Badger Meter iSonic 4000 User manual

UF_iS4000_BA_02_1811
®
Badger Meter Europa GmbH
iSonic 4000
INSTALLATION AND
OPERATION MANUAL
November 2018

Content
UF_iS4000_BA_02_1811
Basic safety recommendations............................................................................1
System description ...............................................................................................2
Installation..............................................................................................................5
Installation with the sensor EchoPod DL-10...............................................................5
Power connections................................................................................................7
Auxiliary power..........................................................................................................7
Configuring input/output (I/O).....................................................................................8
In- and output cable connection.......................................................................9
Programming.......................................................................................................10
Main Menu...............................................................................................................12
Meter Setup...................................................................................................12
Measurement.................................................................................................13
Input and outputs...........................................................................................18
Clear total......................................................................................................21
Communications............................................................................................22
Miscellaneous................................................................................................23
Info................................................................................................................23
PIN................................................................................................................24
Login .............................................................................................................24
Troubleshooting ..................................................................................................25
Control LED.............................................................................................................25
Replace meter’s electronics.....................................................................................26
Technical data......................................................................................................27
Program structure ...............................................................................................29
Flow meter ModBus®register table 2017-06-29, Version “2.00” .....................35
iSonic conversation table.........................................................................................41
Rights......................................................................................................................41
Wiring the iSonic 4000 meter to an ORION®cellular LTE endpoint ..............42
Return of goods for repair................................................................................43

Basic safety recommendations Page 1/43
UF_iS4000_BA_02_1811
Basic safety recommendations
Before installing or using this product, please read this instruction manual thoroughly.
Only qualified personnel should install and/or repair this product. If a fault appears,
contact your distributor.
Installation
Do not place any unit on an unstable surface that may allow it to fall.
Never place the units above a radiator or heating unit.
Route all cabling away from potential hazards.
Isolate from the mains before removing any covers.
Power connection
Use only the type of power source suitable for electronic equipment. If in doubt, contact
your distributor. Ensure that any power cables are of a sufficiently high current rating.
All units must be earthed to eliminate risk of electric shock.
Failure to properly earth a unit may cause damage to that unit or data stored within it.
Protection class
The device has protection class IP 67 and needs to be protected against dripping water,
water, oils, etc.
Setup & operation
Adjust only those controls that are covered by the operating instructions. Improper
adjustment of other controls may result in damage, incorrect operation or loss of data.
Cleaning
Switch off all units and isolate from mains before cleaning.
Clean using a damp cloth. Do not use liquid or aerosol cleaners.
Repair of faults
Disconnect all units from power supply and have it repaired by a qualified service person if
any of the following occurs:
•If any power cord or plug is damaged or frayed
•If a unit does not operate normally when operating instructions are followed
•If a unit exposed to rain/water or if any liquid has been spilled into it
•If a unit has been dropped or damaged
•If a unit shows a change in performance, indicating a need for service.
RoHs
Our products are RoHs compliant.
Battery disposal
The batteries contained in our products need to be disposed of as per your
local legislation acc. to EU directive 2006/66/EG.
Failure to adhere to these safety instructions
may result in damage to the product or
serious bodily injury.

System description Page 2/43
UF_iS4000_BA_02_1811
System description
Ultrasonic flow meter iSonic4000 is designated for flow measurements in open
channels and partially filled pipes and volume measurements of liquids in tanks. It is
possible to connect one level sensor (ultrasonic, pressure...) with 4-20 mA output to
the unit. Flows are consequently calculated from measured levels using pre-
programmed formulas for various primary flow elements (flumes, weirs) or from Q/h
table. Menu also enables the calculation of flow rateas in partially filled pipes and
angular open channels using Manning equation
•iSonic 4000 is IP67 device in robust wall mounted metal case, with large
graphic display.
•iSonic 4000 menu is operated with 3 x front panel high endurance buttons.
•iSonic 4000 is powered from external power AC 92 - 275V / 50..60Hz,
alternatively from external power 9-36 V (max 9 W), only possible with DC
version.
•User can be connected to iSonic 4000 via USB or Ethernet interface with
software Flow Meter Tool, which can be used for parameters setup and also for
datalogger download.
•iSonic 4000 have internal datalogger with 2 MB capacity for approximately
130 000 logged lines. It is possible to download logged data with software Flow
Meter Tool and save in *.csv, format to PC.
•Interfaces USB, Ethernet, ADE, RS232, ModBus RS485 / RS422 galvanic
isolated are mounted on board.
•The iSonic 4000 unit have 1 analog output 0/4..20mA and 2 galvanic isolated
pulse outputs.
Nameplate
Look at the device nameplate to ensure that the device is delivered according to
your order. Check for the correct supply voltage printed on the nameplate.

