UP000XPD.pdf

4210 Ultrasonic Flow Meter

Installation and Operation Guide

Part #60-3213-285 of Assembly #60-3214-110 Copyright © 1994. All rights reserved, Teledyne Isco, Inc.

Revision Y, May 10, 2006 http://www.isco.com

Foreword

This instruction manual is designed to help you gain a thorough understanding of the operation of the equipment. Teledyne Isco recommends that you read this manual completely before placing the equipment in service.

Although Teledyne Isco designs reliability into all equipment, there is always the possi-bility of a malfunction. This manual may help in diagnosing and repairing the malfunc-tion.

If the problem persists, call or e-mail the Teledyne Isco Technical Service Department for assistance. Simple difficulties can often be diagnosed over the phone.

If it is necessary to return the equipment to the factory for service, please follow the shipping instructions provided by the Customer Service Department, including the use of the Return Authorization Number specified. Be sure to include a note describing the malfunction. This will aid in the prompt repair and return of the equipment.

Teledyne Isco welcomes suggestions that would improve the information presented in this manual or enhance the operation of the equipment itself.

Teledyne Isco is continually improving its products and reserves the right to change product specifications, replacement parts, schematics, and instruc-tions without notice.

Contact Information

Customer Service

Phone: (800) 228-4373 (USA, Canada, Mexico)

(402) 464-0231 (Outside North America)

Fax: (402) 465-3022

Email: IscoCSR@teledyne.com

Technical Service

Phone: (800) 775-2965 (Analytical)

(800) 228-4373 (Samplers and Flow Meters)

Email: IscoService@teledyne.com

Return equipment to: 4700 Superior Street, Lincoln, NE 68504-1398

Other Correspondence

Mail to: P.O. Box 82531, Lincoln, NE 68501-2531

Email: IscoInfo@teledyne.com

Web site: www.isco.com

Revised September 15, 2005 http://www.isco.com

4210 Ultrasonic Flow Meter Safety iii

4210 Ultrasonic Flow Meter Safety

General Warnings Before installing, operating, or maintaining this equipment, it is imperative that all hazards and preventive measures are fully understood. While specific hazards may vary according to location and application, take heed of the following general warnings:

WARNING

Avoid hazardous practices! If you use this instrument in any way not specified in this manual, the protection provided by the instrument may be impaired.

AVERTISSEMENT

Éviter les usages périlleux! Si vous utilisez cet instrument d’une manière autre que celles qui sont specifiées dans ce manuel, la protection fournie de l’instrument peut être affaiblie; cela augmentera votre risque de blessure.

Hazard Severity Levels This manual applies Hazard Severity Levels to the safety alerts, These three levels are described in the sample alerts below.

CAUTION

Cautions identify a potential hazard, which if not avoided, may result in minor or moderate injury. This category can also warn you of unsafe practices, or conditions that may cause property damage.

WARNING

Warnings identify a potentially hazardous condition, which if not avoided, could result in death or serious injury.

DANGER

DANGER – limited to the most extreme situations to identify an imminent hazard, which if not avoided, will result in death or serious injury.

4210 Ultrasonic Flow Meter Safety iv

Hazard Symbols The equipment and this manual use symbols used to warn of hazards. The symbols are explained below.

Hazard Symbols

Warnings and Cautions

The exclamation point within the triangle is a warning sign alerting you of important instructions in the instrument’s technical reference manual.

The lightning flash and arrowhead within the triangle is a warning sign alert-ing you of “dangerous voltage” inside the product.

Symboles de sécurité

Ce symbole signale l’existence d’instructions importantes relatives au pro-duit dans ce manuel.

Ce symbole signale la présence d’un danger d’électocution.

Warnungen und Vorsichtshinweise

Das Ausrufezeichen in Dreieck ist ein Warnzeichen, das Sie darauf aufmerksam macht, daß wichtige Anleitungen zu diesem Handbuch gehören.

