINGISCOMPLETED.

4
PULSEINPUT(AR/t)
TheAR/ttransmittersendspulsesignalstotheAR/econtroller.
Each pulse represents a specific quantity of water for a
particularmetersize.
Meter Pulse Rate
RCDL Models 25, 35 and 40 1 pulse = 1 Gallon
RCDL Models 70, 120, 170 and
Industrial Turbo 2", 3" and 4" 1 pulse = 10 Gallons
Industrial Turbo 6" 1 pulse = 100 Gallons
Reedswitchtransmittershavetwoblackleads.Connectthese
leads to terminals 1 & 2 in any order.
Electronic transmitters have one black lead and one white
lead. Connect these leads as per the diagram at right.
IntheAutomatic mode,therelaywill be energizedattheend
of the batch for the amount of seconds programmed via the
SIGNAL DURATION procedure (see page 6). The relay con-
tactscanbewiredtoatimerorregenerationcyclecontroller.
REMOTESTART&STOP(OPTIONAL)
RemoteStartInput
When activated, it will abort a batch before its completion,
initiating tank regeneration at the same time.
In the Manual mode, the output relay will be energized
indefinitelyandthedisplaywillberesettozerountiltheSTOP
command is received.
IntheAutomaticmode,theoutputrelaywillbeenergizedfor
theprogrammedduration(seeoperationsectionpage6)and
thedisplaywillberesettothebatchpresetvalueandcontinue
to count down when pulses are received.
IfaSTARTcommandisreceivedwhiletheLOCKOUTisactive,
thecommandwillbestoredinmemoryandacteduponassoon
as the LOCKOUT signal is terminated.
RemoteStopInput
Isusedtoterminatetheoutputsignal.Thisfunctionisenabled
after a START command is received or after the output relay
is energized at the end of the batch.
IntheManualmode,itwillterminatetheoutputsignal,reset
thecountertothebatchpresetvalueandenablethetransmit-
ter pulse input.
PULSEINPUT(RTR)
The RTR transmitter/register sends pulse signals to the AR/e
controller.Eachpulse represents aspecificquantityofwater
for a particular meter size.
Meter Pulse Rate
RCDL Models 25, 35, 40, & 70 1 pulse = 1 Gallon
RCDL Models120 and170 1 pulse = 10 Gallons
RCDL Turbo Series 1 1/2" - 6" 1 pulse=100 Gallons
These transmitters have one black lead and one red lead.
Connect these leads as per the diagram.
RELAYOUTPUT
The regeneration signal relay is energized at the end of the
batch or when a START command is initiated.
IntheManualmode,therelaywillremainenergizeduntilthe
SIGNAL STOP is initiated. The relay contacts can be used to
activate a warning device to indicate that manual regenera-
tion of the system is necessary.
IntheAutomatic mode,itwillonlyterminatetheoutputsignal.
LOCKOUTINPUT(OPTIONAL)
Toavoidsimultaneousregenerationofmultipletanks,alock-
out signal can prevent a controller from sending a regenera-
tion signal at the end of the batch.

