Badger Meter FC-5000 Operating Manual

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Industrial Flow Computer

FC-5000 Flow Display

CTL-UM-02765-EN-01 (April 2019)

User Manual

Industrial Flow Computer, FC-5000 Flow Display

Page ii April 2019CTL-UM-02765-EN-01

User Manual

CONTENTS

Scope of This Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 Unpacking and Inspection Safety Considerations

Terminology and Symbols Safety Instructions Safety Rules and Precautionary Measures

Description

Installing the Flow Display

Operator Interface

Info/Sensor Data

System Information Basic Setup

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 Functions and Features Flow Meter Input(s) Digital Inputs Relay Control Outputs Power Supply Conguring the Unit Display Information

Mounting Options Wiring the Flow Display

Keypad and Soft Keys Scrolling Control Panel Keys Icon Functionality Navigating the Menus Numeric Editing Alpha-Numeric Editing Selection/Enumeration Editing Conrmation Screen Menu Structure

Info/Sensor Data Table

Display Resets Passcode Setup Disabling a Passcode Units

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26

April 2019 CTL-UM-02765-EN-01

Page iii

Industrial Flow Computer, FC-5000 Flow Display

Advanced Setup � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29

Conguring a Flow Sensor Conguring Outputs Conguring Digital I/O

Conguring Communications Troubleshooting Modbus Interface

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38 Modbus Function Code Support Modbus Register Map

Flow Sensor Types

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39

Part Numbering Construction

Replacement Parts/Accessories

Specications

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 41

Standards and Certications

Agency Approval/Standards EMI/EMC Compliance Enclosure Protection

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 40

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 40

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 44

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 44

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 44

Page iv April 2019CTL-UM-02765-EN-01

Scope of This Manual

SCOPE OF THIS MANUAL

This manual describes how to install and program the FC-5000 Flow Display� The electronic version of this manual is available on our website at www.badgermeter.com�

MPORTANTI

Read this manual carefully before attempting any installation or operation. Keep the manual in an accessible location for future reference.

UNPACKING AND INSPECTION

Upon opening the shipping container, 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�

OTE:N 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 purchaser�

SAFETY CONSIDERATIONS

Terminology and Symbols

Indicates a hazardous situation, which, if not avoided, will result in death or serious personal injury�

Indicates a hazardous situation, which, if not avoided, could result in death or severe personal injury�

Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury or damage to property�

Please consult the user manual in all cases where this symbol is used in order to find out the nature of potential hazards, and any actions which have to be taken to avoid them�

This symbol signifies that the FC-5000 Flow Display may be powered by a DC power supply� Acceptable DC input voltage range is: 10…40V DC�

This symbol signifies that the FC-5000 Flow Display may be powered by an AC power supply� Acceptable AC input voltage range is: 9…28V AC RMS (50…60 Hz)�

• Operating temperature is 32…130° F (0…55° C) with a maximum humidity

of 85% non-condensing� Always select a mounting location with proper ventilation and environmental protection�

• Maximum operating altitude: 2000 meters (6561 feet)

• Pollution Degree 2: Only non-conductive pollution occurs except that

occasionally a temporary conductivity caused by condensation is to be expected

• Over-Voltage Rating: CAT II

Page 5 April 2019 CTL-UM-02765-EN-01

Safety Considerations

Safety Instructions

• LIFE SUPPORT APPLICATIONS: THE FC-5000 IS NOT DESIGNED FOR USE IN LIFE SUPPORT APPLIANCES, DEVICES, OR SYSTEMS WHERE MALFUNCTION OF THE PRODUCT CAN REASONABLY BE EXPECTED TO RESULT IN A PERSONAL INJURY. CUSTOMERS USING OR SELLING THESE PRODUCTS FOR USE IN SUCH APPLICATIONS DO SO AT THEIR OWN RISK AND AGREE TO FULLY INDEMNIFY THE MANUFACTURER AND SUPPLIER FOR ANY DAMAGES RESULTING FROM SUCH IMPROPER USE OR SALE.

• ELECTROSTATIC DISCHARGE INFLICTS IRREPARABLE DAMAGE TO ELECTRONICS. BEFORE INSTALLING OR OPENING THE UNIT, INSTALLERS MUST DISCHARGE THEMSELVES BY TOUCHING A WELL-GROUNDED OBJECT.

• THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH THE EMC (ELECTROMAGNETIC COMPATIBILITY) GUIDELINES.

Safety Rules and Precautionary Measures

The manufacturer accepts no responsibility whatsoever if the following safety rules and precaution instructions and the procedures as described in this manual are not followed�

• Modifications of the Flow Display implemented without preceding written consent from the manufacturer will result in the immediate termination of product liability and warranty period�

• Installation, use, maintenance, and servicing of this equipment must be carried out by authorized technicians�

• Check the mains voltage and information on the manufacturer’s nameplate before installing the unit�

• Check all connections, settings and technical specifications of the various peripheral devices with the Flow Display supplied�

• Never open the enclosure�

• Never touch the electronic components (ESD sensitivity)�

• Never expose the system to heavier conditions than allowed according to the casing classification (see manufacturer’s nameplate)�

• If the operator detects errors or dangers, or disagrees with the safety precautions taken, then inform the owner or the principal responsible�

• Adhere to the local labor and safety laws and regulations�

Page 6 April 2019CTL-UM-02765-EN-01

Description

DESCRIPTION

The FC-5000 Flow Display is a microprocessor-driven device that is designed for flow monitoring� The FC-5000 Flow Display is compatible with the complete line of Badger Meter industrial flow meters, creating a solution to monitor flow rates and totals�

Functions and Features

This product is designed with a focus on:

• Large display for easy viewing

• Ease-of-use with softkeys and a full numeric keypad

• Ruggedness for its application with a robust enclosure, keypad and mechanical relays

• Info/Sensor Data Screen—view raw and calculated data, both to and from the unit, including flow data and output statuses

• User-friendly installation with quality plug-and-play terminals

• A wide range of outputs and functions for a broad fulfillment in many applications

• User defined relay triggers for flow rates and totals

Flow Meter Input(s)

Depending on the configuration, one or two sensor inputs are available, allowing a passive or active pulse signal output to be connected� The input circuit supports low and high frequency (0�5…3500 Hz) flow meters� A 12V DC excitation terminal is available for flow meter sensors that require power�

Digital Inputs

The FC-5000 Flow Display control inputs allow the following functions:

• Unlatch Relays

• Reset Totalizers

• Unlatch Relays and Reset Totalizers

Page 7 April 2019 CTL-UM-02765-EN-01

Description

Relay Control Outputs

The FC-5000 Flow Display has two relay outputs, either a mechanical Form C switch or a solid state Form A switch� The product configuration determines which switches are available� All control functions are always available by dedicated relay outputs� Unneeded outputs may be left disconnected or disabled within the firmware�

Relays can be used for alarm indication or as a totalizing output�

Form-C

• Can be powered directly from mains circuits rated up to 240V�

• Must be powered through circuits that are insulated from mains by at least

• basic insulation�

• Connected sources of power need to be limited to 240V AC and fused at 5A or less�

• Not suitable for connection to external circuits that are insulated from mains by at least double insulation (SELV)�

Form A

• Located on TB4 and recommended to use, if configured as a high-rate, totalizing output�

• Relay energizes (contact closes) with a minimum input current of 3 mA through

• the input LED�

• The relay turns off (contact opens) with an input voltage of 0�8V or less�

Power Supply

The power supply used must be isolated from mains by double or reinforced insulation (for instance, SELV power supply)�

The FC-5000 Flow Display operates on 10…40V DC or 9…28V AC supplied by any suitable source that also meets the requirement listed above� Badger Meter has power supplies available for the FC-5000 Flow Display�

