Flo-Station (AC/DC) Monitor User Manual
Contents
1. Installation 2 m Figure 4 Wiring preparation and insertion 1 Strip inch of insulation 2 Seat insulation against connector with no bare wire exposed Table 1 Wiring information for AC power Terminal description Wire color code for North America Wire color code for EU Hot Black Brown Neutral White Blue Protective Earth PE Green Green w yellow tracer Figure 5 Wiring for AC power 1 Fuse holder 5 Line wire 2 Power reset button 6 AC power block 3 Ground wire 7 Protective earth grounding block 4 Neutral wire 11 Installation 3 2 2 2 DC power WARNING Do not connect AC power to a DC monitor Important Note Always use 18 AWG wire stranded with 85 overall braid 1 Remove the bottom cover Figure 2 on page 8 2 Insert the power cable through the strain relief fitting or conduit hub in the bottom of the enclosure Properly prepare each wire Figure 4 on page 11 4 Install the ground wire or cable braid to the protective earth grounding block Figure 6 item 2 and item 6 Make sure the ground wire is securely connected 5 Install the negative wire first and then the positive wire into the power terminal Tighten each wire and then tug gently to make sure the connection is tight Tighten the strain relief if used to secure the cord Seal any unused openings in the enclosure with conduit sealing plugs Instal2. vapors mists dusts or fibers may be present Before entering any confined space check with your employer for procedures related to confined space entry General information 2 2 Product overview The Flo Station Monitor controls and transmits flow data from Marsh McBirney MMI sensors Figure 1 The Flo Station becomes a powerful open channel flow meter and data reporting system when it is used with the following components e MMI sensors Flo Ware software e Portable computer or pocket PC not supplied Figure 1 Typical Flo Station system 1 AC or DC power cable 4 Flo Dar sensor cable 2 RS232 interface cable 5 Surcharge Velocity Sensor SVS cable 3 Flo Tote 3 sensor cable 2 2 1 System features The flow meter consists of the Flo Station Monitor a sensor unit sold separately and the sensor mounting frame assembly sold separately Refer to Figure 1 There are two versions of mounting hardware permanent and temporary Note The Flo Tote 3 sensor requires a mounting band for installation The four 4 20 mA outputs provide a convenient way to transfer real time flow data to SCADA and other data collection systems control systems and display devices The optional display shows the flow velocity level totalized flow and other channels General information 2 2 2 Applications e Billing purposes EPA permitting requirements Inflow Infiltration studies e Combined sewer overflow
3. This filter is all that is required for most applications If the monitor is installed in a high moisture environment such as a pit install an optional desiccant cartridge Section 7 on page 23 The desiccant cartridge protects the APR tube from moisture and debris that can affect the accuracy of the surcharge level pressure transducer on a Flo Dar sensor or primary level on a Flo Tote 3 sensor 1 Remove the hydrophobic filter and attach the desiccant cartridge to the APR port Figure 10 Note Two cartridges can be used in series for extra protection Replace the desiccant cartridge when the color changes to pink Figure 10 Desiccant cartridges 1 Hydrophobic filter 2 Moist environment desiccant 3 Low maintenance moist cartridge environment desiccant cartridge 3 5 Record the installation measurements 16 o FP P Document the site specific data location site ID and description Enter the installation date Record the serial numbers of the monitor and sensor Record pipe inside dimension ID number Record Level offset Sensor Offset or Level Cal as appropriate Refer to the sensor manual for the installed sensor Record the sediment level if applicable Section 4 4 1 Flo Ware Operation Note The Flo WareTM T200 Software with Flo Dar or Flo Tote 3 file driver is required to set up the Flo Station The Flo Ware for Windows software model T200 is a data man