Der gepfeilte Blitz im Dreieck ist ein Warnzeichen, das Sei vor “gefährlichen Spannungen” im Inneren des Produkts warnt.

Advertencias y Precauciones

Esta señal le advierte sobre la importancia de las instrucciones del manual que acompañan a este producto.

Esta señal alerta sobre la presencia de alto voltaje en el interior del producto.

i

4210 Flow Meter

Table of Contents

Section 1 Introduction

1.1 Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Compatible Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 The Ultrasonic Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5.1 Transducer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5.2 Validity Tests and Error Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5.3 Ambient Air Temperature Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5.4 Return Echo Amplifier Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 Software Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Controls, Indicators, and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.8 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.9 How to Make Battery Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.9.1 Calculating Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Section 2 Programming

2.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Description of Program Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4.1 Step 1 - Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4.2 Step 2 - Flow Conversion Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4.3 Step 3 - Adjust Level, Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.4.4 Step 4 - Reset Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.4.5 Step 5 - Sampler Pacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.4.6 Step 6 - Sampler Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.4.7 Step 7 - Alarm Dialout Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.4.8 Step 8 - Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.4.9 Step 9 - Reports/History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.5 Interpreting The Program Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.6 Step 1: OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.6.1 Optional Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6.2 Serial Output Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.3 Periodic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.4 Report Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.6.5 Other Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.6.6 Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.6.7 The YSI 600 Multi-Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.7 Step 2 - Flow Conversion

(Level-to-Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.7.1 Weir/Flume Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.7.2 Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.7.3 Manning Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.7.4 Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Table of Contents ii

2.7.5 Maximum Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2.7.6 Programming the 4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.8 Step 3 - Parameter to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.9 Step 4 - Reset Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.10 Step 5 - Sampler Pacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.11 Step 6 - Sampler Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

2.12 Step 7 - Alarm Dialout Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2.13 Step 8 - Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

2.14 Step 9 - Reports/History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Section 3 Installation

3.1 Preparation for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Opening the Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.2 Desiccant Canister Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Connection to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.1 Low Power Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.2 Isco Sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.3 Isco Nickel-Cadmium Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.4 Isco Lead-Acid Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.5 AC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.6 External 12 Volt Direct Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Flow Meter Mounting and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.1 Carrying Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.2 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.3 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4 Error Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4.1 Velocity Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4.2 Echo Detect Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4.3 Error Factors and Flow Meter Compensation . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6 Ultrasonic Level Sensor: Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6.1 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6.2 Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6.3 Accidental Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6.4 Mounting the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6.5 Suspension of the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.6 Use a Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.7 Use the Variable Blanking Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.8 Use the Signal Strength Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.9 Minimizing Level Measurement Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6.10 Alternative Flow Measurement Systems . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7 Associated Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.1 Isco Sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.2 Connection to Other Isco Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Section 4 Optional Equipment

4.1 User-Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 4200T Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.1 How the Modem Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.2 Modem and FLOWLINK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.3 Connection to a Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.4 Types of Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Connection to an External Serial Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4 4 to 20 mA (Analog) Outputs (External and Internal) . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4.1 Connecting the 4-20 mA Output Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.5 The Internal Analog Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 iii

4.6 Tipping Bucket Rain Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.7 Isco FLOWLINK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.8 High-Low Alarm Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8.2 Wiring to a 4200 Series Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 Parameter Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9.1 Installation of Parameter Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9.2 The Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 The pH Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10.1 How the pH Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10.2 pH Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.10.3 pH Probe Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.10.4 pH Probe Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.10.5 Storage and Maintenance of pH Probes . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.11 The Dissolved Oxygen (D.O.) Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.11.1 How the D.O. Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.11.2 D.O. Probe Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4.11.3 Membrane Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.11.4 D.O. Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.11.5 Probe Operation and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.11.6 Calibrating the D.O. Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.12 Installation of Parameter Probes in Round Pipes . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4.12.1 Spring Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4.12.2 Universal Mounting Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.12.3 U-Channel or Invert Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

4.12.4 Power-Actuated Stud Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

4.13 The YSI 600 Multiple Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4.14 Mechanical Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Section 5 Maintenance and Service

