Badger Meter MDS 2000 Mounting instructions

®Badger Meter Europa GmbH
MDS2000
Oil management system
INSTALLATION AND
SOFTWARE MANUAL
October 2008
LMS_MDS2000_BA_02_0810

Content Page
1. Installation manual............................................................................................................1
1.1 Safety features...........................................................................................................1
1.2. Schemas ....................................................................................................................2
1.2.1 Cable requirements ........................................................................................2
1.2.2 Oil installation .................................................................................................3
1.2.3 Connections for the junction box ....................................................................4
1.2.4 Connections for the printer, the network & the internal PC card.....................5
1.2.5 Connections for the external PC card.............................................................6
1.2.6 Connections for the keypad............................................................................7
1.2.7 Change of the address of the display.............................................................8
1.2.8 Connections for the solenoids ........................................................................9
1.2.9 Connections for the power and single pulse transmitters.............................10
1.2.10 Connections for the power and dual channel pulse transmitters..................11
1.2.11 I/O card connectors ......................................................................................12
1.3. Cabling.....................................................................................................................13
1.3.1 The network..................................................................................................13
1.3.2 The power.....................................................................................................14
1.3.3 The terminal links..........................................................................................16
1.3.4 The solenoid valves......................................................................................16
1.3.5 The pulse transmitters..................................................................................17
1.3.6 The printer cable...........................................................................................18
1.4. Network....................................................................................................................18
1.4.1 Installation procedure ...................................................................................18
1.4.2 Logic structure of the MDS network..............................................................19
1.4.3 How does the network work?........................................................................19
1.4.4 Level 1..........................................................................................................20
1.4.5 Level 2..........................................................................................................21
1.4.6 Level 3..........................................................................................................22
1.5. Troubleshooting guide..............................................................................................22
1.5.1 Communication problems.............................................................................23
1.5.2 Problems with the display.............................................................................24
1.5.3 Problems with the solenoid valves................................................................24
1.5.4 Problems with the pulse transmitters............................................................24
1.5.5 Problems with the printers ............................................................................25
1.5.6 Problems with the PC software / interface....................................................25
1.5.7 Explanations for the transaction end codes..................................................25
1.5.8 Procedure to change the battery ..................................................................26

Content Page
2. Software manual..............................................................................................................26
2.1 Program license agreement .....................................................................................26
2.2. PC card upgrade......................................................................................................27
2.2.1 Introduction...................................................................................................27
2.2.2 About the PC interface card..........................................................................27
2.2.3 PC card installation.......................................................................................27
2.2.4 PC minimum requirements ...........................................................................28
2.2.5 MDS 2000 requirements...............................................................................28
2.2.6 PC card hardware installation.......................................................................28
2.2.7 PC card software installation........................................................................29
2.2.8 Running the software....................................................................................30
2.3. Using the software....................................................................................................31
2.3.1 Configuration button .....................................................................................31
2.3.2 Display button...............................................................................................35
2.3.3 Report button................................................................................................36
2.3.4 Dispense button............................................................................................37
2.3.5 Exit button.....................................................................................................37
2.4. Export file possibilities..............................................................................................38
2.4.1 Two possibilities are available......................................................................38
2.4.2 Transaction to disk option.............................................................................38
2.4.2.1 How is it working?.........................................................................38
2.4.2.2 General description ......................................................................39
2.4.2.3 Transactions.................................................................................39
2.4.2.4 Responsibility ...............................................................................40
2.4.2.5 Security.........................................................................................40
2.5. Backup - restore or Archive Database .....................................................................41
3. Manufacturer´s declaration.............................................................................................43
4. Warranty...........................................................................................................................44
5. DIN ISO certificate ...........................................................................................................44

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1. Installation manual
1.1. Safety features
1. Before installing or using this product, please read the instruction manual
thoroughly.
2. Unpacking: Please check that the product is complete and free from any
damage (check with the further packing list).
3. Only qualified individual should install and/or repair this product.
4. Unplug the MDS 2000 from the electrical outlet before you clean it. Use a clamp
cloth for cleaning and do not use liquid or aerosol cleaners.
5. Do not place the MDS 2000 on an unstable surface that may allow the unit to
fall.
6. Never place the MDS 2000 near or over a radiator or heat register.
7. Use the type of power source indicated on the label (AC power). If you are not
sure of the type of power available, consult your supplier or local electric
company.
8. The MDS 2000 must be equipped with a plug having a third (grounding) pin,
which fits only into a grounding-type outlet. This is a safety feature. The MDS
2000 should not be used without a properly grounded outlet. Failure to properly
ground the MDS 2000 may cause damage to the unit or the data stored.
9. Do not put the MDS 2000 where the cord will be walked on.
An extension cord is not recommended for use with the MDS 2000. If you use
an extension cord, make sure that the total of the ampere ratings on the
products plugged into the extension cord does not exceed the extension cord's
ampere rating. Also, make sure that the total of all products plugged into the
wall outlet does not exceed 15 amperes.
11. Unplug the MDS 2000 from the wall outlet and have it repaired by a qualified
service person under the following conditions:
a) When the power cord or plug is damaged or frayed.
b) If liquid has been spilled into it.
c) If it has been exposed to rain or water.
d) If it does not operate normally when the operating instructions are followed.
Adjust only those controls that are covered by the operating instructions
since improper adjustment of other controls may result in damage and loss
of data.
e) If it has been dropped or damaged.
f) If it exhibits a distinct change in performance, indicating a need for service.
Warning
Failure to adhere to these safety instructions may result in serious bodily injury.

