ISCO 4230 Operating instructions

4230 Flow Meter
Installation and Operation Guide
Part #60-3233-142 of Assembly #60-3234-051
Copyright © 1994, 2003. All rights reserved, Isco, Inc.
Revision P, April 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

- ADDENDUM -
The 4230 flow meter will become inaccurate displaying the depth, flow, and
total flow when exposed to electromagnetic fields in excess of 1.0V/m between
105 MgHz and 820 MgHz. It is suggested that the instrument be placed in a
location where these electromagnetic fields are not present, or the source of the
radiation is removed from the vicinity of the instrument if possible.

Model 4230
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.

i
4230 Flow Meter
Table of Contents
Section 1 Introduction
1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Compatible Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.1 Operation of the Bubbler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.2 Pressure Transducer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.3 Automatic Drift Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Software Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Controls, Indicators, and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 How to Make Battery Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7.1 Calculating Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Section 2 Programming
2.1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Operation of the Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Description of Program Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5.1 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5.2 Flow Conversion Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.3 Adjust Level, Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.4 Reset Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5.5 Sampler Pacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5.6 Sampler Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.7 Alarm Dialout Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.8 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.9 Reports/History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6 Interpreting the Program Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7 Step 1 - Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7.1 Optional Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.7.2 Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.8 Step 2 - Flow Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.8.1 Flow Metering Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.8.2 Enter Maximum Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2.8.3 Programming the 4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2.9 Step 3 - Parameter to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2.10 Step 4 - Reset Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.11 Step 5 - Sampler Pacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.12 Step 6 - Sampler Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.13 Step 7 - Alarm Dialout Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
2.14 Step 8 - Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.15 Step 9 - Reports/History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Section 3 Installation
3.1 Preparation for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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3.1.1 Install Desiccant Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Install External Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3 Opening the Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.5 AC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.6 External 12 Volt Direct Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Bubble Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 Setting the Bubble Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Bubble Rate and Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 Purging a Clogged Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Adjusting the Bubble Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.5 Locking the Bubble Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.6 Effects of Changing the Bubble Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.7 Super Bubble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4 4230 Mounting and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.1 Carrying Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.2 Location of the Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5 The Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Standard Bubble Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.2 Comparing Vinyl and Teflon Bubble Lines . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.3 Bubble Line Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.4 Teflon Line Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.5 Attaching the Teflon Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.6 Attaching the Vinyl Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.7 Installing the Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.8 High-Velocity Flow Streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.9 Stilling Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.10 Flume Bubble Line Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.11 Bubble Line Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.12 Open Channel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6 Flow Metering Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 The Bubbler Tube Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.8 Connection to a Sampler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.8.1 Connection to Other Isco Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Section 4 Optional Equipment
4.1 4200T Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Modem and FLOWLINK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Connection to a Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.4 Types of Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Connections to External Serial Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 4 to 20 mA (Analog) Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1 External 4-20 mA Output Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.2 Internal Analog Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Tipping Bucket Rain Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Isco FLOWLINK Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.6 High-Low Alarm Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6.2 Wiring to a 4200 Series Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.7 Parameter Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.7.1 Installation of Parameter Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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4.7.2 Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.8 pH Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.8.1 How the pH Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.8.2 pH Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.8.3 pH Probe Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.8.4 Storage and Maintenance of pH Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.9 The Dissolved Oxygen (D.O.) Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.9.1 How the D.O. Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.9.2 Probe Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.9.3 Membrane Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.9.4 Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.9.5 Probe Operation and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.9.6 Calibrating the D.O. Probe with a Flow Meter . . . . . . . . . . . . . . . . . . . . . 4-23
4.10 Installation of Parameter Probes in Round Pipes . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.10.1 Spring Rings (15" and Under) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.10.2 Pipes Larger Than 15” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.10.3 U-Channel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.10.4 Attaching the Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.10.5 Installing the Mounting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.10.6 Finishing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.10.7 Four-Foot Probe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.11 YSI 600 Multiple Parameter Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4.12 Mechanical Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Section 5 Maintenance and Service
5.1 Care of the Flow Meter Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Care of the Case Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Preventing Moisture Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Desiccators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Regenerating the Internal Case Desiccant . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 Regenerating the External Desiccant Cartridge . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Bubble Line Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Inspection of the Bubble Line Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Automatic Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 Maintenance of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.1 Changing the Paper Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.2 Ink Ribbon Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.3 Do Not Lubricate or Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5 Servicing And Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5.1 Disassembling the Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5.2 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.3 Display Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.7 Operation of the Bubbler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7.1 Internal Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7.2 Air Output to Bubble Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.3 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.4 Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.7.5 Automatic Drift Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.8 Preliminary Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.8.1 If Serious Problems Occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.8.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.9 Precautions for Servicing CMOS Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.9.1 Hazard of Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.10 Using FLASH UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.10.1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.10.2 Before Running FLASH UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

