Badger Meter Test Equipment User Manual

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Page 1

Industrial Registers

Models ER-10, ER-10/R & ER-10H Digital Resettable Totalizer and Rate of Flow Indicator

ER-10

ER-10H

For Portable Large Meter Tester Only

This product contains Lithium batteries.

Read this manual before attempting any

installation, wiring or operation.

REG-UM-00471-EN-04 (September 2013)

User Manual

Page 2

Model ER-10, ER-10/R & ER-10H Industrial Register

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User Manual

CONTENTS

ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Battery Installation/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Transmitter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Display Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PROGRAMMING CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Totalizer Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Rate of Flow Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pulse Output Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FIELD CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacing the Meter's Sensor Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Model ER-10, ER-10/R & ER-10H Industrial Register

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User Manual

ABOUT THIS MANUAL

This manual contains information concerning the installation, operation and maintenance of the Badger Meter® ER-10, ER-10/R (Remote) and ER-10H electronic registers.

Installing, wiring and programming these units is fairly simple and straightforward. This manual provides you with a step-bystep guide for this purpose.

Examples are provided only to illustrate the programming function. Your specific application will most likely require a different set of numbers for proper programming.

The troubleshooting section lists the most common problems that can be encountered, their most likely cause and the recommended solution. If a problem persists, please contact our technical support group at:

Badger Meter, Inc. Customer Service 1-800-876-3837

PRODUCT DESCRIPTION

The ER-10, ER-10/R and ER-10H are external or battery powered electronic registers that display rate of flow and total flow. They have independent programmable scale factors for rate and totalization, allowing you to program these displayed values in different but meaningful engineering units, such as gallons per minute and total gallons.

The LCD display with 8 digits for total, and 4 digits plus legend for rate, provides easy viewing at a glance. For conditions where ambient light is poor, the display can be backlit by connecting an external DC (10…30V DC) power supply. A single unit can accept NPN or dry contact inputs for low or high speed applications.

These registers are powered by one 3V Lithium battery each.

Setup is quick and easy. Use the two front panel keys to scroll and preset the values in all Program Modes.

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Duran t

Recommended

Panel Cutout

2.677" (68 mm)

1.299"

(33 mm)

RST

T / R

8-digit LCD display

Front View

Reset/ programming button

Plastic front panel sealed to meet NEMA 4X

Mode select/ programming button

Gasket installed

Install mounting clip

Model ER-10, ER-10/R & ER-10H Industrial Register

INSTALLATION

Panel Installation

Slide the included gasket over the rear of the unit. Place the unit in the panel through a 33 mm x 68 mm cutout. Use the provided panel mount screws to tighten the mounting clips until there is a secure seal against the gasket. Do not over tighten. Slide the mounting clips into the grooves in the side of the ER-10.

Figure 1: Panel installation

Battery Installation/Replacement

The ER-10, ER-10/R & ER-10H are powered by one 3V Lithium battery each. To replace or install the battery, remove the battery cover by pushing inward and down, in the direction of the arrow. Install the battery in the slot. Once the battery in place, the unit goes into a self-test mode, and all the segments on the LCD display illuminate. To exit the self-test mode, press . The unit then displays the model number 10 for the ER-10. Press again to ready the unit for operation.

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Figure 2: Battery installation

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WIRING INSTRUCTIONS

Rear View

Wiring Terminals

User Manual

Reset

Count Input

Ground

7 +10-30VDC7 +10-30VDC

6 DC Common

5 Enable/R

Figure 3: Wiring terminals

RST 4

IN B 2

GND 1

Terminal Function Operation

1 Ground — 2 Input B

Count input

Contact closure of NPN 100 Hz max 3 — Not used 4 Reset Connect to ground to reset totalizer. This is a maintained or level-sensitive reset. 5 Program enable Connect to ground to enter program mode. 6 Backlight common — 7 Backlight power Connect to power to light display.

