Hach Flo-Dar User manual

DOC026.53.00786
Flo-Dar™ Sensor
Open Channel Non-Contact Radar Sensor
with Optional Surcharge Velocity Sensor
USER MANUAL
July 2010, Edition 3
© HACH Company, . All rights reserved. Printed in the U.S.A.

1
Table of contents
Section 1 Specifications....................................................................................................................3
Section 2 General information.........................................................................................................5
2.1 Safety information........................................................................................................................5
2.1.1 Use of hazard information...................................................................................................5
2.1.2 Precautionary labels ........................................................................................................... 5
2.1.3 Confined space precautions ...............................................................................................6
2.1.4 FCC regulations.................................................................................................................. 7
2.2 Product overview .........................................................................................................................7
2.2.1 Theory of operation.............................................................................................................8
Section 3 Installation........................................................................................................................11
3.1 Unpack the instrument...............................................................................................................11
3.2 Mechanical installation...............................................................................................................12
3.2.1 Site location guidelines.....................................................................................................12
3.2.2 Sensor installation.............................................................................................................14
3.2.2.1 Assemble the clamps on the frame and wall bracket...............................................17
3.2.2.2 Install the frame on the wall ..................................................................................... 19
3.2.2.3 Install the sensor on the frame.................................................................................21
3.2.2.4 Align the sensor vertically—Flo-Dar without SVS....................................................21
3.2.2.5 Align the sensor vertically—Flo-Dar with SVS.........................................................22
3.2.2.6 Align the sensor horizontally.................................................................................... 23
3.2.2.7 Make a final alignment check...................................................................................24
3.2.2.8 Optional extended depth sensor installation............................................................24
3.2.3 Measure the sensor offset ................................................................................................26
3.2.4 Measure the pipe diameter...............................................................................................27
3.3 Electrical installation ..................................................................................................................27
3.3.1 Wiring safety information ..................................................................................................27
3.3.1.1 Electrostatic Discharge (ESD) considerations .........................................................27
3.3.2 Connection to the logger or controller...............................................................................28
Section 4 Operation..........................................................................................................................29
4.1 Install the Flo-Ware software on the PC.................................................................................... 29
4.2 Set up the FL900 Series Logger, Flo-Logger or Flo-Station......................................................29
Section 5 Maintenance ....................................................................................................................31
5.1 Preventative maintenance .........................................................................................................32
5.2 Cleaning the instrument.............................................................................................................32
5.3 Cable replacement.....................................................................................................................33
5.4 Changing the sensor dessicant.................................................................................................. 33
5.4.1 Desiccant replacement procedure.................................................................................... 33
5.5 Hydrophobic filter description.....................................................................................................34
5.6 Hydrophobic filter replacement procedure................................................................................. 35
Section 6 Replacement Parts and Accessories.........................................................................37
6.1 Replacement Parts ....................................................................................................................37
6.2 Accessories................................................................................................................................37
Section 7 Contact Information.......................................................................................................39
Section 8 Limited warranty.............................................................................................................41

