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