Page 1
Signal Conditioner
B220-885 K-Factor Scaler and
B220-900 Programming Software Kit
SGN-UM-00282-EN-03 (July 2015)
User Manual
Page 2
CONTENTS
Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminology and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Enclosure Mounting (Necessary for CSA Certication) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbine Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Internal Pullup Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External Pullup Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting to a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using the Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting the Output to Use the Internal or External Pullup Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
K-Factors Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calculating K-Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SGN-UM-00282-EN-03Page ii July 2015
Page 3
Scope of This Manual
SCOPE OF THIS MANUAL
This manual is intended to help you get the B220-885 K-factor scaler and the B220-900 Programming Software 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 B220-885 K-factor scaler and the B220-900 Programming Software 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
SGN-UM-00282-EN-03 Page 3 July 2015
Page 4
Turbine Rotor
Magnetic Pickup
Signal
Introduction
INTRODUCTION
The K-factor scaler is a field-adjustable frequency divider, which converts the output signal from a turbine meter or a similar
device with a magnetic pickup or pulse output, to an input compatible with a PLC, RTU, CPU data acquisition card or similar
totalizer device. The adjustable frequency divider, referred to as a K-factor, allows pulses sent from a turbine meter to
accumulate into a unit recognizable by an end device, such as a PLC, for counting and display.
The use of different K-factor values allows the device to display in any number of volumetric measurements such as gallons,
cubic meters, liters, barrels and like units. The calibration sheet usually provided with a turbine meter lists a nominal K-factor
tested to a specific volumetric flow rate. The K-factor when placed into the K-factor scaler provides an output pulse for each
unit of volume that passes through the turbine. Any units of volume are possible by recalculating the K-factor with the
appropriate conversion factor.
In addition, if the K-factor is set to one, the K-factor scaler becomes a preamplifier, converting the frequency from a low
output level turbine meter to the logic level needed by a PLC or CPU data acquisition card.
OPERATING PRINCIPLE
Fluid passing through the turbine causes the rotor to spin at a speed proportional to the fluid velocity. As each rotor blade
passes through the magnetic field, the blade generates an AC voltage pulse in the pickup coil at the base of the magnetic
pickup (see Figure 1). These pulses produce an output frequency proportional to the volumetric flow through the meter. The
output frequency with further processing represents flow rate and/or totalization of fluid passing through the flow meter.
The K-factor scaler input amplifier modifies the signal generated by the turbine. The amplifier sends the modified signal to an
onboard microcontroller, which counts pulses up to a predetermined number controlled by the K-factor value. The range of
the K-factor is 1…999,999,999. The predetermined value, once reached, triggers a pulse from the output circuitry.
The K-factor is user adjustable through the programming interface. The duration of the output pulse is also selectable. At the
end of the output pulse, the internal counters reset to zero and the process starts over.
Figure 1: Schematic illustration of electric signal generated by rotor movement
or
Other Frequency
Output Device
Output
SGN-UM-00282-EN-03Page 4 July 2015
Page 5
Programming
Internal 3.6k Ω
Resistor Jumper
Available Current =
(Input Voltage - 0.7V)
(3600Ω + 47Ω)
Installation
INSTALLATION
The board connections include power input, turbine meter input and the pulse output to a totalizing device. See Figure 2 for
the I/O terminal connections.
Output
Output
Vin
Vin
Signal
Input
Port
1 2 3 4 5 6
Pullup
Figure 2: Input/Output terminal connections
Enclosure Mounting (Necessary for CSA Certication)
If the circuit board assembly is supplied without an enclosure, it must be mounted in a certified Killark one-inch NPT model
Y-3 conduit elbow outlet box to maintain the CSA “Ordinary Locations” certification.
Electrical Connections
The board connections include power input, turbine meter input and the pulse output to a totalizing device.
Power
The K-factor scaler requires 8.5…30V DC to operate and is diode protected. Figure 2 shows the supply polarity.
Turbine Meter
The turbine meter connections are non-polarized. Use shielded, twisted pair wire for this connection.
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 Figure 2 for the I/O terminal connections.
Internal Pullup Resistor
The internal pullup resistor allows 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. 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.
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 k
is required.