4. metal conduit or pipe e To reduce static build up avoid excessive movement Transport static sensitive components in anti static containers or packaging e To discharge static electricity from your body and keep it discharged wear a wrist strap connected by a wire to earth ground Handle all static sensitive components in a static safe area If possible use anti static floor and work bench pads 3 2 2 Wiring for power 3 2 2 1 AC power 10 The AC and DC units have different power connectors DC units have a fixed 2 terminal connector and AC units have a removable connector for the neutral and line wires Use a screwdriver to secure all wiring connections Important Note Always use 18 AWG wire stranded with 85 overall braid 1 Remove the bottom cover Figure 2 on page 8 2 Insert the power cable through the strain relief fitting or conduit hub in the bottom of the enclosure Properly prepare each wire Figure 4 4 Install the ground wire to the protective earth grounding block Figure 5 Make sure the ground wire is securely connected 5 Install the neutral and line wires into the AC power connector Refer to Table 1 Tighten each wire and then tug gently to make sure the connection is tight Plug the connector into the 100 240 VAC power block Tighten the strain relief if used to secure the cord Seal any unused openings in the enclosure with conduit sealing plugs o 0o N Install the bottom cover
5. monitoring Process control e Modeling Sewer system evaluations e Wastewater treatment plant balancing 2 3 Unpack the instrument Remove the Flo Station and the included RS232 interface cable from the shipping carton Inspect for any visible damage If an item is missing or damaged contact the manufacturer Section 8 on page 25 2 4 Front panel Refer to Figure 2 for the Flo Station Monitor front panel features Figure 2 Flo Station Monitor features Bottom cover 5 RS232 connector 2 Cover attachment screw 6 Atmospheric pressure reference APR port hydrophobic filter 3 Side channel cover access 7 Conduit hubs and strain relief fittings 4 Display if equipped Section3 Installation 3 1 Mount the instrument DANGER Potential confined space hazards The monitor is not suitable for manhole installations DANGER Only qualified personnel should conduct the tasks described in this section of the manual Important Note Do not mount the monitor in locations that receive direct exposure to sunlight or rain Install the monitor on a flat surface indoors or in an environmental enclosure or protective covering outdoors 1 Position the unit on the mounting surface Make sure the unit is approximately eye level with the cable entry side facing downward Figure 3 2 Mark the mounting hole positions and drill the appropriate sized holes at the marked locations 3 Use 6 screws or bolts to attach
6. screwdriver to open the fuse holder and remove the fuse Figure 5 on page 11 Item 1 Replace the fuse with a fuse of the same type and rating Push and twist the cover of the fuse holder to tighten Install the bottom cover NO go RA Apply power to the instrument 5 3 Desiccant replacement Replace the desiccant cartridge when the color changes to pink section 3 4 on page 16 5 4 Lithium battery check Check the back up lithium battery life every six months Use the Flo Ware software to check the battery life 19 Maintenance 20 Section 6 Troubleshooting When a problem occurs try to determine whether the problem is from the monitor the cables or the sensor Check all connections Check the connections and make sure that power is applied to the Flo Station Verify the sensor operation e Determine if the problem is with just one measurement channel or if the sensor is not responding at all e Check the sensor for debris that may have collected If the sensor is not responding remove and inspect the connector on the sensor for moisture Clean and dry if necessary Tighten this connector firmly Verify the monitor operation Write down all error codes that occur and contact the factory Restart the microprocessor If the Flo Station locks up due to a power fluctuation or unknown reason push the red reset button to restart the microprocessor Figure 5 on page 11 or Figure 6 on page 12 21 Tr
7. single pole rated resistive load 0 5A 60 VDC 0 5A 60 VAC normally open pole contact Output voltage 12 VDC 150 mA output to power external devices Input voltage 0 to 5 V input for logging only 1 Disconnect power to the Flo Station Monitor Remove the bottom cover 9 Make sure that the ground wire is connected to the protective earth grounding block Figure 5 on page 11 or Figure 6 on page 12 4 Insert the cable s through the strain relief fitting or conduit hub near the CP2 terminal block Figure 9 5 Install each wire into the terminal block Tighten each wire and then tug gently to make sure the connection is tight Tighten the strain relief if used to secure the cable s Install the bottom cover Figure 9 CP2 terminal block connections for input and contact closure 1 Contact closure normally open 2 Output voltage 12 VDC 3 Input voltage 0 to 5 V 4 Do not use 3 3 Connect the power source DANGER Electrocution hazard Hazardous supply voltage can shock or cause death Do not connect AC power to a DC Monitor 1 Check all connections 2 Replace bottom panel cover 3 Tighten screws on cover 15 Installation 3 4 Optional desiccant Install the Flo Station monitor in a relatively dry environment such as a control room or other suitable space A hydrophobic filter is attached to the atmospheric pressure reference APR port to absorb excess moisture
