Badger Meter RCM 2000 User manual

®Badger Meter Europa GmbH
Model RCM 2000
Research Control MAG meter
Low flow magnetic flow meter
INSTALLATION AND
OPERATION MANUAL
September 2004
Version RCM-09/04-e

Content Page
1. Basic safety advices........................................................................................................1
2. Scope................................................................................................................................2
3. Unpacking & inspection..................................................................................................2
4. System diagram...............................................................................................................2
5. Installation........................................................................................................................3
5.1 AC power..................................................................................................................4
5.2 Sensor & user I/O.....................................................................................................4
5.3 Wiring diagram.........................................................................................................5
5.4 Digital output jumpers...............................................................................................6
5.5 Serial port jumpers...................................................................................................7
6. Operation..........................................................................................................................7
6.1 POR (power on reset) ..............................................................................................8
6.1.1 Rate..............................................................................................................8
6.1.2 Vel.................................................................................................................8
6.1.3 Tot.................................................................................................................8
6.1.4 Sys................................................................................................................9
6.1.5 D1.................................................................................................................9
7. Programming .................................................................................................................10
7.1 Front panel programming.......................................................................................10
7.1.1 Menu structure............................................................................................10
7.1.2 Pushbutton key function .............................................................................10
7.2 User output programming.......................................................................................10
7.2.1 4-20 mA span adj........................................................................................11
7.2.2 4-20 mA zero adj ........................................................................................11
7.2.3 Programming set point................................................................................11
7.2.4 Resetting totalizer.......................................................................................11
7.2.5 LCD contrast adj.........................................................................................12
7.2.6 LCD backlight enable..................................................................................12
7.3 User setup programming........................................................................................12
7.3.1 Flow units selection ....................................................................................13
7.3.2 Tube size programming..............................................................................13
7.3.3 User selected full scale flow rate................................................................14
7.3.4 Number of pulses per unit volume..............................................................14
7.3.5 Low flow cutoff programming......................................................................14
7.3.6 Output response programming...................................................................15
8. Specifications ................................................................................................................16
9. Return of goods / harmlessness declaration..............................................................18

Installation and operation manual •Version RCM-10/03-e
Basic safety advices Page 1/18
1. Basic safety advices
The electromagnetic flow meter is only suitable for the measurement of conductive fluids.
The manufacturer is not liable for damages that result from improper or nor not in
accordance with the requirements use.
The meters are constructed according to state-of-the-art technology and tested
operationally reliable. They have left the factory in a faultless condition concerning safety
regulations.
The mounting, electric installation, taking into operation and maintenance of the meter
may only be carried out by suitable technicians. Furthermore the operating personnel has
to be trained by the operating authority and the instructions of this manual have to be
followed.
Principally the regulations for the opening and repairing of electrical equipment in your
country have to be payed attention.
Repairs
Should you send back a flow meter in operation, please take notice of the following
points:
-Please enclose a description of the fault as well as a precise statement of the
measured medium (if necessary a safety specification sheet).
-The meter has to be in a cleaned condition (outside and inside). Especially with
harmful measuring mediums you have to pay attention that there are no impurities in
the pipe or at the connections.
-If it is not possible to clean the meter completely, particularly with harmful materials, do
not send back the meter.
We reserve the right to repair only cleaned meters. Costs, which result from insufficient
cleaning, will be charged to you.

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Scope Page 2/18
2. Scope
This manual contains information concerning the installation, operation and maintenance
of the RCM-2000. To ensure proper performance of the unit, the instructions 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 identify the
sections in this manual where the changes have occurred.
3. Unpacking & inspection
1. If damage to the shipping container is evident upon receipt, request the carrier to be
present when the product is unpacked.
2. 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.
3. Retain the container and all packing material for possible use in reshipment or
storage.
4. System diagram
Programmable
amplifier
Level
translator
IS
barrier
P3
P1
P2
A/D
Integrator
Buffer
Microcontroller
Programmable
coil driver
Detector
coil
LCD
Backlight
AC/DC supply
DC
regulator(s)
Key input
Comm
Control
logic
Empty pipe

