Badger Meter 2100R+ User manual

SCOPE OF MANUAL
This manual contains information concerning the
installation, operation and maintenance of the Model
2100R+ flow meter. To ensure proper performance of the
meter, the instructions given in this manual should be
thoroughly understood and followed.
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 explain
any differences between the product described in this
manual.
Model 2100R+
TABLE OF CONTENTS
Page Page
Unpacking and Inspection................................. 1-1 OPERATION
General Specifications ...................................... 1-2 Recorder Status and Calibration Modes............ 3-1
INSTALLATION PROCEDURE Recorder Options and Error Screens................. 3-7
Enclosure Mounting ....................................... 2-1 Flow Meter Status and Calibration Modes........ 3-8
Wiring Connections.......................................... 2-2 Flow Meter Option Screens .............................. 3-15
Sensor Mounting............................................... 2-4 Chart Pen Zero & Span Adjustment ................. 3-16
Sensor Cable Connection.................................. 2-10 Hexadecimal Conversions................................. 3-19
Chart Installation and Pen Alignment............... 2-12 Illustrated Parts List.......................................... 3-21
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 on 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.
941181
03/96
1-1

GENERAL SPECIFICATIONS
Recorder:
2 line, 24 alphanumeric character per line Liquid Crystal Display. Displays
instantaneous flow rate, totalization, alarm indication and is used to program the
recorder through menu driven prompts.
DISPLAYS
Flow Meter:
2 line, 24 alphanumeric character per line Liquid Crystal Display. Displays
instantaneous flow rate, level, alarm indication and is used to program the flow
meter
through menu driven prompts.
RECORDING 12 inch circular chart with 24 hour, 7 day or 31 day selectable chart speed, single
disposable red ink pen.
PROGRAMMING Menu driven display prompt with 5 key tactile feedback keypad.
Recorder:
4-20 mADC signal into max. 1000 ohms
2 dry contact SPDT relays assignable to any of the following:
High or low alarms, contact integrator, loss of 4-20 mA signal,
EEPROM failure. Rated for 0.25 amp @ 120 VAC or 0.5 amp @ 24 VDC
OUTPUTS
Flow Meter:
4 dry contact SPDT relays assignable to any of the following:
High or low alarms, loss of echo, transmit failure, EEPROM failure,
overrange and loss of 4-20 mA signal.
Rated for 0.25 amp @ 120 VAC or 0.5 amp @ 24 VDC.
ENCLOSURE Indoor: NEMA 12, metallic; Outdoor: NEMA 4X, non-metallic
TEMPERATURE Indoor: 32° F to 150° F (0° C to 65° C)
LIMITS Outdoor: -40° F to 150° F (-40° C to 65° C)
POWER Standard: 117 VAC, 50/60 Hz +/- 10%, 20 watts
REQUIREMENTS Optional: 230 VAC, 50/60 Hz +/- 10%
Heater & Thermostat: 220 watts
Recording Indicating Totalization
Accuracy: +/- 0.5% of span +/- 1% or 1 LSD +/- 0.25%
Linearity: +/- 0.5% of span +/- 0.5%
PERFORMANCE Hysteresis: +/- 0.5% of span
Repeatability: +/- 0.5% of span
1-2

ENCLOSURE DESCRIPTION
The Model 2100R+ ultrasonic flow meter with circular
chart recorder is housed in either a NEMA 12 or NEMA 4X
enclosure.
The NEMA 12 enclosure is suitable for indoor use and
is designed to be panel mounted. It can be supplied with
heater and thermostat for indoor installations in buildings
that are not heated in the winter. Mounting hardware is
provided for panel mounting of the enclosure. Care
should be taken when selecting the mounting location so
that the recorder door can be opened completely for
access when changing charts.
INDOOR ENCLOSURE DIMENSIONS
The NEMA 4X enclosure is suitable for outdoor use
and can be wall or pole mounted. It comes equipped with
heater and thermostat. The door can be supplied with or
without a window. The door is provided with two
lockable latches. Caution should be used when mounting
the enclosure so that it is not exposed to direct sunlight. A
sun shield is recommended to prevent the temperature
inside the enclosure from reaching above the maximum
rating of the electronics (see temperature specification
under General Specifications). Viewing window is
optional.
INSTALLATION
OUTDOOR ENCLOSURE DIMENSIONS
16"
20"
7-7/8"
INDOOR PANEL MOUNTING
15-5/8"
19-3/16"
8-13/16"
7 "
Prior to mounting the enclosure, it is recommended that
the knockouts for the conduit fittings be removed. This
should be done with the enclosure resting on a solid
surface.
A hole 17-7/8" high by 14-1/4" wide is required for
inserting the enclosure in a panel. Slide the recorder into
the panel. Install the four mounting brackets into the slots
in the sides of the enclosure as shown below. Tighten the
mounting screws until the enclosure is secure to the panel.
14-1/4 "
17-7/8 " PANEL
OPENING
CUTOUT
MOUNTING
BRACKETS
4 EACH
2-1