8. the monitor to the surface Choose a fastener that is suitable for the mounting surface concrete wood metal etc Note The clearance through the mounting holes is 0 2 inches 4 Make sure the unit is secure 257 8 mm 95 3 mm 10 15 in 3 75 in la Figure 3 Instrument dimensions Installation 3 2 Electrical connections A DANGER Electrocution hazard Always disconnect power to the instrument when making any electrical connections When making any wiring connections to the instrument the following warnings and notes must be adhered to as well as any warnings and notes found throughout the individual installation sections For more safety information refer to section 2 1 on page 5 3 2 1 A Electrostatic Discharge ESD considerations Important Note To minimize hazards and ESD risks maintenance procedures not requiring power to the analyzer should be performed with power disconnected Delicate internal electronic components can be damaged by static electricity resulting in degraded instrument performance or eventual failure The manufacturer recommends taking the following steps to prevent ESD damage to your instrument Before touching any instrument electronic components such as printed circuit cards and the components on them discharge static electricity from your body This can be accomplished by touching an earth grounded metal surface such as the chassis of an instrument or a
9. AS MARSH McBIRNEY A Hach Company Brand DOC026 53 00790 Flo Station AC DC Monitor User Manual November 2009 Edition 3 Hach Company 2008 2009 All rights reserved Printed in the U S A mm kt Table of Contents SECON SPecilications zen aan 3 Section 2 General information 422444244004200nnnnnnonnnennnnnennnnnnnnnonnnnnnnnnennnnnnnnnnnnnnnnn 5 27 2 S 3lEWE I A A AA 5 2 1 1 Use 0 hazardinto malas ee ea 5 2 1 2 Precautionary AAA eat a tebaedaanarecendt 5 2 1 3 Confined space precautions miooo 6 2 2 poe SN een 5 een bier 7 2 2 1 System Tfealufes ana naher uk 7 2 2 2 PAPC ALI ON ee else esse etlichen 8 2 3 Unpack the instrument ee 8 2 4 PONE Panel nee eu eat 8 Section 3 Installation 2 2 ses ee reisen 9 Sal Mountthe instrument 2 9 3 2 Ele t ical COMNECIUONS nenne ainiesschlih hausen Bahn 10 3 2 1 Electrostatic Discharge ESD considerations oooccccnnnnncicicnncoccnnnnancccnnnnncncnncnanannnnnna neo 10 32 2 WIRNGTTORPOWEr an ee eltern ee 10 32 2 1 AG POWEr ae eek 10 3 222 DE BOWEr ne ee ei vars aGevandsen Eaa Aaea eas eu a Ental 12 3 2 3 Sensor cable connections A ee haare 13 3 2 4 4 20 mA OUTPUT CONMECHONS caida iz 14 3 2 5 Additional CONNECtONS u sen 15 3 3 Connect INE DOWEr SOU nn ee 15 3 4 OPLONal desice A ee een Ge E EE 16 3 5 Record the installation Measurements ici ea 16 Section 4 OHelalloN unse rd tr s 17 A A EA DA 17 4 1 1 RS232 s
10. S sensor Terminal Flo Dar wire color S1 Flo Tote 3 wire color S1 SVS wire color S2 1 White White White 2 Black Black Black 3 Clear Orange Orange 4 Red Red Red 5 Green Green Green 6 Black Black Black 13 Installation 3 2 4 4 20 mA output connections Important Note Always use 12 to 22 AWG stranded twisted pair wire 1 2 3 N Disconnect power to the Flo Station Monitor Remove the bottom cover Make sure that the ground wire is connected to the protective earth grounding block Figure 5 on page 11 or Figure 6 on page 12 Insert the cable s through the strain relief fitting or conduit hub near the CP1 terminal block Figure 8 Install each wire into the terminal block Tighten each wire and then tug gently to make sure the connection is tight Note Each terminal is labeled for polarity This is the voltage polarity when a load resistance is placed across the terminals Tighten the strain relief if used to secure the cable s Install the bottom cover Figure 8 CP1 terminal block connections for 4 20 mA outputs 1 Flow Channel 1 2 Level Channel 2 3 Velocity Channel 3 4 Surcharge level Channel 4 14 Installation 3 2 5 Additional connections Important Note Always use 12 to 22 AWG stranded twisted pair wire The following optional connections can be made on the CP2 terminal block e Contact closure
