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Turbine Flow Meter

Installation/Operation Manual
February 2005

MNIT001

Table of Contents
Introduction ............................................................................................................................................................. 2
Installation ............................................................................................................................................................... 3
Turbine Flowmeter Maintenance ............................................................................................................................. 3
Magnetic Pickups .................................................................................................................................................... 5
Dimensions ............................................................................................................................................................. 7
Magnetic Pickup Enclosures ................................................................................................................................... 8
Turbine Flowmeter Cable Assemblies .................................................................................................................... 9
Repair Parts Kits ................................................................................................................................................... 10
General Specifications .......................................................................................................................................... 11
Turbine Flowmeter Sizing ..................................................................................................................................... 11
3-A Sanitary Meters/Internals ................................................................................................................................ 12
Flow Related Formulas ......................................................................................................................................... 13
WH Meter/4200/4300 Manual.................................................................................................................................14

FMC
INVALCO
2825 W. Washington
Issue/Rev.
0.6 !(2/06)

Stephenville, Texas 76401

Telephone: 254/968-2181

FAX 254/968-5709

Toll Free: 800/468-25261

Introduction
The INVALCO Turbine Flowmeter is a device used to measure the volumetric flow of a fluid. The flowmeter consists of
the body, a multiblade rotor (usually 6 to 10 blades depending on size), bearings and supports for the rotor. As a fluid
passes through the flowmeter the rotor spins. The speed of the rotor is directly proportional to the fluid velocity or flow
rate.
As the rotor spins, the balde tips pass through a magnetic field generated by permanent magnets in a pickup coil
mounted in close proximity to the rotor but separated from it and the process fluid by the wall of the flowmeter body.
Each time a blade passes the magnet, it generates a small alternating current in the pickup coil. (See Figure 7) The
pickup coil is attached to the pickup by two terminals or wires.
Each rotor blade passing through the magnetic pickup flux lines produce one alternating current cycle. Depending on
the flowmeter size, a certain number of pulses are produced for each volumetric unit of liquid passing through the turbine
flowmeter. This is known as the K-Factor of the turbine flowmeter. The variation of this factor over the specified flow
range is the Linearity or accuracy of the flowmeter.

Mechanical Installation
Turbine Flowmeters are affected by upstream and downstream piping configurations. Upstream piping has a
pronounced effect on flowmeter performance making it necessary to have ten (10) straight pipe diameters upstream of the turbine flowmeter and five (5) pipe diameters downstream of the turbine flowmeter. Flowmeters
should be installed with the arrow marked on the body pointing in the direction of flow.

Figure 1

Control valves should always be located downstream from the flowmeter. If a line is empty and a valve is opened, the
high velocity fluid stricking the flowmeter can cause severe damage. Air eliminators should be used in cases where
gases are flowing in the process stream. Air in the liquid will cause the flowmeter rotor to spin at a different rate than the
liquid giving incorrect readings.
Spools should be installed in the flowmeter position during start up to prevent damage to the flowmeter from solids
(welding slag, rust, scale, etc.) in the process liquid.
Note: Meter should be installed with ten diameters of straight pipe the same size as turbine meter bore
up and 5 straight pipe diameters downstream of meter.
Note: If valve is to be used, it must be downstream from the meter. This is necessary not only to keep the line
full for accuracy in batching applications, but to prevent damage caused by striking an empty meter with a
high velocity stream.
Note: Sleeved bearings used in INVALCO flowmeters are lubricated with the process fluid. Never spin
the flowmeter at high speeds with air. Always confirm that the flow line contains fluid at start up.
The life of the flowmeter can be extended by using a mesh filter in the flow line. Table I shows the recommended filter for
various sizes of flowmeters.
Table 1
Turbine Flowmeter Size
1/2
3/4
1
1-1/2
2
2

Mesh Size
40
40
40
18
14

Opening Size
0.015
0.015
0.015
0.0386
0.051
Issue/Rev. 0.6 (2/06)

Installation (cont)

Turbine Meter Maintenance

Electrical Installation (Figure 2)


Thread the magnetic pickup into the mounting boss
located on the top of the flowmeter. If the pickup does
not have wire leads included, connect the signal cable
to the pickup by threading on the keyed connector.
Note: Hand Tighten Only. Use of tools to tighten
the pickup can damage the flowmeter and pickup.

Removal of Flowmeter Internals


Cartridge Type Sizes 3/4 Inch through 2 (Figure 3)
The cartridge type turbine flowmeter utilizes internals assembled into a single part, eliminating the need for the three
part internals kit.
Note: This type of internals is not interchangeable with any
other body type.
1) Remove the magnetic pickup.
2) Identify the upstream end of the meter by locating
the
two grooves visible from the outside of one end.
3) Remove the retaining ring from the end of the flow
meter
identified by the grooves.
4) Slide the internals out of the flowmeter. It may be
necessary to push the internals out by gently applying
pressure to the opposite end.
5) Inspect the internal bore of the flowmeter for defects.
The internal surface of the flowmeter should be
smooth.
If the surface is damaged, the flowmeter
body should be
replaced.
6) Inspect the internals kit for damage or wear. If it appears
to be damaged, replace it with a new
internals kit.