2
Table of contents

3
Section 1 Specifications
Specifications are subject to change without notice
Flo-Dar sensor
Dimensions (W x L x D) 160.5 x 432.2 x 297 mm (6.32 x 16.66 x 11.7 in.); with SVS, D=287 mm (15.2 in.)
Weight 4.8 kg (10.5 lb)
Enclosure IP68 waterproof rating, polystyrene
Operating temperature –10 to 50 °C (14 to 122 °F)
Storage temperature –40 to 60 °C (–40 to 140 °F)
Altitude 4000 m (13,123 ft) maximum
Power requirements Supplied by FL900 Series Logger, Flo-Logger or Flo-Station
Interconnecting cable (disconnect at
both sensor and logger ends)
Polyurethane, 0.400 (±0.015) in. diameter
IP68
Standard length: 9 m (30 ft); maximum length: 305 m (1000 ft)
Depth measurement
Method: Ultrasonic
Standard operating range from Flo-Dar housing to liquid: 0 to 152.4 cm (0 to
60 in.)
Optional extended operating range from transducer face to liquid: 0 to 6.1 m
(0 to 20 ft) (with 43.18 cm (17 in.) deadband), temperature compensated
Accuracy: ±1% ±0.25 cm (±0.1 in.)
Surcharge depth measurement
Method: Piezo resistive pressure transducer with stainless steel diaphragm
Auto zero function maintains zero error < 0.5 cm (0.2 in.)
Range: 3.5 m (138 in.); overpressure rating: 2.5 x full scale
Velocity measurement
Method: Radar
Range: 0.23 m/s to 6.10 m/s (0.75 to 20 ft/s)
Frequency Range: 24.075 to 24.175 GHz, 15 mW (EIRP) max.
Accuracy: ±0.5%; ±0.03 m/s (±0.1 ft/s)
Certification
The Flo-Dar Transmitter is certified to the following requirements:
- Transmitter type: Field Disturbance Sensor
- Frequency: 24.125 GHz - Doppler pulse
- Maximum rated power output: 128 dbuV (average) @ 3 meters
Certified to:
FCC Part 15.245: FCC ID: VIC-FLODAR24
Industry Canada Spec. RSS210. v7: IC No.: 6149A-FLODAR24
Use of this device is subject to the following conditions:
1There are no used serviceable items inside this device.
2The user must install this device in accordance with the supplied installation
instructions and must not modify the device in any manner whatsoever.
3Any service involving the transmitter must only be performed by
Hach Company.
4The user must ensure that no one is within 20 cm of the face of the radar
transmitter when operating.
Flow measurement
Method Based on continuity equation
Accuracy ± 5% of reading typical where flow is in a channel with uniform flow conditions
and is not surcharged, ± 1% full scale max.

4
Specifications
FCC and Industry Canada Statements
Canadian Interference-causing Equipment Regulation, IECS-003, Class A
This Class A digital apparatus meets all requirements of the Canadian
Interference-causing Equipment Regulations.
Cet appareil numerique de la classe A respecte toutes les exigences du Pegulement sur
le materiel brouilleur du Canada
FCC PART 15, CLASS "A" Limits
The device complies with Part 15 of the FCC Rules. Operation is subject to the following
two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may
cause undesired operation.
Changes or modifications to this unit not expressly approved by the party responsible for
compliance could void the user’s authority to operate the equipment.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designated to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this equipment in
a residential area is likely to cause harmful interference, in which case the user will be
required to correct the interference at the user’s own expense. The following techniques
of reducing the interference problems are applied easily.
1. Disconnect the equipment from it’s power source to verify that it is or is not the
source of the interference.
2. If the equipment is connected into the same outlet as the device with which it is
interfering, try another outlet.
3. Move the equipment away from the device receiving the interference.
4. Reposition the receiving antenna for the device receiving the interference.
5. Try combinations of the above.
Surcharge conditions depth/velocity
Depth (standard with Flo-Dar Sensor) Surcharge depth supplied by Flo-Dar sensor
Velocity (with optional surcharge
velocity sensor)
Method: Electromagnetic
Range: ±4.8 m/s (±16 ft/s)
Accuracy: ±0.15 ft/s or 4% of reading, whichever is greater
Zero stability: >±0.05 ft/s

5
Section 2 General information
2.1 Safety information
Please read this entire manual before unpacking, setting up, or operating this equipment.
Pay attention to all danger and caution statements. Failure to do so could result in serious
injury to the operator or damage to the equipment.
To ensure that the protection provided by this equipment is not impaired, do not use or
install this equipment in any manner other than that specified in this manual.
2.1.1 Use of hazard information
DANGER
Indicates a potentially or imminently hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
Indique une situation de danger potentiel ou imminent qui, si elle n'est pas évitée,
peut entraîner la mort ou des blessures graves.
WARNING
Indicates a potentially or imminently hazardous situation which, if not avoided,
could result in death or serious injury.
AVERTISSEMENT
Indique une situation de danger potentiel ou imminent qui, si elle n'est pas évitée,
pourrait entraîner la mort ou des blessures graves.
CAUTION
Indicates a potentially hazardous situation that may result in minor or moderate
injury.
ATTENTION
Indique une situation potentiellement dangereuse qui peut entraîner des blessures
mineures ou modérées.
Important Note: Indicates a situation which, if not avoided, may cause damage to the
instrument. Information that requires special emphasis.
Remarque importante: Indique une situation qui, si elle n'est pas évitée, peut provoquer
des dommages à l'appareil. Informations nécessitant une insistance particulière.
Note: Information that supplements points in the main text.
Remarque : Informations complétant des points du texte principal.
2.1.2 Precautionary labels
Read all labels and tags attached to the instrument. Personal injury or damage to the
instrument could occur if not observed.
This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential injury. If on the
instrument, refer to the instruction manual for operation or safety information.
Ceci est le symbole d'alerte de sécurité. Se conformer à tous les messages de sécurité qui suivent ce symbole afin
d'éviter des blessures potentielles. Si apposés sur l'instrument, se référer au manuel d'utilisation pour le
fonctionnement ou les informations de sécurité.

