User Manual - Instrumart
Contents
1. F ee S Maximum Internal Switch 5 Off Down Figure 8 Wiring schematic using an external pullup resistor To determine the maximum current available using a specific pullup resistor use the following equation 0 25 Watts Current Draw External Pullup Resistor Page 12 SGN UM 00281 EN 02 September 2014 K Factors Explained K FACTORS EXPLAINED The K factor with regards to flow is the number of pulses that must be accumulated to equal a particular volume of fluid You can think of each pulse as representing a small fraction of the totalizing unit An example might be a K factor of 1000 pulses per gallon This means that if you were counting pulses when the count total reached 1000 you would have accumulated one gallon of liquid Using the same reasoning each individual pulse represents an accumulation of 1 1000 of a gallon This relationship is independent of the time it takes to accumulate the counts The frequency aspect of K factors is a little more confusing because it also involves the flow rate The same K factor number with a time frame added can be converted into a flow rate If you accumulated 1000 counts one gallon in one minute then your flow rate would be one gpm The output frequency in Hz is found simply by dividing the number of counts 1000 by the number of seconds in a minute 60 to get the output frequency 1000 60 16 6666 Hz If you were looking at the pulse output on a frequency counter2. This option is controlled by position 4 of the DIP switch When the switch is in the off position down in reference to Figure 6 the output level is normally low and the duration of the selected pulse width is high When the switch is in the on position up in reference to Figure 6 the output level is normally high and the duration of the selected pulse width is low ON C amp K SDADS A UP ON Switch 4 Switch 5 1 2 314 5 WDOWN OFF Function Function Saas Output Normally High A Internal Pullup used A Figure 5 Switch 4 settings Output Normally Low Y External Pullup required y TSA Table 2 Switch 4 and 5 settings spabs UP ON 1 2 3 4 5 W DOWN OFF m Figure 6 Switch 5 settings Setting the Internal or External Pullup Resistor Either the internal pullup resistor or an external resistor must be used for the K Factor Scaler board to provide an output pulse This option is controlled by position 5 of the DIP switch When DIP switch 5 is in the on position up in reference to Figure 6 the internal 3 6 kQ pullup resistor is connected to the input voltage of the board The output pulse swing is approximately 0 7 volts less than the input voltage to near zero volts Setting DIP switch 5 in the off position down in reference to Figure 6 the internal pullup resistor is disconnected
3. Enclosure Appleton GR Conduit Outlet Box GRL100 A and GRLB100 A explosion proof dust ignition proof Agency Listings Hazardous Locations Class Div 1 Groups C and D Class 1 Groups and and Class Ill CSA Type 4X T6 70 C22 2 No 30 for Canada Pollution Degree 2 Normally only non conductive pollution occurs Occasionally a temporary conductivity caused by condensation must be expected Overvoltage Category 111 Distribution level fixed installation with smaller transient overvoltage than installation category IV Primary supply level Page 6 SGN UM 00281 EN 02 September 2014 Installation INSTALLATION The K Factor Scaler was designed with terminal connections with removable plugs for easy connection and removal from the system after installation Refer to Figure 2 for the I O terminal connections The board connections include power input turbine meter input and the pulse output to a totalizing device DIP Switches for selecting pulse width pulse state and pullup resistor options Power Input 8 5 30V DC Pulse Output Turbine Meter Input Factory Use Only Figure 2 Input Output terminal connections Enclosure Mounting necessary for CSA certification If the circuit board assembly is supplied without an enclosure it must be mounted within a certified Appleton one inch NPT model GRL100 A or GRLB100 A condu
4. an output frequency of 16 666 Hz would be equal to one gpm If the frequency counter registered 33 333 Hz 2 x 16 666 Hz then the flow rate would be two gpm Finally if the flow rate is two gpm then the accumulation of 1000 counts would take place in 30 seconds because the flow rate and hence the speed that the 1000 counts is accumulated is twice as great Calculating K factors Many styles of flow meters are capable of measuring flow in a wide range of pipe sizes Because the pipe size and volumetric units the meter will be used on vary it may not possible to provide a discrete K factor In the event that a discrete K factor is not supplied then the velocity range of the meter is usually provided along with a maximum frequency output The most basic K factor calculation requires that an accurate flow rate and the output frequency associated with that flow rate be known Example 1 Known values are 700 Hz 48 Frequency Il Il Flow Rate 700 Hz x 60 sec 42 000 pulses per min 42 000 pulses per min factor _ 875 pulses per gallon 48 gpm Example 2 Known values are Full Scale Flow Rate 11 85 Full Scale Output Frequency 650 Hz 650 Hz x 60 sec 39 000 pulses per min 39 000 pulses per min K factor 458 82 pulses per gallon 85 gpm The calculation is a little more complex if velocity is used because you first must convert the velocity into a volume
