Bullhorn RM4200 Series User manual

User Guide
RM4210 Wiring Guide
This document is to help technicians plan and install an RM4210 remote monitoring unit based on the
type of measurement that will be taken from atest station. Wiring instructions are included for each
type of measurement, coupons, or other components that may be included in the set up. Refer to the
following figure for an example of test station connections.
Different test stations may have different connection configurations or labels. The following example is
based on aTriton test station.
Figure 1-1. Test Station Connections
RM4210 Input Limits
The RM4210 has the following input limits, which should be observed to prevent damage to the unit:
lThe input voltage measurement should not exceed 100V AC or DC.
lThe input amperage, for AC and DC current density, measurement should not exceed 0.2A AC or
DC.

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Checklist
For additional information on either the RM4210 or Triton coupon test station installation, refer to the
RM4200 Series User Guide and the Triton Coupon Test Station User Guide.
Before wiring the RM4210 to the test station, refer to the following list of considerations and pre-
installation checks.
lIf using aTriton coupon and test station, refer to the Triton Test Station with aTriton Coupon
section and the Triton Coupon Test Station User Guide.
lDetermine what you want to measure. You can measure the following readings with the RM4210:
—Native Pipe to Soil using anon CP-protected coupon and areference cell -refer to
Common Wiring Configurations
—AC Pipe to Soil, using aCP-protected coupon and areference cell -refer to Coupons
—DC Pipe to Soil, using aCP-protected coupon and areference cell -refer to Coupons
—Instant Off, using aCP-protected coupon and areference cell -refer to Coupons
—AC or DC current density, using aCP-protected coupon (CP-protected coupon could be a
test or separate AC coupon) -refer to Coupons
—DC voltage, no scaling available -refer to DC Voltage, AC Voltage, or Shunt Measurements
—AC voltage, no scaling available -refer to DC Voltage, AC Voltage, or Shunt Measurements
—shunt -refer to DC Voltage, AC Voltage, or Shunt Measurements
—PCR, Dairy Land, AC drain, or SSR -refer to Common Wiring Configurations
lMake note of any procedures that you use now to get measurements. This will help with the
installation.
lMake note of the following:
—Size and type of the coupons being used:
¡CP-protected or non CP-protected
—The measurements that are going to be taken from each coupon
—Which wires, and the color of each wire, are currently connected to the coupons
All wire colors and labels shown in the wiring diagrams included in this document refer to the wiring
harness that is shipped with the RM4210.

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Figure 1-1. Wiring Harness Cable Colors and Labels
If not using the included wiring harness, you will need to remove all wires from the phoenix connector
first and then connect your wiring to the connector where it will line up to the labeled ports on the
RM4210 faceplate.

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Figure 1-2. RM4210 Faceplate and Ports
Common Wiring Configurations
The RM4210 can be wired directly to what will be measured. The RM4210 is shipped with awiring
harness that includes six colored and labeled wires for easy identification.

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Figure 1-1. RM4210 Wiring Harness
Common wiring configurations include the following:
lStructure or Pipe Connection —connect the white Structure wire from the wiring harness to
the point on the test station that is connected to the Structure.
lReference Cell —connect the yellow Ref Cell wire from the wiring harness to the point on the
test station that is connected to the reference cell.
lNative or Non CP-protected Coupon —connect the black Native Cpn wire from the wiring
harness to the point on the test station that is connected to the native or non CP-protected
coupon. If there is not anative/non CP-protected coupon, cap off the end of this wire. If the
native/non CP-protected coupon has two wires, connect one wire to the test station and cap off
the other wire.
NOTE: Remove any switch or jumper on the test station head that is used to connect the CP-protected
coupon (AC Coupon or Test Coupon) to the Structure, where the CP-protected coupon is used to
measure AC current density or instant off.
lPCR, AC Drain, SSR, or Dairy Land —connect the positive wire to the PCR+ and the negative
wire to the PCR-connections in the green phoenix connector. The connections match the port
labels (PCR+ ,PCR- )on the RM4210 faceplate. For additional information on using aPCR with
the RM4210, refer to the RM4200 Series User Guide.

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Figure 1-2. PCR- and PCR+ Connections
Triton Test Station with a Triton Coupon
If you are connecting the RM4210 to aTriton test station and Triton coupon, connect the RM4210
wiring harness phoenix connector to the RM4210. Then connect the harness wires to the test station
where the matching colored wires from the coupon are connected to the test station. Refer to the
following wiring diagram for wiring configuration.

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Figure 1-1. Wiring Diagram -Triton Coupon
Coupons
The RM4210 can take measurements from one or two CP-protected coupons at atest station.
If you are using aTriton test station with aTriton coupon, refer to Triton Test Station with aTriton
Coupon
The coupons can be wired for the following types of measurements:
lOne CP-protected Coupon to measure AC and/or DC pipe-to-soil, AC and/ or DC current density,
and instant off.
lTwo CP-protected Coupons,where one CP-protected coupon is used to measure AC or DC pipe-

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to-soil, DC current density, and instant off and the second CP-protected (AC coupon) is used to
measure AC current density.
One CP-protected Coupon
These instructions detail how to wire asingle CP-protected coupon (with either one or two wires) to
measure AC and/or DC pipe-to-soil, AC and/or DC current density, and instant off. Refer to the
following figures for reference.
Figure 1-1. RM4210 Wiring Harness