4230 Flow Meter
Table of Contents
iv
5.10.3 Running FLASH UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.10.4 About Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Appendix A Accessories and Replacement Parts
A.1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Appendix B Programming Worksheets
B.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B.2 Flow Conversion: Level-to-Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.3 Parameter to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.4 Reset Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.5 Sampler Pacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.6 Sampler Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.7 Alarm Dialout Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.8 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
B.9 Reports/History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Appendix C General Safety Procedures
C.1 Practical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.2 Lethal Atmospheres in Sewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C.3 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Appendix D Material Safety Data Sheets
D.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
List of Figures
1-1 4230 Flow Meter, Shown With Bubble Line and Battery . . . . . . . . . . . . . . . . . . . 1-1
1-2 4230 Controls and Indicators (left), Connectors (right) . . . . . . . . . . . . . . . . . . . . . 1-5
1-3 Measuring Flow Meter Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
2-1 The YSI 600 Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2 Flow Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-3 Level Measurement in Round Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2-4 YSI 600 Sonde Calibration Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
3-1 Battery Installed on Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2 4230 Suspended by Handle (handles may vary) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-3 Attaching the Bubble Line to the 4230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-4 Positioning the Bubble Line in the Flow Stream . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 Installing the Stainless Steel Bubble Line Extension . . . . . . . . . . . . . . . . . . . . . 3-16
3-6 Flow Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-7 Bubbler Tube Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
4-1 4-20 mA Output Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-2 674 Tipping Bucket Rain Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-3 Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-4 pH Probe With Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-5 201 pH Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-6 D.O. (Dissolved Oxygen) Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7 D.O. Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-8 Spring Ring (15” and Under) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-9 Universal Mounting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-10 Universal Mounting Ring Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4-11 Mounting of Probe Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4230 Flow Meter
Table of Contents
v
4-12 YSI 600 Multiple Sensor Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
5-1 Location of the Case Desiccating Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Changing the Chart Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3 Ink Ribbon Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-4 Lifting the Flow Meter from the Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-5 Location of the Three Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6 4230 Bubbler System Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 Schematic Diagram of the Bubbler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-8 Update File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-9 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-10 Preferences Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
List of Tables
1-1 4230 Controls, Indicators, and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-2 4230 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 Technical Specifications for FLOWLINK and Bubbler . . . . . . . . . . . . . . . . . . . . . 1-7
1-4 4230 Chart Longevity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-5 Battery Life Expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2-1 ASCII Output Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
4-1 4-20 mA Output Interface: Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2 Multiple Analog Output Board: Technical Specifications (each circuit) . . . . . . . . 4-7
4-3 pH Probe Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-4 D.O. Probe Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-5 YSI 600 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
5-1 Minimum DOS and Computer Hardware Requirements . . . . . . . . . . . . . . . . . . 5-20
A-1 4230 Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
A-2 4230 Pump Base Assembly Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
C-1 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

4230 Flow Meter
Table of Contents
vi

1-1
4230 Flow Meter
Section 1 Introduction
This section provides a general introduction to the 4230 Bubbler
Flow Meter. It includes a description of the flow meter, an expla-
nation of how the unit operates, and technical specifications.
Manual Organization – This manual provides the information
necessary to operate, maintain, and perform minor service on the
4230. The manual is organized into five sections:
Section 1: Introduction, operation, and specifications
Section 2: Keypad operation and programming for the 4230
Flow Meter
Section 3: Installation and options application-specific to the
4230
Section 4: Options and accessories for all 4200 series flow
meters
Section 5: Routine maintenance and minor service
Following Section 5 are appendices covering safety, accessory
parts, replacement parts, and material safety data.
Figure 1-1 4230 Flow Meter, Shown With Bubble Line and Battery

4230 Flow Meter
Section 1 Introduction
1-2
1.1 Description The 4230 uses the bubbler method of level measurement. The
flow meter is normally used with some type of primary mea-
suring device to measure flow in an open channel. The 4230 has
built-in standard level-to-flow conversions, that cover the vast
majority of open channel flow measurement situations. The 4230
is also capable of calculating flow using the Manning Equation.
Additionally, you can enter a non-standard equation or data
points, that effectively plot a user-derived flow profile for a flow
stream. The 4230 supports the Isco data acquisition, storage, and
retrieval system with the use of optional FLOWLINK software.
The 4230 has enough memory to store over 40,000 data readings.
An optional 4200T Modem, with speech capability, is available to
transmit stored data over standard dial-up telephone lines.
1.2 Compatible
Equipment
The 4230 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
• GLS and Glacier Compact Samplers
• 4-20 mA Output Interface
• 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 Equipment and Accessories
• 4200T Modem - Speech-capable, with connector and
cable
• D.O. (dissolved oxygen) and pH parameter probes
• Flow Metering Inserts for round-pipe installations in
sizes of 6", 8", 10", and 12".
• Bubble lines, in lengths of 25 feet (Teflon 0.125" OD,
0.065" ID) and 50 feet (vinyl 0.250" OD, 0.125" ID)
• Stainless steel extension tube for the bubble line (4.0
feet 0.125" OD)
• Isco FLOWLINK® Software for data acquisition,
storage, and management
• Carrier and Mounting rings for mounting the bubble
line outlet in round pipes.