11. agement and instrument communication software package The software package includes an instrument driver chart reports text reports data editing text report designer and language designer site set up data collection real time calibration computer interface cable and an instruction manual The Flo Ware is provided on a CD and the Flo Ware FX is provided on an SD card Detailed instructions for using Flo Ware T200 software are contained in the Flo Ware User Manual The 4 20 mA output setup instructions are found in the extended setup section Instructions are also accessed directly from the T200 program via the Help function The sensor offset and site specific information such as pipe shape pipe ID and sediment level obtained during sensor installation will need to be entered into the site setup section of T 200 Flo Dar communications For Flo Dar sensors the Flow Cal Method is typically set for Direct Mean Velocity for circular pipes If the application is a rectangular channel the Flow Cal Method is set for Velocity Multiplier When using the Flo Dar sensor select Extended Setup if you have the optional extended range feature Select Extended Range level transducer on the ultrasonic level call screen Flo Tote 3 sensors use a Site Calibration Coefficient Refer to the Flo Tote 3 user manual for profiling and setting the site calibration coefficient 4 1 1 RS232 serial communications cable A portabl
12. e computer with Flo Ware software must be connected via a communication cable to the Flo Station to set up and collect data from the flow meter The communication cable is included as part of the Flo Ware software package Extra cables may be purchased by registered Flo Ware users The RS232 Serial Communications Connector is located on the front panel of the Flo Station housing The front panel should remain in place whenever the communication cable is not connected 1 Pull the side channel away from the side of the top cover Figure 11 2 Remove the piece of molding from the channel 3 Push the channel down to release the bottom attachment and open the cover 4 Plug the RS232 cable into the connector on the front of the monitor 17 Operation Figure 11 RS232 front panel access 18 Section5 Maintenance DANGER Only qualified personnel should conduct the tasks described in this section of the manual 5 1 Cleaning Clean the Flo Station periodically Use a damp cloth only Do not submerge or douse with water 5 2 Fuse replacement AC model The Flo Station Monitor contains one 5 x 20 mm 1 A 250 V fuse Failed fuses are an indication that an equipment problem could exist Problem resolution and fuse replacement should be performed only by qualified service personnel 1 Disconnect power to the Flo Station Monitor including power to relays and other components if powered Remove the bottom cover a Use a
13. erial communications Cable in Gaede esonteeneld 17 Section 5 Maintenance ias 19 5 1 GleaniNg cala 19 5 2 Fuse replacement AC model osa ds 19 5 3 Desic ant replacement ici ee 19 5 4 Lithia battery CHECK A Mo O aaae aaa aiaee La E aAA ARa aaeeeiai 19 Section 6 Troubleshooting 4444440440nnennonnennnnnnnnnennnnennennennnnnnnennennennen nennen 21 Section 7 Replacement parts and accessories 4 44nnensennnnnennnennennennennen nen 23 TA Replacement Parse 23 Section 8 Contact Information oonconcnnncicnnncncccnocnconnonnnonncnnnonnnon nono nonnnorn non nnnn nar nnnnncnnnns 25 Table of Contents Section 1 Specifications Specifications are subject to change without notice Housing Dimensions 257 8 mm W x 236 7 mm L x 95 3 mm D 10 15 in x 9 2 in x 3 75 in Weight 2 3 kg 5 Ib Enclosure ABS Plastic NEMA 4 Operating temperature 10 C to 50 C 14 F to 122 F 20 C to 50 C 4 F to 122 F without display Storage temperature 40 C to 60 C 40 F to 140 F without display 20 C to 60 C 4 F to 140 F with display Power requirements AC 85 264 VAC 47 63 Hz 32 watts DC 12 VDC for Flo Station without display or Flo Station with display Backlight off 180 mA 2 1 watts with 1 4 20 mA utilized General Data storage 64 k 16 k cycles of velocity level data Local t