Figure 3
Figure 2

Replacement of Flowmeter Internals


Cartridge Type Sizes 3/4 Inch through 2 Inch
1) Identify the upstream end of the turbine flowmeter by
locating the two grooves visible from the outside of one
end.
2) Identify the upstream end of the turbine flowmeter internals
by locating the end with a cone recessed between
two
supports forming a V.
3) Insert the end opposite of the recessed cone into the
groooves located in the upstream end of the turbine flow
meter body.
4) Slide the flowmeter internals into the turbine flowmeter
body until it seats firmly against the downstream end.
5) Insert the retaining ring into the upstream end of the turbine flowmeter, pushing it far enough into the flowmeter
body to engage the retaining ring slot directly above the
turbine flowmeter internals.

Issue/Rev. 0.6 (2/06)

Removal and Replacement of Flowmeter Internals Size


4 Inch (Shipped Before April 1990) and Size 3 Inch
Shipped Before January 1989
1) Locate the flow direction arrow on the turbine flow
meter body, or the words Inlet or Outlet stamped
near the ends. Set the flowmeter body on end with
the outlet map.
2) Assemble the rear support assembly, giving attention to aligning the grooves in the pinion bolt with the
slots in the cage.
3) Install the lock washer and nut. The threads on the
pinion bolt should only extend halfway through the nut,
(about 2-1/2 turns).
4) Insert three vanes with the tapered bottom edges matching the sloping bottom of the grooves in the pinion bolt.
5) Locate the three wide and shallow grooves running in a
length-wise direction in the turbine flowmeter body.
6) Insert the support assembly into the body, bearing end
first, with the vanes sliding down the shallow grooves.
The assembly will come to rest against a shoulder.
7) Rotate the entire support assembly about 60 degrees,
so that the vanes are no longer lines up with the access grooves in the body.
8) Tighten the nut slowly, working the assembly back
and forth so the vanes will seat properly. Tighten the
nut secruely.
9) Turn the body over and slip the rotor onto the rear
bearing just installed.
10) Assemble and install the front support in the same
manner. It may be necessary to pull or push on the
pinion bolt to work the assembly in far enough to read
the shoulder, before rotating. The pinion bolt is pulled
back, the vanes are forced outward.
The rear pinion bolt can be identified by the 1/2 inch diameter carbide bearing which protrudes 1-7/32 inches.
The rear pinion body, or cage, can be identified as follows:
4 inch flowmeter front and rear cages are identical.
3 inch (shipped before January 1989) front cage overall
length is 2-21/32 inches and the slots begin 3/8 inches from
the open end.
Rear cage overall length is 2-15/16 inches and the slots
begin a little over 3/4 inch from the open end.

Removal of Flowmeter Internals


Size 4 Inch (Figure 5)
1) Remove the internals by retracting the set screw and rapthe sliding vane, if necessary, to relieve the locking pressure.
2) If spirolox rings are installed, remove them before attempt
ing to remove the supports.
3) Remove the rotor support fromt he flowmeter.
4) Remove the rotor from the flowmeter.
5) Repeat steps 1 through 3 to remove the second support.
Replacement of Flowmeter Internals
Size 4 Inch (Figure 5)
1) If your flowmeter body is grooved for spirolox rings, it is
recommended that the rings be installed.
Note: Lock rings are provided to absorb shock and
should be replaced when replacing the internals.
2) Advance the sliding vane with the set screw until the whole
support assembly fits closely in the bore of the flowmeter
body.
3) Position the support assembly against the shoulder in the
flowmeter body and tighten the set screw.
4) Install a spirolox ring if a groove has been provided for.
5) Meter bodies shipped after December 1, 1970 have three
grooves machined in each end. The sliding vane has an
ear, detail B, to engage one of these grooves. The front
support assembly should be positioned so that the sliding
vane engages the upper-left-hand groove. The sliding vane
on the rear support should engage the upper-right-hand
groove. Both sliding vanes should be in line.
6) For installation in older bodies (prior to December 1, 1970),
which are not grooved, the sliding vane can be turned
upside down (Figure 5) so the ear is buried in the support.

Figure 5
4

Issue/Rev. 0.6 (2/06)

Magnetic Pickups
Flow in the turbine flowmeter is sensed by a non-wetted sensor called a variable reluctance magnetic pickup. The
magnetic pickup is an assembly consisting of a permanent magnet and a coil bobbin on which several hundred turns of
wire are wound (Figure 6). This combination produces a magnetic field at the top of the pickup. The pickup is placed in
close proximity to the rotor blades, but is separated from it and the process fluid by the wall of the flowmeter housing. As
the rotor turns, the blades disrupt the magnetic field of the pikcup and generate a sine wave voltage signal across the
terminals of the magnetic pickup coil. Each time a rotor blade passes through the magnetic field, one alternating current
(AC) cycle is generated (Figure 7). The number of pulses produced by a turbine flowmeter per gallon of water is known
as the K-Factor.

