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INSTALLATION & OPERATION
MANUAL
IT400
Remote Totalizer & Rate Indicator
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
Page: ii DOC#: MN-IT400-R2d.doc |
Sponsler, Inc. |
Notice
Proprietary Notice
The information contained in this publication is derived in part from proprietary data and trade secrets. This information has been prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any rights to use or reproduce it or to use for any purpose other than in connection with the installation, operation and maintenance of the equipment described herein.
Copyright 2008
Printed in the USA. All Rights Reserved.
SAFETY INSTRUCTIONS
The following instructions must be observed.
•Every effort has been made to design and manufacture this instrument to be safe for its intended use. A hazardous situation may occur if this instrument is not used for its intended purpose or is used incorrectly. Please note operating instructions provided in this manual.
•The instrument must be installed, operated and maintained by personnel who have been properly trained. Personnel must read and understand this manual prior to installation and operation of the instrument.
•An auto-resettable fuse internally protects this instrument. To reset the fuse, remove all power from the unit for one minute.
•The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modifications or changes made to the instrument.
Technical Improvements
Liquid Controls Sponsler, Inc. may modify the technical data herein without notice.
Warning: Do not open the enclosure when an explosive gas atmosphere is present.
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
Page: iii DOC#: MN-IT400-R2d.doc |
Sponsler, Inc. |
Table of Contents
Description............................................................................................................................................ |
1 |
CE Declaration of Conformity............................................................................................................ |
2 |
Specifications .................................................................................................................................... |
3 |
Wiring and Hookup Diagrams ............................................................................................................... |
4 |
IT400 Operational Overview ................................................................................................................. |
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Calibration ......................................................................................................................................... |
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Temperature Compensation.............................................................................................................. |
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Linearization...................................................................................................................................... |
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LCD Display ...................................................................................................................................... |
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User Controls .................................................................................................................................. |
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Non-User interfaces ........................................................................................................................ |
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Inputs............................................................................................................................................... |
12 |
Backlight.......................................................................................................................................... |
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Power .............................................................................................................................................. |
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Enclosure ........................................................................................................................................ |
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Menu System ...................................................................................................................................... |
15 |
Button functions............................................................................................................................... |
15 |
Editing numbers .............................................................................................................................. |
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Menu descriptions ........................................................................................................................... |
16 |
Appendix............................................................................................................................................. |
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Appendix 1: Menu Quick Reference................................................................................................ |
25 |
Appendix 2: Coefficient of Thermal Expansion for Common Fluids................................................. |
26 |
Appendix 3: Menu Flow Chart ......................................................................................................... |
27 |
Appendix 4: Manual Revision History.............................................................................................. |
34 |
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
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DOC#: MN-IT400-R2d.doc |
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Description
General Unit Operation
The IT400 Remote Totalizer and Rate Indicator is a microcontroller based flow instrument capable of translating flow information and conditions to the built-in display and various outputs.
