ISCO 4210 Operating instructions

4210 Flow Meter
Installation and Operation Guide
Part #60-3213-285 of Assembly #60-3214-110
Copyright © 1994, 2003. All rights reserved, Isco, Inc.
Revision R, August 2003

Foreword
This instruction manual is designed to help you gain a thorough understanding of the
operation of the equipment. Isco recommends that you read this manual completely
before placing the equipment in service.
Although Isco designs reliability into all equipment, there is always the possibility of a
malfunction. This manual may help in diagnosing and repairing the malfunction.
If the problem persists, call or email the Isco Customer Service Department for assis-
tance. Contact information is provided below. Simple difficulties can often be diag-
nosed 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.
Isco welcomes suggestions that would improve the information presented in this man-
ual or enhance the operation of the equipment itself.
Isco is continually improving its products and reserves the right to change
product specifications, replacement parts, schematics, and instructions
without notice.
Contact Information
Phone: [phone] (USA, Canada, Mexico)
[phone] (Outside North America)
Repair Service: [phone] (Analytical and Process
Monitoring Instruments)
[phone] (Samplers and Flow Meters)
Fax: [phone]
Email address: [email protected]
Website: www.isco.com
Return equipment to: 4700 Superior Street, Lincoln, NE 68504-1398
Other correspondence: P.O. Box 82531, Lincoln, NE 68501-2531
Revised February 12, 2003

4210 Flow Meter
Safety
4210 Flow Meter
Safet y
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 in the following general
warnings:
WARNING
Liquids associated with this instrument may be classified
as carcinogenic, biohazard, flammable, or radioactive.
Should these liquids be used, it is highly recommended that
this application be accomplished in an isolated
environment designed for these types of materials in
accordance with federal, state, and local regulatory laws,
and in compliance with your company’s chemical/hygiene
plan in the event of a spill.
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.
WARNING
If this system uses flammable organic solvents, Isco
recommends that you place this system in a well-ventilated
environment, designed for these types of materials. This
environment should be constructed in accordance with
federal, state, and local regulations. It should also comply
with your organization’s plan concerning chemical and
hygiene mishaps. In all cases use good laboratory
practices and standard safety procedures.
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.

4210 Flow Meter
Safety
DANGER
DANGER – limited to the most extreme situations
to identify an imminent hazard, which if not
avoided, will result in death or serious injury.
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.

4210 Flow Meter
Safety
IMPORTANT – PLEASE READ
WARNING
The installation and use of this product may require you to work in locations where
you could be seriously injured or even
killed. Take whatever precautions are neces-
sary to ensure your safety before entering the installation.
Never work alone or unsu-
pervised. Install and operate this product in accordance with all applicable safety and
health regulations, as well as any appropriate local ordinances.
This product is often installed in confined spaces. Examples of confined spaces are manholes, pipelines,
digesters, and storage tanks. These places can be dangerous or fatal if you are not suitably prepared. The
primary hazards are the presence of poisoned air, the lack of ventilation, and the possibility of falls. Other
hazards may be present, as well. Work in such places is governed by OSHA 1910.146, and may require a
permit before entering.
Material Safety Data Sheets (MSDS) for chemical agents supplied or recommended for use with this
product are in the MSDS Appendix.These sheets provide information about possible hazards from the
chemicals. Additional MSDS, covering various proprietary agents (name-branded or trademarked mix-
tures) that can also be used with this product, are available from the manufacturers of those agents.
NOTE
FLOWLINK is a registered trademarks of Isco Inc. All other brand or product names used in this manual are trademarks
or registered trademarks of their respective companies and/or organizations.
This manual uses the following notations to set
apart hazard warnings and notes:
DANGER
DANGER describes situations which if not
avoided,
will result in loss of life or serious
personal injury. The emphasis is on a clear
and immediate threat to your life or safety.
WARNING
WARNING describes situations which if not
avoided,
could
result in loss of life or serious per-
sonal injury. The emphasis here is on the
poten-
tial
for a serious accident.
CAUTION
CAUTION describes situations which if not avoided,
may result in moderate personal injuries, property
damage, or damage to the equipment.
NOTE
NOTES draw your attention to specific features, prac-
tices, or other information useful in setting up or
installing the product.

4210 Flow Meter
Safety

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 The Ultrasonic Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.1 Transducer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.2 Validity Tests and Error Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.3 Ambient Air Temperature Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.4 Return Echo Amplifier Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Software Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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
2.7.5 Maximum Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.7.6 Programming the 4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

4210 Flow Meter
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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 . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.6 Ultrasonic Level Sensor: Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6.1 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
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
4.6 Tipping Bucket Rain Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7 Isco FLOWLINK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

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4.8 High-Low Alarm Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.10.4 pH Probe Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.11.3 Membrane Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.11.4 D.O. Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.11.5 Probe Operation and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.11.6 Calibrating the D.O. Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.12 Installation of Parameter Probes in Round Pipes . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.12.1 Spring Rings (15" and Under) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.12.2 Pipes Larger Than 15” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.12.3 U-Channel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.12.4 Attaching the Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.12.5 Installation of the Spring Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.12.6 Installing the Universal Mounting Ring . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.13 The YSI 600 Multiple Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.14 Mechanical Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
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

4210 Flow Meter
Table of Contents
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 The 4210 Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 3012 Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3 4210 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-4 4210 Side View Showing Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-5 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-7 D.O. Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-8 Spring Ring (15” and Under) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-9 Universal Mounting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-10 Four-Foot Probe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-11 Universal Mounting Ring Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4210 Flow Meter
Table of Contents
v
4-12 The YSI 600 Multiple Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
5-1 Location of the Internal Desiccant Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-5 YSI 600 Technical Specifications (Complete Unit) . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-6 YSI Sensor Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
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

4210 Flow Meter
Table of Contents
vi

1-1
4210 Flow Meter
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.

4210 Flow Meter
Section 1 Introduction
1-2
Figure 1-1 The 4210 Flow Meter
1.3 Compatible
Equipment
The 4210 Flow Meter may be used with the following equipment:
Manufactured by 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

4210 Flow Meter
Section 1 Introduction
1-3
•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
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 programming 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.

4210 Flow Meter
Section 1 Introduction
1-4
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.
Figure 1-2 3012 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 21/2foot 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

4210 Flow Meter
Section 1 Introduction
1-5
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 Isco representative or call the factory.
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 1-3
for a view of the controls and indicators, and Figure 1-4 for a
view of the connectors.
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
Replacement Parts List.

4210 Flow Meter
Section 1 Introduction
1-6
Figure 1-3 4210 Controls and Indicators