Figure 6

Issue/Rev. 0.6 (2/06)

Magnetic Pickups

Standard Magnetic Pickup


Stock No. 64908265
Temp. Range: -65 to 225F
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S

Extended Temperature
Magnetic Pickup
Stock No. 64919755

Wire Lead
Magnetic Pickup Kit
Stock No. 49020839

Low Drag
Magnetic PIckup
Stock No. 64920774

Temp. Range: -450 to 450F

Use with all meter mounted readout


devices.

For special applications

Hermetically Sealed
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S

Temp. Range: -65 to 225F


Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Signal Connection: 7 Wire Leads

Temp. Range: -65 to 225F


Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S

RF (Radio Frequency) Pickup Kit


Non Magnetic
Stock No. 49020795

NEMA 6 Watertight
Magnetic Pickup
Stock No. 64920920
Molded 15 thermo-plastic rubber
cable and connector, ozone and
ultraviolet resistant, excellent heat
aging/abrasion resistance. Suitable for outdoor applications and
installations that require hose
down cleaning of meter.
Temp. Range: -65 to 225F
Housing: Stainless Steel

Pre-Amp Magnetic
Pickup Kit
Stock No. 49016811
Temp. Range: -40 to 180F
Housing: Stainless Steel
Output: Square Wave
Supply Voltage: 5 to 26 VDC
Output Impedence: 2.2K OHMS
Load Current: 15mA (NOM)
Output Voltage: 90% Supply
Mating Connector: 10SL-3P

Temp. Range: -40 to 212F Continuous


250F Intermittant
Housing: Plastic
Output: Square Wave
Supply Voltage: 5-26 VDC
Load Current: 20mA (NOM)
Output Voltage: 5 VDC Regulated
Mating Connector: 10 SL-3P
This pickup must be used with the 1/2 Turbine Meter to
achieve stated accuracy over the 10:1 range of the meter.

Not Pictured
Special Extended High Temp. Magnetic Pickup
Stock No. 64917721
Temp. Range: -450 to 800F Continuous
+1000F Intermittent
Housing: Stainless Steel
Supplied with 3 Stainless Steel Shielded Overbraid Cable
with connector
Mating Connector: 10 SL-4P
Requires Turbine Flow Meter Modification.

Issue/Rev. 0.6 (2/06)

Dimensions

Issue/Rev. 0.6 (2/06)

Magnetic Pickup Enclosures


Magnetic pickup assemblies may require an enclosure to assure protection against the environment. Three types of enclosures
are available. These are:

WAK-2 Weatherproof Adapter


This kit provides an enclosure for the magnetic pickup to
protect it from physical damage, weather, hose down or high
humidity environments. A one inch (1) NPT outlet is provided at the top for the adapter for a conduit connection. The
adapter is provided with a factory installed cable clamp designed to squeeze the cable for weather-proofing. When
conduit is used, the cable clamp is removed.

EAK-2 Explosion-proof Adapter


This kit provides an explosion-proof enclosure for the
magnetic pickup. The enclosure is rated Class I, Division I, Group D. The enclosure is provided with a one
and a quarter inch (1-1/4) NPT connection for conduit.

EAK-2AX-P Explosion-proof Adapter with Terminal Block (Figure 10)


This kit provides an explosion-proof enclosure with a 3 point terminal strip. The enclosure is provided with either a
two wire lead magnetic pickup, a pre-amp magnetic pikcup (requires a 5 to 32 volts DC external power) or an RF
pickup (requires 5 to 26 volts DC external power).

Model EAK-2BX-P Explosionproof adapter with RF or


Transmission Signal Pre-amp
type pickup. 8 cable with
mating connector and terminal strip.

Model EAK-2AX-P Explosionproof adapter with wire lead


magnetic pickup and 3 point
terminal strip.

Issue/Rev. 0.6 (2/06)

Turbine Flowmeter Cable Assemblies


Turbine flowmeter cables are 18 gauge shielded, heavy duty neoprene-jacketed complete with mating connector
for magnetic pickup and terminated for interconnection to a readout or junction box.
Length
Part No.
8
81001471
15
81001483
25
81001484
50
81001479
Standard Turbine Meter Cable
Assembly

Standard Cable Assembly (Figure 11)


The standard cable is made up of two conductor cables with a 10Sl-4S connector for mating with the standard
magnetic pickup or the low drag magnetic pickup. Maximum Temperature: +225F
Part No.
Length
81001471
8
81001483
15
81001484
25
81001479
50
High Temperature
Turbine Meter
Cable Assembly

High Temperature Cable Assembly (Figure 12)


The high temperature cable is made up of two conductor cable with a high temperature version of the 10SL-4S
connector for mating with the extended temperature magnetic pickup. Maximum temperature: +450F

Length
8
15
25
50

Part No.
81001485
81001494
81001507
81001510

Pre-Amplifier and RF Cable Assembly (Figure 13)


The pre-amp/RF cable is made up of three conductor cable with a 10SL-3S connector for mating with the preamplifier or RF pickup. Maximum temperature: +225F

Issue/Rev. 0.6 (2/06)

Repair Parts Kits


All INVALCO repair parts kits include all flowmeter internal components. The assembly is calibrated on water at
70F, with a viscosity of 1 centistoke. Each repair kit has a K-factor guaranteed to be within +/-1 percent of the
original.