Internal 3.6k Ω
Pullup
Resistor Jumper
Open Collector
Pulse Output
8 mA
Maximum
Vin
Figure 3: Wiring schematic with internal pullup resistor in circuit
Output
Output
Vin
Vin
1 2 3 4 5 6
TB1
3.6k Ω
Internal
SGN-UM-00282-EN-03 Page 5 July 2015
Page 6
R =
Supply Voltage
Current
Installation
External Pullup Resistor
Using an external pullup resistor offers greater flexibility in controlling the output pulse provided by the K-factor scaler. Power
sources and receiving devices differ in individual situations, requiring 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 4). The power source
voltage is the maximum input voltage (of the pulse) to the receiving device. Use the following equation to determine the
pullup the correct resistor value.
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.
Open Collector
Pulse Output
250…10k
Pullup
Resistor
100 mA
Maximum
Output
Output
Vin
Vin
1 2 3 4 5 6
TB1
Internal
+V
Vin
Figure 4: 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
SGN-UM-00282-EN-03Page 6 July 2015
Page 7
Startup
STARTUP
Connecting to a Computer
The programmable K-factor scaler can be factory- or user-configured through the serial port of a PC by a Windows®
compatible software utility. A programming adapter that interfaces the serial port of the PC to the programming port on the
board is required.
To connect the K-factor scaler:
1. Make sure the power is o. Then connect the adapter cable to the K-factor scaler board using the programming port
(see Figure 2 on page 5).
2. Connect the serial-to-TTL converter to the adapter cable. See Figure 5.
3. Attach the serial extension cable to the serial-to-TTL converter and connect the opposite end to the PC 9-pin serial port.
OTE:N For computers without a 9-pin serial port, a serial-to-USB converter may be required.
4. Turn on the power to the K-factor scaler.
OTE:N Power to the K-factor scaler is required in order to perform any programming.
Model 232LPTTL
TTL
RS-232TO TTL Converter
RS-232
- OUTPUT
+ OUTPUT
8.5 - 30 VDC
TURBINE
PICK UP
PROGRAMMING
®
C US
FILE #215035
- VIN
+ VIN
K-FACTOR SCALER
MAX INPUT CURRENT: 18 mA
PORT
1 2 3 4 5 6
INPUT 8.5 - 30 VDC
INTERNAL
3.6K PULL-UP
RESISTOR
JUMPER
1 2 3 4 5 6
Racine, WI
U.S.A.
B220-886
OR
Flow Meters
LOGIC RS232
Serial Interface Converter
Figure 5: Interface connection
SGN-UM-00282-EN-03 Page 7 July 2015
Page 8
Startup
Using the Programming Software
OTE:N The programming software is sold separately.
The programming interface uses two functional divisions as shown in Figure 6. The Program Values column contains the
user-selected information for downloading into the K-factor scaler. The Board Values column shows the information that the
K-factor scaler currently contains and is not alterable by the user. The Board Values column will only display the contents of the
board after performing a Program, Read or Verify function.
Blancett K-Factor Programming Software
File Tools Version
File Options Tools
Program Values Board Values
K-Factor
K-Factor
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Program
Status: Com1 9/23/2008
Status: Idle Com Port 1
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Read Verify
Figure 6: Programming software screen
Selecting the Com Port
Select the proper Com port within the programming software so the software can communicate with the board. To select the
Com port, in the menu bar select Tools and then Com Port. Select the Com port (1…16) that the serial programming cable is
connected to on the computer.
Blancett K-Factor Programming Software
File Tools Version
File Options Tools
Program
Program Values Board Values
Read
K-Factor
Verify
Com Port
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Program
Status: Com1 9/23/2008
Status: Idle Com Port 1
K-Factor
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Read Verify
Com 1
Com 2
Com 3
Com 4
Com 5
Com 6
Com 7
Com 8
Com 9
Com 10
Com 11
Com 12
Com 13
Com 14
Com 15
Com 16
Figure 7: Tools drop down Figure 8: Com port menu drop down
Blancett K-Factor Programming Software
File Tools Version
File Options Tools
Program
Program Values Board Values
Read
K-Factor
Verify
Com Port
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Program
Status: Com1 9/23/2008
Status: Idle Com Port 1
K-Factor
Pulse Width
150us
1ms
25ms
100ms
500ms
1s
Auto
Pulse Output
High
Low
Read Verify
If the Com port selected is invalid, the software shows the message ERROR – Invalid Com Port when trying to program the
board. If the incorrect Com port is selected, or if there is a problem with the cable, the software shows the message
No Response after trying to program the board.
Setting the K-Factor
The K-factor is the ratio of input pulses per each output pulse, for example, if the K-factor is set to 1, then each input pulse
would yield one output pulse. The range that the K-factor can be set to is 1…999,999,999. The K-factor is set by entering it in
the Program Values column of the software in the K-factor field.
