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FC-5000 BTU
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Operating Manual
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Badger Meter FC-5000 BTU Operating Manual

Industrial Flow Computer
FC-5000 BTU Monitor
CTL-UM-02038-EN-03 (March 2019)
User Manual
Industrial Flow Computer, FC-5000 BTU Monitor
CONTENTS
Scope of This Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Unpacking and Inspection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Safety Considerations� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Terminology and Symbols� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 Safety Instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6 Safety Rules and Precautionary Measures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Description � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Functions and Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 Flow Meter Input � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 Digital Inputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 Relay Control Outputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 Power Supply� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 Conguring the Unit � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 Display Information� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Installing the BTU Monitor� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Mounting Options� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10 Wiring the BTU Monitor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
Keypad and Soft Keys � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19 Scrolling � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19 Control Panel Keys � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19 Icon Functionality � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20 Numeric Editing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21 Alpha-Numeric Editing� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21 Selection/Enumeration Editing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22 Conrmation Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22 Navigating the Menus � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23 Menu Structure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
Display � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27 Resets � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27 Passcode Setup � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28 Units � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
Conguring a Flow Sensor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
Page ii March 2019CTL-UM-02038-EN-03
User Manual
Conguring a Temperature Sensor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34 Conguring Outputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35 Conguring Digital I/O � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39 Conguring Fluid Properties � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 40 Conguring Communications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 41
Modbus Function Code Support� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 45 Modbus Register Map � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 45
BACnet Map � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 46
Agency Approval/Standards � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51 EMI/EMC Compliance� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51 Enclosure Protection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51
March 2019 CTL-UM-02038-EN-03
Page iii
Industrial Flow Computer, FC-5000 BTU Monitor
Page iv March 2019CTL-UM-02038-EN-03

Scope of This Manual

SCOPE OF THIS MANUAL
This manual describes how to install and program the FC-5000 BTU Monitor� 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 read the information in this 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 BTU Monitor may be powered by a DC power supply� Acceptable DC input voltage range is: 10…40V DC�
This symbol signifies that the FC-5000 BTU Monitor 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 March 2019 CTL-UM-02038-EN-03
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 BTU Monitor 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 BTU Monitor 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 March 2019CTL-UM-02038-EN-03

Description

DESCRIPTION
The FC-5000 BTU Monitor is a microprocessor-driven device that is designed for energy (BTU) and flow monitoring� The FC-5000 BTU Monitor is compatible with the complete line of Badger Meter industrial flow meters and temperature sensors, creating a solution to monitor hydronic energy usage, flow rates and totals� This manual was written for firmware version 1�2�8�655�

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, energy data, temperature readings 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, temperatures or energy rates and totals

Flow Meter Input

The FC-5000 BTU Monitor accepts passive or active signal outputs� The input circuit supports low and high frequency (0�5…3500 Hz) flow meters� A 12V DC exitation terminal is available for flow meter sensors that require power�

Digital Inputs

The FC-5000 BTU Monitor control inputs allow the following functions:
• Unlatch Relays
• Reset Totalizers
• Unlatch Relays and Reset Totalizers
Page 7 March 2019 CTL-UM-02038-EN-03
Description

Relay Control Outputs

The FC-5000 BTU Monitor 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 BTU Monitor 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 BTU Monitor�
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 BTU Monitor is designed for many types of applications� See
“Advanced Setup” on page 32 for instructions on configuring your
FC-5000 BTU Monitor to your specific requirements�
All information is stored in EEPROM memory and will not be lost in the event of power failure�
Page 8 March 2019CTL-UM-02038-EN-03

Installing the BTU Monitor

Display Information

The FC-5000 BTU Monitor 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 29�
INSTALLING THE BTU MONITOR
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 BTU MONITOR 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 47�
Page 9 March 2019 CTL-UM-02038-EN-03
Installing the BTU Monitor

Mounting Options

The FC-5000 BTU Monitor 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 March 2019CTL-UM-02038-EN-03
Wall-Mount Installations
8.00 in.
(203.20 mm)
6.00 in.
(152.40 mm)
Installing the BTU Monitor
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 BTU Monitor in an enclosure
9.38 in.
(238.25 mm)
To install the FC-5000 BTU Monitor on a wall, secure the enclosure to the wall with four mounting screws (customer-supplied)�
Page 11 March 2019 CTL-UM-02038-EN-03
Installing the BTU Monitor

