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Badger Meter FC-5000 User Manual

Btu monitor
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Industrial Flow Computer
FC-5000 BTU Monitor
User Manual
CTL-UM-02038-EN-03 (March 2019)

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Summary of Contents for Badger Meter FC-5000

  • Page 1 Industrial Flow Computer FC-5000 BTU Monitor User Manual CTL-UM-02038-EN-03 (March 2019)

  • Page 2: Table Of Contents

    Industrial Flow Computer, FC-5000 BTU Monitor CONTENTS Scope of This Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 Unpacking and Inspection �...
  • Page 3 User Manual Configuring a Temperature Sensor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34 Configuring Outputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35 Configuring Digital I/O �...
  • Page 4 Industrial Flow Computer, FC-5000 BTU Monitor Page iv CTL-UM-02038-EN-03 March 2019...

  • Page 5: Scope Of This Manual

    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�...

  • Page 6: Safety Instructions

    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...

  • Page 7: Description

    Description DESCOIPTION 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�...

  • Page 8: Relay Control Outputs

    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�...

  • Page 9: Display Information

    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 MONITOO...

  • Page 10: Mounting Options

    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 OTEE: Mounting clips can accommodate a maximum panel thickness of 1�5 in�...
  • Page 11 9.65 in. (242.83 mm) 9.38 in. (238.25 mm) Figure 3: FC-5000 BTU Monitor in an enclosure To install the FC-5000 BTU Monitor on a wall, secure the enclosure to the wall with four mounting screws (customer-supplied)� March 2019 CTL-UM-02038-EN-03 Page 11...

  • Page 12: Wiring The Btu Monitor

    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�...
  • Page 13 Installing the BTU Monitor The plug-in connectors on the rear panel of the FC-5000 BTU Monitor are: Configurations/Part Numbers Terminal Connection FC5-BM- FC5-BM- FC5-BM- FC5-BM- Block P1-FC6A-* P1-FA6A-* P1-AC6A-* P1-AA6A-* SHLD Power I/O GND PWR + I/O 1 I/O 2...
  • Page 14 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�...
  • Page 15 Installing the BTU Monitor 2-Wire RTD or Thermistor Jumper Wire 3-Wire RTD Jumper Wire 4-Wire RTD OTEE: 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�...
  • Page 16 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�...
  • Page 17 OUTPUT SIGNAL. THE RECEIVING DEVICE MUST NOT PROVIDE POWER TO THE LOOP. Oelay Output Connectors The FC-5000 BTU Monitor has either two Form C relay output terminals or one Form C and one Form A terminal� Two Form C TB3 (OELAY 1) and TB4 (OELAY 2)
  • Page 18 Installing the BTU Monitor Flow Sensor Input The FC-5000 BTU Monitor 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)�...

  • Page 19: Operator Interface

    Operator Interface OPEOATOO INTEOFACE 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�...

  • Page 20: Icon Functionality

    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 press the button without saving first)

  • Page 21: Numeric Editing

    Move cursor Return to to the right previous menu Existing Value Move cursor to the left Save value FC-5000 Value Return to Make entry Clear entire new value or Add a parent setup positive or decimal cancel edit (press twice, consecutively)

  • Page 22: Selection/Enumeration Editing

    Operator Interface Selection/Enumeration Editing OTEE: Depending on the menu, the selection during an enumeration style edit may appear different� Save/Select Move up or down in Create a Enter Set totalizer menu custom conversion rollover point Return to label factor parent setup screen Figure 10: Selection editing Confirmation Screen...

  • Page 23: Navigating The Menus

    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� Press UP/DOWN to toggle views on the Home screen: • Flow Rate •...

  • Page 24: Menu Structure

    Operator Interface Menu Structure The available menu items depend on the BTU Monitor configuration� Each menu item is explained in detail in the following pages� HOME MAIN MENU SCREEN SYSTEM SETUP DISPLAY RESETS INFORMATION Language Reset Flow Total Vendor Contrast Reset Energy Total Model Brightness...

  • Page 25: Info/Sensor Data

    Info/Sensor Data INFO/SENSOO DATA The FC-5000 BTU Monitor 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�...

  • Page 26: System Information

    System Information SYSTEM INFOOMATION 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�...

  • Page 27: Basic Setup

    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 ENTEO� 3� Scroll through available options, then press ENTEO to select and save your changes�...

  • Page 28: Passcode Setup

    2� Press UP/DOWN to scroll to UNLATCH R1 or UNLATCH R2, then press ENTEO� 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�...

  • Page 29: Units

    3� On the confirmation screen, press ENTEO to confirm removal of the passcode� 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�...
  • Page 30 Basic Setup For Energy Rate the available units are: Unit Description Unit Description kBTU/H Thousand BTU per Hour Ton (RT) 12,000 BTU/H BTU/MIN BTU per Minute Joules per Second Kilowatts CUST Custom Table 13: Energy rate units For Energy Total the available units are: Unit Description Unit...
  • Page 31 Basic Setup 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 ENTEO� 2�...

  • Page 32: Advanced Setup

    "Flow Sensor Types" on page 46 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�...
  • Page 33 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 ENTEO� 3�...