4230 Flow Meter
Section 1 Introduction
1-3
1.3 Operating Principles When measuring flow rate, the 4230 is used with a primary mea-
suring device (typically a weir or a flume) or other open channel
flow arrangement where a known relationship exists between
level and flow rate. The level measuring device is a bubbler
which measures the liquid level in the flow stream. The flow
meter electronically converts the level reading into a
properly-scaled flow rate value. The flow meter also provides
standard or optional flow-related output signals to be used for:
• Flow-proportional sampler pacing and enabling
• Recording flow rate information on an external
printer/plotter or circular chart recorder
• Data transfer through a modem
• Control of a 4-20 mA device
• Data transfer by a laptop computer
The flow meter contains microprocessor-controlled circuitry to
calculate level and flow rate from the signals produced by the
pressure transducer, store the program you entered, and operate
the display and the internal printer. An alphanumeric liquid
crystal display (LCD) is provided to show current total flow, level,
and flow rate, and to prompt you in programming the flow meter
during setup or subsequent program changes. An internal
printer provides a “hard copy” printout of the information com-
puted by the flow meter, plots level or flow rate, and generates
reports. Connectors for other equipment used with the 4230 are
arranged vertically on the right side of the flow meter case.
1.3.1 Operation of the
Bubbler System
The bubbler system, used by the 4230 to sense level in the flow
stream, works as follows: A small compressor pumps air into a
reservoir. This air is released slowly by a needle valve into a
bubble line, a length of small diameter flexible tubing. The other
end of this tube is submerged in the flow stream. Inside the flow
meter, the bubble line also connects to one side of a differential
pressure transducer. As air is released slowly into the bubble line
by the needle valve, pressure builds inside the line to force the
air out of the line into the flow stream. When there is enough
pressure to counteract the hydrostatic pressure of the flow
stream, a bubble will be forced from the end of the line. The
amount of pressure required to force the bubble from the end of
the line is directly dependent on the hydrostatic pressure of the
flow stream over the end of the bubble line. The pressure trans-
ducer inside the flow meter senses this pressure and converts it
into an electrical signal that the 4230 converts into level. From
the measured level detected by the bubbler and consulting
lookup tables for the primary device you are using, the flow
meter then calculates flow rate and total flow.
1.3.2 Pressure Transducer
Operation
The differential pressure transducer used with the bubbler con-
tains a resistance bridge on a silicon diaphragm. Pressure
against one side of this diaphragm causes it to flex slightly. This
flexing causes the resistors on one side of the bridge to stretch
slightly. At the same time the resistors on the other side of the
bridge compress slightly. The result is an unbalance in the

4230 Flow Meter
Section 1 Introduction
1-4
bridge, proportional to the increase of air pressure, caused in
turn by an increase in level of the flow stream. This bridge is fed
from a constant-voltage source; changes in output are the result
of changes in pressure.
1.3.3 Automatic Drift
Compensation Valve
The 4230 Flow Meter contains the software and circuitry nec-
essary to measure the output of the pressure transducer at zero
pressure. When the flow meter is first turned on, and periodically
after that, the processor actuates the automatic drift compen-
sation valve, which connects the input port of the pressure trans-
ducer to the reference port. With the two ports connected, it then
measures the output offset. The flow meter stores this offset
reading in memory and uses it in level calculations. The flow
meter periodically repeats this zero-offset measurement and
stores the new reading in memory. The repetition of this process
causes zero drift in the pressure transducer or the amplifier to
cancel out, eliminating the most significant cause of drift, espe-
cially when the flow meter is operating at low water levels.
The valve also provides temperature compensation at zero
pressure. The software controlling the 4230 determines how
often this compensation cycle is repeated. Drift compensation
cycles range from two to fifteen minutes.
1.4 Software Upgrades To update the software in a 4200 Series Flow Meter, you do not
have to return the unit to the factory or replace an EPROM. With
Flash Memory, software updates can easily be installed in the
field with a disk, a computer, and a cable. See Section 5 for
instructions for Flash software updates. For more information
about installing software upgrades in the 4230 Flow Meter,
contact your Isco representative or call the factory.
1.5 Controls, Indicators,
and Connectors
The controls, indicators, and connectors of the 4230 Flow Meter
are listed in Table 1-1, and their functions are briefly described.
Refer to Figure 1-2 for a view of the controls, indicators, and con-
nectors.
1.6 Technical
Specifications
The technical specifications for the 4230 Flow Meter are found in
Table 1-2. The anticipated longevity for a roll of paper used in the
printer is shown for various chart speeds in Table 1-4. Battery
life expectancy for three programming combinations is found in
Table 1-5, with a brief description of how to make battery calcu-
lations immediately following.
Note
Various options and accessories used with the 4230 are
described throughout the manual. For convenience, the Isco
part numbers for these items are listed on the Accessory Parts
List found at the end of the Replacement Parts List. Part num-
bers for equipment not listed on this sheet are available from
the factory.