Table 1: Wiring terminals

Transmitter Connections

For connecting to Badger Meter transmitters, refer to the literature for your specific transmitter and to Table 2 below. The Connections column refers to the wires on the transmitter. The numbers in parenthesis refer to the terminal numbers on the ER-10. Connect the wire coming from the transmitter to the corresponding terminal number for the ER-Series Remote models.

Connecting to a generic reed switch

To connect a generic reed switch to the ER-10, connect one of the wires to terminal 1. Connect the remaining wire to terminal 2.

Connecting to a generic NPN transmitter

To connect a generic NPN transmitter to the ER-10, connect the emitter to terminal 1. Connect the collector to terminal 2.

Transmitter Connections

FT-1 (1/2" OP) Black (1) Black (2)

FT-1 White (1) White (2)

FT-2 White (1) White (2)

FT-420 Pulse Output Terminal – (1) Pulse Output Terminal + (2)

MS-E1 Black (1) Red (2)

MS-E5 Black (1) Red (2)

PFT-2 White (1) White (2)

PFT-3 White (1) White (2)

PFT-420 Pulse Output Terminal – (1) Pulse Output Terminal + (2)

PFT-420/2 Pulse Output Terminal – (1) Pulse Output Terminal + (2)

PM-5 Black (1) Red (2)

Table 2: Transmitter connections

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Model ER-10, ER-10/R & ER-10H Industrial Register

OPERATION

Display Types

34675890

Figure 4: Total display Figure 5: Rate display

Total Display

Total Display indicates the present count value, which is equal to the number of pulses received (since the last reset) multiplied by the Totalizer Scaler Value in Program Mode 1.

Rate Display

Rate Display indicates the rate value, which is equal to the input frequency multiplied by the Rate Prescale Value in Program Mode 3. If no pulses are received for 2 seconds, the rate value goes to zero.

R 2345

Control Keys

Total/Rate Key

Normal operating mode

When you press the Total/Rate key during normal operation, the ER-10 toggles the display between the Flow Total and the Flow Rate. The letter R on the left of the screen indicates that the Flow Rate is being displayed.

Programming mode

To scroll through the menu items, press and hold down then press . After choosing a menu item to edit, press

to move through the digits, then press to set the value for the currently selected (flashing) digit.

Reset/Select Key

While the Total Value displays, press the Reset/Select key to reset the value to zero. The front panel Reset function works only when Program Mode 6 is preset to enable.

When the program input is active (see “WIRING INSTRUCTIONS” on page 7), press to select a menu item for editing.

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User Manual

PROGRAMMING

MPORTANTI

You must connect terminals 1 and 5 together to enable the programming mode. After all programming is complete, remove the connection between terminals 1 and 5 to prevent the unit from being reprogrammed by mistake. To access the programming screens, press and hold the key while repeatedly pressing the key until the Program Mode (1 through 6) you want displays on the screen.

Mode 1: Totalizer Scaler lets you enter the count scale factor. The far right digit will be flashing.

1 01.000

2 000000

3 0000

1. Press to select a digit value or press and hold to scroll through the numbers.

2. Press to move the ashing digit one place to the left.

3. Press to change the value of the digit.

4. Repeat this process until all digits are set correctly.

OTE:N Setting the count scale factor to 00.0000 allows scaling by 100 in the ER-Series.

Mode 2: Totalizer Decimal Point lets you enter the decimal point display on the totalizer screen.

1. Press and hold and then press to move from screen one to screen two.

2. Press to move the decimal point to the new position.

Mode 3: Rate Scale Factor display shows the lowercase letter d on the right when it is time to enter the decimal point position for the rate scaler.

OTE:N This decimal point is used for the rate scaler only and will not appear on the ratemeter

screen.