Power Supply Part Numbers:

• 68334-001: includes wall mount (wall wart) power supply and various adapters

• 68334-002: power module that allows discrete power wiring

A power supply not sourced from the factory must be capable of supplying a minimum of 8 Watts�

Conguring the Unit

The FC-5000 Flow Display is designed for many types of applications� See

“Advanced Setup” on page29 for instructions on configuring your

FC-5000 Flow Display to your specific requirements�

All information is stored in EEPROM memory and will not be lost in the event of power failure�

Page 8 April 2019CTL-UM-02765-EN-01

Installing the Flow Display

Display Information

The FC-5000 Flow Display has a large transflective LCD with a bright LED backlight that displays symbols and digits for measuring units, status information and keyword messages� See “Units” on page27 for more information on how to configure the units�

INSTALLING THE FLOW DISPLAY

MOUNTING, ELECTRICAL INSTALLATION, STARTUP AND MAINTENANCE OF THIS INSTRUMENT MAY ONLY BE CARRIED OUT BY TRAINED PERSONNEL AUTHORIZED BY THE OPERATOR OF THE FACILITY. PERSONNEL MUST READ AND UNDERSTAND THIS OPERATING MANUAL BEFORE CARRYING OUT ITS INSTRUCTIONS.

THE FC5000 FLOW DISPLAY MAY ONLY BE OPERATED BY PERSONNEL WHO ARE AUTHORIZED AND TRAINED BY THE OPERATOR OF THE FACILITY. OBSERVE ALL INSTRUCTIONS IN THIS MANUAL.

OBEY ALL SAFETY PRECAUTIONS MENTIONED IN “SAFETY CONSIDERATIONS” ON

PAGE5.

OTE:N For a complete list of parts and accessories, refer to “Replacement Parts/

Accessories” on page40�

Page 9 April 2019 CTL-UM-02765-EN-01

Installing the Flow Display

Mounting Options

The FC-5000 Flow Display can be mounted on a wall, shelf or instrumentation panel� Wall-mount units are shipped in a NEMA 4X enclosure, ready to mount�

Panel-Mount Installations

OTE:N Mounting clips can accommodate a maximum panel thickness of 1�5 in�

(38�1 mm)�

5.40 in.

(137.16 mm)

2.65 in.

(67.31 mm)

Figure 1: Panel cutout

3.07 in.

(78.00 mm)

Panel Cutout

5.38 in.

(136.65 mm)

3.50 in.

(89.00 mm)

2.54 in.

(64.52 mm)

6.22 in.

(158.00 mm)

Figure 2: Mounting dimensions

To install:

1� Measure and cut a mounting hole to the dimensions shown in Figure 1� 2� Verify that the gasket is secure inside the mounting bezel� 3� Insert the unit through the panel cutout� 4� Secure the unit to the panel with the provided mounting clips�

Page 10 April 2019CTL-UM-02765-EN-01

Wall-Mount Installations

8.00 in.

(203.20 mm)

6.00 in.

(152.40 mm)

Installing the Flow Display

4.88 in.

(123.95 mm)

8.75 in.

(222.25 mm)

9.65 in.

(242.83 mm)

9.38 in.

(238.25 mm)

Figure 3: FC-5000 Flow Display in an enclosure

9.38 in.

(238.25 mm)

To install the FC-5000 Flow Display on a wall, secure the enclosure to the wall with four mounting screws (customer-supplied)�

Page 11 April 2019 CTL-UM-02765-EN-01

Installing the Flow Display

Wiring the Flow Display

At installation, be sure to comply with the following requirements:

• Disconnect power to the unit before attempting any connection or service to the unit�

• Avoid using machine power service for AC power� When possible, use a dedicated circuit or a lighting circuit�

• Observe all local electrical codes�

• The unit must be wired with wires and/or cables with a minimum temperature rating of 167° F (75° C)�

TO PREVENT ACCIDENTS, DO NOT APPLY POWER UNTIL ALL OTHER CONNECTIONS HAVE BEEN COMPLETED.

Terminal Connectors

Figure 4: One sensor input, frequency output

Figure 5: One sensor input, analog out

Page 12 April 2019CTL-UM-02765-EN-01

Figure 6: Two sensor inputs, frequency output

Installing the Flow Display

Figure 7: Two sensor inputs, analog output

Power Input

The FC-5000 Flow Display power input is internally fused and protected from common line noise by a filtering network�

TB1 (POWER)

Connector Pin

1 Line (L) Positive (L+) 1 2 Shield (Chassis GND) 2 3 Neutral (N) Negative (L–) 3 4 Digital I/O GND 4

AC Power DC Power

THE FC5000 IS MICROPROCESSOR CONTROLLED. IT IS VERY IMPORTANT THAT THE POWER SUPPLY BE FREE OF ELECTRICAL NOISE. AVOID USING POWER LINES THAT FEED HEAVY LOAD ELECTRICAL DEVICES SUCH AS PUMPS AND MOTORS.

Function

Table 1: Power input

Reference Pin

Page 13 April 2019 CTL-UM-02765-EN-01

Installing the Flow Display

Digital Inputs and Outputs

The FC-5000 Flow Display has six independent channels available for digital input� The channels accept TTL voltage signals in the 0…5V DC range� The control inputs are triggered when the voltage signal on the pin is pulled low (active low)� Input range for a logic low signal is 0…1V, logic high is 4…5V�

TB2 (DIG I/O)

Connector Pin Function

1 Excitation or Power 5 2 Input/Output 1 Signal 6 3 Input/Output 1 Signal 7 4 Input/Output 1 Signal 8 5 Input/Output 1 Signal 9 6 Input/Output 1 Signal 10 7 Input/Output 1 Signal 11 8 Ground or Neutral 12

Table 2: Digital inputs

Reference Pin

Communications

The FC-5000 Flow Display comes with a Modbus (RTU or ASCII) communication protocol� Signals are transmitted over an EIA-485 (RS-485) physical layer�

TB8 (RS485)

Connector Pin Function Reference Pin

1 Shield (Chassis GND) 36 2 Negative (–) 37 3 Positive (+) 38 4 Output Ground 39

Table 3: Communications input

Page 14 April 2019CTL-UM-02765-EN-01

Installing the Flow Display

Scaled Outputs

The FC-5000 Flow Display has two scaled output channels for use in applications requiring remote data collection and/or monitoring� The outputs are firmware configurable, and can be tied to parameters such as rates or total volume�

TB7 (FREQ OUT) or (ANALOG OUT)

Connector Pin Function Reference Pin

1 Output 1 Signal 32 2 Output 2 Signal 33 3 Output Ground 34 4 Shield (Chassis GND) 35

Table 4: Scaled output channels

ANALOG OUTPUT CONFIGURATIONS ARE DESIGNED TO PROVIDE A SOURCING OUTPUT SIGNAL. THE RECEIVING DEVICE MUST NOT PROVIDE POWER TO THE LOOP.