OUTDOOR ENCLOSURE MOUNTING
The NEMA 4X outdoor enclosure is provided with four
mounting feet which are to be installed by the user at the
orientation desired. Pictured below is the installation
detail of the feet and the mounting hole dimensions.
If the outdoor enclosure has the window option, do not
mount facing the sun or install a sun shade to prevent
overheating of the electronics inside the enclosure.
MOUNTING FEET
14.55 "
17.03 "
10.40 "
20.96 "
WIRING CONNECTIONS
The indoor case has six 7/8" diameter knockouts for
use of 3/4" conduit connections. Three are located on the
bottom of the case and three on the back of the case. The
three you use will depend on whether you panel or wall
mount the enclosure. The outdoor enclosure has three
7/8" diameter knockouts located at the bottom of the case.
Local regulations for proper grounding and connection
of the power to the recorder should be strictly followed.
The power wires are connected to the terminals located
on the inside back of the enclosure (see Figure 2-1). To
gain access, open the enclosure door and loosen the two
screws at the top and bottom left side of the chart plate
and swing out the chart plate. The AC voltage for which
the unit has been set up for will be clearly marked near
the terminal strip. Verify that you are connecting the proper
voltage to the recorder. The terminal labeled H is the High
(black) wire, the terminal labeled N is the Neutral (white)
wire and the terminal labeled G is the Ground (green)
wire. The power wires from the terminal strip to the
recorder circuit board and the flowmeter power board are
prewired from the factory.
The terminal blocks on the recorder circuit board have
snap-on connectors. To connect the output wires for the
relays or 4-20 mA retransmission, pull off the connectors
from the terminal strips. Route the signal wires through
the wiring clips. Loosen the screws on the connectors.
Strip off about 1/4 inch of insulation from the wires.
Insert the wire into the proper connector and tighten the
screw securely. After connecting all of the wires to the
connector, snap the connector back on the terminal strip.
DRY CONTACT
RELAYS MAX
LOAD 250 MA
+4-20 MA
OUTPUT
NO
C SW 1
NC
NO
C SW 2
NC
1
2
3
4
5
6
7
8
TB5
RECORDER RELAY OUTPUT
S
2-2

+4-20 MA
OUTPUT
NO
C SW 1
NC
NO
C SW 2
FACTORY WIRED
FROM 2100 4-20MA
AN1
AN2
AN3
NOT
USED
+
FREQ IN
PWR
PWR
117/230VAC
FACTORY
WIRED
TB1 1
2
3
NC
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
3
TB5
TB4
TB3
TB2
HNG
117/230 VAC
CONNECTIONS
MODEL 2100
FLOWMETER
FIGURE 2-1
The recorder relay outputs are located on TB5 of the
recorder circuit board. The relays are assignable to
different functions. See the Recorder Operating Section
of this manual.
RECORDER 4-20 mADC OUTPUT
The 4-20 mADC output is a retransmitted output of the
flow signal which can be connected to other external
devices. The wiring connections must be connected in
series with the load, as shown above.
RELAY OUTPUTS - TB2 also is the terminal block
for the connections for the relay outputs. 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 Model
2100 Operation Section of this manual on Page 3-13.
MAX. 1000
OHM LOAD
+
FREQ IN
PWR
PWR
TB2 1
2
3
+4-20 MA
OUTPUT
NO
C SW 1
NC
NO
C SW 2
NC
1
2
3
4
5
6
7
8
TB5
+
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 NPT mounting nipple to
secure the sensor to the mounting bracket and attaching a
conduit fitting for routing the sensor cable back to the
electronic 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 100 feet of triaxial cable.
The sensor can be ordered with 300 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 is required
depending on the length of the cable. This is done at the
factory based on the amount of cable ordered with the meter.
The critical lengths of cable for the component change are
150 feet and 750 feet. If the user increases or decreases the
length of cable, and the length change steps above or below
the critical length points, the factory should be contacted for
information regarding the correct component change.
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
flow meter. 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
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 headrise of
the maximum capacity of the flume or weir plus 12 inches
for the offset. This is done so that the flow meter 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 than 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
2-5

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 fluid.
This completes the FB-1 sensor installation procedure.
Refer to the Electronic Wiring Section for connecting the
sensor cable to the electronics.

PARSHALL FLUME INSTALLATION
Vcal
H
FLOW
H
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
H
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
H
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 10.77 165 800 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 1900 13.87
18 38.00 28.16 85 2600 16.16
20 40.00 30.78 90 3400 18.78
24 46.00 35.07 95 7000 23.07
PALMER-BOWLUS FLUME INSTALLATION
Vcal FLOW
H
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