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Installation Page 3/18
5. Installation
Note: I/O wiring should not be in close proximity or in the same conduit as any AC
power, controller/driver or relay wiring.
The enclosure is rated IP 66 (NEMA 4X) and can be mounted indoors or out. The PG
fittings provided must be tightened around any cables to maintain the rating.
Do not expose the electronics to vibration or direct sunlight. If an outdoor installation is
required and intense sunlight is expected, provide a sun shade to reduce ambient
temperature and to make the display easier to read.
The RCM-2000 detector and electronics are matched at the factory and will have the
same serial numbers. When replacing the detector there is a configuration file that can be
downloaded through the front panel RS-232 serial port for simple setup.
Install RCM flow sensor in the process line. The arrow on the sensor tag indicates flow
direction. The detector can be mounted with the electronics or it can be remote mounted.
Mounting position is not critical but if possible ensure that the electrodes are always
wetted even at zero flow conditions.
For vertical pipe runs, the fluid should move upwards. As with any metering device it
should be upstream of any control valves. A good rule of thumb is the detector should
always be mounted on the pressurized system side in a flow control system. This is
mandatory for low flow applications below 250CCM.
RS232 serial
Digital I/O
85/240 VAC
24 VDC Detector
4-20 mA DC output

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Installation Page 4/18
Install interconnecting wires between RCM detector and the electronics. The shield needs
to be connected on both ends of each cable.
Important: Do not strip the shield more than 1 inch (2.5 cm) from conductors!
5.1 AC power
AC power is clearly marked in the terminal block
labelled TB1 located under the front panel. The unit is
designed to handle voltage from 90 to 240 VAC. The
unit requires 5 VA for proper operation. Proper
personnel shall wire the unit in accordance with local
codes.
Green GND
White LO (neutral)
Black HI (hot)
For power spikes a replaceable fuse is located on the
board, just above AC power terminal. It is a 240 Volt,
0.25 amp 5mm fuse.
5.2 Sensor & user I/O
The RCM-2000 main terminal block is located under
the front panel and can be easily accessed by
removing the four screws. Except for AC power and
RS232 communication port, all of the I/O connectors
are brought out on a two row 22 pin terminal strip.
The wiring connections are made via two cables from
the RCM sensor.
1. Coil cable – A three conductor cable connecting
the RCM sensor coil to the magnet current
connections in the electronics.
2. Sensor cable – A five conductor cable connecting
the RCM sensor preamp to the electronics.

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Installation Page 5/18
5.3 Wiring diagram
TB2 Pin Function Sensor wire color Previous marking
1 24VDC +
2 24VDC -
3 Magnet current HI Black 11
4 Magnet current LO Red 12
5 Magnet current shield Yellow 13
6 Isolated GND
7 Set point 1 out collector
8 Zero In
9 Set point 1 out emitter
10 Empty pipe output
11 Option out collector
12 Empty pipe input
13 Option out emitter
14 Preamp 9VDC power + White 31
15 Frequency out collector
16 Preamp 9VDC power - Green 30
17 Frequency out emitter
18 Preamp probe IN + Black 46
19 4-20mA out +
20 Preamp probe IN - Red 45
21 4-20ma out -
22 Preamp probe shield Yellow 44
1
3
5
7
9
11
13
15
17
19
21
2
4
6
8
10
12
14
16
18
20
22
24VDC
optional
+
-
Sensor
White
Red
Green
Black
Yellow
Red
Yellow
Black
TB2
Optional
DC supply
4-20mA
flow output
+
-
Set point
output
Total
Zero In
External
counter
Sensor coil
Sensor probes

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Installation Page 6/18
5.4 Digital output jumpers
With J1 and J4, J2 and J5, J3 and J6 jumpers in place the output is an isolated 0-5
VDC output. With the jumpers removed the outputs are open collector and are
capable of switching 30 VDC @ 50 mA.
This type of output is duplicated for the totalizer, set point and optional outputs.
J1 J2 J3 J4 J5 J6
Totalizer (0-5 VDC) x x
Totalizer open collector
Set point (0-5 VDC) x x
Set point open collector
Optional (0-5 VDC) x x
Optional open collector
λ
10K
Isolated
Isolated DC Com
J1, J2, J3
J4, J5, J6
Open collector
or
source out
p
ut