5
The regeneration signal will be sent as soon as the lockout
signalisterminated.Alighteddecimalpointatthelowerright
corner of the display will indicate the presence of a lockout
signal.(An open collector/switch contact or a 115 VAC signal
can be used as the lockout signal.) When using a 115VAC
lockoutsignal,thelockoutlogiccanbereversed.(Seesettings
forSwitch2insectionbelow.)Ifthe115VAClockoutsignalis
not used, Switch 2 must be in the off position. The lockout
signal will be ignored if the output is energized.
SELECTINGTHEMODEOFOPERATION
Select the mode of operation and maximum batch size re-
quired for your particular system. (For location of switches,
see page 7.)
Switch 1: ON (Manual operation)
OFF (Automatic operation)
Switch 2: ON (Lockout when115VACis not applied
to TB-3)
OFF (Lockout when115VACis appliedtoTB-3)
Note: Switch2mustbeintheoffpositionwhennotusing115
VAC lockout function.
Switches 3 & 4: (See chart) Set switches for the maximum
batch size for your particular size of meter.
Example: Youhavea2"IndustrialTurbometerandyourbatch
size is 500000 gallons, set switch 3 to the off position, and set
switch4totheoffposition.(Thiswillallowyoutosetamaximum
batchsizeof 999000 gallons.)AttachtheX1000 sticker tothe
front panel.
Batch Capacity Selection Table
Zeros are not displayed.
Attach appropriate multiplier label to front panel.
Switch
Position Max. Preset Value in US Gal.
for Meter Size (inches)
on
999
RCDL 25, 35,
40 & 70 (RTR)
Turbo Series
1 1/2" - 6" and
Ind. Turbo 6"
1234 9990 99900
1234 999009990 999000
1234 99900 9990000999000
1234 99900000999000 9990000
X1
X10
X100
X1000
X10
X1000
blank X10
X1000
X10000
(no label)
X1000
X10000
X100000
(no label)
(no label)
RCDL 70 (AR/t),
120 & 170 and
Ind. Turbo 2", 3" & 4"
■ OPERATION
ThebasicfunctionoftheAR/econtroller
is to provide a signal to external equip-
ment once a predetermined amount of
water has been measured by the water
meter. The batch is preset and the dis-
play counts down to zero. At this point
the output relay is energized for a pro-
grammed period of time providing the necessary signal for
manual or automatic regeneration.
The controller is designed to function with a minimum of
operatorcontrolaftertheinitialsetupprocedures.Alldisplays
and controls are located on the front panel for fast, accurate
and convenient operation.
GENERALPROGRAMMINGPROCEDURE
In addition to the LED display and the digit keys, the front
panel of the AR/e controller has two command keys (START
andSTOP)andthreeprogramkeys(PRESET,SIGNALDURA-
TION and UP-DOWN COUNT).
Topreventtamperingoraccidentalmistakes,thekeysmustbe
depressed twice in succession for the command to be recog-
nizedandactedupon.Ifthesecondcommandisnotreceived
withintensecondsofthefirst,theunitwillrevertbacktoits
previousoperation.
PROGRAMMINGSEQUENCE
Tointerrogatethepresentvalueofaprogrammablefunction,
depress the appropriate function key. The display will show
the function symbol and the present value of the function
alternately for ten seconds and then revert back to normal
operation.
To preset a new value,presstheappropriatekeyandchange
the value by using the "digits" keys. Pressing a digit key
continuouslywillcausethenumbertoscroll.Whenthedesired
number is reached, remove your finger from the digit key.
Change one digit at a time, within ten seconds of each other.
After the new value is displayed, press the key again, to store
it in memory.
Theunitwillnotreacttoanynewvaluesuntilitcountsdown
tozero.Toacceptthenewvaluesimmediately,"zero"theunit
usingthe UP/DOWNkey.