4230 Flow Meter
Section 1 Introduction
1-5
Figure 1-2 4230 Controls and Indicators (left), Connectors (right)
Table 1-1 4230 Controls, Indicators, and Connectors
CONTROLS SETTINGS FUNCTION
ON/OFF On - Off Turns the flow meter on and off. Internal memory is protected with a standby
battery. See Section 2.
Keypad Momentary Switches 24-key. 4 column matrix - Program flow meter through series of keystrokes
prompted by messages on the display. Certain keys perform specific func-
tions, (printing reports or entering program choices into memory). Arrow
keys move through menus. Number keys enter numeric values.See Section
2.
Bubble Rate
Adjust Valve
1 bubble per second
(normally)
Controls the rate of air discharge from the pump and reservoir into the bub-
ble line.
INDICATOR READING FUNCTION
Display Multi-function 2-line, 40 characters per line, liquid crystal display (LCD.) Prompts you
through program procedure; displays total flow,. present flow rate and level.
May also display parameter readings, if sensors present.

4230 Flow Meter
Section 1 Introduction
1-6
Internal
Printer
Various Provides hard copy of total flow, level or flow rate variation over time; pro-
vides sampling information and a printout of the program. Prints reports.
Generates up to 3 different linear data plots. Chart characters and plots are
generated on plain paper roll with an ink ribbon.
CONNECTOR TYPE FUNCTION
12 VDC 2-pin male M/S Connects 12 VDC power to flow meter
Sampler 6-pin male M/S Connects flow meter to sampler; provides flow pulse to sampler; receives
sampler bottle number, composite sample and event mark signal.
Rain Gauge/
YSI 600
Sonde
9-pin female M/S
(Custom)
Connects flow meter to an Isco Rain Gauge or YSI 600 Multi-Parameter
Sonde. Also provides output to High-Low Alarm Relay Box.
Interrogator 6-pin female M/S Provides serial data in/out and power. Can also be used with 4-20 mA Out-
put Interface.
Modem
(optional)
5-pin male M/S Connects flow meter to telephone line for remote data transmission. This
connector will only be present on units that have the optional modem
installed.
Parameter 7-pin female M/S Connects flow meter to parameter sensor: temperature, pH, or D.O. Note
that you can only have temperature and one parameter (pH or D.O.) at the
same time.
Table 1-1 4230 Controls, Indicators, and Connectors (Continued)
Table 1-2 4230 Technical Specifications
Physical and Electrical
Size 17" high ×111⁄2" wide × 10 1⁄2" deep (without power source)
Weight 19 lb. 1 oz
Material High-impact molded polystyrene structural foam
Type Self-certified NEMA 4X Enclosure
Display Type 2-line, 40 character/line alphanumeric dot matrix liquid crystal
Power 12 -14 VDC, 16 mA average at 12.5 VDC (Printer set at 1" per hour)
Typical Battery Life 7-10 days with printer at 1" per hour and 4 Ampere-hour Ni-Cad battery
12 days with purge and printer turned off and bubble rate set at 1 bubble per second
Operating Temperature 0° to 140°F (–18° to 60°C)
Storage Temperature –40° to 158°F (–40° to 70°C)
Additional Power Required for Optional Equipment
Modem 60 mA maximum during operation; 0.1 mA maximum standby
High-Low Alarm Relay Box 10 mA standby, typical; 190 mA - both relays operated
Internal Printer
Chart Speeds Off,1⁄2, 1, 2, or 4 inches per hour
Ribbon 19.7 ft. (6 m) black nylon - replaceable
Operating Speed 1.5 lines per second at 68°F. (20° C)
Character Size 0.09" high ×0.07" wide (2.4mm ×1.7 mm), 12 pitch