W Series - Tungsten Carbide Bearings


Meter
Size
1/2
3/4
3/4
1
1-1/2
2
3
3*
4
4**
6

Flow
Range
0.6 to 6
1.5 to 15
3.2 to 23
6.5 to 65
17.5 to 175
33 to 330
60 to 600
60 to 600
110 to 1100
110 to 1100
300 to 3000

W2
Stock No.
81001901
81001904
81004044
81001905
81001906
81001907
-

W3
Stock No.
81001901
81001904
81004044
81001905
81001906
81001907
81004048
81004049
-

W4
Stock No.
81001904
81004044
81001905
81001906
81001907
81004050
81004240
81004051
81004244
81014474

W6
Stock No.
81001905
81001906
81001907
81004048
81004049
81003112

W9
Stock No.
81003747
81003749
81003735
81003733
81003731
81004095
81004096
-

Cartridge Internals
WC-1/2%
WC-1%
Stock No.
Stock No.
81014400
81004400
81014401
81004401
81014402
81004402
81014403
81004403
-

*3 Internal kit for turbine flowmeters purchased after January 1989.


**4 Internal kit for turbine flowmeters purchased after April 1990.
Cartridge
Internals

WFP Series -Rulon 641 Bearings


Meter
Size
1/2
3/4
3/4
1
1-1/2
2
3
3*
4
4**
6

Flow
Range
0.6 to 6
1.5 to 15
3.2 to 23
6.5 to 65
17.5 to 175
33 to 330
60 to 600
60 to 600
110 to 1100
110 to 1100
300 to 3000

W2
Stock No.
81001901
81001904
81004044
81001905
81001906
81001907
-

W3
Stock No.
81001901
81001904
81004044
81001905
81001906
81001907
81004048
81004049
-

W4
Stock No.
81001904
81004044
81001905
81001906
81001907
81004050
81004240
81004051
81004244
81014474

W6
Stock No.
81001905
81001906
81001907
81004048
81004049
81003112

W9
Stock No.
81003747
81003749
81003735
81003733
81003731
81004095
81004096
-

WC-1/2%
Stock No.
81014400
81014401
81014402
81014403
-

*3 Internal kit for turbine flowmeters purchased after January 1989.


**4 Internal kit for turbine flowmeters purchased after April 1990.
WSP Series -3A Sanitary Approved Carbide Bearings
Meter
Size
3/4
1
1-1/2
2

10

Flow
Range
1.5 to 15
6.5 to 65
17.5 to 175
33 to 330

W2
Stock No.
81003845
81003846
81003847
81003848

Issue/Rev. 0.6 (2/06)

General Specifications
Response Time
1/2 to 2
2-5 milliseconds for step change in flow rate
3 to 6
10-25 milliseconds for step change in flow rate
Temperature Range of Pickups
Standard Pickup
-100 F to 248 F (-73 C to 120 C)
Hi-Temp Pickup
-450 F to 450 F (-268 C to 268 C)
Extended Temp Pickup
-450 F to 800 F (-268 C to 426 C)
Pre-Amp Pickup
-40 F to 248 F (-40 C to 120 C)
RF Zero Drag Pickup
-20 F to 160 F (-29 C to 71 C)
Sanitary Options Available
Frequency Output Over Linear Flow Range
1/2 to 1-1/2 - 100 Hz to 1000 Hz
2 - 100 Hz to 900 Hz
3 to 6 - 50 Hz to 500 Hz
Voltage Output
1/2 to 2
Approximately 100 MV @ 100 Hz to 1.5 Volts (rms) 1000Hz
3 to 6
Approximately 80 MV @ 50 Hz to 800 MV (r.m.s.) 500 Hz
Pressure Rating
The working pressure of W Series Turbine Meters is
limited to a maximum of 7500 psig on 3/4 bore and to
5000 psig on 1/2, 1, 1-1/2 and 2 bores. Flanged
meters are limited by flange rating.