5. and an external pullup resistor and supply voltage are required Pulse Output Either the internal or an external pullup resistor is required for the K Factor Scaler to provide an output pulse An onboard jumper controls the pullup resistor selection With the jumper installed the internal pullup resistor is connected Without the jumper an external pullup is required Refer to Table 2 for the I O terminal connections Page 10 SGN UM 00281 EN 02 September 2014 Startup And Configuration Internal Pullup Resistor The internal pullup resistor allows for a simple installation but be careful to ensure that the device being connected to the pulse output can accept voltage levels as high as the supply feeding the K Factor Scaler Another important setup consideration when using the internal pullup resistor is to make certain the output pulse from the K Factor Scaler can supply enough current for the receiving device to read the pulse Calculation of the available current that the K Factor Scaler can supply to the receiving device uses the following equation see Figure 7 Input Voltage 0 7V 36000 470 Available Current Using the above equation the maximum current available at an input voltage of 30V is 8 mA Verify that the receiving device input current requirement is below this value for proper operation Otherwise an external pullup resistor less than 3 6 is required Internal Open Collector Pulse Output ig IPER
6. be calculated with the following equation Input Voltage 0 7V 36000 470 Available Current Verify that the receiving device input current requirement is below this value for proper operation Otherwise an external pullup resistor less than 3 6 kO will have to be used External Pull up Resistor Using an external pullup resistor offers the user greater flexibility of controlling the output pulse provided by the K Factor Scaler to a receiving device Since power sources and receiving devices differ between users different resistor values may be required by different setups The external pullup resistor is connected between the receiving device s input and a power source This power source would be the maximum input voltage of the pulse to the receiving device Refer to the following equation to help determine the resistor value needed Supply Voltage Current Where R Resistor value in ohms Supply Voltage External supply voltage connected to the external pullup resistor Current Input current required by the receiving device in amps After the resistor value has been calculated make sure the following equation that P is less than or equal to 0 25 P represents the power capability of the output and should not exceed 0 25 Watts Exceeding this value could damage the K Factor Scaler Raising the resistor value will decrease the power requirement Supply Voltage Supply Voltage R 4
7. flow rate This K factor can be placed directly into the K Factor Scaler to provide an output with the same volumetric flow rate or modified to a different volumetric flow rate by recalculating the K factor with the appropriate conversion factor In addition if the K factor is set to one the K Factor Scaler can be used as a preamplifier where the frequency from a low level turbine meter is proportional to the logic level frequency output needed by a PLC or CPU data acquisition card This option allows the end device to control the dividing process of the turbine meter output to a recognizable flow rate OPERATING PRINCIPLE Fluid moving though a turbine flow meter causes the rotor to rotate in relation to the flow rate The rotation of the rotor blades cuts through the magnetic field generated by the magnetic pickup which in turn generates a frequency output signal that is directly proportional to the speed of the rotor Magnetic Pickup or Other Frequency Output Device S 1 1 1 1 an i Output Turbine Rotor Signal Figure 1 Schematic illustration of electric signal generated by rotor movement The signal produced is received by the Factor Scaler input amplifier which has an input sensitivity of 30 mV 30 as The signal is then sent to an onboard microcontroller which acts as a divisor with a range of 1 999 999 999 The divisor K factor is user ad
8. 7Q Page 8 SGN UM 00281 EN 02 September 2014 Startup And Configuration STARTUP AND CONFIGURATION After the K Factor Scaler has been properly installed power can be applied The unit can be configured with the power either on or off If the power is on the onboard microcontroller constantly scans for any changes and adjusts accordingly Note that the pulse output should be ignored while any changes are being made with the power applied Any changes cause the internal counter to reset and the dividing process to start over Configuring the K Factor Scaler consists of the following four items 1 Setting the K factor divider 2 Setting the output pulse width 3 Setting the pulse output level normally high or normally low 4 Setting the output pulse to use the internal or external pullup resistor Setting the K Factor The K factor is the ratio of input pulses per each output pulse and can be viewed as a divisor The minimum K factor can be set to 1 where each input pulse yields an output pulse The maximum K factor can be set to 999 999 999 where it would take this many input pulses to yield one output pulse The K factor is set using the eight rotary switches Each switch is a ten position switch that is used to select a number from 0 to 9 by pointing the arrow to the corresponding digit inscribed on its casing When looking at the K Factor Scaler board so that the text 99 999 999 is below the switches the right most switch represents th