1. Press to change the rst digit to a new value.

2. Press to select the next digit to be changed.

3. Repeat this process until all the digits are correct.

4. When the d displays, press to move the decimal point to another position.

4 0000

5 1

6 r

Mode 4: Rate Scale Factor Decimal Point lets you enter the decimal point position for the ratemeter run-mode display. The display shows the Program Mode number (4) and four zeros.

Press to move the decimal point to another position.

Mode 5: Rate x1/x10 selects the Rate Display Multiplier of one or ten. Selecting rate x10 adds a zero to the far right of the display. This zero will not change value and does not affect the decimal point. The display shows the Program Mode number (5) at the left and a 1 at the right.

Press to select 1 or 10.

Mode 6: Reset Key Enable/Disable determines if the front panel Reset key will function. The display shows the Program Mode number 6 on the left and the lowercase letter r on the right.

1. Press to select an option (R=Reset, NoR=Non-Reset).

OTE:N The Reset (RST) terminal on the rear panel is still active when the front panel Reset

function is disabled.

2. To exit the programming mode, remove the connection between terminals 1 and 5.

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Model ER-10, ER-10/R & ER-10H Industrial Register

PROGRAMMING CALCULATIONS

Totalizer Programming

Totalizer values can be expressed in any engineering unit of measure such as gallons, quarts, or liters. For each unit, a unique scale factor must be programmed.

Totalizer scale factor

To determine the Totalizer Scale Factor (Program Mode 1), use the following formula:

Totalizer Scale Factor = 1/(Transmitter pulses per unit X Decimal Factor)

where: Transmitter Pulses per Unit is the number from “Table 3: Transmitter pulses per unit” on page 11 or the literature for your particular transmitter/meter combination. The chart is expressed in gallons and liters. If you wish to read in other units, use the appropriate conversion factor.

Decimal Factor (from 1.0 to .001) determines the resolution of the reading. If you wish to read to the nearest 1/10 unit, the Decimal Factor would be 0.1.

Example: You have a model 35 RCDL meter with a PFT-2 transmitter that has a pulse output of 126.7 pulses per gallon. You wish to read the totalizer to the nearest tenth gallon.

1/(126.7 X 0.1) = 0.0789 (scale factor)

1. Set the Totalizer Scale Factor (Program Mode 1) to 0.0789.

2. Set the Totalizer Decimal Point Factor (Program Mode 2) to 0.0 (one decimal place).

Rate of Flow Programming

Rate of flow can be expressed in any engineering unit of measure for any time base such as gallons/minute, liters/second, barrels/hour.

Rate scale factor

To determine the Rate Scale Factor (Program Mode 4), use the following formula:

Rate Scale Factor = (Seconds / Transmitter Pulses per Unit x Decimal Factor)

where: Seconds is the number of seconds in the rate time unit. If you wish to read flow in units per minute, seconds would equal 60. If you wish to read flow in units per hour, seconds would equal 3600.

Transmitter Pulses per Unit is the number from “Table 3: Transmitter pulses per unit” on page 11 or the literature for your particular transmitter/meter combination. The chart is expressed in gallons and liters. If you wish to read in other units, use the appropriate conversion factor.

Decimal Factor (from 1.0 to 0.001) determines the resolution of the reading. If you wish to read the rate to the nearest 1/10 unit, set the Decimal Factor to 0.1.

Before you program the Rate Scale Factor, you must set the Rate Decimal Point position (Program Mode 4). This decimal point corresponds to the decimal in the Rate Scale Factor number.

Example: You have a model 35 RCDL meter with a PFT-2 transmitter that has a pulse output of 126.7 pulses per gallon. You wish to read rate of flow in gallons per minute.

60 seconds /126.7 pulses per gallon x 1.0 = 60/126.7 = 0.473(rate scale factor)

1. Set the Rate Scale Factor (Program Mode 3) to 0.473.

2. Since we are reading in whole gallons, set Rate Decimal Point (Program Mode 4) to 0000.

3. Since we are reading in whole gallons (no multiplier), set Program Mode 5 to 1.

Pulse Output Programming

The Pulse Output can be programmed for any engineering unit of measure. A Pulse Output Scale Factor must be calculated and programmed (Program Mode 6) using the same formula and procedure as described under the Totalizer Scale Factor (Program Mode 1).

