Page 1
K-Factor Scalers
Models B220-880, B220-881, B220-882 and B220-885
B220-880
B220-882
B220-881
B220-885
SGN-UM-00281-EN-05 (June 2017)
User Manual
Page 2
K-Factor Scalers, Models B220-880, B220-881, B220-882 and B220-885
Page ii June 2017
Page 3
User Manual
CONTENTS
Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Enclosure Mounting (necessary for CSA certication). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbine Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Startup and Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting the K-Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting the Output Pulse Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting the Output Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting the Internal or External Pullup Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Internal Pullup Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
External Pullup Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
K-Factors Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calculating K-Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Page iii June 2017
Page 4
K-Factor Scalers, Models B220-880, B220-881, B220-882 and B220-885
Page iv June 2017
Page 5
Scope of This Manual
SCOPE OF THIS MANUAL
This manual is intended to help you get the K-Factor scalers up and running quickly.
MPORTANTI
Read this manual carefully before attempting any installation or operation. Keep the manual accessible for future reference.
UNPACKING AND INSPECTION
Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such
as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.
OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the
carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.
SAFETY
Terminology and Symbols
Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing death or
serious personal injury.
Indicates a hazardous situation, which, if not avoided, could result in severe personal injury or death.
Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing minor or
moderate personal injury or damage to property.
Considerations
The installation of the B220-880 and B220-881 K-Factor scaler must comply with all applicable federal, state, and local rules,
regulations, and codes.
CAUTION
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY
THE EQUIPMENT MAY BE IMPAIRED.
AVERTISSMENT
DANS LE CAS D'UNE UTILISATION NON PRÉVUE PAR LE FABRICANT, LA PROTECTION FOURNIE PAR L'ÉQUIPEMENT PEUT
ÊTRE RÉDUITE.
CAUTION
FOR FIELD WIRING CONNECTIONS, WIRE MUST BE RATED AT 158° F (70° C) OR HIGHER.
AVERTISSMENT
POUR DES CÂBLAGES SUR LE TERRAIN, LES CÂBLES DOIVENT ÊTRE ÉVALUÉS À 70° C (158° F) MINIMUM.
MPORTANTI
Not following instructions properly may impair safety of equipment and/or personnel.
MPORTANTI
Must be operated by a class 2 power supply suitable for the location.
Electrical Symbols
Function Direct Current Caution
Symbol
Page 5 June 2017 SGN-UM-00281-EN-05
Page 6
Turbine Rotor
Magnetic Pickup
Signal
Introduction
INTRODUCTION
The 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 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 generates a frequency output signal that is
directly proportional to the speed of the rotor.
or
Other Frequency
Output Device
Output
Figure 1: Schematic illustration of electric signal generated by rotor movement
The signal produced is received by the K-factor scaler input amplifier, which has an input sensitivity of 30 mV
…30V
p-p
p-p
. 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 adjustable 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.
Page 6 June 2017SGN-UM-00281-EN-05
Page 7
Pulse Output
(for selecting pulse width,
Installation
INSTALLATION
The K-Factor scaler was designed with terminal connections with removable plugs for easy connection and removal from the
system after installation. See Figure 2 for the I/O terminal connections. The board connections include voltage input, turbine
meter input and the pulse output to a totalizing device.
P1
DIP Switches
Voltage Input
8.5…30V DC
ON C&K SDA05
S10
1 2 3 4 5
0
0
0
0
0
0
1
1
9
2
8
3
7
4
6
5
9 9 9 9 9 9 9 9
1
9
9
2
8
7
2
8
3
3
7
4
4
6
6
5
5
, ,
1
1
9
9
2
2
8
8
7
3
3
7
4
4
6
6
5
5
0
1
1
9
9
2
8
8
3
7
7
4
4
6
6
5
5
pulse state and pullup
resistor options)
0
1
9
2
2
8
3
3
7
4
6
5
Turbine Meter
P2
P4
Figure 2: Input/Output terminal connections
Factory Use Only
Input
Enclosure Mounting (necessary for CSA certication)
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 conduit 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. Use shielded, twisted pair
wire for this connection.
Page 7 June 2017 SGN-UM-00281-EN-05
Page 8
, ,
DOWN (OFF)
Startup and Conguration
STARTUP AND CONFIGURATION
After the K-factor scaler has been properly installed, apply power. 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. 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 cause the dividing process to start over.
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…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 the least significant digit of the K-factor
number (see Figure 2 on page 7). For example, to set the K-factor as 4572, the switches should be set as shown in Figure 3.