Features
•Pulse input supports turbine as well as many other pulse-type flowmeters
•All features/configuration settings are available via field programmability
•Independent rate/total display
•Magnetically operated internal switches maintain enclosure integrity
•Built-in digital multimeter and simulation functions for testing
•2-20 point Linearization available
•Non-resettable “Grand” totalizer
•All outputs are fully opto-isolated (not RS-232)
•RS-232 port available
•Temperature compensation (RTD probe) available
•Backlight and backlight timer for low light display viewing
•Autoranging Rate display (decimal point will shift based on the size of the rate)
•Selectable power modes for customized battery life
•Available Datalogger can capture up to seven process/system values
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IT400 Remote Totalizer & Rate Indicator |
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DOC#: MN-IT400-R2d.doc |
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CE Declaration of Conformity
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IT400 Remote Totalizer & Rate Indicator |
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Specifications
Display
•Total
•8 digit 5.40mm high LCD (continuous display)
•Batch total (magnetic reset)
•Grand total (no reset)
•Rate
•5 digit 8.66mm high LCD (continuous display)
•Range over/under limit indication
•Refresh rate: Multiple depending on power mode (1/16s, 1/8s, 1/4s, 1s, 0.5s)
•Backlighted green w/ LED (magnetically activated and timed)
•Dual segment low-battery warning
•Maintenance due warning
•Temperature range warning
Power:
•Internal: D Lithium battery
•Battery life: Various: typical per power mode: 1: 1yr, 2: 1yr; 3: 3.6yr; 4: 3yr; 5: 8yr
•External DC: 5 to 48VDC +/- 2 VDC reverse polarity protected (Max: 12mA w/ backlight)
•Loop: requires 7VDC of loop supply
•Loop powered from the 4-20mA loop input (non-isolated)
K-Factor range
•Pulses per gallon: 0.0000001 to 999999
Signal Input (flow)
•Frequency: 0-3000Hz
•Impedance: 10k ohms
•Magnetic
•Sensitivity: 50mV-36V (field adjustable) sine or square wave
•Modulated carrier
•Carrier frequency 50kHz (requires external power or loop power)
Compensation Input
•Temperature - RTD
•Two wire 10k ohm
•Coefficient of Thermal Expansion method
•Frequency
•Linearization table 2 to 20 points
Engineering Unit Conversions
•Pre-programmed units: Gallons, Liters, Ft3, M3, Pounds, BBL, KG (custom weight available)
•Custom units available with given units/gallon
•Rate and Total may have separate unit displays
Decimal Locations
•Total: Two places (and x10, x100)
•Rate: Three places (and x10, x100), autorange
Time Base
•Rates can be displayed in units per second, minute, hour, day, and custom (in seconds)
Outputs
•Factored Pulse (Max: 150mA, 30VDC, 150mW)
•Opto-isolated open collector output
•Frequency or fixed pulse width (1, 2, 5, 10, 50, 100, & custom ms) output setting
•Output pulse Divider: 1, 2, 5, 10, 50, 100, 1000, & custom
•Alarm (Max: 150mA, 30VDC, 150mW)
•Programmable opto-isolated open collector output
•Can be used to control totalization
(Max values at 25°C. Max combined Pulse/Alarm output power: 190mW @ 25°C, 32mW @) 65°C)
•Rate (4-20mA)
•Factored rate to current loop output
•Programmable low and high
•Fully isolated (unless loop powered)
•Loop Voltage limit: 7-36VDC
Accuracy
•Display: ±0.01% reading (rate) or ± 1 count (total)
•Analog output: ±0.025% of fs @20°C
•Digital output: ±1 count
Environmental
•Operating: -30 to 65°C (22 to 150°F)
•Storage: 40 to 85°C (40 to 185°F)
Enclosure
•Explosion Proof Aluminum
•FM Approved, CSA Certified
•Class I, Division1, Groups B, C, & D
•Class II, Division 1, Groups E, F, & G
•NEMA 4X, IP66
•All openings ¾” FNPT
•Weight: 2.5lbs.
•Mount: Directly on flowmeter or Wall mount
Compliance
•CE 0575
•ATEX Ex II 2 G Ex d IIC T6 Gb (X and WX enclosure types only)
•DNV-2008-OSL-ATEX-19241X
Communications
•RS-232
Datalogger
•Up to four triggers (including timer)
•Up to seven system values
•Real-time clock
•RS-232 or Internal SD/MMC Flash media card
Other features
•EEPROM setup storage (>100 year retention)
•All features/settings are field programmable. Convenient number input via 0-9 rotary switch and two pushbuttons
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
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Wiring and Hookup Diagrams
The IT400 has many connections all made through the bottom/mounting board. It is recommended to remove the battery when connecting wires to the connectors and when plugging the connectors into their sockets.