System description Page 3/43
UF_iS4000_BA_02_1811
System settings
Flow meter tool settings
Settings control panel

System description Page 4/43
UF_iS4000_BA_02_1811
Driver details

Installation Page 5/43
UF_iS4000_BA_02_1811
Installation
Installation instructions given in the following are to be observed in order
to guarantee a perfect functioning and a safe operation of the meter.
Installation with the sensor EchoPod DL-10
Installation of the sensor:
Screw the sensor into the stainless steel mounting bracket while using the
gaskets.
Sensor must be installed maximum 125 cm above the flume bottom (minimal
measured level) with a minimum of 5 cm distance above the maximal
measured level.
EchoPod DL-10 connection to the 4-20 mA input terminal (on the bottom side of
display board):
Viton Gasket
Sensor EchoPod
Max
125 cm
Min
5 cm

Installation Page 6/43
UF_iS4000_BA_02_1811
Mounting position of the iSonic ultrasonic sensor for manhole flume
Size
Max.
flow
Max.
water level
V-Mt
H-Mt
DN/Inch
l/sec
mm
mm
mm
100/4“
5
148
600
146
150/6“
16
227
600
197
200/8“
35
312
600
248
250/10“
63
395
700
298
300/12“
94
457
700
349
Mounting position of the iSonic’s ultrasonic sensor for parshall flume
Size
Max.
flow
V-Mt
H-Mt
DN/Inch
l/s
mm
mm
75/3
54
780
305
150/6“
114
780
406
230/9“
284
970
572
305/12“
598
contact
factory
contact
factory
455/18“
94
contact
factory
contact
factory
Sensor
MT
V
H

3Power connections Page 7/43
UF_iS4000_BA_02_1811
Power connections
Caution: For the 2 x M20 cable inlets only use flexible electric cables.
Use separate cable inlets for auxiliary power, signal and input/output
cables.
Auxiliary power
Warning: Do not connect meter under impressed mains voltage.
Take national applicable rules into account
Observe type plate (mains voltage and frequency)
Equipment shall be installed with an external means for disconnecting
it from each operating energy supply source. The disconnecting
means shall disconnect all current-carrying conductors.
1. Slightly loosen the lower cover screws and both upper cover screws
completely. Open cover to the lower side.
2. Push auxiliary power cable through the upper cable inlet.
3. Connection as shown in the picture.
4. In the following close connection cover again firmly.
Power supply 92-275 VAC (50/60 Hz) Recommended cable size min. 0,75 mm²
Power supply 9-36 VDC (max. 9 W) Recommended cable size min. 0,75 mm²

3Power connections Page 8/43
UF_iS4000_BA_02_1811
RS-Interface
Dig. Out- and Input
Analog Output
Solid State Relay
RS-Interface
DIP switch
Display
Sensor input
Configuring input/output (I/O)
Input/Output Description Terminal
Analog output*
0 - 20 mA
4 - 20 mA RL < 800 Ohm
0 - 10 mA
7 (+)
8 (-)
9 (GND)
Digital output
1*
Open collector max. 10 kHz
•Passive max. 32 VDC, <100 Hz 100 mA, >100 Hz 20 mA
•Active 24 VDC, 20 mA
(can be powered by analog output if not used)
3 (-)
4 (+)
2*
Open collector max. 10 kHz
•Passive max. 32 VDC, <100 Hz 100 mA, >100 Hz 20 mA
•Active 24 VDC, 20 mA
(can be powered by analog output if not used)
1 (-)
2 (+)
3
Solid State Relais max. 230 VAC, 500 mA, max 1 Hz
(Function is linked with Output 2)
S1 and
S2
Digital input* 5 - 30 VDC 5 (-) and 6 (+)
RS interfaces*
RS232, RS485 and RS422 with ModBus®RTU.
Mode can be configured by DIP switches also termination
ON or OFF. In case of the RS485 the A wire has to be
connected to Y terminal and the B wire has to be
connected to Z terminal.
422 232 485
A RxD
B
Z TxD B
Y A
G (GND)
USB USB Device CDC (Host Mass Storage) Micro USB
Ethernet* Ethernet Interface connection RJ45 socket
* all marked in- and outputs are according to safety data TNV-1 IEC 60950-1
Auxiliary power
USB
Ethernet