Performance Specifications
Linearity: +/- 0.5%
WG Series: +/-1.0%
GT Series: +/-1.0%
Repeatability
Within +/- 0.1% of indicated flow throughout the
linear range.
Maximum Overrange
To 125% of maximum flow rate for intermittent periods.
Standard Materials of Construction
Body
316 S.S.
Rotor
CD4MCu
Rotor Shaft
Tungsten Carbide or 316 S.S.
Bushings
Tungsten Carbide or High Performance Polymer
Thrust Ball
316 S.S. or Tungsten Carbide
Rotor Support Retainers
302 S.S.
Rotor Supports
316 S.S.
Temperature Rating of Bearing Structure
Tungsten Carbide
-20 F to 300 F (-29 C to 149 C)
High Performance Polymer
-20 F to 250 F (-29 C to 121 C)
Extended Temperature
-200 F to 800 F (-130 C to 426 C)

Turbine Flowmeter Sizing


Flow Range
Meter
Size
1/2***
1/2
3/4
3/4**
1
1-1/2
2
3
4
6

Nominal K-Factor*

GPM

BPH

P/GAL

P/BBL

0.6 to 6.0
0.8 to 6.0
1.5 to 15
3.2 to 23
6.5 to 65
17.5 to 175
33 to 330
60 to 600
110 to 1100
300 to 3000

.86 to 8.6
1.14 to 8.6
2.1 to 21
4.6 to 46
9.3 to 93
25 to 250
47.1 to 471
85.7 to 857
157 to 1571
428 to 4286

10,500
10,500
4,605
1,875
953
341
185
50
28
10

441,000
441,000
193,410
78,750
40,026
14,322
7,770
2,100
1,176
420

Freq. Output
(Hertz)
100-1,000
150-1,000
100-1,000
100-1,000
100-1,000
100-1,000
100-1,000
50-500
50-500

*Actual K-Factor will be within +/- 1% of Nominal Value. Data based on water calibration at 25C.
**Extended range.
***RF Pickup is required when using a flow range below 0.8 GPM

Issue/Rev. 0.6 (2/06)

11

3-A Sanitary Meters/Internals


The INVALCO 3-A (28-03) Sanitary Turbine Flow meter is certified for use in the food and beverage industry where
3-A is required. The meter has been specially designed to have the same characteristics, flow ranges, and life as
all the Invalco industrial meters, and also meet or exceed the requirement of 3-A (28-03). The meter has a
maximum surface finish of 32ra on all internal parts; all components are manufactured out of 3-A approved
material, and can be cleaned in place to save time and money in disassembling cleaning and reassembling the
meter. The wear surfaces are made from FDA (3-A) approved carbide for superior wear resistance.
The meter can be cleaned as long as the following conditions are met:
! Caustic solutions that are acceptable with 316 stainless steel components
! Temperatures of less than 275F (135C) for less than a 60 minute duration
! Instantaneous flow Ranges of the fluids must never exceed the chart below.
Meter Size
3/4
1
1 1/2
2
3
!
!

12

Flow Range (GPM)


1.5-15
6.5-65
17.5-175
33-330
60-600

Air purging must be done with care not to create severe shock loading to the meter, and velocity through the
meter must not exceed the instantaneous published flow ranges of the meter.
Radii at ends of meters and the thrust bearing pockets (see figure 14) must be periodically checked for
cleanliness and adjustments in cleaning may be required to clean these areas. If areas do not clean in place
the meter may need to be disassembled from the line and cleaned by hand or other method to insure proper
cleanliness is being achieved. If the meter is disassembled for cleaning or inspection, care must be
taken not to lose the thrust bearings located at either end of the shaft. All replacement internals utilize a
sanitary paste to ensure that the bearings remain in place during assembly.

Issue/Rev. 0.6 (2/06)

Flow Related Formulas


U.S. GPM = Imperial GPM x 1.200955

GPM = Hz x 60
K

Pounds Per Hour = 500 x S.G. x GPM

HZ = GPM x K
60

Pounds Per Gallon = S.G. x 8.33 (water)


BPH = GPM x 1.42857

K = Hz x 60
GPM

BPD = GPM x 34.286

GPM = GPD
1440
Pulses Per Liter =

BPM = GPM x 0.0238


GPS = GPM x .01666

K
3.785

GPD = GPM x 1440.0

Pulses Per Barrel = K x 42


Pulses per Cubic Meter =

Pulses Per Pound =

GPM = BPH x 0.7


K
.003785

K
Pounds per Gallon

GPM = Pounds Per Hour


500 x S. G.

CFM = GPM x .13368


GPM = GPH x .01666
GPM = CC/MIN x .000264173
Specific Gravity = LBS/GAL
8.33

LPM (liters per min) = 3.785 x GPM


GPM = LPM
3.785

Issue/Rev. 0.6 (2/06)

13

Introduction

Specifications

The Model 4200 Rate/Totalizer is designed to accept frequency or pulse inputs from a wide range of flowmeters and
to display flowrate and a re-settable total directly in engineering units. Scaled pulse output is standard. The Model 4200
is fully programmable with K-Factors, linearization of multiple
K-Factors, decimal point positions, and timebase being programmed via the front panel switches. The instrument is
housed in a durable weatherproof polycarbonate enclosure
that can be mounted directly on a flowmeter, panel mounted
or wall mounted using a pivoting bracket.