Wiring
In order to maintain the rated CE marking, the following practices must be followed:
•All wires connected to the IT400 must be shielded (exception: SI supplied signal cable).
oAll shields must be connected to one of the internal mounting screws to achieve their ground connection.
oIt is recommended that the non-IT400 end of these shields is left unconnected. This will help avoid ground loops and unexpected behavior.
oIt is recommended that only one spade type terminal be used on each of the screws.
Care should be taken to avoid shorting any spade with other circuitry on the mounting board. If a longer screw is needed to attach the shielding spade, then the screw must be chosen to ensure at least one extra thread of space behind the screw. The
hole depth is approximately 0.250 inches.
oShields should not cover more than one pair of signal wires at a time.
•The IT400’s chassis must be connected to an earth ground via the screw attached to the outside of the unit. At least a 12 AWG preferably green wire is recommended.
•All connections are to be made to the unit via rigid conduit.
•All connected wires must not exceed 98’ length.
•DC powered devices requiring the CE marking must be 4-20mA loop powered.
If no wires are required for a particular installation; the only requirement is the chassis ground connection.
Battery Removal and Installation
Battery Replacement: The internal battery may only be replaced with one of two batteries:
-E8010 from Liquid Controls Sponsler, Inc.
-TL-5930/F from Tadiran Batteries, Ltd.
Battery Removal: Unscrew the IT400 cover, press and hold the menu button until the option to reset the totalizer appears, the totalizer/grand totalizer/service timer will be saved to memory.
Using two fingers inserted in the slots on the top and bottom of the main board overlay, gently rock the board top to bottom while pulling straight out. If this is done too quickly or unevenly, the main board will be damaged. After the main board is removed, the battery is accessible by opening the hook-loop strap. Once the battery is loose, the battery clip is removed by compressing the locking tab on the connector (locking tab is on the top of the connector {J3}) and pulling it out.
Battery installation: Reverse the process for installation. Ensure the battery connector key is in the proper orientation prior to insertion.
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IT400 Remote Totalizer & Rate Indicator |
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DOC#: MN-IT400-R2d.doc |
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Diagrams: |
Figure 1 IT400 Connections
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
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DOC#: MN-IT400-R2d.doc |
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SPONSLER Precision Turbine Flowmeters |
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UNIT OF IDEX CORPORATION |
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2363 SANDIFERA |
BLVD. WESTMINSTER, SC 29693 |
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1.864.647.2065 WWW.SPONSLER.COM |
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LIQUID CONTROLS GROUP |
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SPONSLER Precision Turbine Flowmeters |
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A UNIT OF IDEX CORPORATION |
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2363 SANDIFER BLVD. WESTMINSTER, SC 29693 |
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Figure 2 IT400 Board Stack Assembly and Battery Removal
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
Page: 7 |
DOC#: MN-IT400-R2d.doc |
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Sponsler, Inc. |
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Grand |
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LIQUID CONTROLS GROUP |
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SPONSLER Precision Turbine Flowmeters |
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A UNIT OF IDEX CORPORATION |
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2363 SANDIFER BLVD. WESTMINSTER, SC 29693 |
1.864.647.2065 WWW.SPONSLER.COM |
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Figure 3 Meter Mounting and Dimensional
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
Page: 8 |
DOC#: MN-IT400-R2d.doc |
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IT400 Operational Overview
The IT400 flowmeter system will perform the necessary calculations to provide the user with an optional temperature compensated and optional linearized output of the following values:
•Rate
•Total
•Grand total
•Errors/warnings
•Various outputs
Calibration
Calibration of the IT400 is accomplished using either a linear K-Factor (pulses per gallon) or a linearized K-Factor linearization table (when the linearizer is enabled). Independent unit conversion factors and decimal points are available for the rate and total displays. Calibration and configuration data are stored in an onboard EEPROM for permanent storage. Calibration of the IT400’s reference circuitry is factory set and is not user accessible. Calibration of the IT400’s reference circuitry should be performed by factory trained service personnel.