5.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Care of the Flow Meter Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.2 Care of the Case Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.3 Preventing Moisture Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.4 Checking and Regenerating the Desiccant . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.5 Care of the Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.1.6 Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 Maintenance of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.1 Changing the Roll of Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.2 Ink Ribbon Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.2.3 Do Not Lubricate or Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3 Isco Software Updates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3.1 Flash Memory and the UPDATE Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3.2 Running UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.3.3 Setting Preferences for Flash Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.3.4 Flash Update: Minimum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4 Servicing and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.1 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.2 Display Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.4.3 System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.4.4 If Serious Problems Occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.4.5 Processor Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.4.6 Preliminary Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.5 Precautions for Servicing CMOS Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.5.1 Hazard of Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 iv

Appendix A Replacement Parts List

A.1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Appendix B Programming Worksheet

Appendix C General Safety Procedures

C.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C.1.1 Adverse Atmosphere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C.1.2 Deteriorated Rungs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.1.3 Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.1.4 Falling Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.1.5 Sharp Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.1.6 Lifting Injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C.2 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.3 Adverse Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.4 Entering Manholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C.4.1 Traffic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 C.4.2 Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 C.4.3 Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 C.4.4 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C.4.5 Field Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C.4.6 Lethal Atmospheres in Sewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Appendix D Material Safety Data Sheets

List of Figures 1-1 Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-2 4210 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-3 4210 Side View Showing Connectors and Pin Functions . . . . . . . . . . . . . . . . . . . . 1-7 1-4 Measuring Flow Meter Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 2-1 The YSI 600 Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-2 YSI 600 Sonde Calibration Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 3-1 Battery Installed on Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-2 4210 Suspended by Handle (handles may vary) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-3 Ultrasonic Level Sensor Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3-4 Mounting the Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-5 Mounting the Ultrasonic Level Sensor (Continued) . . . . . . . . . . . . . . . . . . . . . . . 3-13 3-6 Foam and Oil on the Surface of the Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-7 Small Pipes and Narrow Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 4-1 4-20 mA Output Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-2 Isco 674 Rain Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-3 Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4-4 pH Probe (With Protective Cap On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-5 pH Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4-6 The D.O. Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4-7 D.O. Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4-8 Sensor Installed on a Spring Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 4-9 Universal Mounting Ring Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 4-10 Universal Mounting Ring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 4-11 The YSI 600 Multiple Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 5-1 Location of the Internal Desiccant Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 v

5-2 Paper Roll and Spool Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-3 Flash Update: File Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-4 Flash Update Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-5 Flash Update Preferences Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5-6 Lifting the Flow Meter from the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5-7 Location of the Three Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

List of Tables 1-1 4210 Controls, Indicators, and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1-2 4210 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-3 4210 Chart Longevity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1-4 Battery Life Expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 2-1 ASCII Output Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 4-1 External 4-20 mA Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4-2 Internal 4-20 mA Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4-3 pH Probe Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4-4 D.O. Probe Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4-5 YSI 600 Technical Specifications (Complete Unit) . . . . . . . . . . . . . . . . . . . . . . . . 4-31 4-6 YSI Sensor Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 5-1 Minimum Requirements for Flash Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 A-1 4210 Flow Meter Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 C-1 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6 vi

1-1

Section 1 Introduction

The following section provides a general introduction to the 4210 Ultrasonic Flow Meter. It includes a description, an explanation of how the unit operates, and technical specifications.

1.1 Manual Organization This manual provides the information necessary to operate, maintain, and perform minor service on the 4210. The manual is organized into five sections:

Section 1 – Introduction, operation, and technical specifications for the flow meter.

Section 2 – Keypad operation and programming.

Section 3 – Installation and options application-specific to this flow meter.

Section 4 – Options and accessories for all 4200 Series Flow Meters.

Section 5 – Routine maintenance procedures and minor ser-vicing information.

Following Section 5 are appendices covering replacement and accessory parts, safety information, and material safety data sheets.

1.2 Description The 4210 uses ultrasonic reflection to measure level in flow stream. The flow meter is normally used with some type of primary measuring device to measure flow in an open channel.

