Teledyne 3010 Operating instructions

3010 Flow Transmitter
Installation and Operation Guide
Part #60-3403-171 of Assembly #60-3404-070
Copyright © 2001. All rights reserved, Teledyne Isco
Revision V, February 2012.

3010 Flow Transmitter
Safety
iii
3010 Flow Transmitter
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
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.
DANGER
DANGER – limited to the most extreme situations
to identify an imminent hazard, which if not
avoided, will result in death or serious injury.

3010 Flow Transmitter
Safety
iv
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
produit 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.

v
3010 Flow Transmitter
Table of Contents
Section 1 Introduction
1.1 Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2.1 Interfacing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 SETUP Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.2 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Controls, Indicators, and Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Section 2 Programming
2.1 Operating Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Ultrasonic Level Sensor Theory and Applications . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Error Factors Affecting Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.3 Error Factors and Flow Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Keypad Layout and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.3 Power Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.1 Programming Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.2 List of Program Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.3 Programming Sequence in Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.4 Equations Used in Flow Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.5 Default Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4 Programming Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.1 Programming for a Parshall Flume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.2 Programming for a Cipolletti Weir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.4.3 Programming with the Equation (Device #34) . . . . . . . . . . . . . . . . . . . . . . 2-22
2.4.4 Rectangular Weirs with End Contractions . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.4.5 Programming Example for a Rectangular Weir with End Contractions . 2-27
Section 3 Installation
3.1 General Comments on Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Location of the Flow Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Portable Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 General Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Mounting and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2 Connection to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.3 Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.4 Wiring the Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Connection to an Isco Sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Connection to a Non-Isco Sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 Connection to Other Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.7 Installing the Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3010 Flow Transmitter
Table of Contents
vi
3.7.1 Mounting the Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.7.2 Minimization of Level Measurement Errors . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Section 4 Options and Accessories
4.1 High-Low Alarm Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Setting the Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Connection to External Serial Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Remote Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 Extension Cables for the Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.1 Connecting the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5 Quick-Disconnect Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.6 4-20 mA Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.6.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Section 5 Maintenance and Troubleshooting
5.1 Care of the Flow Transmitter Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Care of the Case Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Preventing Moisture Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Care of the Sensor and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Mechanical and Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.1 Accessing the Terminal PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.2 Accessing the Flow Transmitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Display Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.6 Troubleshooting Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.6.1 If Serious Problems Occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6.2 Processor Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6.3 Preliminary Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6.4 Precautions for Servicing AC-Powered Equipment . . . . . . . . . . . . . . . . . . . 5-5
5.6.5 Precautions for Servicing CMOS Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.6 Call for Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7 Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7.1 Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7.2 CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7.3 Ultrasonic Board Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Appendix A Replacement Parts List
A.1 Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Accessories List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Appendix B General Safety Procedures
B.1 Practical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1.2 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.1.3 Adverse Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.1.4 Entering Manholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.1.5 Traffic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.1.6 Falling Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.1.7 Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.1.8 Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

3010 Flow Transmitter
Table of Contents
vii
B.1.9 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.1.10 Field Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.2 Lethal Atmospheres in Sewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.3 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
List of Figures
1-1 Model 3010 Flow Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Ultrasonic Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Interior View of Transmitter, Showing Terminal Blocks . . . . . . . . . . . . . . . . . . . 1-5
2-1 Simplified 3010 Programming Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3-1 View of Case Latch, Showing Lock Shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 USLS Floor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-3 Foam and Oil on the Surface of the Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-4 Small Pipes and Narrow Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-5 Ultrasonic Level Sensor “Dead Band” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-6 USLS Mounting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-7 USLS Mounting Methods (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4-1 High-Low Alarm Relay Box (Cover Removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Interconnection of 3010 and Alarm Boxe(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3 Remote Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5-1 Terminal Printed Circuit Board Component Layout . . . . . . . . . . . . . . . . . . . . . . 5-11
5-2 CPU PCB Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-3 Ultrasonic PCB Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
List of Tables
1-1 3010 Controls, Indicators, and Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2 Technical Specifications for the Model 3010 Flow Transmitter . . . . . . . . . . . . . . 1-6
1-3 Technical Specification for the USLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Primary Measuring Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2 Equations Used in the Model 3010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-3 Values of N1 for Flow Rate in CFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-4 Values of N2 for Flow Rate in CFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
4-1 3000 Series Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
B-1 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