6
■ TROUBLESHOOTING
Most problems encountered when applying the AR/e control
are due to wiring errors, improperly set functions or faulty
transmitterconnections.Thissectionprovidesguidelinesfor
the detection and correction of these and other problems.
However, should the problem persist, contact our nearest
representative or the factory for further assistance.
SELFTESTPROCEDURE
1. Switch power off and on again. If the displays shows
anythingbutthree eights,anerrorexists intheprocessor
and the unit has to be replaced.
2. Ifselftestissatisfactoryproceedtotesttheinputswitches
as follows:
a. Pressthe hidden test switch twice.At firstthedisplay
will show three fives then one eight.
b. Press all keys once in the following sequence: Signal
START(7),SignalSTOP(6),SignalDuration(5),UP/
DOWN(4),PRESET(3),HiddenTestSwitch(2),least
significantdigit(1),centerdigit(0),andmostsignifi-
cantdigit(BatchCount).Eachtimeakeyisdepressed
theappropriatenumberwillbe displayed.Ifone ofthe
numbers remain in display after the next key is de-
pressed,that particular input is defective.
■ START-UP CHECKLIST
1. Set DIP switch 1 for manual or automatic operation.
2. SetDIPswitch2forproperlockoutoperation.(Setto"off"
positionifnotused.)
3. Set internal DIP switches (3 & 4) for meter size and
maximumbatchsize.
4. InstallNiCadbattery.
5. Program unit for batch size wanted.
6. Program unit for output signal duration wanted.
7. "Zero" the unit using UP/DOWN key.
■ FIELD REPLACEABLE PARTS
Thefollowingpartscanbeobtainedlocally.Brandnamesand
model numbers are for reference only.
Relay: Potter & Brumfield® T81H5D212-05 (or equal)
Fuse: Fusetron® slow blowing 1/10 amp MDL series
(or equal)
Battery: Eveready®CH227.2voltNiCadrechargeable
battery
(Do not use non-rechargeable battery.)
If you find it necessary to send unit to factory, contact your
Badger representative or dealer for material return authori-
zation.Packagetheunitproperly,andincludeabriefdescrip-
tionoftheproblem.
®
The START and STOP command
keys have the same effect as the
equivalent remote functions (see
wiringsectiononpage4).Thekey
mustbedepressedtwiceinsucces-
sionforthecommandtoberecog-
nized and acted upon.
The PRESET key is used to set the
amountofwatertobemeasuredbefore
tankregenerationisrequired.Thepre-
set value is a three digit variable number times a multiplier.
Depress the key and the display will show the present preset
batchvalueandthepresetsymbol.Usethedigitkeystosetthe
new value. Depress the PRESET key again to enter the new
valueinmemory.
TheUP/DOWNkeyisusedto"zero"the
unit or change the present count to a
larger or smaller number in order to
avoid simultaneous regeneration in multi-tank systems. The
new number will affect the batch in progress.
• Depress the key and the display will show the present
batch count and the UP/DOWN symbol.
• Use the digit keys to change the count value.
• DepresstheUP/DOWNkeyagaintoenterthenewcount
valueinmemory.
TheSIGNALDURATIONkeyisusedto
preset the time period for which the
output relay will remain energized at
the end of a batch, or when a START
commandisreceived.The default valueforsignalduration is
5 seconds. This function is valid only if the control is set to
operate in the automatic mode. The duration can be pro-
grammed from 1 to 999 seconds.
• Depress the key and the display will show the present
signal duration period and the function's symbol.
• Use the digit keys to change the period.
• DepresstheSIGNALDURATIONkeyagaintoenterthe
newvaluein memory.
TheSELFTESTkeyisusedtorunaself
test procedure in case of malfunction.
Theprocedureitselfandthediagnostic
isexplainedintheTroubleshootingsec-
tion on this page.

7
PROBLEM POSSIBLE CAUSES REMEDIES
Displaydoes not light when 1. No power on terminals 1 and 2. 1. Connect terminals 1 and 2 to power source.
AC power is turned on. 2. Blown fuse. 2. Replace fuse.
3. Shorted power wiring. 3. Removeshortcircuit.
Counter does not decrement 1. No flow through meter. 1. Establish flow through meter.
whentransmitterisactivated. 2. Defectivetransmitter. 2. Replacetransmitter
3. Transmitterimproperlyconnected. 3. Correct wiring error.
4. Dipswitchesimproperlyset. 4. Verify switch settings for your meter size.
Regeneration output is not 1. Defectiverelay. 1. Replace relay. (See page 7.)
energized at end of batch or 2. Lockout is active. 2. Check switch 2 position andwiring to
whenaSTARTcommandis lockoutterminals.
received.(Signal indicatorislit.)
Cannot change programmed 1. Function key is not being pressed 1. Refer to page 6 for proper programming
values. twice. sequence.
2. Unit not "zeroed" with UP/DOWN 2. Use UP/DOWN key to "zero" unit, which will
key. force acceptance of new values.
Regeneration signal is active 1. Outputisimproperlywired. 1. Correct wiring errors.
when signal light is off. 2. Unitisdefective. 2. Replaceunit.
Test procedure does not work. 1. Unitisdefective. 1. Replaceunit.
Memory does not function 1. Batteryisdefective. 1. Replacebattery.
during power outage.
AR/e Circuit Board

®
Due to continuous research, product improvements and enhancements,
Badger Meter reserves the right to change product or system specifications
without notice, except to the extent an outstanding bid obligation exists.
BadgerMeter,Inc.
P.O. Box 245036, Milwaukee, WI 53224-9536
Telephone: [phone]
Fax: [phone]
www.badgermeter.com
Copyright©BadgerMeter,Inc.2001.Allrightsreserved,alldatasubjecttochangewithoutnotice.
Please see our website at
www.badgermeter.com
for specific regions and contacts.