Display
Continuously powered LCD
Total
6 digits, 0.5 (12.7mm) high, resettable from the front panel
Rate
6 digits, 0.5 (12.7mm) high
Resolution
16 bits (0.05% of span)
Accuracy
.01% of Total, +/- 1 count
K-Factor
Programmable, pulses per unit of measure, .001 to
999.999
Timebase
Rate displayed in units per second, minute, hour or day
Frequency Range
0.00 Hz to 4250 Hz
Input Signal
Sine wave (20mV P/P min), Pulse, Reed Switch, others
Operating Temperature
-40F to 158F (-40C to 70C)
Mounting
Meter mount or panel/wall mount
Enclosure
Weatherproof and corrosion resistant

Model Number Designation


Field Mounted Base Unit
4200 - x0 Battery (Lithium) Powered Version - Pulse Output
4200 - x1 Loop Powered Version w/4-20mA Rate Output
Mounting Options
1x
Standard Weatherproof Wall Mount/Panel Mount
3x
Standard Weatherproof Swivel Meter Mount Stem 1 FNPT

Quick Setup
The steps below are to be used only if you do not require
pulse or analog output.
1. Press and hold the [Program] to enter the programming
mode.
2. Press [Program] to skip Linear.
3. In Factor mode.
a. Press [+] to increase number.
b. Press [-] to decrease number.
4. Press [Enter/Next] to move cursor left, press [K
Factor] to move cursor right.
5. Repeat steps 4 and 5 until entire K Factor is entered.
6. Press [Program] once to show F.dEc (Flow Rate Decimal Point) mode.
a. Press [+] to increase number.
b. Press [-] to decrease number.
7. Press [Program] once to show t.dEc (Total Decimal
Point).
a. Press [+] to increase number.
b. Press [-] to decrease number.
8. Press [Program] once to show tScale (Time Scale)
mode.
a. Press [+] or [-] to change time scale shown.
b. Sec = rate per second
c. 60 Sec = rate per minute
d. Per hr = rate per hour
e. 24 hr = rate per day.
9. Press [Program] once to SPULSE mode.
10. Press [Program] once to ANALOG mode.
11. Press [Program] once to PASS mode.
12. Press [Program] once to ACCEPT mode.
13. Press [Enter/Next] to exit programming mode.

14

Battery Operated Version


Approvals
Intrinsically safe to Class 1, Div. 1 Grp A,B,C&D; CUL/UL
pending
Battery Type
3.6 volt Lithium Battery pack
Battery Life
5 years typical (Without utilizing the Scaled Pulse Output)
Activating pulse out requires additional processing resources
that will increase battery drain and shorten battery life.
Connection
Two wire connection to probe
Output Type
Open drain transistor to ground (Resistive closure to
ground)

Issue/Rev. 0.6 (2/06)

Operating Mode
The Model 4200 Rate Totalizer will display:
Total
Rate
Totals greater than 999,999 are viewable by pressing
the Enter/Next button. The roll over total screen displays a r in the left most position and then any digits
in excess of the six that are normally viewable.
K-factor is viewable by pressing the k-factor button on
the keypad, and pressing the k-factor button again will
return to the Totalizing display.
Software Version is viewable by pressing the + button on the keypad
Program Steps
1. Hold the Program button for 5 seconds. This will
put the 4200 into programming mode.
2. The first time that the 4200 is setup, the program
will take you directly to the K-factor entry screen. The
4200 will now prompt for using a single K-factor or to
linearize using multiple K-factors. Selecting oFF will
use a single K-factor (go to Step 3). Selecting on will
allow the input of multiple K-factors (go to Step 4).

Button operation:
Program = progress to next screen regardless of
where cursor is positioned
Enter/Next = move cursor left one position
K-factor = move cursor right one position
+ = increments number where cursor is positioned
- = decrements number where cursor is positioned
Reset = replaces numbers with default and returns
the cursor to the right most position
3. Input the appropriate K-factor. Insertion of the
decimal position is the last step required to
input a new k-factor. After the last numerical
position is entered, the + and - buttons will
move the decimal position through the 3 positions. After placing the decimal in the correct
position, the Enter/Next button will progress
the screen. If linearization is required proceed
to Step 4. If linearization is not required proceed to Step 7.

Issue/Rev. 0.6 (2/06)

Button operation:
Program = progress to next screen regardless of
where cursor is positioned
Enter/Next = move cursor left one position
K-factor = move cursor right one position
+ = increments number where cursor is positioned
- = decrements number where cursor is positioned
Reset = replaces numbers with default and returns
the cursor to the right most position
4. Input the 1st pulse rate (Hz) starting with the lowest.

Button operation:
Program = progress to next screen regardless of
where cursor is positioned
Enter/Next = move cursor left one position
K-factor = move cursor right one position
+ = increments number where cursor is positioned
- = decrements number where cursor is positioned
Reset = replaces numbers with default and returns the
cursor to the right most position
5. Input the 1st k-factor matching the 1st pulse rate
entered in the previous step. Insertion of the decimal position is the last step required to input a
new k-factor. The decimal position is limited to 3
positions. After the last numerical position is
entered, the + and - buttons will move the
decimal position through the 3 positions. After
placing the decimal in the correct position, the
Enter/Next button will progress the screen.