0
0
0
0
0
0
1
9
8
7
6
5
1
9
2
8
3
7
4
9
2
8
3
7
4
6
6
5
0
1
9
2
8
3
7
4
6
5
5
1
1
9
2
8
3
7
4
6
5
1
9
2
8
3
7
4
9
2
8
3
7
4
6
6
5
0
1
1
9
2
2
8
3
3
7
4
4
6
5
5
9 9 9 9 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 the resting state. The K-factor scaler
has six different pulse widths. Some end devices require that the pulse be a certain length or longer for proper detection of
each incoming pulse. For these devices, 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 correct pulse width output.
Pulse Width
150 µs
1 ms
25 ms
100 ms
500 ms
1 s
Auto
Factory Test
1 2 3
▼ ▼ ▼
▲ ▼ ▼
▼ ▲ ▼
▲ ▲ ▼
▼ ▼ ▲
▲ ▼ ▲
▼ ▲ ▲
▲ ▲ ▲
Table 1: DIP switch settings for selecting the width of the output pulse Figure 4: Pulse width settings
DIP Switch
ON C&K SDA05
1 2 3 4 5
UP (ON)
Page 8 June 2017SGN-UM-00281-EN-05
Page 9
DOWN (OFF)
Startup and Conguration
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.
This option is controlled by position 4 of the DIP switch.
When the switch is in the off position (see Figure 5), the output level is normally low and the duration of the selected pulse
width is high. When the switch is in the on position (see Figure 5), the output level is normally high and the duration of the
selected pulse width is low.
Switch 4 Function Switch 5 Function
Output (Normally High)
Output (Normally Low)
Table 2: Switch 4 and 5 settings
Internal Pullup used
▲
External Pullup required
▼
▲
▼
ON C&K SDA05
1 2 3 4 5
Figure 5: Switch 4 settings
UP (ON)
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.
ON C&K SDA05
1 2 3 4 5
Figure 6: Switch 5 settings
When DIP switch 5 is in the on position (see Figure 6), the internal 3.6 k 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 (see Figure 6), the internal pullup resistor is disconnected and an external pullup
resistor and supply voltage are required.
UP (ON)
DOWN (OFF)
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. See Table 2 for the I/O terminal connections.
Page 9 June 2017 SGN-UM-00281-EN-05
Page 10
Available Current =
(Input Voltage - 0.7V)
(3600Ω + 47Ω)
Startup and Conguration
Internal Pullup Resistor
The internal pullup resistor is used for a simple installation. Make sure that the device being connected to the pulse output
can accept voltage levels as high as the supply feeding the K-factor scaler. Make sure the output pulse from the K-factor scaler
can supply enough current for the receiving device to read the pulse when using an internal pullup resistor. Use the following
equation to calculate the available current that the K-factor scaler can supply to the receiving device. See Figure 7.
Using the equation above, 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. Use an external pullup resistor less than 3.6 k if the value
is higher than the available current.
Voltage Input
Internal
3.6k Ω
0
1
9
2
8
3
7
4
6
5
Open Collector
Pulse Output
8 mA
Maximum
P1
ON C&K SDA05
S10
1 2 3 4 5
0
0
0
0
0
0
1
1
9
2
8
3
7
4
6
5
9 9 9 9 9 9 9 9
1
9
9
2
2
8
8
TB1
3
3
7
7
4
4
6
6
5
5
, ,
1
9
2
8
3
7
4
6
5
0
1
1
1
9
9
9
2
2
2
8
8
8
3
3
7
7
7
4
4
4
6
6
6
5
5
5
3
P2
C&K SDA05
P4
ON
1 2 3 4 5
Switch 5 On
(Up)
Figure 7: Wiring schematic with internal pullup resistor in circuit
Page 10 June 2017SGN-UM-00281-EN-05
Page 11
R =
Supply Voltage
Current
Startup and Conguration
External Pullup Resistor
Using an external pullup resistor creates greater flexibility in controlling the output pulse provided by the K-factor scaler.
Power sources and receiving devices differ in individual situation so make sure you are using the correct resistor. 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. Use the following equation to determine
the correct pullup resistor value.
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, the power capabilty of the output, is
less than or equal to 0.25 Watts. Exceeding this value can cause damage to the K-factor scaler circuit. Raising the resistor value
decreases the available power output and safeguard the circuit.
P = ( Supply Voltage )
Supply Voltage
R + 47 Ω
Voltage Input
250…10k
Resistor
Open Collector
Pulse Output
Maximum
Pullup
100 mA
P1
ON C&K SDA05
S10
1 2 3 4 5
0
0
0
0
0
1
9
9
2
8
8
3
3
7
7
4
6
6
5
, ,
0
1
1
9
2
2
8
TB1
3
3
7
4
4
6
5
5
P4
1
9
2
8
7
4
6
5
9 9 9 9 9 9 9 9
0
1
1
1
9
9
9
2
2
2
8
8
8
3
3
3
7
7
7
4
4
4
6
6
6
5
5
5
P2
0
1
9
2
8
3
7
4
6
5
Internal
C&K SDA05
ON
1 2 3 4 5
Switch 5 O
(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.