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Schemas Page 2/44
1.2. Schemas
1.2.1 Cable requirements
18 Volts DC power cable 2 Core + earth 0.75 mm²
Network cable Type 1 twisted pair screened
Apple Talk 9999 Belden or Belden
8451, or Alpha 24561 or
equivalent
Terminal cable Type 2 twisted pair screened by
pair, Belden 9723 or equivalent
Pulse transmitter cable Type 1 twisted pair screened
Solenoid cable 2 core + earth 0.75 mm²
Printer cable Type 3 core screened (or higher)
Suggestion:
For small and medium installations, we suggest to use the same cable for:
- 24 VDC + network
- Terminal cable
- Pulse transmitter (18690) + solenoid
type 2 twisted pair 0.75mm² min. shielded by pair (capacitance ≤65 pF/m),
Belden 1474 or equivalent.

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1.2.2 Oil installation

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1.2.3 Connections for the junction box
2 core 0,75mm power cable + earth
1 twisted pair
screened
type Alpha 2461
Belden 8451
18V
0V Schield
Can H
Can L
TERMINAL
CABLE
2 twisted pair
shielded by pair (belden 9723)
POWER
NETWORK

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1.2.4 Connections for the printer, the network & the internal PC card
TXDO
GND
RXDO / CTSO
CAN H
Shield
CAN L Key
J 5 LEN
0V
18V
Terminal cable
9DB - to PC
Pin 3 - TXD
Pin 7 - GND
Pin 20 - RXDO/CTSO I/O

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1.2.5 Connections for the external PC card
TXDO
GND
RXDO / CTSO
CAN H
Shield
CAN L Key
J 5 LEN
Terminal cable
I/O
9DB
9DB
PC : 9DB

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1.2.6 Connections for the keypad
18V NEUT
18V LIVE
WAND POWER
CTS
RXD
GND
TXD
CAN L
SHIELD
CAN H
PIN 2 - RXD
PIN 7 - GND
PIN 9 - WAND POWER
PIN 3 - TXD
PIN 7 - GND
PIN 20 - CTS
0V
24V
Junction Box
Terminal cable
Optical
Pen

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1.2.7 Change of the address of the display
Addr. SW1 SW2 SW3 SW4
0 ONONONON
1 OFF ON ON ON
2 ON OFF ON ON
3OFFOFFONON
4 ONONOFFON
5 OFF ON OFF ON
6ONOFFOFFON
7 OFF OFF OFF ON
8 ONONONOFF
9 OFF ON ON OFF
10 ON OFF ON OFF
11 OFF OFF ON OFF
12 ON ON OFF OFF
13 OFF ON OFF OFF
14 ON OFF OFF OFF
15 OFF OFF OFF OFF
Display
Junction Box
Terminal cable
CAN L
SHIELD
CAN H
18V
0V

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1.2.8 Connections for the solenoids
OP8
+V
OP7
+V
OP6
+V
OP5
+V
OP4
+V
OP3
+V
OP2
+V
OP1
+V
OP0
+V
MAIN AIR
SOLENOID
SOLENOID 8
HOSE 8
SOLENOID 7
HOSE 7
SOLENOID 6
HOSE 6
SOLENOID 5
HOSE 5
SOLENOID 4
HOSE 4
SOLENOID 3
HOSE 3
SOLENOID 2
HOSE 2
SOLENOID 1
HOSE 1
FRAME NUT
key
O
KEY SWITCH

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1.2.9 Connections for the power and single pulse transmitters
SPARE
GND
IN8
+V
GND
IN7
IN6
+V
GND
IN5
IN4
+V
GND
IN3
IN2
+V
GND
IN1
IN0
+V
Hose # 8
Hose # 6
Hose # 5
Hose # 2
Waste Oil
Level Detector
18V
0V
Hose # 7
Hose # 4
Hose # 3
Hose # 1
18690
18690
18690
18690
18690
18690
18690
18690
Power
I/O

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1.2.10 Connections for the power and dual channel pulse transmitters
S P A R E
G N D
I N 8
+ V
G N D
I N 7
I N 6
+ V
G N D
I N 5
I N 4
+ V
G N D
I N 3
I N 2
+ V
G N D
I N 1
I N 0
+ V
Hos e#4
Hos e#3
Hos e#2
Hose #1
W aste O i l
Level De t e c t o r
1 8 V
0 V
18692
18692
18692
18692
P o
w
e r
I/O