Button operation:
Program = progress to next screen regardless of where
cursor is positioned
Enter/Next = move cursor left one position
K-factor = move cursor right one position
+ = increments number where cursor is positioned
- = decrements number where cursor is positioned
Reset = replaces numbers with default and returns the
cursor to the right most position
6. Repeat step 4 and 5 for as many different pulse
rate and k-factor combinations up to 10 entries. If
you have less than 10 combinations to enter, enter
000000 in the next pulse rate prompt to finish
combination entry. If you have 10 combinations,
after you enter the last k-factor the 4200 will go to
the next screen.
15

7. Set how many decimal positions you want in


the flow rate display.

000000 = no decimal positions


00000.1 = one decimal position
0000.02 = two decimal positions
000.003 = three decimal positions
0000-.1 = flow rate x 10
0000.-2 = flow rate x 100
Button operation:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = increments amount of decimal positions
- = decrements amount of decimal positions
Reset = replaces default
8. Set how many decimal positions you want in
the total display.

000000 = no decimal positions


00000.1 = one decimal position
0000.02 = two decimal positions
000.003 = three decimal positions
Button operation:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = increments amount of decimal positions
- = decrements amount of decimal positions
Reset = replaces default
9. Set the time scale in which that the flow rate
will be displayed on the display.

10. Select on for a scaled pulse output. Select


oFF if a scaled pulse output is not desired (go
to Step 13).

Button action:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = toggle between oFF and on
- = toggle between oFF and on
Reset = replaces default
11. Set the scale of the scaled pulse output.

_____1 = 1 pulse per 1 increment of least significant


digit in total LCD
____10 = 1 pulse per 10 increment of least significant
digit on total LCD
___100 = 1 pulse per 100 increment of least significant
digit on total LCD
__1000 = 1 pulse per 1000 increment of least significant
digit on total LCD
_10000 = 1 pulse per 10000 increment of least significant digit on total LCD
100000 = 1 pulse per 100000 increment of least significant digit on total LCD
Button operation:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = increments scale of pulse output
- = decrements scale of pulse output
Reset = replaces default
12. This option is not operable or available for the
battery powered 4200. Verify that oFF is displayed. To select oFF push the + or - key and
go to Step 13.

SEc = unit of volume per second


60 SEc = unit of volume per minute
PEr hr = unit of volume per hour
24 hr. = unit of volume per day
Button operation:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = increments unit of time scale
- = decrements unit of time scale
Reset = replaces default
16

Button operation:
Program = progress to next screen
Enter/Next = progress to next screen
K-factor = no action
+ = toggle between oFF and on
- = toggle between oFF and on
Reset = replaces default
Issue/Rev. 0.6 (2/06)

13. At this point the user has the option to establish a


password. Once a password has been set, the 4200 will
always prompt the user for a password, before program changes can be made. When no password or the
wrong password is entered, the 4200 will go back to
the normal display. THE ESTABLISHMENT OF A
PASSWORD IS OPTIONAL. If locking the 4200 with a
password is not needed, enter 000000 and the 4200
will operate unlocked. **

Button operation:
Program = progress to next screen regardless of
where cursor is positioned
Enter/Next = move cursor left one position
K-factor = move cursor right one position
+ = increments number where cursor is positioned
- = decrements number where cursor is positioned
Reset = replaces numbers with default and returns the cursor to the right most position
** It is highly recommended that the
password function not be used unless it
is required. If a password is required
write down the password in the manual
and keep in a secure location. If you
forget the password you must consult the factory for procedures on
how to reset the current password.
14. Now the 4200 will prompt for user to accept
the password. Display should read 000000 in RATE
area of LCD if no password is required

Changing Batteries

New batteries can be purchased through INVALCO or


our distributors and replaced in the field.
WARNING - To prevent ignition of flammable or
combustible atmospheres, read, understand, and
adhere to the manufacturers live maintenance procedures.
Replace battery with an INVALCO battery assembly
ONLY. Battery assembly part number is P524017. The
model 4200 is designed to operate on one battery.
NEVER attempt to power the unit with two battery assemblies or with a non-INVALCO battery assembly.
There is one Lithium battery pack in each instrument and
care must be taken to replace so that there is always power
connected to the memory. Connect the new battery pack
into J3 or J4 before disconnecting the old battery. Failure to
not supply the board with continuous power will result in loss
of setup parameters and totals. Please dispose of old
batteries by sending them to an Approved Battery
Recycle Location.