The 4210 has built-in level-to-flow conversions that cover the vast majority of open channel flow measurement situations.

Additionally, the flow meter lets you enter an equation, or data points. The 4210 supports the Isco data storage, acquisition, and retrieval system with the use of optional FLOWLINK software.

The 4210 has enough memory to store 40,000 data readings. An optional 4200T Modem, with speech capability, is available to transmit stored data over standard dial-up telephone lines and call out on alarms.

Section 1 Introduction

1-2

1.3 Compatible

Equipment

The 4210 Flow Meter may be used with the following equipment:

Manufactured by Teledyne Isco

• 6700 Series Portable and Refrigerated Samplers

• 3700 Series Sequential, Composite, and Refrigerated Samplers

• 4 - 20 mA Output Interface

• 674 Tipping Bucket Rain Gauge

• High Low Alarm Relay Box

Manufactured by Others

• IBM Personal Computer or compatible clone with Isco FLOWLINK software

• Laptop Computer with Isco software

• YSI 600 Multi-Parameter Sonde

Optional Accessories

•4200T Modem - Speech-capable, with connector and cable

•Parameter Modules (pH and D. O.)

•Ultrasonic level sensor extension cable in length of 25 feet

• Isco FLOWLINK Software

•Cable stiffener for the level sensor

•Mounting bracket for the level sensor

•Ultrasonic Sunshade

•Calibration Target

•Cable Clamp

•Floor Mount

1.4 Operating Principles The 4210 normally measures flow rate with a primary measuring device (weir or flume) or other open-channel flow arrangement where there is a known relationship between liquid level and flow rate. The 4210 can also measure flow in round pipes by using the Manning equation. The level-sensing device is an ultrasonic transducer. The flow meter electronically converts the level reading into a properly scaled flow rate. The flow meter also provides standard or optional flow-related output signals to be used for:

• Flow-proportional sampler pacing

• Transmitting level and flow data to an external device on a serial communication loop

• Data transfer through a modem

• Control of a 4 - 20 mA device

• Data transfer by a laptop computer

1-3

The flow meter contains a microprocessor that calculates level and flow rates from the signals produced by the ultrasonic level sensor, stores programming instructions and operates the display and internal printer. An alphanumeric liquid crystal display (LCD) shows total flow, level, and flow-rate. It also assists in pro-gramming the flow meter during initial set up or subsequent changes. An internal printer provides a “hard copy” printout of the information computed by the flow meter, plots level or flow rate, and generates reports. Connectors for other equipment used with the 4210 are on the side of the case.

1.5 The Ultrasonic Level

Sensor

The ultrasonic level sensor (USLS) mounts directly over the flow stream. The flow meter measures level by transmitting an ultra-sonic pulse toward the liquid surface and then measuring the time it takes for the echo to return. The ultrasonic level sensor consists of an enclosure with a single transducer acting both as pulse transmitter and echo receiver. Since the speed of the pulse through the air varies with temperature, compensation is built-in. A temperature sensor inside the enclosure measures ambient temperature. The microprocessor program automati-cally compensates for speed-of-sound changes caused by air-tem-perature changes.

1.5.1 Transducer Operation Several times a second, the ultrasonic level sensor emits a pulse.

Between pulses the transducer becomes a receiver or micro-phone, ready to sense the echo reflected from the surface of the liquid. When the transducer receives the echo, the sound energy changes into a small electrical pulse, that is amplified and detected by the flow meter to produce an echo-received signal.

The time between the transmitted pulse and echo-received signal is proportional to the distance between the transducer and the liquid surface. This distance determines the liquid level.

1.5.2 Validity Tests and Error

Display

The flow meter checks the measured level for validity. If it cannot obtain a valid level, it will repeat the process. If the flow meter cannot obtain a valid reading after about one minute the level reading will drop to zero with an asterisk (*) to indicate there is an error.

1.5.3 Ambient Air

Temperature Factor

The ultrasonic measurement technique used in the 4210 Flow Meter is based on the speed of sound in air.