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Figure 1-2. Wiring Diagram -Single CP-Protected Coupon
If the coupon has onewire connecting it to the test station, connect both the red Test Cpn 1wire and
the blue Test Cpn 2from the RM4210 wiring harness to the test station where the coupon wire is
connected.
If the coupon has two wires connecting it to the test station, complete the following steps:
1. Connect one of the coupon wires to one side of the switch on the test station. Connect the red
Test Cpn1 wire from the RM4210 wiring harness to the other side of the switch.
2. Connect the blue Test Cpn 2wire from the RM4210 wiring harness to the point on the test
station where the second coupon wire is connected.
3. Cap off the orange AC Coupon wire from the RM4210 wiring harness, as it is not used for this set
up.
To set up for this type of measurement on Bullhorn Web, complete the following:

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1. Make note of the size of the CP-protected coupon (Protected Cpn 1in the wiring diagram). This
data will be entered in Bullhorn Web using the following steps:
a. Go to the Unit Setup page for the unit.
b. Under Settings,enter the CP-protected coupon size in the Test Coupon Size field.
Figure 1-3. Unit Setup for Test Coupon Settings
NOTE: Remove any switch or jumper on the test station head that is used to connect the CP-protected
coupon (AC Coupon or Test Coupon) to the Structure, where the CP-protected coupon is used to
measure AC current density or instant off.

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Two CP-protected Coupons
These instructions detail how to wire two CP-protected coupons, where one CP-protected coupon is
used to measure AC and/or DC pipe-to-soil, DC current density, and instant off, and the second CP-
protected (AC coupon) is used to measure AC current density. Refer to the following figures for
reference.
Figure 1-1. RM4210 Wiring Harness

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Figure 1-2. Wiring Diagram -One CP-protected Coupon and One CP-protected AC Coupon
To set up for these types of measurements, complete the steps described for each coupon as follows:
lCP-protected Coupon for AC and/or DC Pipe-to-Soil, DC Current Density, and Instant Off
Measurements
lCP-protected Coupon (AC Coupon) for AC Current Density Measurements
CP-protected Coupon for AC and/or DC Pipe-to-Soil, DC Current Density, and Instant
Off Measurements
1. If the coupon has one wire connecting it to the test station, connect both the red Test Cpn 1wire
and the blue Test Cpn 2from the RM4210 wiring harness to the test station where the coupon
wire is connected.
2. If the coupon has two wires:

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a. Connect one of the coupon wires to one side of the switch on the test station. Connect the
red Test Cpn1 wire from the RM4210 wiring harness to the other side of the switch.
b. Connect the blue Test Cpn 2wire from the RM4210 wiring harness to the point on the test
station where the second coupon wire is connected.
3. Make anote of the size of the CP-protected coupon (Protected Cpn 1in the wiring diagram
inTwo CP-protected Coupons). This data will be entered in Bullhorn Web:
a. Go to the Unit Setup page for the unit.
b. Under Settings,enter the CP-protected coupon size in the Test Coupon Size field.

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Figure 1-1. Unit Setup for First of Two Coupons (Test Coupon)
NOTE: Remove any switch or jumper on the test station head that is used to connect the CP-protected
coupon (AC Coupon or Test Coupon) to the Structure, where the CP-protected coupon is used to
measure AC current density or instant off.
CP-protected Coupon (AC Coupon) for AC Current Density Measurements
1. Connect the orange AC Cpn wire from the RM4210 wiring harness to the point on the test
station that is connected to the CP-protected (AC coupon).

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2. Make anote of the size of the CP-protected (AC coupon). This data will be entered in Bullhorn
Web:
a. Go to the Unit Setup page for the unit.
b. Under Settings ,enter the CP-protected (AC coupon) size in the Triton Coupon Size field.
Figure 1-1. Unit Setup for Second of Two Coupons (Triton Coupon)
NOTE: Remove any switch or jumper on the test station head that is used to connect the CP-protected
coupon (AC Coupon or Test Coupon) to the Structure, where the CP-protected coupon is used to
measure AC current density or instant off.

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DC Voltage, AC Voltage, or Shunt Measurements
If not using the included wiring harness, you will need to remove all wires from the phoenix connector
first and then connect your wiring to the connector where it will line up to the labeled ports on the
RM4210 faceplate. Refer to the following figures when wiring the RM4210 for DC voltage, AC voltage,
or shunt measurements:
Figure 1-1. Wiring Diagram -DC Voltage, AC Voltage, and Shunt

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Figure 1-2. RM4210 Faceplate and Port Labels
DC voltage measurement
lConnect your positive to the RM4210’s wiring harness black Native Cpn wire and the negative to
the yellow Ref Cell wire.
lIf you need asecond DC voltage measurement, connect the positive to the blueTest Cpn2wire
and the negative to the yellow Ref Cell wire (along with the first DC negative) on the wiring
harness.

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Figure 1-3. RM4210 Wiring Harness
IMPORTANT: If you are taking two DC measurements —use the Ref Cell connection on the
RM4210 as acommon ground for both (refer to DC Voltage, AC Voltage, or Shunt Measurements).
lIf you need athird DC voltage measurement, connect the positive to the PCR+ and the negative
to the PCR- connections on the RM4210’s green phoenix connector.
Figure 1-4. PCR- and PCR+ Connections on RM4210 Connector
AC voltage measurement —connect the blue Test Cpn2wire and the yellow Ref Cell wire on either
side of where you want to measure AC potential.

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Shunt measurement —connect the positive for the shunt to the PCR+ and the negative to the PCR-
connections on the RM4210’s green phoenix connector.