  • Page 34: Configuring A Temperature Sensor

    Advanced Setup Configuring a Temperature Sensor Temperature Sensor Type Use this menu to select the temperature sensor type the device is connected to� 1� Navigate to SETUP > ADVANCED SETUP > SENSOR INPUTS� 2� Press UP/DOWN to scroll to either temperature sensor, then press ENTEO� OTEE: In most applications, Temperature Sensor 1 is used for the supply line, and Temperature Sensor 2 is used for the return line�...

  • Page 35: Configuring Outputs

    Advanced Setup The calibration setting options are described below� The settings that appear on the device are relative to the sensor type and will only show if a sensor type is chosen� Temperature Option Description Sensor Type ALPHA COEFF 2, 3 and BETA COEFF Callendar-Van Dusen coefficients 4-Wire RTDs...
  • Page 36 Advanced Setup Scaled OutputsE: 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 ENTEO� 3�...
  • Page 37 Advanced Setup Oelay OutputsE: Oelay 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 ENTEO� 3�...
  • Page 38 Advanced Setup Output Mode Option Description OUTPUT SOURCE Parameter assignment (such as Flow Rate or Temperature) Instructs the device to energize the relay if this value reached/ HIGH SETPOINT 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 HYSTERESIS HI...

  • Page 39: Configuring Digital I/O

    Advanced Setup Configuring Digital I/O The FC-5000 BTU Monitor 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...

  • Page 40: Configuring Fluid Properties

    Advanced Setup Configuring Fluid Properties The Fluid Properties menu configures the device for the fluid medium that is being measured� Figure 22: Fluid properties menu Fluid ID Use this menu to enter a user-defined text entry for naming or identification� 1�...

  • Page 41: Configuring Communications

    Advanced Setup Creating a Custom Heat Transfer Fluid If CUSTOM FLUID is selected, the polynomials for Specific Heat and Density must be programmed� These settings will not appear unless CUSTOM FLUID is selected as a fluid type� 1� Navigate to SETUP > ADVANCED SETUP > FLUID PROPERTIES� 2�...
  • Page 42 Advanced Setup 4� Press BACKSPACE to return to the COMMUNICATIONS menu� 5� Scroll to and edit each option, as necessary� The options are: Modbus OTU 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...

  • Page 43: Troubleshooting

    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 BTU Monitor is extensively tested at the factory before shipment� However, the unit may get damaged during transit or installation�...
  • Page 44 Troubleshooting Problem Possible Causes Oemedies 1� The rate or total values 1� Change the unit of measure associated indicated on the Home Screen with the parameter (see “Unit of Measure” Alarm are in an overrun condition on page 29) or reset the totalizer (see notification from (value exceeds 8 digits) “Resets”...

  • Page 45: Modbus Interface

    MODBUS INTEOFACE Modbus Function Code Support The FC-5000 BTU Monitor 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�...

  • Page 46: Bacnet Interface

    FLUID DENSITY Analog Value SPECIFIC HEAT Analog Value Table 34: BACnet register map FLOW SENSOO TYPES The table below lists the Badger Meter products suitable for use with the FC-5000 BTU Monitor� Meter Technology Product Line Output Type Flow Sensor Input...

  • Page 47: Part Numbering Construction

    Part Numbering Construction PAOT NUMBEOING CONSTOUCTION FC5 - BM - P1 - Badger Meter FC-5000 BTU Monitor FUNCTION BTU Monitor SENSOR INPUTS One Pulse / Two Temperature SCALED OUTPUTS Two Analog Outputs Two Frequency Outputs RELAY OUTPUTS One Form C Relay / One Form A Relay...

  • Page 48: Specifications

    Specifications 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 at minimum) Power Supply Isolated from power ground Over-voltage, transient and reverse polarity protected Input Range: 0�3 Hz…10 kHz One (1) independent channel Configurable as square wave 0…30V pulse with 2�5V threshold Configurable as sine wave, zero-centered with 200 mV amplitude and 45 mV...
  • Page 49 Specifications Uncertainty: ± 0�01% Flow Calculation Calculations Adjustable FIR/IIR filtering BTU Calculation Meets EN 1434 requirements Configuration Option "C" Two (2) Form C Mechanical Relays One (1) Form C Mechanical Relay and Configuration Option "A" One (1) Form A Solid State Relay Isolated coil drivers Over-voltage, transient and reverse polarity protected Load...
  • Page 50 Specifications Oates Max 8 (7 with decimal) Maximum Displayed Digits Totals Max 9 (8 with decimal) Oesolution/Display Precision Configurable, 0…4 Volumetric Flow Oate Units US Gallons (US GAL), Imperial Gallons (I GAL), Seconds (S), Minute (MIN), Mega US Gallons (US MGAL), Mega Imperial Hour (H), Day (D) Gallons (I MGAL), Liters (L), Mega Liters (ML), Cubic Meters (M...

  • Page 51: Standards And Certifications

    Standards and Certifications STANDAODS AND CEOTIFICATIONS 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�...
  • Page 52 The Americas | Badger Meter | 4545 West Brown Deer Rd | PO Box 245036 | Milwaukee, WI 53224-9536 | 800-876-3837 | 414-355-0400 México | Badger Meter de las Americas, S.A. de C.V. | Pedro Luis Ogazón N°32 | Esq. Angelina N°24 | Colonia Guadalupe Inn | CP 01050 | México, DF | México | +52-55-5662-0882 Europe, Eastern Europe Branch Office (for Poland, Latvia, Lithuania, Estonia, Ukraine, Belarus) | Badger Meter Europe | ul.

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