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1.2.11 I/O card connectors
SPARE
GND
IN8
+V
GND
IN7
IN6
+V
GND
IN5
IN4
+V
GND
IN3
IN2
+V
GND
IN1
IN0
+ V
OP8
+V
OP7
+V
OP6
+V
OP5
+V
OP4
+V
OP3
+V
OP2
+V
OP1
+V
OP0
+V
Printer Network
I/O
UNIT

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1.3. Cabling
1.3.1 The network
The MDS 2000 is based on a network to vehicle the different information.
The use of a preconised cable and the correct architecture are very
important to avoid information conflicts and bad communication between the
different components of your installations.
The different components connected to the network:
I/O unit(s)
Keypad(s)
Display(s)
Terminal for printer
PC,...
Network cable: Type 1 twisted pair shielded, "Appletalk" 9999 Belden,
Belden 8451, Alpha 24561 or similar.
(CAN H & CAN L): Capacitance <= 65 pF/m.
Network structure: Type "in line"
correspond equally to an I/O unit, a display, a terminal for printer or a
PC (only one PC by installation).
Junction box
resistor 120 Ohm

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You can see that all the different components of the installation are placed
one after the other and that the architecture of the network is "in line"
opposite to the schema at the next page, the network "in star" must be
avoided.
N.B. a star branch of 3 meters maximum is allowed.
The maximum length of the network will be approximately 750 meters with
the recommended cables.
Each end of the "line" is terminated by a 120 Ohm resistor fitted between
CAN H and CAN L. A special jumper socket (JP) is mounted on the
electronic board of each device and gives you the possibility to connect (IN
position) or disconnect (OUT position) this resistor.
The use of junction boxes is deeply recommended.
Star network: BAD NETWORK!
1.3.2 The power
The power supply unit (PSU):
- Input: - 100 or 220 Volts AC
- Output - 18 VDC-power: 310 VA
Power for the I/O units, keypads, displays and solenoids.
- An I/O unit uses 2,0 VA and needs a minimum of 10 VDC. (We are
talking about the I/O card without any solenoid)
- A keypad uses 3,6 VA and needs a minimum of 10 DC.
- A display uses 3,6 VA and needs a minimum of 10 VDC.
- A 24 VDC Burkert valve uses 8,0 W and needs a minimum of 8 VDC. The
number of solenoids by PSU depends on the type of solenoids you
selected.

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On each PSU, the connector shows:
L (Live) – (Earth) – N (Neutral): 220 VAC input
(Earth) – 0V (-) – 18 VDC (+): 24 VDC output
On each I/O unit, a connector shows you: L (+) – E (Earth) – N (-): 24 VDC
input.
The earth must be connected with the frame nut and the shield. The input
connector is valid for the alimentation of the electronic board and the
solenoids.
On each keypad, a connector shows you: 18V Neut (-) – 18V Live (+): 24
VDC input.
The earth must be connected with a frame nut and the shield (between Can
H and Can L).
On each display, a connector shows you: 18V Neut (-) – 18V Live (+): 24
VDC input.
The earth must be connected with a frame nut and the shield (between Can
H and Can L).
A 2 Volts deviation range is allowable.
The power cable is: type 2 core + earth 0,75 mm² minimum.

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1.3.3 The terminal links
The terminal cable corresponds to a star's branch of maximum 3 meters.
The terminal cable is: Type 2 twisted pair shielded by pair (Belden 9723 or
equivalent)
This cable contains the 24 VDC power (+ & -), the network (CAN H, CAN L)
and shield/earth.
1.3.4 The solenoid valves
Each solenoid valve is powered individually from the I/O unit.
On each I/O unit, a connector shows you V+ / Opx / ... frame connection.
The solenoids 1 to 8 are connected to the I/O ID 0, the solenoids 9 to 16 to
the I/O ID 1 etc.
2 core 0,75mm power cable + earth
1 twisted pair
screened
type Alpha 2461
Belden 8451
18V
0V Schield
Can H
Can L
TERMINAL
CABLE
2 twisted pair
shielded by pair (belden 9723)
POWER
NETWORK

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The solenoids cable is: Type 2 core + earth 0,75 mm²
It is important to remember that the loss of tension in the cable is
proportional to the distance and invertially proportional to the cable section.
Then, it is important to use a sufficiently big cable and to reduce the length
of the cable if possible.
1.3.5 The pulse transmitters
Each pulse transmitter is connected individually to the I/O board.
On each I/O board, a connector shows you: V+ / Inx / Inx / GND...
The two pulse transmitter's conductors need to be connected
indiscriminately on the connectors INx and GND.
The pulse transmitters 1 to 8 are connected in the I/O ID 0, the pulse
transmitters 9 to 16 in the I/O ID 1 etc...
The single channel pulse transmitter cable is: Type 1 twisted pair screened
The double channel pulse transmitter cable is: Type 2 twisted pair screened
At the right of the pulse transmitter connectors, you see: 1N8 – GND.
These inputs are for the connection of a level switch (N.O.) for the waste oil
high level detection. When the switch is activated, it sends a signal to the
system and the MDS 2000 will print an alert message.