Wiring the BTU Monitor

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: Terminal connectors, analog out
OTE:N Terminal/pin descriptions shown on next page�
Page 12 March 2019CTL-UM-02038-EN-03
Installing the BTU Monitor
The plug-in connectors on the rear panel of the FC-5000 BTU Monitor are:
Terminal
Block
TB1
Power
TB2
Digital I/O
TB3
Relay 1
TB4
Relay 2
TB5
Pulse Input
TB6
Temperature
Inputs
TB7
Scaled
Outputs
TB8
Comms
USB
Connection
Pin
1 + 2 SHLD 3 -
4 I/O GND
5 PWR + 6 I/O 1 7 I/O 2 8 I/O 3
9 I/O 4 10 I/O 5 11 I/O 6 12 I/O GND 13 N�O� 14 COM 15 N�C� 16 N�O� X1 N�O� X1 17 COM N�C� COM N�C� 18 N�C� X2 N�C� X2 19 EXCI + 20 IN + 21 SNS GND 22 SHLD 24 EXCI 1 + 25 SENS 1 + 26 SENS 1 ­27 EXCI 1 ­28 EXCI 2 + 29 SENS 2 + 30 SENS 2 ­31 EXCI 2 ­32 OUT 1 OUT 1 33 OUT 2 OUT 2 34 OUT GND A GND 35 SHLD SHLD 36 SHLD 37 ­38 + 39 485 GND
Device Mini-B Receptacle (Used for Firmware Updates)
Host Type-A Receptacle (Not Used)
P1-FC6A-*
Configurations/Part Numbers
FC5-BM-
FC5-BM-
P1-FA6A-*
FC5-BM-
P1-AC6A-*
FC5-BM-
P1-AA6A-*
Page 13 March 2019 CTL-UM-02038-EN-03
Installing the BTU Monitor
Power Input
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.
The FC-5000 BTU Monitor 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
Function
Table 1: Power input
Reference Pin
Temperature Inputs
Two temperature inputs allow the FC-5000 BTU Monitor to measure hydronic energy usage with potentially varying temperature readings�
TB6 (2 TEMP IN)
Connector Pin Function Reference Pin
1 T1 Excitation (+) 24 2 T1 Sensor Input (+) 25 3 T1 Sensor Input (–) 26 4 T1 Excitation (–) 27 5 T2 Excitation (+) 28 6 T2 Sensor Input (+) 29 7 T2 Sensor Input (–) 30 8 T2 Excitation (–) 31
Table 2: Temperature inputs
OTE:N See Figure 5 on page 15 for a wiring diagram�
Page 14 March 2019CTL-UM-02038-EN-03
Installing the BTU Monitor
Jumper Wire
2-Wire RTD or Thermistor
3-Wire RTD
4-Wire RTD
RTD RTD
Jumper Wire
RTDRTD
RTDRTD
OTE:N The wires in your application may not be the same color as the wires in the
diagram� The number of each color represents the number of a color of wire that your application will have� For example, the 3-Wire RTD diagram has two green wires and one blue wire� Your application may have two yellow wires and one red wire� To wire the system you would wire the two yellow wires the same way the green wires are in the diagram, and the same with the red and blue wires�
Figure 5: RTD Wiring Diagram
Page 15 March 2019 CTL-UM-02038-EN-03
Installing the BTU Monitor
Digital Inputs
The FC-5000 BTU Monitor 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 Reference Pin
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 3: Digital inputs
Communications
The FC-5000 BTU Monitor comes with Modbus (RTU or ASCII) and BACnet communication protocols� Signals are transmitted over an EIA-485 (RS-485) physical layer�
TB8 (RS-485)
Connector Pin Function Reference Pin
1 Shield (Chassis GND) 36 2 Negative (–) 37 3 Positive (+) 38 4 Output Ground 39
Table 4: Communications input
Page 16 March 2019CTL-UM-02038-EN-03
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