Current Draw =
0.25 Watts
External Pullup Resistor
Page 11 June 2017 SGN-UM-00281-EN-05
Page 12
Specications
SPECIFICATIONS
CAUTION
FOR THE DEVICES CSA RATING TO BE VALID, THE CIRCUIT BOARD MUST BE MOUNTED IN A CERTIFIED APPLETON 1 IN.
MODEL GRL100-A, GRLB100-A OR GRT100-A CONDUIT OUTLET BOX.
External Power
Environmental
Inputs
(Magnetic Pickup)
Output Signal
Pulse Output
(using internal
pullup resistor)
Pulse Output
(using external
pullup resistor)
Enclosure Ratings
Certifications
Input voltage 8.5…30V DC (diode protected)
Maximum current draw 18 mA (using internal resistor @ 30V DC input)
Operating temperature –22…158° F (–30…70° C)
Altitude 2000 m
Use Indoor/outdoor
Humidity 0…90% non-condensing
Frequency range 0…4000 Hz
Trigger sensitivity 30 mV p-p…30V p-p
Max voltage 30V DC
Max power 0.25 W
Maximum current 8 mA
VH = Power input voltage 0.7V DC
VL = Less than 0.4V @ maximum input power
Internal pullup resistor 3.6 k (enabled/disabled by jumper)
Maximum current 100 mA
VH = Input voltage to external pullup resistor
VL = [VH /(selected resistor value + 47 )] × 47
Pulse length 150 µs, 1 ms, 25 ms, 100 ms, 500 ms, 1 s, or auto mode
Model B220-885
Models B220-880,
B220-881and B220-882
CSA Ordinary location
Pollution Degree 2, Overvoltage Category I
Killark aluminum-capped elbow, Y3 CSA approved Class I, Div 1 & 2, Groups
C, D; Class II, Div 1 & 2, Groups E, F, G; and Class III
Appleton GR conduit outlet boxes GRL100-A, GRLB100-A and GRT100-A,
CSA approved Class I, Div 1, Groups B, C, D; Class II,
Groups E, F, G; and Class III
CAN/CSA-C22.2 No. 61010-1-12, UL Std. No. 61010-1 (3rd Edition)
Page 12 June 2017SGN-UM-00281-EN-05
Page 13
K-Factors Explained
KFACTORS 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).
1000 ÷ 60 = 16.6666 Hz. If you were looking at the pulse output on a frequency counter, an output frequency of 16.666 Hz
would be equal to one gpm. If the frequency counter registered 33.333 Hz (2 × 16.666 Hz), then the flow rate would be 2 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:
Frequency = 700 Hz
Flow Rate = 48 gpm
700 Hz × 60 sec = 42,000 pulses per min
K-factor
Example 2
Known values are:
Full Scale Flow Rate = 85 gpm
Full Scale Output Frequency = 650 Hz
650 Hz × 60 sec = 39,000 pulses per min
K-factor
The calculation is a little more complex if velocity is used because you first must convert the velocity into a volumetric 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.
Example 3
Known values are:
Velocity = 4.3 ft/sec
Inside Diameter of Pipe = 3.068 in.
42,000 pulses per min
48 gpm
39,000 pulses per min
85 gpm
875 pulses per gallon= =
458.82 pulses per gallon= =
Page 13 June 2017 SGN-UM-00281-EN-05
Page 14
A
A
2
7
= 0.384 gallons
231 in
K-
42,000 pulses per min
99.1 gpm
n
K-Factors Explained
Find the area of the pipe cross section.
rea =
rea
Find the volume in one foot of travel.
2
πr
3.068
= π = π x
2
2
2.35 = 7.39 in
88.71in
2
.39 in2 x 12 in. (1 ft)ft=
What portion of a gallon does one foot of travel represent?
88.71 in
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 × 4.3 FPS × 60 sec (1 min) = 99.1 gpm
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 × 60 sec = 42,000 pulses per gallon
3
3
factor
= =
423.9 pulses per gallo
Page 14 June 2017SGN-UM-00281-EN-05
Page 15
INTENTIONAL BLANK PAGE
Page 15 June 2017 SGN-UM-00281-EN-05
Page 16
K-Factor Scalers, Models B220-880, B220-881, B220-882 and B220-885
Control. Manage. Optimize.
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product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding
contractual obligation exists. © 2017 Badger Meter, Inc. All rights reserved.
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