1-4

Figure 1-1 Ultrasonic Level Sensor

Since the speed of sound in air varies with temperature (approxi-mately 1% for 10° variation), compensation must be provided.

The ultrasonic level sensor uses both air temperature and micro-processor-based compensation to accurately account for air tem-perature variations.

1.5.4 Return Echo Amplifier

Compensation

The strength of the echo depends on several factors, including the distance between the transducer and the water surface. For every 21/2 foot increase in the distance between the transducer and the liquid surface, the strength of the returned echo decreases by half. Consequently, the flow meter must com-pensate the gain of the return echo amplifier for distance. As the distance increases between the transducer and the liquid surface, the gain of the echo amplifier increases with time to compensate for the decreasing signal strength of the echo. This type of amplifier, whose gain characteristic is based on a repeating time interval, is referred to as a ramp-gain amplifier.

1.6 Software Upgrades 4200 Series Flow Meters can be upgraded without being returned to the factory or having the EPROM replaced. With Flash memory, software updates can easily be installed in the field with a disk, a computer, and a cable. Flash update instruction can be found in Section 5 Maintenance. For more information about installing software upgrades in the 4210 Flow Meter, contact your Teledyne Isco representative or call the factory.

1-5

1.7 Controls, Indicators, and Connectors

The controls, indicators and connectors of the 4210 Flow Meter are listed in Table 1-1, with brief descriptions. Refer to Figure 1-2 for a view of the controls and indicators, and Figure 1-3 for a view of the connectors and their pin functions.

1.8 Technical

Specifications

The technical specifications for the 4210 are found in Table 1-2.

Chart longevity for the 4210 internal printer is found in Table 1-3. Battery life expectancy is in Table 1-4, followed by a section on making battery calculations.

Note Various accessories are available for the 4210 Flow Meter. The part numbers for these items are listed on an Accessory Parts List, which will be found at the back of Appendix A Replace-ment Parts List.

1-6

Figure 1-2 4210 Controls and Indicators

1-7

Figure 1-3 4210 Side View Showing Connectors and Pin Functions

Power

Sampler

Rain Gauge

Interrogator

Modem (or Analog Output)

Parameter

Ultrasonic Sensor

A Ground B 12V

Pin Function

A 12V B Ground C Flow Pulse Output D Bottle Number Input E Event Mark Input F Inhibit/Enable Output

A 12V B Ground

C SDO

D Rain Gauge Input

A 12V B Ground C Sense Line

D SDO

E SDI

F Analog Output Pulse

A = Channel 1 (-) Red B = Channel 3 (+) Green C = Channel 1 (+) White D = Channel 2 (-) Brown E = Channel 3 (-) Black F = Channel 2 (+) Blue

A 12V B Ground C Input Signal (+) D Temp (-) E Temp (+) F Switched 12V G Input Signal (-)

A Ultrasonic + B Ultrasonic Ground C Temp + D Temp -

C Ring

B Tip

1-8

Table 1-1 4210 Controls, Indicators, and Connectors

CONTROLS SETTINGS FUNCTION

ON/OFF On - Off Turns the flow meter on and off. Internal memory is protected with a standby battery. See Section 2.

Keypad Momentary Switches 24-key. 4 column matrix - Program flow meter through series of keystrokes prompted by messages on the display. Certain keys perform specific functions, (printing reports or entering program choices into memory). Arrow keys move through menus. Number keys enter numeric values. See Section 2.

INDICATOR READING FUNCTION

Display Multi-function 2-line, 40 characters per line, liquid crystal display (LCD.) Prompts you through program procedure; displays total flow,. present flow rate and level. May also display parameter readings, if sensors present.

Internal Printer Various Provides “hard copy” of total flow, level or flow rate variation over time; provides sampling information and a printout of the program.

Prints reports. Generates up to 3 different linear data plots. Chart characters and plots are generated on plain paper roll with an ink ribbon.