3010 Flow Transmitter
Table of Contents
viii

1-1
3010 Flow Transmitter
Section 1 Introduction
The first section of the 3010 Flow Transmitter instruction
manual provides a general introduction to the instrument. It
includes a brief discussion of the organization of the manual, an
overall description of the flow transmitter and ultrasonic level
sensor (USLS), and technical specifications.
1.1 Manual Organization The purpose of this manual is to provide the information nec-
essary to program, operate, maintain, and service the 3010 Flow
Transmitter. To accomplish this, the manual is organized into
five sections and an appendix. This first section is a general
introduction to the flow transmitter. The second section contains
information on operation, programming, and some examples of
programming for specific objectives. The third section provides
installation instructions. The fourth section describes available
options and their uses. The fifth section contains maintenance
information and servicing tips to assist you in correcting
problems that may occur. Appendix A contains lists of
replacement parts and accessories.
1.2 Description The 3010, shown in Figure 1-1, uses ultrasonic level mea-
surement. You normally use the flow transmitter with some type
of primary measuring device to measure flow rate in an open
channel. The 3010 uses level-to-flow rate conversions derived
from a stored equation, covering the majority of open channel
flow measurement situations. If needed, you can enter the coeffi-
cients and powers of the flow equation. However, you can use
most standard weirs and flumes without the need for the
equation. A 6-digit LCD (Liquid Crystal Display) prompts you
through setup, displays the choices for the current programming
step, and displays level and/or flow rate.
Figure 1-1 Model 3010 Flow Transmitter

3010 Flow Transmitter
Section 1 Introduction
1-2
1.2.1 Interfacing Equipment The 3010 is compatible with the following Teledyne Isco
equipment:
• 3700 series samplers, 6700 series samplers, and GLS
and Glacier compact samplers
Options and Accessories:
• Resettable 7-digit mechanical flow totalizer. (A nonre-
settable flow totalizer is a standard feature of the 3010.)
• High-Low Alarm Relay Box
• Quick-Disconnect Box
• Extension Cables for the Ultrasonic Level Sensor
• Ultrasonic Level Sensor Cable Clamp and Spreader Bar
• Ultrasonic Mount, Calibration Target, Cable
Straightener, and Sunshade
• Remote Totalizer
• Flow Transmitter-to-Sampler Connect Cable
Note
Throughout this manual, we describe various accessories
available for the 3010. We have listed the part numbers for all
these items on an Accessory List, that you will find at the back
of Appendix A Replacement Parts List. You can obtain part
numbers for other Teledyne Isco equipment by calling the fac-
tory.
1.3 Ultrasonic Level
Sensor
The Ultrasonic Level Sensor, or USLS, shown in Figure 1-2, mea-
sures liquid level without contacting the flow stream. The USLS
consists of an ultrasonic transducer and associated electronics
mounted in a housing, and a shielded cable that connects the
level sensor to the flow transmitter. This cable lets you suspend
the level sensor by the cable alone over a flow stream in tem-
porary installations. For more permanent installations, a
mounting bracket is available to attach the ultrasonic level
sensor securely to the mounting surface. The level sensor is pro-
vided with a 50-foot cable (15.2 meters). For distances greater
than 50 feet, you must use the Quick-Disconnect Box (a type of
splice box) with extension cables. The maximum distance
between the flow transmitter and the level sensor is 1,000 feet
(304.8 meters).
The USLS mounts over the flow stream, and periodically
transmits an ultrasonic pulse to the surface of the stream. The
water surface reflects the echo of the pulse back from the stream
to the level sensor. The elapsed time between pulse and return
echo is proportional to the distance from the level sensor to the
liquid surface. The 3010 uses this time/distance relationship and
a referenced “zero” point in the flow stream to calculate liquid
level. Then, by applying values specific for the primary device in
use, the 3010 calculates flow rate from the measured level. The
USLS has a temperature probe built into its housing to measure