Relay Output Connectors

The FC-5000 Flow Display has either two Form C relay output terminals or one Form C and one Form A terminal�

Two Form C

TB3 (RELAY 1) and TB4 (RELAY 2)

Connector Pin Function

1 Normally Open (N�O�) 13 16 2 Signal Common 14 17 3

Normally Closed (N�C�) 15 18

Table 5: Relay output connectors, relay option "C"

Reference Pin

Relay 1 Relay 2

One Form C and One Form A

TB3 (RELAY 1) - Form C

Connector Pin Function

1 Normally Open (N�O�) 13 2 Signal Common 14 3

Connector Pin Function

1 Connection Point 1 16 2 Not Used (No Contact) 17 3 Connection Point 2 18

Normally Closed (N�C�) 15

Figure 8: Form C Relay Output Connector

TB4 (RELAY 2) - Form A

Figure 9: Form A Relay Output Connector

Reference Pin

Relay 1

Reference Pin

Relay 2

Page 15 April 2019 CTL-UM-02765-EN-01

Installing the Flow Display

Flow Sensor Input

The FC-5000 Flow Display is designed to accept pulses from open collector transistors or dry contact closure transmitters�

Before making any connections:

• Always use shielded wire to protect the signal line from external noise (ground shield to terminal #3)�

• Make sure the signal lines are not bundled with or touching power lines�

OTE:N In the tables below, RF Pin refers to RF type pickups/amplifiers�

TB5 - Single Channel Pulse Input Terminal

Connector

1 Sensor Excitation (+) 19 A 2 Sensor Input (+) 20 C 3 Sensor Input/Common (-) 21 B 4 Shield (Chassis GND) 22 —

TB5 - Dual Channel Pulse Input Terminal

Connector

1 Excitation (+12V output) 19 A 2 Sensor Input CH1 20 C 3 Sensor Common (GND) 21 B 4 Sensor Input CH2 22 C 5 Shield (Earth GND) 23

Function

Table 6: Flow sensor input, single

Function

Table 7: Flow sensor input, dual

Reference

RF Pin

Powering Radio Frequency (RF) Type Pickups

Radio Frequency (RF) type pickups require a power source to generate a radio frequency field� Similar to magnetic pickups, as fluid velocity provides rotational energy on the flow meter rotor, the field generated by the pickup is disturbed, producing output pulses that are proportional to flow rate�

OTE:N Maximum current draw from the Excitation pin cannot exceed 200 mA� RF

style pickups will require a signal conditioning amplifier�

0…5V, 0…10V Configuration Source Voltage Configuration

From

Pickup/

Amplier

Figure 10: Pickup configurations

From

Pickup/

Amplier

Page 16 April 2019CTL-UM-02765-EN-01

Flow

Display

Operator Interface

OPERATOR INTERFACE

Keypad and Soft Keys

The keypad and soft keys are for programming, editing and changing views�

Scrolling

The screens can display up to four lines at a time� Some menus have more than four items to display� To see the off-screen items, press UP/DOWN to scroll through the entire list�

THE FLOW DISPLAY MAY BE OPERATED ONLY BY PERSONNEL WHO ARE AUTHORIZED AND TRAINED BY THE FACILITY. OBSERVE ALL INSTRUCTIONS IN THIS MANUAL. OBEY ALL SAFETY PRECAUTIONS MENTIONED IN “SAFETY CONSIDERATIONS” ON PAGE5.

Control Panel Keys

OTE:N Always press (ENTER) to save a new value�

The numbered keys are used to enter or change parameter values�

In editing mode, BACKSPACE deletes the character to the left of the cursor� While navigating, BACKSPACE moves to a previous menu selection�

Depending on the current screen, ENTER:

• Saves the current value and ends the editing session

• Advances deeper into the menu structure

• Toggles enumerations

The UP/DOWN keys:

• Toggle the display views on the home screen

• While editing, use UP/DOWN to advance the cursor to the right or left

• In the menu structure, scroll through the menus and parameters

The F1…F4 function keys are soft keys that change function to whichever icon is present above them� See “Icon Functionality” on page18�

Table 8: Key functions

Page 17 April 2019 CTL-UM-02765-EN-01

Operator Interface

Icon Functionality

Depending on the task being performed, one or more of the following icons may appear on the screen� To activate an icon, press the Function key (F1, F2, F3 or F4) directly under the icon, where applicable�

Icon Function

Display the Home screen or cancel an edit (if you activate it without saving first)

Display the menu structure

Create a custom label (name) for unit of measure

Return to Setup menu

Cycle through alpha characters

Enter a decimal point

Cycle through special characters

Reveal raw and calculated info/sensor data for the Flow Display

Clear the selected value or cancel edit (press twice, consecutively)

Enter conversion factor for custom unit of measure

Change selected value to positive ( + ) or negative ( – )

Set totalizer rollover point

Appears on Home screen for various events� Refer to “Troubleshooting” on page36 for details�

Enter K-factor in multi-point calibration table

Enter frequency-in-hertz calibration data

Toggle flow sensor channels

Table 9: Icon functions

Page 18 April 2019CTL-UM-02765-EN-01

Operator Interface

Navigating the Menus

The Home screen display shows rates and totals, either separately or simultaneously� Status and alarm messages or alarm icons appear on the display when appropriate�

Single Input Configurations

Press UP/DOWN to toggle between parameter views on the Home screen:

• Flow Rate

• Flow Total

• Flow Rate and Flow Total

Figure 11: Single input display

Dual Input Configurations Press UP/DOWN to toggle between parameter views on the Home screen� Press

F3 to toggle between flow meters/sensors 1 and 2�

• Flow Rate 1 or Flow Rate 2

• Flow Total 1 or Flow Total 2

• Flow Rate 1 and Flow Total 1

• Flow Rate 2 and Flow Total 2

Figure 12: Dual input display

Press F1 to enter the Main menu to access Setup and System Information, or press F2 to enter the INFO/SENSOR DATA menu�

Page 19 April 2019 CTL-UM-02765-EN-01

Operator Interface

Numeric Editing

On-screen instruction

Move cursor to

the right Existing Value

Move cursor to the left

New Value

Return to parent setup screen

Make entry positive or negative

Alpha-Numeric Editing

On-screen instruction

Move cursor

to the right Existing value

Move cursor to the left

New value

Add a decimal point

Clear entire new value or cancel edit (press twice, consecutively)

Figure 13: Numeric editing

FC-5000

Delete character to the left OR Return to previous menu

Save value

Delete character to the left OR Return to previous menu

Save value

Return to parent setup screen

Cycle through letters

Cycle through special characters

Clear entire new value or cancel edit (press twice, consecutively)

Figure 14: Alpha-numeric editing

Page 20 April 2019CTL-UM-02765-EN-01

Operator Interface

Selection/Enumeration Editing

OTE:N Depending on the menu, the selection during an enumeration style edit

may appear different�

Move up or down in menu

Save/Select

Return to parent setup screen

Conrmation Screen

Create a custom label

Enter conversion factor

Figure 15: Selection editing

Figure 16: Confirmation screens

Set totalizer rollover point

Yes

Page 21 April 2019 CTL-UM-02765-EN-01

Operator Interface

Menu Structure

The available menu items depend on the Flow Display configuration� Each menu item is explained in detail in the following pages�

Home

Screen

Main Menu

Display

Language

Contrast

Brightness

Part Number (P.N.)

Serial Number (S.N.)