The transmitter pulses per unit in Table 3 apply to the following transmitters:

• FT-1

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• FT-1E

• FT-2

• PFT-2

• PFT-2E

• PFT-3

• FT-420

• PFT-420

Size (Inches) Meter Model Gallons Liters

1/2" OP 223.0 58.9

1/2" OP(FT-1 only) 111.5 29.4

1" OP 76.6 20.2

2" OP 20.6 5.4

2" IND'L TURBO * 17.36 * 4.6

3" IND'L TURBO * 12.4 * 3.2

4" IND'L TURBO * 2.56 * 0.6

6" IND'L TURBO * 1.08 * 0.2

5/8" 25 IND RCDL 198.4 52.4

3/4" 35 IND RCDL 126.7 33.5

1" 40 IND RCDL 89.8 23.7

1" 70 IND RCDL 46.8 12.4

1-1/2" 120 IND RCDL 23.8 6.3

2" 170 IND RCDL 14.6 3.9

3" TSM METER 1.598 0.422

* If using a PFT-3E transmitter, multiply number by 2.

User Manual

Table 3: Transmitter pulses per unit

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Model ER-10, ER-10/R & ER-10H Industrial Register

TROUBLESHOOTING

Problem Possible Causes Remedies

Screen is blank Battery is dead. Replace battery.

Will not count in totalizer mode 1. Improperly programmed.

2. Broken or defective wiring.

3. Improperly connected.

4. Transmitter defective.

Will not indicate rate of flow 1. Improperly programmed.

2. Improperly connected.

3. Transmitter defective.

Cannot program Program-enable jumper is not installed or

is installed improperly.

Cannot reset from front panel Reset enable is not programmed. Reprogram mode to R

Erroneous readings 1. Improperly programmed.

2. Defective transmitter.

Table 4: Troubleshooting

1. Check programming.

2. Check wiring.

3. Check connections.

4. Repair or replace transmitter.

1. Check programming.

2. Check connections.

3. Repair or replace transmitter.

Install jumper from Terminal 1 to Terminal 5.

(Program Mode 6).

1. Check programming.

2. Repair or replace transmitter.

For further assistance, call our Technical Support Staff at 1-800-876-3837.

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User Manual

FIELD CALIBRATION

Field calibration consists of determining the exact transmitter pulse output per unit of measure for your particular meter/ transmitter combination and then using this value as the transmitter pulse output value when calculating the counter and time base values. The procedure is as follows:

1. Set the Totalizer Scale Factor (Program Mode 1) to 01.0000.

2. Set the Totalizer Decimal Point (Program Mode 2) to 000000.

3. Reset the counter to 0.

4. Run uid into a weigh tank or into a calibrated vessel.

5. Determine the number of pulses per gallon by dividing the indicator reading by the number of gallons of uid in the vessel. Use this value for your calculations.

Example: You programmed the indicator for calibration and connected the outlet of a 1" OP meter to a calibrated vessel. You opened the valve and allowed fluid to flow into the vessel. You determined that there were 22.35 gallons of fluid in the vessel. The reading on the indicator is 1720.

1720 / 22.35 = 76.95

The transmitter output is 76.95 pulses per gallon. Use 76.95 when calculating the “Totalizer scale factor” on page 10.

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Model ER-10, ER-10/R & ER-10H Industrial Register

Replacing the Meter's Sensor Pickup

Oscillating

Piston

Figure 6: Meter mount components

Industrial

Turbo Disc

To replace the sensor pickup on your meter, follow these steps:

Industrial turbo meter

1. Remove the front cover from the ER-10 unit and disconnect all wiring.

2. Remove meter head bolts and the lift the meter head assembly from the housing.

3. Remove the retaining ring that holds the accessory unit to the head.

4. Loosen the side seal screw on the accessory adapter, twist the adapter 90° and pull entire assembly unit from the meter head.