14. erminal RS232C at 19 2K Baud Optional display Dimensions 1 in x 3 in Four lines of text display FLOW LEVEL VELOCITY TOTAL or any combination of any four channels containing data Screens may be programmed to alternate values displayed Timebase accuracy 1 second per day Outputs Four 4 20 mA outputs system isolated up to 600 ohm load The 4 20 mA outputs are flow level velocity or surcharge level Contact closure Dry contact closure with adjustable duration selectable 2 seconds maximum for flow proportional or alarm based on flow level velocity or surcharge level temperature battery voltage each sample bad sample or analog input Rating 1 A at 30 VDC resistive 0 5 A at 125 VAC resistive Setup Data retrieval Flo Ware for windows software is the user on site setup data management and report generation software It is compatible with desktop portable computers using Windows 95 98 2000 Me NT XP Flo Ware for windows software can retrieve data from both Flo Tote and Flo Dar flow meters Flo Ware FX for Pocket PC has all of the same functionality as Flo Ware for Windows with the exception of report generation Warranty Warranty 1 year Specifications Section 2 General information The contents of this manual is thought to be accurate The manufacturer is not liable for direct indirect special incidental or consequential damages resulting from any defect or o
15. ining in pre entry testing ventilation entry procedures evacuation rescue procedures and safety work practices is necessary to ensure against the loss of life in confined spaces Important Note The following information is provided to guide users of Flo Station Flow Meters on the dangers and risks associated with entry into confined spaces On April 15 1993 OSHA s final ruling on CFR 1910 146 Permit Required Confined Spaces became law This new standard directly affects more than 250 000 industrial sites in the U S A and was created to protect the health and safety of workers in confined spaces Definition of a confined space A confined space is any location or enclosure that presents or has the immediate potential to present one or more of the following conditions Anatmosphere with less than 19 5 or greater than 23 5 oxygen and or more than 10 ppm Hydrogen Sulfide H S Anatmosphere that may be flammable or explosive due to gases vapors mists dusts or fibers e Toxic materials which upon contact or inhalation could result in injury impairment of health or death Confined spaces are not designed for human occupancy They have restricted entry and contain known or potential hazards Examples of confined spaces include manholes stacks pipes vats switch vaults and other similar locations Standard safety procedures must always be followed prior to entry into confined spaces and or locations where hazardous gases
16. l the bottom cover Figure 6 Wiring for DC power 1 Power reset button 4 Positive wire 2 Ground wire 5 DC power terminal 3 Negative wire 6 Protective earth grounding block 12 Installation 3 2 3 Sensor cable connections A DANGER Potential confined space hazards If conduit is installed from the monitor to the sensor the conduit must be sealed to keep sewer gases out of the electronics The S1 terminal block is used for the Flo Dar or Flo Tote 3 sensor connections The S2 terminal block is used for the optional Flo Dar SVS sensor connections Figure 7 1 Disconnect power to the Flo Station Monitor 2 Remove the bottom cover 3 Make sure that the ground wire is connected to the protective earth grounding block 4 Insert the sensor cable s through the strain relief fitting or conduit hub near the S1 and S2 terminal blocks 5 Install each wire into the terminal block as shown in Figure 7 and Table 2 Tighten each wire and then tug gently to make sure the connection is tight 6 Insert the APR reference tube into the strain relief fitting until it stops Figure 7 item 2 7 Tighten the strain relief if used to secure the cable s 8 Install the bottom cover O Figure 7 S1 and S2 terminal blocks 1 Strain relief fitting 2 APR reference tube 3 Sensor cable Table 2 Terminal block connections for Flo Dar Flo Tote 3 and Flo Dar optional SV