CONNECTOR TYPE FUNCTION

12 VDC 2-pin male M/S Connects 12 VDC power to flow meter

Sampler 6-pin male M/S Connects flow meter to sampler; provides flow pulse to sampler;

receives sampler bottle number, composite sample and event mark signal.

Ultrasonic Level Sensor 4-pin, male M/S Connects ultrasonic level sensor to flow meter.

Rain Gauge/ YSI 600 Sonde

9-pin female M/S

(Custom)

Connects flow meter to an Isco Rain Gauge or YSI 600 Multi-Parameter Sonde. Also provides output to High Low Alarm Relay Box.

Interrogator 6-pin female M/S Provides serial data in/out and power. Can also be used with 4-20 mA Output Interface.

Modem (optional)

Analog Output (optional)

5-pin male M/S

6-pin male M/S

Connects flow meter to telephone line for remote data transmis-sion. This connector will only be present on units that have the optional modem installed.

Provides analog data output from the flow meter to external, non- Isco control and recording devices.

Parameter 7-pin female M/S Connects flow meter to parameter sensor: temperature, pH, or D.

O. Note that you can only have temperature and one parameter (pH or D. O.) at the same time.

1-9

Table 1-2 4210 Technical Specifications

Physical and Electrical

Size 16" high × 111⁄2" wide × 101⁄2" deep (41.9 cm × 29.2 cm × 26.7 cm) without power source.

Weight 17 lb. 4 oz. (7.84 kg)

Material High-impact molded polystyrene structural foam.

Type Self-certified NEMA 4X Enclosure.

Display Type 2-line, 40 character/line alphanumeric dot matrix liquid crystal.

Power 12 -14 VDC, 16 mA average at 12.5 VDC (Printer set at 1" per hour).

Typical Battery Life 7-10 days with printer at 1" per hour and 4 Ampere-hour Ni-Cd battery.

14 days with printer turned off, and 1 minute level reading intervals.

Operating Temperature 0° to 140°F (–18° to 60°C).

Storage Temperature –40° to 158°F (–40° to 70°C).

Additional Power Required for Optional Equipment

Modem 60 mA maximum during operation; 0.1 mA maximum standby.

High-Low Alarm Relay Box 10 mA standby, typical; 190 mA - maximum.

Internal Printer

Chart Speeds Off, 1⁄2, 1, 2, or 4 inches per hour.(1.27, 2.54, 5.08 or 10.16 cm/h).

Ribbon 19.7 ft. (6 m) black nylon - replaceable.

Operating Speed 1.5 lines per second at 68° F. (20° C).

Character Size 0.09" high × 0.07" wide (2.4mm × 1.7 mm), 12 pitch.

Printer Recording Span

(for level, other plots possible)

Chart Resolution

Display Resolution

User-selected from1/4 ft. (3.6 cm) to over 30 ft. (9.1 m) with multiple over-ranges.

1/240 of selected recording span

0.001 ft. (0.3 mm)

Paper 4.5" wide × 65 ft. (11.4 cm × 19.8 m) plain white paper, replaceable.

Printer Reliability 2.5 million lines MCBF (mean cycles before failure).

Reports Printed Program selections, interval activity reports, flow meter history.

Printer Recording Modes Level over time, flow rate over time; includes totalized flow, sampler events, rain-fall, temperature, pH (or) D. O. (dissolved oxygen).

Plotted Linear Data 3 different linear plots can be printed at the same time.

1-10

Isco FLOWLINK Data Storage and Retrieval System

Memory Partitions Maximum of 6 user-defined memory partitions for level or event storage

Data Storage Rate for data storage user-selected in 1, 2, 5, 10, 15, 30, 60, or 120 minute intervals.

Baud Rates Serial connection - 300, 1200, 2400, 4800, or 9600 baud

Serial connection with the optional internal modem - 2400 baud

Storage 80,000 bytes, apportioned per reading as follows: flow = 4 bytes, level = 2 bytes, sample = 4 bytes, pH or D. O. = 1 byte)

Level Data Level readings are stored as a 16-bit number representing 1/10,000 meter.