9. E 8 mA Maximum Switch 5 On Up Figure 7 Wiring schematic with internal pullup resistor in circuit September 2014 SGN UM 00281 EN 02 Page 11 Startup And Configuration External Pullup Resistor Using an external pullup resistor offers the end user greater flexibility in controlling the output pulse provided by the K Factor Scaler Power sources and receiving devices differ in individual situations This fact requires the use of different pullup resistor values Connection of the external pullup resistor is between the receiving device s input and external power source see Figure 8 The power source voltage is the maximum input voltage of the pulse to the receiving device Refer to the following equation to help determine the pullup resistor value needed _ Supply Voltage 7 Current Where R Resistor value in ohms Supply Voltage External supply voltage connected to the external pullup resistor Current Input current required by the receiving device in amps After the resistor value is calculated make sure in the following equation that power P is less than or equal to 0 25 Watts P represents the output power capability This value should not exceed 0 25 Watts Damage to the K Factor Scaler circuit is likely by exceeding this value Raising the resistor value will decrease the available power output and safeguard the circuit 250 10k Pullup Resistor 9 Open Collector t a Pulse Output 100
10. External Pullup Resistor 0 10 Pulse 5 0 sta dean aa Ri RAE ae a wR OR a ee ines a ae a a ate et 10 Internal Pullljp Resistor eS a OW SR ae 11 External Pullup ResistOf sa gate ke ahaa ee eas eae Rea ee ea 12 K Factors Explained 2 ata ale ee a abe Db ee Secs edie bee 13 Calculating 5 eh ado Sage EERIE RESTS ER ORAS QE LR ES 13 September 2014 Page iii Signal Conditioner B220 880 and B220 881 K Factor Scaler Page iv September 2014 Introduction INTRODUCTION The Blancett K Factor Scaler is a field adjustable frequency divider which interfaces the output signal from a turbine meter with a magnetic pickup to the input of a PLC RTU CPU data acquisition card or similar totalizer device The adjustable frequency divisor referred to as the K factor allows the pulses being sent from a turbine meter to be divided into a recognizable unit that an end device such as a PLC can count and display Different K factors allow the device to display in any number of volume measurements such as gallons cubic meters liters barrels and like units A calibration sheet provided with a turbine meter lists a nominal K factor or other frequency information specific to that particular flow meter tested to a specific volumetric
11. LS Blancett Blancett signal conditioner Turbine Flow Meters gt Flow Meters B220 880 and B220 881 K Factor Scaler B220 880 B220 881 gt Badger Meter SGN UM 00281 EN 02 September 2014 U 5 r M a n u a Signal Conditioner B220 880 and B220 881 K Factor Scaler Page ii September 2014 User Manual CONTENTS INEFOGUCHON cot Dead ae ee eae oh a Oe eRe a Coe Oe aaa tee eat eae 5 Operating Principle pesasi ets ee haa e Pa Laces awe gd aha Pa be ae ase Sa bes 5 6 Installation dg nda ake ns a Ree EPERE beet eae Bas 7 Enclosure Mounting necessary for CSA certification 6 ee ee eee 7 ER ee adage Sha wade EU Rea ee Ra ee ERAS eee eee ee 7 TUBING dhe Deas ade Gaeta OE eee whe Ohad eas Geeta ae Oe eae wees 7 Puls Output 2 2208 ace ee aternir Meade ake hede ee kee dae hewn Saw 8 Startup And GConfguration 4 2 0 0c8s doe eee Ae hE ee EEA AE GEE NESE GEES 9 Setting the K FactON ose Ree eee Rh 9 Setting the Output Pulse Wid a 2 4 e450 ORG oe CS OTe Oe ee 9 Setting the Output Level REEERE PEE EEE RRR eee 10 Setting the Internal or
12. ademarks appearing in this document are the property of their respective entities Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists 2014 Badger Meter Inc All rights reserved www badgermeter com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina N 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Europe Middle East Branch Office Badger Meter Europe PO Box 341442 Dubai Silicon Oasis Head Quarter Building Wing Office 209 Dubai UAE 971 4 371 2503 Czech Republic Badger Meter Czech Republic s r o Ma kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 06 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 Legacy Document Number 02 SGN UM 00116