6
General information
2.1.3 Confined space precautions
DANGER
Explosion hazard. Training in pre-entry testing, ventilation, entry procedures,
evacuation/rescue procedures and safety work practices is necessary before
entering confined spaces.
DANGER
Danger d'explosion. Une formation incluant des tests de pré-entrée, la ventilation,
les procédures d'entrée, les procédures d'évacuation/de sauvetage et des pratiques
de travail de sécurité est nécessaire avant d'entrer dans des espaces restreint.
Important Note: The following information is provided to guide users of Flo-Dar Sensors
on the dangers and risks associated with entry into confined spaces.
Remarque importante : Les informations suivantes sont fournies dans le but d'informer
les utilisateurs des capteurs Flo-Dar des dangers et des risques associés à l'accès aux
espaces confinés.
On April 15, 1993, OSHA’s final ruling on CFR 1910.146, Permit Required Confined
Spaces, became law. This new standard directly affects more than 250,000 industrial
sites in the U.S.A., and was created to protect the health and safety of workers in
confined spaces.
Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after
12 August of 2005. In conformity with European local and national regulations (EU Directive 2002/96/EC),
European electrical equipment users must now return old or end-of life equipment to the Producer for disposal at no
charge to the user.
Note: For return for recycling, please contact the equipment producer or supplier for instructions on how to return
end-of-life equipment, producer-supplied electrical accessories, and all auxiliary items for proper disposal.
L'équipement électrique marqué de ce symbole ne devra pas être détruit dans les systèmes de
destruction publics Européens après le 12 août 2005. En conformité avec les dispositions européennes
locales et nationales (Directive EU 2002/96/EC), les utilisateurs européens d'équipements électriques
doivent maintenant renvoyer au fabricant pour destruction les équipements anciens ou en fin de vie,
sans frais pour l'utilisateur.
Remarque : Pour le retour à des fins de recyclage, veuillez contacter le fabricant ou le fournisseur
d'équipement pour obtenir les instructions sur la façon de renvoyer l'équipement usagé, les accessoires
électriques fournis par le fabricant, et tous les articles auxiliaires pour une mise au rebut appropriée.
This symbol, when noted on a product enclosure or barrier, indicates that a risk of electrical shock and/or
electrocution exists.
Si ce symbole ce trouve sur l’instrument, il indique la présence d’un danger de choc électrique ou d’électrocution.
This symbol, when noted on the product, identifies the location of the connection for Protective Earth (ground).
Ce symbole, lorsqu’il est apposé sur le produit, indique l’emplacement de la connexion de mise à la terre.
This symbol, when noted on the product, identifies the location of a fuse or current limiting device.
Lorsque ce symbole se trouve sur un produit, il indique l’emplacement d’un fusible ou autre protection contre les
surcharges.
This symbol, when noted on the product, indicated the presence of devices sensitive to Electro-static Discharge
(ESD) and indicated that care must be taken to prevent damage with the equipment.
Ce symbole, s'il figure sur le produit, indiqué la présence des dispositifs sensibles à la décharge électrostatique
(ESD) et la nécessité d'agir avec précaution pour éviter d'endommager l'équipement.

7
General information
Definition of a confined space:
A confined space is any location or enclosure that presents or has the immediate
potential to present one or more of the following conditions:
•An atmosphere with less than 19.5% or greater than 23.5% oxygen and/or more than
10 ppm Hydrogen Sulfide (H2S).
•An atmosphere that may be flammable or explosive due to gases, vapors, mists, dusts
or fibers.
•Toxic materials which upon contact or inhalation, could result in injury, impairment of
health or death.
Confined spaces are not designed for human occupancy. They have restricted entry and
contain known or potential hazards. Examples of confined spaces include manholes,
stacks, pipes, vats, switch vaults, and other similar locations.
Standard safety procedures must always be followed prior to entry into confined spaces
and/or locations where hazardous gases, vapors, mists, dusts or fibers may be present.
Before entering any confined space check with your employer for procedures related to
confined space entry.
2.1.4 FCC regulations
Use of this device is subject to the following conditions:
•There are no used serviceable items in this device.
•The user must install this device in accordance with the supplied installation
instructions and must not modify the device in any manner whatsoever.
•Any service involving the transmitter must only be performed by Hach Company.
•The user must ensure that no one is within 20 cm of the face of the radar transmitter
when operating.
2.2 Product overview
The Flo-Dar Sensor measures the flow velocity and liquid depth in open channels using
radar and ultrasonic technology. The unit is designed to withstand submersion during
surcharge conditions. The optional surcharge velocity sensor provides velocity
measurements during surcharge conditions.
Figure 1 on page 8 shows the configuration of a Flo-Dar system in a non-hazardous
location.