(0.0394 inch); effective range is 0–65279 meters.

Ultrasonic Level Sensor

Dimensions 3.63" diameter × 4" long (9.1 × 10.2 cm)

Weight (including cable) 2.2 lbs (1 kg)

Body Material Housing: glass filled polyester Accoustic window: glass reinforced epoxy

Cable Length 25 ft. (7.6 m). PVC Jacket

Operating Temperature –22° to 140°F (–30° to 60°C)

Storage Temperature –40°to 158°F (–40° to 70°C)

Level Measurement Specifications

Measurement Range Minimum: 1 ft. (0.3 m) from sensor to liquid surface

Maximum 11 ft. (3.3 m) from sensor to liquid at minimum level

Measurement Accuracy 1 ft. (0.3 m) or less: ±0.02 ft. at 72°F (22°C).

1 to 11 ft. (0.3 - 3.3 m): ±0.03 ft. at 72°F (22°C)

Maximum Temperature Error Over Compensated Temperature Range

±0.000085 × D per degree C (Where “D” is the distance from the

±0.000047 × D per degree F transducer to the liquid surface.)

Beam Angle 12 degrees.

Level Resolution 0.004 ft. (0.12 cm).

Optional Extension cable of 25 ft. (7.6 m) Custom lengths available by special order. Maxi-mum distance is 1,000 ft. (304.8 m) if unit is AC-powered; 250 ft. (76.2 m) if unit is battery-powered.

Miscellaneous

Flow Rate Calculations The flow meter creates a table of level-versus-flow rate from program selections; this table divides the level span into 256 equally spaced level increments. Each level increment corresponds to a specific flow rate. During data collection, if the measured level falls between two table values, the flow meter will perform a linear interpolation to calculate the flow rate value.

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Table 1-3 4210 Chart Longevity

Note Report Generator is turned off.

Chart Speed, Inch/Hour Time to Empty Roll

4 195 Hours (81/8 Days)

2 161/4Days

1 321⁄2 Days

0.5 65 Days

Table 1-4 Battery Life Expectancy

Flow Meter Settings Minimum Default Maximum

Reading Interval 5 Minutes 30 Seconds Continuous

Printer Off Off 4" per Hour

Report Generator Off Off Every Hour

Average Current 12 mA 40 mA 125 mA

Nickel-Cadmium3 12.5 Days5 3.7 Days 1.2 Days

Lead-Acid4 20.3 Days 6 Days 1.9 Days

1. These figures are approximations based on calculations; actual times for your flow meter may vary due to factors of battery age, charge condition, operating temperatures, and component differ-ences. “Minimum” settings are those providing the lowest average current draw. “Maximum” settings are those requiring the highest current draw. Your program should draw somewhere between the two.

2. The default settings are the program entered at the factory. You can reset the flow meter to the default program at any time by pressing the 1 and CLEAR ENTRY keys at the same time.

3. The nickel-cadmium battery has a capacity of 4.0 ampere-hours at 20° C.

4. The lead-acid battery has a capacity of 6.5 ampere-hours at 20° C.

(Both batteries are assumed to be fully-charged with at least 95% of rated capacity and in good condition. These calculations also assume a 5% safety factor at the end of discharge. Lead-acid batter-ies should never be completely discharged.)

5. All fractional times are rounded down, rather than up.

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1.9 How to Make Battery

Calculations

To calculate battery life expectancy for an installation, you must know two things:

• The capacity of the battery you are using

• The average current draw of the flow meter or (other device) powered

Battery capacity is expressed in ampere-hours. The battery manufacturer provides this information for each battery. This value is the product of a load current times an arbitrary time period, ten hours for nickel-cadmium batteries, and twenty hours for lead-acid types. The terminal voltage of the battery at the end of this time period is the discharged cell voltage, 10 volts for nickel-cadmium and 10.5 volts for lead-acid types. Note that bat-teries are fully discharged well before the terminal voltage drops to zero volts.