Units

Flow Rate Units Flow Total Units

Sensor Input

Flow Sensor Type

Flow Sensor Calibration

Flow Sensor Properties

System

Information

Vendor

Model

Function

Version

MFG Date

Logic Board

Power Board

Uptime Ontime

Starttime

Relay Output

Relay 1 Settings

Relay 2 Settings

Relay 1 Mode

Relay 2 Mode

Setup

Advanced

Setup

Resets

Reset Flow Total

Reset Faults

Reset Defaults

Passcode Setup

Setup Menu Passcode Reset Menu Passcode

Communications

Network Type

*Network settings vary

based on the Network

Type that is selected

Scaled Output

Output 1 Mode

Output 1 Settings

Output 2 Mode

Output 2 Settings

Figure 17: Menu structure

Page 22 April 2019CTL-UM-02765-EN-01

Digital I/O

Disabled Reset Relay 1 Reset Relay 2

Reset Flow Total Reset R1/Flow Total Reset R2/Flow Total

Info/Sensor Data

INFO/SENSOR DATA

The FC-5000 Flow Display features a quick method to view measured data transmitting to and from the device� You can use the data for informational purposes or for troubleshooting� The type of data displayed can include raw input frequency, relay status or calculated data, such as flow rate�

Info/Sensor Data Table

Item Description

Flow Freq Raw frequency of the flow sensor Flow Count Raw pulse count of the flow sensor Flow Rate Calculated flow rate of the flow sensor Flow Tot Calculated flow total of the flow sensor Flow Freq 1* Raw frequency of flow sensor 1 Flow Count 1* Raw pulse count of flow sensor 1 Flow Rate 1* Calculated flow rate of flow sensor 1 Flow Tot 1* Calculated flow total of flow sensor 1 Flow Freq 2* Raw frequency of flow sensor 2 Flow Count 2* Raw pulse count of flow sensor 2 Flow Rate 2* Calculated flow rate of flow sensor 2 Flow Tot 2* Calculated flow total of flow sensor 2 Relay 1 ENABLED/DISABLED status of relay 1 Relay 2 ENABLED/DISABLED status of relay 2 D-I/O 1 ENABLED/DISABLED status of digital I/O port 1 D-I/O 2 ENABLED/DISABLED status of digital I/O port 2 D-I/O 3 ENABLED/DISABLED status of digital I/O port 3 D-I/O 4 ENABLED/DISABLED status of digital I/O port 4 D-I/O 5 ENABLED/DISABLED status of digital I/O port 5 D-I/O 6 ENABLED/DISABLED status of digital I/O port 6 *For Dual pulse input configurations, rate and total data appear with a 1 or 2 to indicate which flow

meter/sensor its depicting

Table 10: Info/sensor data

To return to the home screen, press BACKSPACE or F1 (home)�

Figure 18: Info/sensor data screen

Page 23 April 2019 CTL-UM-02765-EN-01

System Information

SYSTEM INFORMATION

The System Information menu contains build information specific to the configuration of the unit�

To view your system information, navigate to System Information from the Main menu�

Item Description

Vendor Manufacturer of the product Model Product family/series Function For factory/diagnostic purposes only P�N� Configured part number S�N� Serial number Mfg Date The original manufacture/build date Version Loaded firmware version Logic Brd For factory/diagnostic purposes only Power Brd For factory/diagnostic purposes only Uptime Time, in seconds, since last power-on session start Ontime Total lifetime power-on, in seconds Starttime Ontime at start of power-on session

Table 11: System information menu

Figure 19: System information screen

Page 24 April 2019CTL-UM-02765-EN-01

Basic Setup

BASIC SETUP

Display

Use this menu to change the display settings for Language, Contrast or Brightness�

1� Navigate to Display from the main menu� 2� Press UP/DOWN to scroll through the available display parameters, then

press ENTER�

3� Scroll through available options, then press ENTER to select and save

your changes�

Figure 20: Display configuration screen

Resets

Use this menu to reset Totalizers, Faults, Defaults and latched relays:

1� Navigate to Resets from the main menu�

OTE:N If a passcode was configured, enter the passcode, then press ENTER to

access this menu�

2� Press UP/DOWN to scroll through the available reset options, then

press ENTER�

3� On the conrmation screen press ENTER to conrm the reset�

Figure 21: Resets menu

Page 25 April 2019 CTL-UM-02765-EN-01

Basic Setup

Clearing a Latched Relay

To clear a relay that latches after a trigger:

1� Navigate to the main menu� 2� Press UP/DOWN to scroll to UNLATCH R1 or UNLATCH R2, then press ENTER�

Passcode Setup

Enabling Passcodes

FC-5000 units are shipped without passcode protection enabled� You can enable a unique password for the Setup Menu and the Reset Menu� To enable a passcode:

1� Navigate to SETUP > PASSCODE SETUP� 2� Press UP/DOWN to scroll to the passcode you want to enable, then

press ENTER�

Figure 22: Enable passcode screen

3� Enter a numeric passcode from 4 to 8 digits in length, then press ENTER� 4� On the conrmation screen, press ENTER again to conrm the passcode�

OTE:N An asterisk ( * ) appears next to each passcode if it is enabled�

Figure 23: Asterisk indicates enabled passcode

Disabling a Passcode

1� Navigate to SETUP > PASSCODE SETUP� 2� Press UP/DOWN to scroll to the passcode you want to delete, then press

F4 (clear)�

3� On the conrmation screen, press ENTER to conrm removal of the passcode�

Page 26 April 2019CTL-UM-02765-EN-01

Basic Setup

Forgotten Passcodes

If you have forgotten your passcode, call Badger Meter customer service and they will be able to assist you in resetting the passcode�

1� Navigate to System Information from the main menu� 2� Locate and write down the valves shown for "STARTTIME" and "S�N�

(Serial Number)"�

3� Call Badger Meter customer service� See “Troubleshooting” on page36 for

contact information�

Units

Use the UNITS menu to configure units of measure, display precision (resolution) and radix (comma or decimal point)� You can configure these settings for each Parameter Unit: Flow (Rate and Total)�

1� Navigate to SETUP > UNITS� 2� Press UP/DOWN to scroll through the available parameter units� 3� Scroll to Unit of Measure, Display Precision or Radix, then press ENTER to

activate the drop-down menu for that setting�

Unit of Measure

The Unit of Measure setting determines the engineering unit and/or time interval for calculated measurements of the selected parameter unit�

Press UP/DOWN to scroll through the available units of measure, then press

ENTER to select and save the new setting�

OTE:N For most rate measurements, all options are available in time intervals of

seconds (S), minutes (M), hours (H) and days (D)�

For any of the Flow parameters (Rate or Total), the available units are:

Unit Description Unit Description

US GAL US Gallon M

IG Imperial Gallon AC-FT Acre Feet

MG US Million Gallons BBL Oil Barrels [42 US Gallons]

MIG Imperial Million Gallons FBBL Liquid Barrels [31�5 US Gallons]

L Liters US OZ US Ounces

ML Million Liters I OZ Imperial Ounces

Cubic Feet CUST Custom

Table 12: Flow units

Cubic Meters

Page 27 April 2019 CTL-UM-02765-EN-01

Basic Setup

Creating Custom Units for Rate or Total Measurement

1� Follow the procedure outlined in “Unit of Measure” on page27 to enter the

Unit of Measure menu for a parameter�

2� Press UP/DOWN to choose CUST, then press ENTER�

OTE:N The display populates with additional icons that need to be modified for

custom units�

3� Press F2 (custom label)� Use the soft keys in conjunction with the numeric

keypad and UP/DOWN to create a custom label, then press ENTER�

OTE:N See Table 8 on page17 and Table 9 on page18 for button functionality�

4� On the conrmation screen, press ENTER to conrm the new custom unit� The

new label displays in the selection list�

5� Press F3 (conversion) to assign a conversion factor for this custom unit� The

number entered will be a factor related to the specic parameter� ◊ FLOW RATE: GAL/MIN

◊ FLOW TOTAL: GALLONS (GAL)

6� Press ENTER to save the change� 7� On the conrmation screen, press ENTER to conrm the change�

OTE:N For example, if making a custom unit for Flow Rate and 2 is programmed

as a conversion factor, the custom unit is equivalent to 2 GAL/MIN� If 0�5 is entered, the custom unit is equivalent to 0�5 GAL/MIN�

Display Precision

The Display Precision setting determines the resolution of a value, indicated by the number of digits after the decimal place, for the selected parameter unit�

1� Press UP/DOWN to scroll to DISPLAY PRECISION, then press ENTER� 2� Scroll through the available options (0…4), then press ENTER to select and

save the change�

Radix

The Radix parameter determines if a period or comma is used to represent a decimal place for the selected parameter unit�

1� Press UP/DOWN to scroll to RADIX, then press ENTER� 2� Scroll through available options (decimal point or comma), then press ENTER

to select and save the change�

Page 28 April 2019CTL-UM-02765-EN-01

Advanced Setup

ADVANCED SETUP

Use the ADVANCED SETUP menu to configure flow meters, outputs, relays and communication�

Conguring a Flow Sensor

Flow Sensor Type

See "Flow Sensor Types" on page39 for more details on flow type selection for Badger Meter products� Use this menu to select the flow meter that the device is connected to�

1� Navigate to SETUP > ADVANCED SETUP > SENSOR INPUTS� 2� Press UP/DOWN to scroll to FLOW SENSOR TYPE, then press ENTER� 3� Scroll through the available sensor types, then press ENTER to select and save

the new settings� The ow sensor types are shown in Table 13�

Option Description

No Sensor/Disabled Disables the sensor input in the firmware

Sine K-Factor

Pulse: K-Factor

Sine Multi-Point Cal

Pulse Multi-Point Cal

Pulse K-Factor Pullup

Pulse Debounce K-Factor

Pulse Dic

• Frequency input channel ◊ Examples: Mag pick-offs, Low level signals (~100 mV)

• Single K-Factor entry

• Pulse input channel ◊ Any pulse producing sensor ◊ Examples: TTL, RF carriers w/ amplifier

• Single K-Factor entry

• Active sensor: No pullup resistor

• Frequency input channel ◊ Examples: Mag pick-offs, Low level signals (~100 mV)

• Multi-point linearization

• Pulse input channel ◊ Any pulse producing sensor ◊ Examples: TTL, RF carriers w/ amplifier

• Multi-point linearization

• Active sensor: No pullup resistor

• Pulse input channel ◊ Any pulse producing sensor ◊ Examples: TTL, RF carriers w/ amplifier

• Single K-Factor entry ◊ Pulses per unit of volume

• Passive sensor: Pullup resistor to 12V for excitation

• Unique to products with raw reed switches

• Pulse input channel ◊ Any pulse producing sensor coupled with a reed switch ◊ Example: Industrial Oval Gear

• Single K-Factor entry ◊ Pulses per unit of volume

• Passive sensor: Pullup resistor to 12V for excitation

• Unique to the Data Industrial (DIC) product line

• Pulse input channel ◊ Any pulse producing sensor ◊ Examples: TTL, RF carriers w/ amplifier

• K and Offset values entered ◊ K = unit of volume per pulse

• Active sensor: No pullup resistor

Table 13: Flow sensor types

Page 29 April 2019 CTL-UM-02765-EN-01

Advanced Setup

Flow Sensor Calibration

Use this menu to change the calibration settings (K-factor, offset and low flow cutoff) for the selected Flow Meter Type�

1� Navigate to SETUP > ADVANCED SETUP > SENSOR INPUTS� 2� Press UP/DOWN to scroll to FLOW SENSOR CAL, then press ENTER� 3� Scroll to and edit each option, as necessary� The options include:

Option Description

K-Factor A singular K-factor entry point� Offset Used to apply an offset to sensor input calibration Low Flow

Cutoff Multi-Point

Table

The point at which the display reads zero� Represented in configured unit of measure

Appears when a "Multi-Point Cal" option is picked for a flow sensor type, to replace a single K-Factor� Allows you to program a linearization table�

Table 14: Flow sensor calibration options

10-Point Linearization

The FC-5000 Flow Display can be set up to linearize the output from an eligible flow meter� The calibration data for a particular flow meter are included when the meter, calibration and FC-5000 unit are ordered from the factory� The calibration data is represented as FREQUENCY (f: Hz) vs K-FACTOR (KFct)�To manipulate or enter the linearization parameters:

1� Navigate to SYSTEM SETUP > ADVANCED SETUP > SENSOR INPUT >

FLOW SENSOR CAL�

OTE:N For dual pulse input versions, navigate to FLOW SENSOR 1 CAL or FLOW

SENSOR 2 CAL� 2� Press UP/DOWN to scroll to MULTI-POINT TABLE, then press ENTER� 3� For each calibration point, press F2 (f:Hz) to enter a frequency value or press

F3 (kFct) to enter or edit the K-factor value�

4� On the numeric entry screens, enter the value, then press ENTER to save the

value and return to the previous screen�

OTE:N Each entry, 1…10, represents each calibration data point� Any number of

points can be entered, up to 10� Leave the fields at 0�000 if

no data exists�

Flow Sensor Properties

Use this menu to change flow meter damping� Damping is a smoothing coefficient� As the number increases, averaging becomes greater� As the number decreases, it approaches the raw reading� Valves range from 0…10�

1� Navigate to SETUP > ADVANCED SETUP > SENSOR INPUTS� 2� Press UP/DOWN to scroll to FLOW SENSOR PROP, then press ENTER� 3� Press ENTER to select the DAMPING option and edit it�

OTE:N Each time you press ENTER, the value (0…10) will increase� If the value is

10, pressing ENTER again will restart the list at 0�

Page 30 April 2019CTL-UM-02765-EN-01

Advanced Setup

Conguring Outputs

Scaled Outputs: Output Mode

Use this menu to change the mode of one or both scaled outputs� The mode defines the behavior of the output�

1� Navigate to SETUP > ADVANCED SETUP > SCALED OUTPUTS 2� Press UP/DOWN to scroll to an output mode, then press ENTER� 3� Scroll through the available modes, then press ENTER to select and save

the setting� The Output Mode options will vary based on device conguration�

Device Configuration

Frequency Output

FC5-FD-**-F***-*

Analog Output

FC5-FD-**-A***-*

Option Description

NO OUTPUT/DISABLED Disables Output

PULSE: TOTAL Sends pulse(s)-per-total unit of measure

PULSE: RATE Sends pulse(s)-per-rate unit of measure

NO OUTPUT/DISABLED Disables Output

ANALOG: 0…5V

ANALOG: 0…10V

ANALOG: 4…20 mA

Table 15: Output mode options

0…5V output signal, scaled to an output source

0…10V output signal, scaled to an output source

4…20 mA output signal, scaled to an output source

Scaled Outputs: Output Settings

Use this menu to change the output settings for the respective output mode�

1� Navigate to SETUP > ADVANCED SETUP > SCALED OUTPUTS� 2� Press UP/DOWN to scroll to the applicable output settings, then press ENTER� 3� Scroll to and edit each option, as necessary�

a� Frequency output options are:

Output Mode

PULSE: RATE

PULSE: TOTAL

Option Description

OUTPUT SOURCE Parameter assignment of the output (such as rate or total) SCALE MINIMUM Minimum parameter value associated with output minimum SCALE MAXIMUM Maximum parameter value associated with output maximum MAXIMUM

FREQUENCY OUTPUT FREQ (Read Only) Real-time output frequency

OUTPUT SOURCE

SCALING FACTOR Units of measure transmitted, per pulse SCALED PULSE COUNT (Read Only) Number of transmitted pulses

Maximum frequency output value

Parameter assignment of the output (such as rate or total or temperature)

Table 16: Frequency output settings

Page 31 April 2019 CTL-UM-02765-EN-01

Advanced Setup

b� Analog output options are:

Option Description

OUTPUT SOURCE Parameter assignment of the output (such as rate or total)

ANALOG FULL SCALE Maximum value associated with output maximum

ANALOG LOW SCALE Minimum value associated with output minimum

Table 17: Analog output settings

Relay Outputs: Relay Mode

Use this menu to change the mode of one or both relay outputs� The mode defines the behavior of the output�

1� Navigate to SETUP > ADVANCED SETUP > RELAY OUTPUTS. 2� Press UP/DOWN to scroll to an output mode, then press ENTER� 3� Scroll through the available modes, then press ENTER to select and save

the setting�

Option Description

NO RELAY/DISABLED Disables output

TOTALIZER Totalizer output

ALARM: HIGH On/Off function, energized at the high set point

ALARM: LOW On/Off function, energized at the low set point

ALARM: RANGE On/Off function, energized beyond high and low set points

MANUAL On/Off function of manual operation

Table 18: Relay mode options

Page 32 April 2019CTL-UM-02765-EN-01

Advanced Setup

Relay Outputs: Relay Settings

Use this menu to change the relay settings for the respective relay mode�

1� Navigate to SETUP > ADVANCED SETUP > RELAY OUTPUTS� 2� Press UP/DOWN to scroll to the applicable relay setting, then press ENTER� 3� Scroll to and edit each option, as necessary�

OTE:N Alarm icons "R1" and "R2" will appear in the upper right section of the

Home Screen to provide a local indication when a relay condition has been met and when the relay has be energized�

Output Mode Option Description

TOTALIZER

ALARM: HIGH

ALARM: LOW

OUTPUT SOURCE

SCALING FAC TOR

UNITS Converts output unit of measure

PULSE WIDTH Time between the rising and falling edges of a single pulse

OUTPUT SOURCE Parameter assignment (such as Flow Rate)

HIGH SETPOINT

HYSTERESIS HI

SET DELAY

RELEASE DELAY

LATCHING

OUTPUT SOURCE Parameter assignment (such as Flow Rate)

LOW SETPOINT

HYSTERESIS LO

SET DELAY

RELEASE DELAY

LATCHING

Parameter assignment (e�g� Flow Total)

Pulse(s) transmitted per unit of measure

Instructs the device to energize the relay if this value reached/ exceeded� This value is linked to the OUTPUT SOURCE and its unit of measure (for example, Flow Rate in GPM)

Creates a window/zone below the HIGH SETPOINT value where the relay remains in an energized state

Time in seconds that will elapse before the relay energizes, if the HIGH SETPOINT value is reached/exceeded

Time in seconds that the relay will remain energized, if the HYSTERESIS HI value is reached/exceeded

Leaves the relay in an energized state until it is manually cleared on the device, either through the keypad interface or through the Digital I/O channels

Instructs the device to energize the relay if this value reached/ exceeded� This value is linked to the OUTPUT SOURCE and its unit of measure (for example, Flow Rate in GPM)

Creates a window/zone above the LOW SETPOINT value where the relay remains in an energized state

Time in seconds that will elapse before the relay energizes, if the LOW SETPOINT value is reached/exceeded

Time in seconds that the relay will remain energized, if the HYSTERESIS LO value is reached/exceeded

Leaves relay in an energized state until it is manually cleared on the device, either through the keypad interface or through the Digital I/O channels

Page 33 April 2019 CTL-UM-02765-EN-01

Advanced Setup

Output Mode Option Description

OUTPUT SOURCE Parameter assignment (such as Flow Rate)

Instructs the device to energize the relay if this value reached/

HIGH SETPOINT

HYSTERESIS HI

LOW SETPOINT

ALARM: RANGE

MANUAL OVERRIDE

HYSTERESIS LO

SET DELAY

RELEASE DELAY

LATCHING

exceeded� This value is linked to the OUTPUT SOURCE and its unit of measure (for example, Flow Rate in GPM)

Creates a window/zone below the HIGH SETPOINT value, where the relay remains in an energized state

Instructs the device to energize the relay if this value reached/ exceeded� This value is linked to the OUTPUT SOURCE and its unit of measure (for example, Flow Rate in GPM)

Creates a window/zone above the LOW SETPOINT value, where the relay remains in an energized state

Time in seconds that will elapse before the relay energizes, if either setpoint value is reached/exceeded

Time in seconds that the relay will remain energized, if either hysteresis value is reached/exceeded

Leaves relay in an energized state until it is manually cleared on the device, either through the keypad interface or through the Digital I/O channels

Bypasses any programmed triggers to trigger the relay, which will remain triggered until deactivated

Table 19: Relay settings

Conguring Digital I/O

The FC-5000 Flow Display has remote reset capabilities for relays and totalizers through any one of six different channels�

All six channels are input-only and can be configured for any combination of the following�

Option Description

Disabled The I/O channel will have no function Reset: Relay 1 Resets latch on Relay 1 Reset: Relay 2 Resets latch on Relay 2 Reset: All Relays Resets latches on Relays 1 and 2 Reset: Flow Total Resets Flow Total Reset: Relay 1 And Flow Total Resets latch on Relay 1 and resets Flow Total Reset: Relay 2 And Flow Total Resets latch on Relay 2 and resets Flow Total Reset: All Relays And All Totals Resets Relay 1, Relay 2 and Flow Total

Table 20: Channel options

Page 34 April 2019CTL-UM-02765-EN-01

Advanced Setup

Figure 24: Digital I/O menu

1� Navigate to SETUP > ADVANCED SETUP > DIGITAL I/O� 2� Press UP/DOWN to scroll to any of the six input channels� 3� Press ENTER repeatedly until the desired function appears� Each time ENTER is

pressed, the channel toggles through the available functions�

To disable any channel, simply highlight the digital I/O channel, and press ENTER until DISABLED appears�

Conguring Communications

The Communications menu configures the device to communicate to other systems via Modbus�

The available communication settings vary based on Network Type�

Figure 25: Modbus communications menu

1� Navigate to SETUP > ADVANCED SETUP > COMMUNICATIONS� 2� Press UP/DOWN to scroll to NETWORK TYPE, then press ENTER� 3� Scroll through the available options, then press ENTER to select save

the change� 4� Press BACKSPACE to return to the COMMUNICATIONS menu� 5� Scroll to and edit each option, as necessary� The options are listed in

“Table 21: Modbus settings” on page36�

Page 35 April 2019 CTL-UM-02765-EN-01

Troubleshooting

Modbus RTU and Modbus ASCII

Settings Options

BAUD RATE 1200, 2400, 4800, 9600, 14400, 19200, 28800, 34800, 57600 or 115200

PARITY No Parity, Odd Parity or Even Parity

STOP BIT No Stop Bit, One or Two Stop Bit

SLAVE ADDRESS 1…255

DEVICE NAME User-defined ID

Table 21: Modbus settings

TROUBLESHOOTING

This section lists common problems that may be encountered with the Flow Display, the possible causes and the recommended remedies� Most problems are due to improper wiring and/or programming procedures� The problem may also be in the flow meter, valve, pump or other piece of equipment�

Be sure that all other equipment is functioning properly� The FC-5000 Flow Display is extensively tested at the factory before shipment� However, the unit may get damaged during transit or installation� If after all possible remedies have been tried and the problem persists, contact your local representative or Badger Meter�

Problem Possible Causes Remedies

Unit has power but display does not light up�

Transmitter is connected but the FC-5000 does not count�

Valve does not close at setpoints�

Counter accumulates too many counts�

Incorrect power wiring� Re-check power wiring�

1� Incorrect transmitter wiring or

broken wire� 2� Transmitter is defective� 3� No sensory type selected�

4� Wrong scale factor�

5� Low frequency input must be

on terminal #7� 6� Meter is defective, rotor not

turning� 1� Relay output is not properly

connected� 2� Relay is defective� 3� Valve components are

defective� 1� Wrong scale factor� 2� Electrical noise causing extra

pulses�

3� Excessive vibration�

1� Check wiring diagrams�

2� Replace parts or entire unit� 3� Select a sensor type� See “Flow Sensor

Type” on page29�

4� Check scale factor calculation� For

example, if programmed 0�001 instead of 0�100, unit will wait for 100 pulses before decrementing one count�

5� Verify connection�

6� Disassemble meter, check rotor, replace

if defective�

1� Reconnect relay wiring�

2� Contact factory for replacement� 3� Check and replace valve components�

1� Check scale factor calculation� 2� Check wiring� Make sure power lines are

not touching or close to pulse signal line� Always use shielded cable�

3� Dampen vibration�

Page 36 April 2019CTL-UM-02765-EN-01

Problem Possible Causes Remedies

Some of the keys on the control panel are not operational�

Display Overrun Error (Shown as "DISPOVR")

Alarm notification from the Home screen

"R1" and/or "R2" appear on home screen

"DISABLED" displays on home screen

1� Broken switch behind

control panel�

2� Function not available on

this model�

3� Problem with internal

components�

There are more digits to display than the maximum quantity�

1� The rate or total values

indicated on the Home Screen are in an overrun condition (value exceeds 8 digits)

1� Relay 1 and/or Relay 2

are latched

2� Relay 1 and/or 2 are energized

1� Flow sensor type setting set to

"NO SENSOR/DISABLED"

Table 22: Troubleshooting

1� Replace the Flow Display�

2� See “Operator Interface” on page17�

3� Return the Flow Display to the factory

for repair�

4� Cycle the power to the Flow Display 1� Check the unit of measure and change

to a larger unit if possible (for example, change gallons to mega gallons)

2� Check the display precision and reduce

it, if possible�

1� Change the unit of measure associated

with the parameter (see “Unit of Measure”

on page27) or reset the totalizer (see “Resets” on page25)�

1� See “Clearing a Latched Relay” on

page26

2� The programmed alarm conditions are

met� Check process or programming

1� Congure a ow sensor� See

“Configuring a Flow Sensor” on page29

Troubleshooting

THERE ARE NO FIELDREPLACEABLE PARTS INSIDE. OPENING THE UNIT WILL VOID ALL WARRANTIES.

If a repair or evaluation from the factory is required, call your local representative or the factory to obtain a Return Material Approval (RMA)�

The shipping address, RMA number and any other required information will be provided to send the unit to an appropriate location�

Company Website www�badgermeter�com

Customer Service Email indorders@badgermeter�com

Customer Service Number (877) 243–1010

Table 23: Contact information

Page 37 April 2019 CTL-UM-02765-EN-01

Modbus Interface

MODBUS INTERFACE

Modbus Function Code Support

The FC-5000 Flow Display supports access through all four of the Modbus data types� Both single and multiple write-access commands are supported for register and coil data types� For multiple register writes, the command must initiate on a valid parameter address and end on last register of a valid parameter address� Multiple register writes that start in the middle of a multiple register parameter or do not end on the last register of a multiple register parameter are not supported� The table below lists the supported function codes�

Description Function Code Subcode

Read Coils 01 — Read Discrete Inputs 02 — Read Holding Registers 03 — Read Input Registers 04 — Write Single Coil 05 — Write Single Register 06 — Diagnostic – Return Query Data 08 00 Write Multiple Coils 15 — Write Multiple Registers 16 — Report Slave ID 17 —

Table 24: Supported Modbus function codes

Modbus Register Map

Single Pulse Input

Flow Rate 0×0000 — Float Read Only Register Flow Total 0×0002 — Float Read Only Register Flow Total Precision 0×0004 — Double Read Only Register

Dual Pulse Input

Flow Rate 1 0x0000 — Float Read Only Register Flow Total 1 0x0002 — Float Read Only Register Flow Total Precision 1 0x0004 — Double Read Only Register Flow Rate 2 0x0008 — Float Read Only Register Flow Total 2 0x000A — Float Read Only Register Flow Total Precision 2 0x000C — Double Read Only Register Flow Rate Quad 0x0010 — Float Read Only Register Flow Total Quad 0x0012 — Float Read Only Register Flow Total Precision Quad 0x0014 — Double Read Only Register

Table 25: Modbus register map

Page 38 April 2019CTL-UM-02765-EN-01

Coil

Addr.

Data Type

Read/Write

Access

Type

Flow Sensor Types

FLOW SENSOR TYPES

The table below lists the Badger Meter products suitable for use with the FC-5000 Flow Display�

Meter Technology Product Line Output Type Flow Sensor Input

Impeller Impeller

Oval Gear Oval Gear Reed Switch Pulse Pulse: Debounce K-Factor

OP Meters

Positive Displacement

Recordall

Blancett

Cox

Turbine

Turbo

Flo-tech

Vision Frequency Pulse: K-Factor Pullup

Square Wave Frequency

Unscaled Pulse Pulse: Debounce K-Factor Scaled Pulse Pulse: Debounce K-Factor Unscaled Pulse Pulse: Debounce K-Factor Scaled Pulse Pulse: Debounce K-Factor

MAG Pickup

MAG Pickup with K-Factor Scaler

MAG Pickup Sine: K-Factor MAG Pickup with

K-Factor Scaler RF Pickup Pulse: K-Factor Unscaled Pulse Pulse: Debounce K-Factor Scaled Pulse Pulse: Debounce K-Factor

MAG Pickup

MAG Pickup with K-Factor Scaler

Table 26: Badger Meter flow sensors

Pulse: DIC

Sine: K-Factor Sine Multi-Point Cal

Pulse: K-Factor Pulse Multi-Point Cal

Pulse: K-Factor

Sine: K-Factor Sine Multi-Point Cal

Pulse: K-Factor Pulse Multi-Point Cal

Page 39 April 2019 CTL-UM-02765-EN-01

Part Numbering Construction

- -

A C 6 A

PART NUMBERING CONSTRUCTION

FC-5000 Flow Display

Frequency Output

FUNCTION

Flow Display FD

SENSOR INPUTS

One Pulse P0

Two Pulse P3

SCALED OUTPUTS

Two Frequency Outputs F

RELAY OUTPUTS

Two Form C Relays C

DIGITAL INPUTS/OUTPUTS

Six Programable Inputs/Outputs 6

COMMUNICATIONS

EIA-485(RS-485); Modbus; USB A

MOUNTING METHOD

Panel Mount P

Wall Mount | Includes NEMA 4X (IP67) Rated Enclosure W

FC-5000 Flow Display

Analog Output

FUNCTION

Flow Display FD

SENSOR INPUTS

One Pulse P1

Two Pulse P2

SCALED OUTPUTS

Two Analog Outputs A

RELAY OUTPUTS

Two Form C Relays C

DIGITAL INPUTS/OUTPUTS

Six Programable Inputs/Outputs 6

COMMUNICATIONS

EIA-485(RS-485); Modbus; USB A

MOUNTING METHOD

Panel Mount P

Wall Mount | Includes NEMA 4X (IP67) Rated Enclosure W

FC5-FD

FC5

- -

F C 6 A

Figure 26: Part numbering construction

Replacement Parts/Accessories

Part Number Description

68334-001 P/S Plug; 100-264V AC ln; 24V DC out 68334-002 P/S Module; 85-264V AC ln; 24V DC out 809041 Panel mounting clips (2) 68788-001 Wall-mount enclosure kit 68231-001 Terminal connector kit (P2 configuration) 68231-002 Terminal connector Kit (P1 configuration) 68231-004 Terminal connector kit (P0 configuration) 68231-005 Terminal connector kit (P3 configuration)

Table 27: Replacement parts/accessories

Page 40 April 2019CTL-UM-02765-EN-01

SPECIFICATIONS

Input range: 10…40V DC and 9…28V AC RMS (50…60 Hz)

Maximum power consumption: 8 Watts (power supply must provide 8 watts

Power Supply

Flow Meter Input

Scaled Outputs

Digital I/O

at minimum)