17. mission in this manual even if advised of the possibility of such damages In the interest of continued product development the manufacturer reserves the right to make improvements in this manual and the products it describes at any time without notice or obligation Revised editions are found on the manufacturer s website 2 1 Safety information Please read this entire manual before unpacking setting up or operating this equipment Pay attention to all danger warning and caution statements Failure to do so could result in serious injury to the operator or damage to the equipment To make sure that the protection provided by this equipment is not impaired do not use or install this equipment in any manner other than that specified in this manual 2 1 1 Use of hazard information DANGER Indicates a potentially or imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially or imminently hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation that may result in minor or moderate injury Important Note Indicates a situation which if not avoided may cause damage to the instrument Information that requires special emphasis Notice Indicates a situation that is not related to personal injury 2 1 2 Precautionary labels Read all labels and tags attached to the instrument Personal i
18. njury or damage to the instrument could occur if not observed This is the safety alert symbol Obey all safety messages that follow this symbol to avoid potential injury If on the instrument refer to the instruction manual for operation or safety information This symbol when noted on the product indicates that a risk of electrical shock and or electrocution exists This symbol when noted on the product identifies the location of the connection for Protective Earth ground This symbol when noted on the product identifies the location of a fuse or current limiting device This symbol indicates the presence of devices sensitive to Electro static Discharge ESD and indicates that care must be taken to prevent damage to the equipment Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12 August of 2005 In conformity with European local and national regulations EU Directive 2002 96 EC European electrical equipment users must now return old or end of life equipment to the Producer for disposal at no charge to the user Note For return for recycling please contact the equipment producer or supplier for instructions on how to return end of life equipment producer supplied electrical accessories and all auxiliary items for proper disposal xt pop e General information 2 1 3 Confined space precautions A DANGER Explosion hazard Tra
19. oubleshooting 22 Section7 Replacement parts and accessories 7 1 Replacement Parts Description Item number Moisture block cartridge air tube 151000201 Desiccant cartridge moist environment 55032 Desiccant cartridge moist environment low maintenance 5027 RS232 interface cable 570007301 Fuse AC 015804 Cord power AC 24500M Software CD Flo Ware 800015301 23 Replacement parts and accessories 24 Section 8 Contact Information Ordering information for the U S A By Mail Hach Company By Telephone By Fax 4539 Metropolitan Court 800 368 2723 301 874 8459 Frederick MD 21704 9452 U S A Ordering information by e mail hachflowsales hach com Information Required e Hach account number if available e Billing address Your name and phone number e Shipping address e Purchase order number e Catalog number e Brief description or model number e Quantity European Union Flow Tronic Rue J H Cool 19a B 4840 Welkenraedt Belgium Tel 32 87 899799 Email site flow tronic com www flow tronic com Outside the U S A and EU Hach Company maintains a worldwide network of dealers and distributors To locate the representative nearest you send E mail to hachflowsales hach com or visit www hachflow co Technical Support Technical and Customer Service Department personnel are eager to answer questions about our products and their use In the U S A call 1 800 635 1230 Outside the U S A and Europe
20. send E mail to hachflowservice hach com or call 1 301 874 5599 Repair Service Authorization must be obtained from Hach Company before sending any items for repair To send the monitor to the factory for repair 1 Identify the serial number of the monitor unit 2 Record the reason for return 3 Call the Customer Service Department 1 800 368 2723 and get a Service Request Number SRN and shipping label 4 Use the shipping label provided and ship the equipment in the original packaging if possible Note Do not ship manuals computer cables or other parts with the unit unless they are required for repair 25 Contact Information 26 5 6 7 8 Make sure the equipment is free from foreign debris and is clean and dry before shipping Sensors returned without cleaning will be charged a fee Write the SRN number on the shipping box Make sure that all return shipments are insured Address all shipments to Hach Company 5600 Lindbergh Drive North Dock Loveland Colorado 80539 0389 U S A Attn SRN XXX
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