13. e least significant digit of the K factor number see Figure 2 For example to set the K factor as 4572 the switches should be set as shown in Figure 3 PERAR 4 5 7 2 Figure 3 Setting the rotary switches Setting the Output Pulse Width The output pulse width is the length of time the pulse remains active before resetting to its resting state The K Factor Scaler has a total of six different pulse widths to choose from Some end devices require that the pulse be a certain length or longer in order for proper detection of each incoming pulse For these devices it is important to select a pulse width that is long enough for the end device to recognize DIP Switch The pulse width options are selected by the DIP switch positions 1 2 and 3 Table 1 shows the position of each switch to select the desired pulse width output s DIP Switch Pulse Width 1 2 3 150 us M v M ETES 1ms A v ION SDAO05 A UP ON 25 ms v A v 100 ms A A v i 500 ms v v A 1 2 3 4 5 WY DOWN OFF 1s A v A Auto y A A Factory Test A A A Table 1 DIP switch settings for selecting the width of the output pulse Figure 4 Pulse width settings September 2014 SGN UM 00281 EN 02 9 Startup And Configuration Setting the Output Level Most end devices are unaffected by this setting but the K Factor Scaler board has the ability to invert the output pulse level
14. it outlet box to maintain the CSA Ordinary Locations certification The label containing the hookup information should be placed on the inside of the cover of the enclosure The label containing the CSA logo should be placed on the bottom exterior of the enclosure Power The K Factor Scaler requires 8 5 30V DC to operate The power connections are reverse polarity protected by a diode but must be connected properly for operation of the device Polarity is shown in Figure 2 Turbine Meter The turbine meter connections are non polarized and located on a separate 2 position terminal Shielded twisted pair wire is recommended for this connection September 2014 SGN UM 00281 EN 02 Page 7 Installation Pulse Output Either the internal pullup resistor or an external resistor must be used for the K Factor Scaler to provide an output pulse This option is controlled by position 5 of the DIP switch Internal Pull up Resistor The internal pullup resistor allows for a simple installation but care must be taken to ensure that the device being connected to by the pulse output can handle voltage levels as high as the power feeding the K Factor Scaler Another important setup consideration when using the internal pullup resistor is to make sure the output pulse from the K Factor Scaler can supply enough current for the receiving device to be able to read the pulse The available current that the K Factor Scaler can supply the receiving device can
15. justable and set by programming it into the board The microcontroller handles the dividing process by counting the input pulses and comparing it to the programmed K factors Once the count equals this value an output pulse occurs for a selectable time period and the counting process starts over September 2014 SGN UM 00281 EN 02 5 Specifications SPECIFICATIONS FOR THIS DEVICES CSA RATING BE VALID THE CIRCUIT BOARD MUST BE MOUNTED IN A CERTIFIED APPLETON 1 IN MODEL GRL100 A OR GRLB100 A CONDUIT OUTLET BOX External Power Input Voltage 8 5 30V DC diode protected Maximum Current Draw Environmental 18 mA using internal resistor 30V DC input Operating Temperature 22 158 F 30 70 Inputs Magnetic Pickup Frequency Range 0 4000 Hz Trigger Sensitivity 30 mV p p 30V Output Signal Max Voltage 30V DC Max Power 0 25 W Pulse Output using internal pullup resistor Maximum Current 8 mA VH Power input voltage 0 7V DC VL Less then 0 4V maximum input power Internal Pullup Resistor 3 6 enabled disabled by jumper Pulse Output using externa pullup resistor Maximum Current 100 mA VH Input voltage to external pullup resistor VL selected resistor value 47 Q x 47 Pulse Length 150 us 1 ms 25 ms 100 ms 500 ms 1 s or auto mode
16. tric flow rate to be able to compute a K factor To convert a velocity into a volumetric flow the velocity measurement and an accurate measurement of the inside diameter of the pipe must be known Also needed is the fact that one US gallon of liquid is equal to 231 cubic inches September 2014 SGN UM 00281 EN 02 Page 13 K Factors Explained Example 3 Known values are Velocity 4 3 ft sec Inside Diameter of Pipe 3 068 in Find the area of the pipe cross section Area 3 068 2 35 7 39 Find the volume one foot of travel 88 7 1in ft 7 39 in x 12 in 1 ft What portion of a gallon does one foot of travel represent 88 71 in 231 in 0 384 gallons So for every foot of fluid travel 0 384 gallons will pass What is the flow rate in gpm at 4 3 ft sec 0 384 gallons x 4 3 FPS x 60 sec 1 min 99 1 Now that the volumetric flow rate is known all that is needed is an output frequency to determine the K factor Known values are Frequency 700 Hz By measurement Flow Rate 99 1 gpm By calculation 700 Hz x 60 sec 42 000 pulses per gallon 42 000 pulses per min K factor 423 9 pulses per gallon 99 1 gpm Page 14 SGN UM 00281 EN 02 September 2014 K Factors Explained INTENTIONAL BLANK PAGE September 2014 SGN UM 00281 EN 02 Page 15 Control Manage Optimize BLANCETT is a registered trademark of Badger Meter Inc Other tr
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