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5.5 Serial port jumpers
With the two jumpers installed vertically the serial output can be used with a straight
through DB-9 serial cable and connect directly to a PC serial input port. With the
jumpers installed horizontally the serial port can be used to connect directly into a
PDA.
6. Operation
The RCM-2000 detector contains a nonconductive ceramic tube mounted in a stainless
steel housing. Two DC pulsed electromagnetic coils are mounted in the stainless housing
outside of the tube. Two platinum electrodes are inserted into the ceramic tube
perpendicular to the coils. When the coils are energized, a magnetic field is created
across the whole diameter of the tube. When a conductive fluid flows through this
magnetic field, a voltage is induced across the electrodes based upon Faraday’s law.
ffs VkDBe =
This voltage is directly proportional to the average flow velocity of the fluid and is picked
up by the two electrodes. This induced voltage is then amplified and processed digitally
by the converter to produce a very accurate analog or digital output signal. The signal can
then be used to indicate flow rate and totalization or to communicate to remote
controllers. The main advantages of this technology are that with no parts in the flow
stream, there is no pressure loss, the accuracy is not affected by temperature, pressure,
viscosity, density or flow profile and with no moving parts, there is practically no
maintenance required.

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6.1 POR (power on reset)
After power is applied the microcontroller goes through an initialization process. As
it goes through this process the following screens are displayed.
Display shows the installed firmware revision.
Normal flow measurement screen shows rate,
velocity, totalization and system status.
6.1.1 Rate
The current flow rate in the programmed units. The flow units available are:
Gallons per minute GPM
Cubic centimeters per minute CCM
Liters per minute LPM
6.1.2 Vel
The current velocity in feet per second or meters per second. Units
determined by rate setting. FPS if flow rate is GPM. MPS if flow rate is CCM
or LPM.
6.1.3 Tot
Totalized flow since system was last reset.

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6.1.4 Sys
System status codes
OK No error or warning flags present – normal operation.
OR Over range – Either reduce the flow or change the user selected flow
range. Always make sure the user selected flow rate is greater than
or equal to the expected maximum flow. If an overrange condition
exists the analog output will not track it. The totalizer will however
indicate properly even past the user specified flow rate.
42 4-20 mA warning – Check the 4-20 mA wiring and make sure there
isn’t an open circuit. If this output is not used and you don’t want to
see this warning, attach a jumper wire between terminal TB2-19 and
TB2-21.
LC Low flow cutoff – No action should be needed unless you have the
low flow cutoff set below where the user wants it. The factory default
is 2%.
TM Test mode – If the board is placed in the factory test mode for some
reason, the meter will not indicate live flow.
CH Coil high – This message could appear if there is a short circuit or
partial short circuit in the detector coil wiring or sensor. Another
possibility is that the coil current setting is too high.
CL Coil low – This normally happens when the coil is not connected or in
an open circuit mode. Another possibility is that the coil current
setting is too low.
6.1.5 D1
This indicates the status of the set point output.
ON Flow rate is at or above the programmed set point value.
-- Flow rate is below the programmed set point value.

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Programming Page 10/18
7. Programming
7.1 Front panel programming
The three buttons are used to program the RCM-2000 for a specific application, as
well as other features.
7.1.1 Menu structure
The unit is setup and programmed from the front panel. The menu structure
is a “drill down” structure with menus and submenus providing access to
specific programming parameters and allowing certain options and features
to be selected. There are 6 main menus with a set of submenus for all but
one of the main menus.
7.1.2 Pushbutton key function
The UP key is used for scrolling a menu selection or increasing a
programmable parameter
The Right key is used to select a menu item or decreasing a
programmable parameter.
The Enter key allows you access the next menu or to store
programming values.
When entering numerical values, a flashing cursor appears on the number
to be changed. The programming parameter is changed using a decade
increasing method to speed up programming. By pressing and holding the
up or down key the least significant digit is changed 10 times then the next
significant digit begins to change until it has change 10 times. This continues
up into the most significant digit until the key press is terminated. Most all of
the programming values will rollover from max to min or max to min values.
7.2 User output programming
These menus are entered by first pressing the Enter
key.
Use the up arrow to move the > prompt next to
outputs location on the screen, then press the right
arrow key to select the next set of menus.
Press the up arrow key until the prompt > is next to
change then press the right arrow key to enter the
analog output adjustment menus.
E