Temperature Compensation
The temperature compensator utilizes a platinum RTD to detect the process temperature. Process temperature is used in conjunction with the reference temperature and Coefficient of Thermal Expansion of the measured liquid (menu items) to adjust the rate and total values. When the temperature compensation is enabled, the temperature warning annunciator (thermometer on the
LCD) will indicate when the process temperature is out of a programmable range. Optionally, an alarm output as well as a totalizer inhibit function can also be tied to this temperature warning. Various Coefficient of Thermal Expansions and their reference temperatures can be found in the appendix. The temperature circuit and associated algorithm, when enabled, increase the IT400 current consumption from the power source and diminish battery life if running solely from the battery.
A programmable delay function has been provided in order to minimize the impact of the temperature sampling on the battery life. The delay feature specifies the number of seconds between temperature value samples. The higher the delay, the longer the battery will last.
Linearization
The linearizer utilizes a linear interpolation algorithm to calculate the rate and total based on a set of calibration data points programmed by the user. The linearizer has21 points, the first point (lowest) is automatically set at zero hertz, the remaining 2 to 20 are user programmable. The linearizer table must have at least two data points in addition to the first (fixed) point and must be ascending in frequency from the first point to the last. To have fewer than 20 points in the linearizer table, after the last desired linearization point add one additional point and set the frequency at zero. Zero is an invalid frequency; this will indicate the end of the table. The IT400 will not allow frequencies to be entered out numerical order. Frequencies between zero and the first programmed point will use the K-Factor of the first programmed point.
Liquid Controls |
IT400 Remote Totalizer & Rate Indicator |
Page: 9 |
DOC#: MN-IT400-R2d.doc |
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LCD Display
The LCD display has three main areas: The 8 digit totalizer,
5 digit rate indicator, and the annunciators.
•The 8-digit totalizer shows the total number of units of volume through put of the flowmeter since the last time the totalizer was reset. The totalizer is resettable by 2 methods, via a magnetic reed switch in the lower left side of the unit and by menu. The grand total is displayed as long as a magnet is placed near the top of the face of the unit. The word "GRAND" indicates the displayed value is the grand total. Grand should be activated prior to battery replacement to save total/grand total values to nonvolatile memory. Engineering unit annunciators
display the units and decimal place selected to compute total and grand total values. grand totalizer uses the same engineering unit as programmed for the totalizer.
8 digit
Total
5 digit Rate
The
•The 5-digit rate display shows the rate of the flowmeter throughput. If the rate exceeds the
high flow warning setpoint, "- oL- " is displayed. “- UL- “ is displayed when the rate is less than the low flow warning setpoint. The warning is displayed until flowrate within these setpoints resumes. The totalizer is not affected by this warning unless programmed to inhibit totalizer when out of range. The range limits are established by the flow warning setpoints (Warning menu) in the menu system. Indicators on the display also show the engineering units of volume, time and decimal place used to compute the rate value.
Note: When the Grand Total magnetic reed switch is activated (and GRAND is displayed on the screen), the rate display will display the current rate regardless of the range limits. This is helpful when troubleshooting flow condition problems when the low rate setpoint is set above zero.
•Refresh rate of the display of the unit happens at pre-determined intervals depending on the selected power mode (see “Power”). Once the power mode is programmed (in the menu), the refresh rate is fixed. This prevents a low refresh rate from being automatically selected which could cause measurement delay.
•Other display annunciators. These are warning indicators and do not inhibit the operation of the unit (unless explicitly enabled to do so by the alarm option). These indicators may however indicate the condition causing an inaccurate reporting of rate or total information.
o Wrench – The service annunciator is user programmable to a specific amount of
“turbine hours” (active flowmeter hours).
o Thermometer – The thermometer annunciator is displayed continuously any time the temperature compensator is enabled and the process temperature is out of range.
o Battery – The battery annunciator is composed of two segments. The segments indicate the level of the battery charge, like an automotive gas gauge.
Two segments – The battery is within normal operating voltage range.
One segment – A replacement battery should be acquired and installed. This will also cause high temperature range on the temperature circuit to be reduced.
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