Typical Connections

Button operation:
Program = return to password screen (step 14)
Enter/Next = accepts password and exits program
mode
K-factor = return to beginning of setup
+ = return to password screen (step 14)
- = return to password screen (step 14)
Reset = return to password screen (step 14)

Calculation of Rate and Total


Gallons (US) to Barrels (oil)42.00
Liters to Kiloliters .1000.00
mL to Liters ..1000.00
Mgallons to Acre-feet ..0.32587
Issue/Rev. 0.6 (2/06)

Flowmeter Input
The Model 4200 input circuit which will accept signals
from most pulse or frequency producing flowmeters.
The input will interface directly to:
Turbine Flowmeters
For flow meters with coils, the minimum input voltage is
20mV P-P. See the drawing below and sketches on the
next two pages for hook-up information.
1. Squarewave, CMOS or Pulse
2. Reed or Switch
5. Coils (Magnetic Pick-up)
Wiring
When connecting the 4200 it is good practice to use a
shielded cable. The shield should be connected to
earth at one end of the cable. The other end of the
shield should not be connected.

17

Input Signal Wiring Options


Two-wire coil pickup

The Circuit Board


Terminal Designations
Input - (+TFM)
Input - (-TFM)

Grounded Switch Closure or Reed


3.6V DC

Powered Switch Closure or Reed Switch


3.6V DC

Warnings

Output Wiring Options


Scaled Pulse Connection
3.6V DC

The 4200s are affected by EMF (Electric Magnetic


Fields); due to this the unit needs to be located in an
area with little affects from externally omitting EMF
devices. The turbine and pickup uses EMF in pulses
to calculate rate. Interference in this field by other
devices will cause inaccuracies with the meter. Electric motors, spark driven engines, transformers, and
other high current or high voltage devices create EMF
and should be kept as far away as feasible to lessen
their chances of effecting the meter.
Vibration can cause false readings or counted rate
when not in use. Portable units should be reset after
transport to re-zero the meter. Place meter in a location where it is well grounded, free of vibration and
stable when metering.

Installation
Wall Mounting
A wall mounting bracket is supplied with each instrument.
The instrument is then attached to the bracket at
the bottom with knobs.
Removing the Front Panel:
The front panel of the instrument is removed as follows:
1. Loosen knobs and tilt unit down.
2. Undo the eight screws retaining the front panel.
3. Pull the front panel free from the housing.
Unit can then be tilted up to access internal components.

18

Issue/Rev. 0.6 (2/06)

Intrinsic Safety Connections


When installing the Model 4200 in hazardous areas, the wiring and installation must comply with appropriate installation standards. The Model 4200 will connect directly to turbine or paddlewheel flowmeters with a certified IS coil or
other certified IS sensors which produce a pulse output, provided they do not exceed the following input parameters:
Entity Parameters for TB3
Vmax = 3.6 Vdc
Imax = 72 mA
Ci = 12.34 uF
Li = 0 mH

Entity Parameters for TB2 Terminals 1 & 2

Voc = 3.6
Isc = 72 mA
Ca = 12.34 uF
La = 0 mH

Vmax = 3.6 Vdc


Imax = 72 mA
Ci = 12.34 uF
Li = 0 mH

Control Drawing

i
i

i
i
i
i

Installation must be in accordance with the National Electric Code (NFPA 70, Article 504) and ANSI/ISA-RP12.6.
Selected intrinsically safe equipment must be listed and have entity parameters such that:
Vmax * Voc
Imax * Isc
Ci + Ccable * Ca
Li + Lcable * La
-orMay be connected to simple apparatus that does not generate more than 1.5V, 100mA and 25mW. If cable
parameters are unknown, the following values can be used:
Cable Capacitance - 60pF/ft
Cable Inductance - 0.20uH/ft

Issue/Rev. 0.6 (2/06)

19

Dimensions
Wall Panel Mount

The 4200 Wall/Panel mounted version can be mounted with an offset utilizing the supplied bracket, or it can be mounted directly
to a panel or wall using the 4 tapped holes located on the back of the unit.

Direct Mount

The 4200-30 and 4200-31 are direct mounted. Care must be taken the follow these steps during installation:
1. Screw Pickup into TFM body, hand tight (do not over tighten).
2. Attach wires to Pickup.
3. Loosen screws on swivel (do not remove).
4. Hold totalizer body steady and screw swivel-neck onto TFM threaded adapter. Hand tighten (do not over tighten)
5. Adjust totalizer for required viewing position.
6. Retighten swivel neck screws.
Note: Dimensions - Inches to the nearest tenth (millimeters to the nearest whole mm), each independently dimensioned from respective engineering drawings.

www.fmcinvalco.com

The specifications contained herein are subject to change without notice and any user of said specifications should verify from the manufacturer that the specifications are
currently in effect. Otherwise, the manufacturer assumes no responsibility for the use of specifications which may have been changed and are no longer in effect.
FMC INVALCO Fluid Control P.O. Box 1377, Stephenville, TX 76401, Phone: 254/968-2181, FAX: 254/968-5709, Toll Free: 800/468-2526

20Printed in U.S.A. 2/04 FMC INVALCO All rights reserved. Issue/Rev. 0.1 (2/04)

Issue/Rev. 0.6 (2/06)