8
General information
2.2.1 Theory of operation
The Flo-Dar Sensor is mounted above an open channel of water and measures the
surface velocity and depth from above the surface of the water. The two measurements
are used to calculate the flow rate.
During surcharge (submerged) conditions, a pressure transducer measures depth. The
optional surcharge velocity sensor (SVS) can be used to measure velocity during
surcharge conditions.
Surface velocity measurement
The surface velocity of the water is measured using radar technology. A radar beam is
transmitted from the sensor to the water surface at the center of the channel. A portion of
the signal is reflected back at a slightly different frequency. The difference in frequency,
known as the Doppler frequency, is directly proportional to the speed of the flow.
Proprietary algorithms are then used to calculate the average speed of the flow stream.
Note: The radar velocity sensor does not operate under surcharge conditions.
Velocity measurements during surcharge
The optional surcharge velocity sensor (SVS) is activated when the flow level rises to
within 7 inches of the sensor mounting frame and remains active until the flow falls to
7 inches below the sensor mounting frame. The mounting frame is installed 5 to 6 inches
above the crown of the pipe. This places the velocity-sensing electrodes at the correct
location in the flow below the elevation of the crown of the pipe.
The SVS measures velocity using an electromagnetic sensor that generates a magnetic
field. When the water passes through the magnetic field, a voltage is generated that is
directly proportional to the speed of the water passing the sensor.
Figure 1 System overview
1Flo-Dar sensor with optional surcharge velocity sensor 3Mounting frame
2Logger or controller 4Non-hazardous environment

9
General information
Depth measurement
The water depth is measured using an ultrasonic pulse echo sensor. An electronic pulse
is sent to the water surface and a portion of the signal is returned to the sensor. The
transit time to the surface and back is used to calculate the distance from the water
surface to the sensor. The pipe diameter is used to convert the distance to water depth.
The depth sensor on the Flo-Dar unit can measure distances up to 1.5 m (5 ft). For larger
channels, an extended range sensor is available to measure up to 6.1 m (20 ft).
During surcharge conditions, a pressure transducer in the Flo-Dar unit is used to
measure depth.
Flow calculations
The velocity and depth measurements are used with the pipe diameter to determine the
flow rate. The flow rate is calculated from the continuity equation (1):
(1)
where
Flow rate = volume of liquid that passes the sensor per unit time (e.g. 200 gallons per minute)
Average velocity = average velocity of the liquid, calculated using surface velocity
measurements and algorithms
Area = cross-sectional area of the liquid in the channel, calculated using the channel
dimensions and depth measurement.
Flow rate Average velocity Area×=

10
General information

11
Section 3 Installation
DANGER
Explosion hazard. Trained personnel only must install or commission the
equipment.
DANGER
Danger d’explosion. Seul le personnel formé est autoriséà installer ou à mettre en
service l’équipement.
3.1 Unpack the instrument
The instrument components with options are shown in Figure 2.
Figure 2 Instrument components
1Surcharge velocity sensor (SVS) (optional) 10 Clamp bolt, ¼-20 x 1 in. (8x)
2Flo-Dar sensor 11 Anchor nut, 3/8-16 (2x)
3Optional extended depth sensor 12 Anchor washer (2x)
4Bubble level 13 Anchor nut, 3/8x 2¼ in. (2x)
5Cable connectors 14 Adjustable wall bracket
6Spacer, 12-inch 15 Wall mount bracket
7Spacer, 2¼-inch 16 Standard frame
8Clamp half, threaded (2x) 17 Frame for extended depth sensor (optional)
9Clamp half, not threaded (2x)