I sco bat ter ies are rated at 4 ampere -hours for the nickel-cadmium and 6.5 ampere-hours for lead-acid types.

Convert the battery current capacity into milliamperes and then divide this figure by the average current drawn by the unit. This will give you a number in hours. Divide that figure by 24, and you will have the number of days.

The published ampere-hour figures do not mean that you can expect to draw 4 amperes from the nickel-cadmium battery (or

6.5 amperes from the lead-acid battery) for one hour. At the one-hour rate, discharges are typically less than half the ten- or twenty-hour rate.

To convert ampere-hours to milliamperes, multiply by 1,000.

Examples:

4 ampere-hours × 1,000 = 4,000 mAh

6.5 ampere-hours × 1,000 = 6,500 mAh

If you divide this figure by the average current of the flow meter, say 15 mA, you will have:

4,000 ÷ 15 = 266.67 hours

Divide this number by twenty-four to get days:

266.67 hours ÷ 24 = 11.1 days

For considerations of safety, we suggest you subtract 10% from this number (100% – 5% for 95% capacity and 5% for a reserve at the end of discharge).

11.1 – 1.1 = 10 days

This is the battery expectancy for a nickel-cadmium battery with a 15 mA continuous average drain, with a 10% derating factor.

You can use the same method to calculate for lead-acid batteries, except the current will be 6,500 mA, and the period correspond-ingly longer, in this case a little over 16 days. You can run the full number of days calculated without derating if your batteries are new and at 100% capacity, but you will leave yourself no safety factor if you are in error on either of these assumptions.

Remember, if the battery fails, there will be a period of time during which no measurements will be taken, (and no data stored, if you are also using FLOWLINK® software).

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Batteries lose capacity as they age. Capacity also drops off as temperature falls. Low temperatures make less capacity available due to the slowing of the chemical reactions, while high temperatures accelerate the deterioration of battery plate sepa-rators, particularly if they are aged. Nickel-cadmium batteries show fairly rapid rates of self-discharge. A battery that is fully charged and then placed in storage will lose some capacity each day. In a week, this could easily be 5% or more.

When using lead-acid batteries, you must be careful to avoid complete discharge, as this may cause cell reversal, which will ruin the battery. Also, complete discharge in low temperature ambients may cause the battery to freeze, which can deform the plates or even crack the case. Always operate these batteries with a reserve factor.

1.9.1 Calculating Current

Draw

Calculating current draw for a 4210 Flow Meter is somewhat more difficult than calculating the battery capacity. You cannot simply measure the idle current of the unit unless the printer and report generator are turned off in the program. These func-tions require power periodically, but not all the time. If the figures given in the previous table are not satisfactory for your application, you can use the following procedure (shown in Figure 1-4) to measure the actual current draw.

Note Do not attempt this procedure unless you have the proper equipment available and know how to make electrical mea-surements.

To measure current for a varying load requires a more-sophisti-cated type of multimeter, one that is capable of averaging high and low readings over a period of time. The Fluke® 87 Multi-meter is one example of this type of meter. You should set the meter on MIN/MAX and let it run with your program for several hours or more. Other manufacturers’ meters are also acceptable, but only if they are capable of averaging current draw. You should run the test for at least eight hours, longer if necessary, or until the flow meter has exercised the entire program. The longer you run the test, the more accurate the average will be.

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Figure 1-4 Measuring Flow Meter Current

More information about batteries used to power Isco equipment is available from the Isco Power Products Guide, which is shipped with this manual and any flow meter order.

Com

Battery, 12 Volt

Flow Meter mA A

A

FLUKE 87 TRUE RMS MULTIMETER

00I5 mA μA V Ω

Fluke® 87

Connect Cable 60-1394-023, (or other current-averaging meter)

+ clip

+ lead or you can make

A good quality, adjustable, regulated DC power…