SGN-UM-00282-EN-03Page 8 July 2015
Page 9
Startup
Setting the Output Pulse Width
The output pulse width is the length of time the pulse remains active before resetting to its original state. The K-factor scaler
has a total of seven different pulse widths. The Auto option does not restrain the output pulse to a specific length. Instead, it
varies and is dependent on output frequency. The higher the output frequency, the shorter the pulse width output. The lower
the frequency output, the longer the pulse width output. This option turns off the Pulse Output selection buttons because
they do not apply in this mode.
Some end devices require the pulse to 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 it.
The pulse width option is set by clicking the required pulse width radio button in the Program Values column of the software.
Setting the Output Level Normally High or Normally Low
Most end devices are unaffected by this setting, but the K-factor scaler can invert the output pulse level. This option is set by
clicking the required pulse output radio button in the Program Values column of the software.
When High is selected, the output level is normally low and the duration of the selected pulse width is high. When Low is
selected, the output level is normally high and the duration of the selected pulse width is low.
Programming the K-Factor Scaler
OTE:N All information in the Program Values column must be entered before the software can download the information to
the K-factor scaler.
Press Program to download the K-factor, pulse width and pulse output values to the K-factor scaler. At the completion of the
programming cycle, the circuit performs automatic verification of the downloaded information. The K-factor scaler retains
downloaded values in the memory if it is disconnected from power.
Press Read to load the current information from the K-factor scaler and display it in the Board Values column.
Verify performs the same function as Read, but compares the Board Values to the Program Values and displays an error if the
two do not match.
Setting the Output to Use the Internal or External Pullup Resistor
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 the onboard jumper and not by the software.
With the jumper installed, the internal 3.6 k pullup resistor is connected to the input voltage of the board. With the jumper
removed, the internal pullup resistor is disconnected and an external pullup resistor and supply voltage are required.
SGN-UM-00282-EN-03 Page 9 July 2015
Page 10
Specications
SPECIFICATIONS
External Power
Environmental
Inputs (Magnetic Pickup)
Output Signal
Pulse Output (using
internal pullup resistor)
Pulse Output (using
external pullup resistor)
Enclosure
Agency Listings
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 then 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
Killark aluminum capped elbow Y-3. Class I, Div. 1 & 2, Groups C & D; Class II, Div. 1 & 2, Groups E,
F and G; Class III
Ordinary Locations
CSA
CAN/CSA C22.2 No. 61010-1-12, UL Std. No. 61010-1 (3rd Edition)
Pollution Degree 2
Overvoltage Category I
MPORTANTI
For this CSA rating to be valid, the circuit board must be mounted in a certified Killark one-inch model Y-3 conduit outlet box.
SGN-UM-00282-EN-03Page 10 July 2015
Page 11
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.
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 1 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 1 gpm. The output frequency, in Hz, is found simply by dividing the number of counts (1000) by the
number of seconds (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 1 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 2 gpm, then the accumulation of 1000 counts would take place in 30 seconds because the flow rate,
and hence the speed at which 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. An accurate
flow rate and the output frequency associated with that flow rate is required for the most basic K-factor calculation.
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. 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 rate, you need to know the velocity and the inside pipe diameter. Also keep in
mind that one US gallon of liquid is equal to 231 cubic inches.
42,000 pulses per min
48 gpm
39,000 pulses per min
85 gpm
875 pulses per gallon= =
458.82 pulses per gallon= =
SGN-UM-00282-EN-03 Page 11 July 2015
Page 12
Signal Conditioner, B220-885 K-Factor Scaler and B220-900 Programming Software Kit
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.
2
πr
Area =
2
3.068
Area
= π = π x
2
2.35 = 7.39 in
2
Find the volume in one foot of travel.
2
7.39 in2 x 12 in. (1 ft)ft=
88.71in
Determine what portion of a gallon one foot of travel represents.
231 in
3
= 0.384 gallons
3
88.71 in
So for every foot of fluid travel, 0.384 gallons will pass.
Determine 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 you know the volumetric flow rate, all you need is the 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
K factor
42,000 pulses per min
99.1 gpm
423.9 pulses per gallon= =
Control. Manage. Optimize.
Blancett is a registered trademarks of Badger Meter, Inc. Other trademarks 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 specications without notice, except to the extent an outstanding
contractual obligation exists. © 2015 Badger Meter, Inc. All rights reserved.
www.badgermeter.com
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