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Programming Page 11/18
7.2.1 4-20 mA span adj
At this point you can adjust the 4-20 mA output span.
Use a calibrated 41/2 digit DMM set for 199.99 mA
range and attach the test leads to TB2 pins 19 and
21. Use the up and right arrow keys to change the
span value on line 2. Monitor the current indication
until the current is set for 20.00 +-.001. Then press
the enter key to store the span value and proceed to
the next menu.
7.2.2 4.20 mA zero adj
The 4-20 mA output zero can now be adjusted. Use a
calibrated 41/2 digit DMM set for 19.999 mA range
and attach the test leads to TB2 pins 19 and 21. Use
the up and right arrow keys to change the zero value
on line 2. Monitor the current indication until the
current is set for 4.00 +-.001. Then press the enter
key to store the zero value and proceed to the next
menu.
7.2.3 Programming set point
The next menu selection is the set point adjustment.
Use the up arrow to move the > prompt to the
change location on the screen, then press the right
arrow key to select the next menu.
Use the up or right arrow to adjust the set point value
from a value ranging from 0 to 100%. To save the
value, press the Enter key. This action will
automatically move to the next menu.
7.2.4 Resetting totalizer
The next menu selection is the totalizer reset. Use
the up arrow to move the > prompt to the change
location on the screen, then press the right arrow key
to select the next menu.
Use the up arrow to clear the totalizer to zero. To
move on to the next menu press the Enter key

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7.2.5 LCD contrast adj
The next menu selection is the LCD contrast
adjustment. Use the up arrow to move the > prompt
to the change location on the screen, then press the
right arrow key to select the next menu.
Use the up or right arrow to adjust the contrast to the
desired setting. Depending upon whether the RCM-
2000 has a 6 or 12 o’clock viewing angle LCD the
number will range between 20 to 70. To save the
value, press the Enter key. This action will
automatically move to the next menu
7.2.6 LCD backlight enable
The next menu selection is the LCD backlighting
enable menu. Use the up arrow to move the >
prompt to the change location on the screen, then
press the right arrow key to select the next menu.
Use the up or right arrow to enable (ON) or disable
(OFF) the LCD backlighting feature. This feature
does consume several watts of continuous power; do
not use in low power applications. To save this
feature, press the Enter key.
This key will automatically move to the beginning
analog output menu.

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Programming Page 13/18
7.3 User setup programming
These menus are entered by first pressing the Enter
key.
Use the up arrow to move the > prompt next to Setup
location on the screen, then press the right arrow key
to select the next set of menus.
7.3.1 Flow units selection
The first setup menu selection is the flow unit
selection menu. Use the up arrow to move the >
prompt to the change location on the screen, then
press the right arrow key to select the next menu.
Use the right arrow to select the flow rate units
(GPM, LPM, CCM). When selecting the flow units the
velocity units are automatically selected based upon
whether they are metric (mps) or English (fps). To
save the units press the Enter key. This action will
automatically move to the next menu.
Note. When changing units remember to check the
full scale flow and the pulse output and change to the
desired values. It is also a good practice to reset the
totalizer to prevent mixed units in the totalizer value.
7.3.2 Tube size programming
This menu selection changes the flow tube I.D. Use
the up arrow to move the > prompt to the change
location on the screen, then press the right arrow key
to select the next menu.
Use the up or right arrow to adjust the tube I. D. The
tube size is always represented in mm. To save the
value, press the Enter key. This action will
automatically move to the next menu.
Note: If the tubes size is changed the sensor
configuration file must be downloaded through the
serial port to ensure maximum accuracy.

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Programming Page 14/18
7.3.3 User selected full scale flow rate
This menu selection changes the full scale flow. Use
the up arrow to move the > prompt to the change
location on the screen, then press the right arrow key
to select the next menu.
Use the up or right arrow to adjust the full scale flow.
To save the value, press the Enter key. This action
will automatically move to the next menu.
This setting dictates the analog output full scale, but
does not affect the pulse per unit output.
7.3.4 Number of pulses per unit volume
This menu selection scales the pulse output and the
indicated volume total. Use the up arrow to move the
> prompt to the change location on the screen, then
press the right arrow key to select the next menu.
Use the up or right arrow to adjust the number of
pulses per unit volume. The units have been
automatically selected in the previous units menu. To
save the value, press the Enter key. This action will
automatically move to the next menu.
This setting dictates the analog output full scale, but
does not affect the pulse per unit output.
The selection range for the number of pulses for
gallons and liters is 1-1000, 1 for CCM.
7.3.5 Low flow cutoff programming
This menu selection programs when a zero condition
exists. Use the up arrow to move the > prompt to the
change location on the screen, then press the right
arrow key to select the next menu.
Use the up or right arrow to adjust the low flow cutoff.
To save the value, press the Enter key. This action
will automatically move to the next menu.