Isolated from power ground

Over-voltage, transient and reverse polarity protected

Input Range: 0�3 Hz…10 kHz

One (1) or two (2) independent channels

Configurable as square wave 0…30V pulse with 2�5V threshold

Configurable as sine wave, zero-centered with 45 mV threshold

Configurable debounce

Excitation Output 12V DC source

Voltage

Impedance Pullup to 12V DC

VDC Current ±50 mA, short circuit current

Response 100 µs/3�5 ms min pulse (high/low speed)

Two (2) independent channels

Isolated from power ground

Over-voltage, transient and reverse polarity protected

Output is multiplexed on the process out pins

Analog Output (option A)

Frequency Output (option F)

Six (6) independent channels

Isolated from power ground

Over-voltage, transient and reverse polarity protected

0…30V as input

Debounce

0…5V, TTL, 200 ms 90-10% step response, driving < 0�1 uF

Specications

Low: –0�3…1�85V DC

High: 2�5…25V DC

Configurable to 0…5V, 0…10V or 4…20 mA

Uncertainty: ±0�1% of reading

16-bit resolution (0…10V and 4…20 mA), 15-bit resolution (0…5V)

200 ms, 90-10% step response

Sourcing analog output signal

TTL, 1…4000 Hz, square wave

Uncertainty: ±0�01% reading

Resolution: 0�01 Hz

Page 41 April 2019 CTL-UM-02765-EN-01

Specications

Calculations Flow Calculation

Configuration

Option "C"

Configuration

Option "A"

Isolated coil drivers

Over-voltage, transient and reverse polarity protected

Form C Relay

Relay Outputs

Form A Relay

(N�O� SPST)

Network Types/

Communication

Protocols

Network Communications

Physical Layer EIA-485 (RS-485)

Baud Rates 1200…115�2K

4-wire interface/half duplex

Over-voltage/ESD Protection

Isolated from power ground

USB (HOST) Type-A Receptacle | Currently not supported

USB Communications

USB (DEVICE) Mini-B Receptacle (used for field updates)

Over-voltage/ESD/transient protected

Keypad Membrane overlay, domed tactile response keys

Display/User interface

Display 128 × 64 pixel LCD graphical display, LED backlit

Protected from EMI/RFI

Keypad interface is protected from ESD

± 0�01% uncertainty

Adjustable FIR/IIR filtering

Two (2) Form C Mechanical Relays

One (1) Form C Mechanical Relay and One (1) Form A Solid State Relay

Load Resistive

Rated Carry Current

Maximum Switching Voltage

Minimum Permissible Load

5 A (N�C� or N�O�)

250V AC, 30V DC

10 mA at 5V DC

Coil Rating 5…24V DC

Life Expectancy 5,000,000 operations

Switching Speed On (0�25 ms), Off (0�02 ms)

Current Rating (IO) 1 A

Maximum Output Voltage (V

)

Output OnResistance (R

Output Withstand Voltage (V

O(OFF)

60V

0�5 Ohms (Ω) @ IF = 5 mA, IO = 1 A

)

(ON)

60-65V @ VF = 0�8V, IO = 250 µA, TA =

)

77° F (25° C)

Modbus RTU or Modbus ASCII

Page 42 April 2019CTL-UM-02765-EN-01

Environmental Ratings

Weights (Approx.)

Operator Functions

Parameters

Pollution Degree 2

Altitude Restriction

Over-Voltage Rating

Up to 2000 m (6561 ft)

Category II (CAT II)

Ambient Temperature

32…130° F (0…55° C)

Range

Storage Temperature

–40…160° F (–40…70° C)

Range

Humidity 0…85%, non-condensing

Panel Mount

Wall Mount (Including Unit)

1�25 lb (0�57 kg)

4�54 lb (2�06 kg)

Unlatch Relays, Reset Totalizers, Unlatch Relays and Reset Totalizers

Maximum Displayed Digits

Resolution/Display Precision

Volumetric Flow Rate Units Seconds (S), Minute (MIN), Hour (H), Day (D)

Volumetric Flow Total Units

Rates Max 8 (7 with decimal)

Totals Max 9 (8 with decimal)

Configurable, 0…4

US Gallons (US GAL), Imperial Gallons (I GAL), Mega US Gallons (US MGAL), Mega Imperial Gallons (I MGAL), Liters (L), Mega Liters (ML), Cubic Meters (M

), Cubic Feet (FT3), Acre Feet (AC-FT), Oil Barrels (OBBL), Liquid Barrels (LBBL), US Ounces (US OZ), Imperial Ounces (I OZ), Custom (user-specified)

Specications

Page 43 April 2019 CTL-UM-02765-EN-01

Industrial Flow Computer, FC-5000 Flow Display

STANDARDS AND CERTIFICATIONS

Agency Approval/Standards

• CE Marked for Low Voltage Directive and RoHS

• CSA Marked per Class C225286 and C225206, Process Control Equipment

• CSA C22�2 No� 61010-1-12, General requirements

• CAN/CSA-C22�2 No� 61010-1-12 Safety requirements for electrical equipment for measurement, control and laboratory use� Part 1: General requirements— Tri-national standard with UL 61010-1 and ANSI/ISA-61010-1 (82�02�01)

EMI/EMC Compliance

Conducted and Radiated Emissions per CISPR11:2009 / EN55011

IEC 61000-4-2:2008 Electrostatic Discharge

IEC 61000-4-3:2006 Radiated RF Immunity

IEC 61000-4-4:2004 EFT Immunity (Signal and Power lines)

IEC 61000-4-5:2005 Surge Protection

IEC 61000-4-6:2008 Conducted RF Immunity (Signal and Power lines)

IEC 61000-4-11:2004 Voltage Dips, Interruptions, and Dropouts

Class A, Group 1

2/4 kV - Contact Discharge, 2/4/8 kV Air Discharge Performance Criteria B

Test levels: 80…1000 MHz & 1400…2000 MHz Performance Criteria A

Tested per specification to Performance Criteria B

Test Levels: 0�15…80 MHz Level 3, Performance Criteria A

Tested per specification to Performance Criteria B & C

Table 28: EMI/EMC compliance

Enclosure Protection

• IEC/CSA/UL 60529-1: Degrees of protection provided by enclosures (IP65), when installed with all four mounting clips in a similarly rated enclosure, which includes the optional wall mount enclosure�

• Additional Protection (optional): NEMA 4X (wall mount enclosure only)�

Control. Manage. Optimize.

Trademarks appearing in this document are the property of their respective entities� Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists� © 2019 Badger Meter, Inc� All rights reserved�

www.badgermeter.com

Badger Meter FC-5000 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Scope of This Manual

UNPACKING AND INSPECTION

SAFETY CONSIDERATIONS

Terminology and Symbols

Safety Instructions

Safety Rules and Precautionary Measures

Description

Functions and Features

Flow Meter Input(s)

Digital Inputs

Relay Control Outputs

Power Supply

Installing the Flow Display

Display Information

Mounting Options

Wiring the Flow Display

Operator Interface

Keypad and Soft Keys

Scrolling

Control Panel Keys

Icon Functionality

Navigating the Menus

Numeric Editing

Alpha-Numeric Editing

Selection/Enumeration Editing

Menu Structure

Info/Sensor Data

Info/Sensor Data Table

System Information

Basic Setup

Display

Resets

Passcode Setup

Disabling a Passcode

Units

Advanced Setup

Troubleshooting

Modbus Interface

Modbus Function Code Support

Modbus Register Map

Flow Sensor Types

Part Numbering Construction

Replacement Parts/Accessories

SPECIFICATIONS

STANDARDS AND CERTIFICATIONS

Agency Approval/Standards

EMI/EMC Compliance

Enclosure Protection