12
Installation
3.2 Mechanical installation
3.2.1 Site location guidelines
For best accuracy, install the sensor where the flow is not turbulent. An ideal location is in
a long, straight channel or pipe. Outfalls, vertical drops, baffles, curves or junctions cause
the velocity profile to become distorted.
Where there are outfalls, vertical drops, baffles, curves or junctions, install the sensor
upstream or downstream as shown in Figure 3 and Figure 4. For upstream locations,
install the sensor at a distance that is at least five times the pipe diameter or maximum
fluid level. For downstream locations, install the sensor at a distance that is at least ten
times the pipe diameter or maximum fluid level.
If the location contains a junction and the flow in one pipe is much higher, install the
sensor on the wall near the lower flow pipe.
Figure 3 Sensor location near an outfall, vertical drop or baffle
1Acceptable upstream sensor location 5Distance downstream: 10 x pipe diameter
2Outfall 6Vertical drop
3Distance upstream: 5 x maximum level 7Baffle
4Acceptable downstream sensor location

13
Installation
Figure 4 Sensor location near a curve, elbow or junction
1Acceptable upstream sensor location 3Distance downstream: 10 x pipe diameter
2Acceptable downstream sensor location 4Distance upstream: 5 x pipe diameter

14
Installation
3.2.2 Sensor installation
CAUTION
Potential hearing loss risk. Hearing protection required. The level transducer emits
ultrasonic sound energy when powered. Ear protection must be worn when
working within 1 meter of this device. Do not point the transducer output towards
ears during installation, calibration and maintenance.
ATTENTION
Risque de perte auditive. Protections auditives requises. Une fois activé, le
transducteur de niveau émet une énergie ultrasonore. Des protections auditives
doivent être portées lors de toute intervention à moins d’un mètre de cet appareil.
Ne pointez pas la sortie du transducteur vers des oreilles lors d’opérations
d’installation, d’étalonnage et de maintenance.
WARNING
Explosion hazard. Installation of equipment into hazardous locations must be done
so that no friction can be generated between the Flow Meter and any surrounding
surfaces (Figure 1 on page 8).
ATTENTION
Risque d’explosion. L’installation de l’équipement dans des zones dangereuses
doit être effectuée de sorte qu’aucun frottement ne soit provoqué entre le
débitmètre et toute surface environnante (Figure 1de la page 8).
Mount the Flo-Dar sensor above the open channel on the wall of the manhole. A pole is
available for retrieval of the Flo-Dar sensor without entry into the manhole.
For temporary installation, an optional Jack-bar is available (see Accessories on
page 41). Instructions are included with the Jack-bar.

15
Installation
The Flo-Dar sensor dimensions are shown in Figure 5 and Figure 6.
Figure 5 Flo-Dar sensor dimensions
1Optional extended depth sensor 3Minimum clearance for cable
2Minimum clearance for cable with extended depth sensor

16
Installation
Figure 6 Flo-Dar sensor with SVS dimensions
1Minimum clearance for cable

17
Installation
The dimensions of the standard frame for wall installation are shown in Figure 7.
3.2.2.1 Assemble the clamps on the frame and wall bracket
Install the clamps on the frame and wall mount bracket before installation on the wall.
Prerequisites
•Frame
•Wall mount bracket
•Clamps
•Hardware—wall bracket, spacer, nuts and bolts
Procedure
1. Position two clamp halves (one with threads and one without threads) around the wall
mount bracket as shown in Figure 8.
2. Connect the clamp halves together with four bolts. Lightly tighten the bolts to
temporarily hold the clamp in position.
Figure 7 Standard frame dimensions
122.8 in. with 2¼ in. spacer; 32.6 in. with 12 in. spacer

18
Installation
3. Position the other two clamp halves around the front end of the frame as shown in
Figure 8.
Note: In most cases the front of the frame will point toward the wall as shown in Figure 8 (see
also Figure 12 on page 23). If flow conditions require the sensor to point away from the wall,
use the 12-inch spacer and position the two clamp halves around the back end of the frame.
4. Connect the clamp halves together with four bolts. Lightly tighten the bolts to
temporarily hold the clamp in position.
Figure 8 Clamps assembled on wall bracket and frame
1Adjustable wall bracket 5Frame
2Clamp half, threaded 6Spacer
3Clamp bolt, ¼–20 x 1 in. 7Wall mount bracket
4Clamp half, not threaded