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Programming Page 15/18
7.3.6 Output response programming
This menu selection programs response time of the
meter. Use the up arrow to move the > prompt to the
change location on the screen, then press the right
arrow key to select the next menu.
Use the up or right arrow to adjust the response
between slow, medium and fast. Use the fast setting
for velocities > 2 fps and applications that have low
flow noise and require quick batching. Use the
medium setting for normal applications. Use the slow
setting for low velocity or high flow noise
applications.
To save the value, press the Enter key. This action
will automatically move back to the units menu.
Pressing the End key again will move to the main
menu.
Use the up arrow key to move to another set of
menus or press the End key to move to the main
display

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Specifications Page 16/18
8. Specifications
RCM detector
Type pulsed DC
Conductivity: Minimum 0.5µS/cm (0.5µmhocm)
Liner: Ceramic
Electrodes: Platinum
Seal material: EPDM Std. – Buna N, Viton or Teflon
available
End connections: 316 SS Std. – Kynar or Hastelloy C
available
Housing 300 series: SS
Rating: NEMA 4X (IP67)
Max CIP temperature: 265°F (130°C)
Max pressure: 360 psig (25 bar)
Maximum cable length: 200 feet (60.96 m)
Detector cable
Coil cable: 2 conductor common shield (foil-shield
or braid shield) AWG 18 to22 e.g.
Belden cable 9462; 9962; 8760 (22
AWG / 20AWG / 18AWG)
Sensor cable: 4 conductors (2 conductor foil-shield, 2
conductor unshielded) AWG 22 e.g.
Belden cable 8730; 8724; 8722
(22AWG).
Output
4-20 mA DC isolated; 800 ohms max. The output is monitored to
detect open circuit and has RFI and surge protection built in.
Three isolated outputs, sink or source rated at 30 VDC @ 50 mA:
- Pulse (volume)
- Set point (% F.S.)
- Optional (batch, etc.)
RS232 serial port, 9600 used for local serial access for
downloading data, programming the meter or viewing status
information.
Input One isolated input, O.C. or contact closure force zero

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Specifications Page 17/18
Display 4 lines, 16 character per line LCD display. Indicating up flow,
velocity, totalization, system and I/O status.
Programming Front panel accessible 3 pushbuttons
Power 85/240 VAC, 50/60 Hz (fuse rating 0.1A) or 24 VDC @ 200 mA
continuous. 5 Watt power dissipation.
Accuracy Standard: ± .5% of reading for velocities > 0.8fps (.24mps)
± 0.004fps (.00125mps) < 0.8fps (.24mps)
Electronic enclosure IP66/NEMA 4X standard Enclosure: 6”H x 6”W x 3.5”D
Temperature range: -4° to 160° F (-20 to 70°C)

Installation and operation manual •Version RCM-10/03-e
Return of goods Page 18/18
9. Return of goods for repair
Please copy, fill in and sign hereafter harmlessness declaration and enclose it for any return
of goods you may send back for repair.
No repair will be performed prior to receiving the harmlessness declaration duly filled and
signed.
Harmless declaration
To : __________________________________________________________________
Attn. : __________________________________________________________________
From : __________________________________________________________________
Dept. : __________________________________________________________________
Please note that no repair will be performed prior to receiving of this declaration duly
singed by you!
Please send all parts clean from medium and inform us about possible medium wastes
remaining in the part. For this purpose, please use this form. A security specification sheet
of the medium must accompany this declaration in the following cases: Toxical, dangerous
or objectionable media, or media beloning to any dangerous materials class. We inform you
that uncleaned parts lead to additional costs. Extra clean costs will be charged to you.
Furthermore, we reserve us the right to send the parts back to you for cleaning!
Declaration
We herewith confirm that the part(s) sent for repair has/have been cleaned and is/are free of
any liquid and/or solid wastes of the medium and/or cleaning medium: Any eventually
remaining wastes are:
harmless
dangerous, toxic, etc. – Security specifications are attached
Signature of person in charge: ______________________________________
Name of the person in charge in capital letters: ______________________________________
Date: ______________________________________
Company stamp: ______________________________________