5. Twist the drop pipe in a counterclockwise direction to remove it and the ER-10 unit from the adapter assembly.

6. Attach the new adapter assembly to the drop pipe and ER-10 unit.

7. Reverse the balance of the above steps to re-assemble the unit.

Disc meter

1. Remove the front cover on the ER-10 unit and disconnect the sensor wiring.

2. Loosen the side seal screw on the assembly adapter, twist the adapter 90° and lift the entire accessory unit o the bare meter.

3. Pull the reed switch pickup assembly and pad from the adapter.

4. Replace the reed switch pickup and pad in the adapter, feeding the wires up through the drop pipe.

5. Reposition the entire assembly on the meter.

6. Rewire the sensor to the ER-10 unit.

Oscillating piston meter

1. Remove the front cover on the ER-10 unit and disconnect the sensor wiring.

2. Remove the back plate on the meter to expose the pickup assembly.

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3. Remove the reed switch pickup assembly and replace it.

4. Feed the wires up through the drop pipe.

5. Reassemble the back plate to the meter.

6. Rewire the sensor wires to the ER-10 unit.

User Manual

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SPECIFICATIONS

Power

Internal battery 3V, Lithium

Battery life

5 years

expectancy

Replacement part 65765-001

External DC power

10…30V DC

source

Maximum current

30 mA

draw

Backlight

Required power

10…30V DC

input

Maximum current

30 mA

draw

• Derate operating temperature 1° C/Volt above 17V DC

• Reverse polarity protected

Physical

Operating

32…130°F (0…55°C)

temperatures

Storage temperature – 4…160°F (–20…70°C)

Operating humidity 60% non-condensing

Weight 2.2 ounces net

Display size 0.43" high

Front panel rating NEMA 4X when mounted with

gasket provided

Case material Cycolac X-17

Totalizer

Digits 8

Scaler 0.0001…99.999

Decimal point 5 positions, programmable

Rate Indicator

Digits 4/5, (4 calculated, 5 displayed with

fixed zero in LSD)

Scaler range 0.001…9999

Decimal point 5 positions, programmable

Accuracy +/-0.2%

Update time 0.7 seconds

Zero time 10 seconds

DC Common (Terminal 1)

Count Input (Terminal 2)

Speed 0…100 Hz

Minimum low time 3.3 mS

Minimum high time 6.7 mS

Impedance 101K Ohm

Voltage thresholds Low 0…0.4 V DC

High 2.0…28V DC Max High 28V DC

Reset Input (Terminal 4)

• Resets totalizer to zero when connected to DC common.

• The required pulse width varies with count speed, scale factor and number of digits displayed

Minimum low time 0.25…1.0 sec (maintained)

Voltage thresholds Low 0…0.4V DC

High 2.0…28V DC

Program Enable Input (Terminal 5)

Operation Level sensitive (maintained)

Count Accuracy

100% when operated within specifications

Trademarks appearing in this document are the property of their respective entities. Due to contin uous re search, product improv ements and enhancements, Badg er Meter rese rves th e right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2013 Badger Meter, Inc. All rights reserved.

www.badgermeter.com

Badger Meter Test Equipment User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ABOUT THIS MANUAL

PRODUCT DESCRIPTION

INSTALLATION

Panel Installation

Battery Installation/Replacement

WIRING INSTRUCTIONS

Wiring Terminals

Transmitter Connections

OPERATION

Display Types

Control Keys

PROGRAMMING

PROGRAMMING CALCULATIONS

Totalizer Programming

Rate of Flow Programming

TROUBLESHOOTING

FIELD CALIBRATION

Replacing the Meter's Sensor Pickup

SPECIFICATIONS