INVALCO

January 1, 1999

Meter Mounted Rate/Totalizer Installation/Operation Manual

Bulletin MNIT001

Model 505

Table of Contents
Introduction................................................................................................................................2 Specifications................................................................................................................................2 Model Number Designation..............................................................................................................................2 Operation..................................................................................................................................2 Intrinsic Safety Considerations............................................................................................................................3 Programming Overview..........................................................................................................................................3 Program Steps.................................................................................................................................................3 Calculation of Rate and Total ..............................................................................................................................4 Total Conversion..............................................................................................................................................4 Filtering................................................................................................................................4 Simplified Setup for Model 505...........................................................................................................................5 Battery Powered Version..................................................................................................................................5 4-20mA Output Version.......................................................................................................................................6 DC Power Version............................................................................................................................................7 Flowmeter Input..............................................................................................................................................7 Installation........................................................................................................................................................9 Intrinsic Safety Connections...........................................................................................................................10 505 Settings for Cubic Meters/Day..........................................................................................................................11 Dimensions..............................................................................................................................................12
1 Issue/Rev. 0.2 s (1/99) FMC INVALCO Fluid Control s P.O. Box 1377 s Stephenville, Texas 76401 s Telephone: 254/968-2181 s FAX 254/968-5709 s Toll Free: 800/468-2526

Introduction
The Model 505 Rate/Totalizer is designed to accept frequency or pulse inputs from a wide range of flowmeters and to display flowrate, a re-settable total and an accumulated total directly in engineering units. The instrument is compatible with a wide range of flowmeters and a DIP switch on the input board enables the circuit to be configured for millivolt signals, reed switches, pulse trains and most other signal types. Three different versions of the instrument are available: Battery Powered Version Loop Powered Version DC Powered Version with high and low flow alarms The Model 505 is fully programmable with K-Factors, decimal point positions, filter constants and timebase being programmed via the front panel switches. The instrument is housed in an attractive polycarbonate enclosure which is completely watertight and which enables it to be mounted directly on a flowmeter or wall mounted using a special universal bracket.

Specifications (cont)
Battery Powered Version
Battery Type Two Lithium Battery packs; Optional NiCad Batter pack (1/2 life-span) Battery Life 2 to 3 years (dependant on % of time the instrument is totalizing flow)

Loop Powered 4-20mA Output Version

Scale The 4mA and 20mA points are programmable. Accuracy 0.5% of range Connection Two wire Voltage Input 18 to 28 VDC (16 VDC voltage drop) Memory Backup Long life battery

Specifications
General Specifications
Display Continuously powered LCD Resettable Total 7 digits, 0.4 (10mm) high, resettable from the front panel Accumulated Total 7 digits (as above), Not resettable Rate 4 digits, .33 (8.5mm) high K-Factor Programmable, pulses per unit of measure, 0.2 to 29,999 Timebase Rate displayed in units per second, minute, hour, or day Frequency Range 0-5000 Hz Input Signal Switch settable; Sinewave (20mV P/P min), Pulse, Reed Switch, others

DC Power/Alarm Version
Outputs Two open collector, fully programmable, High/Low, Low/Low, or High/High contacts based on rate of flow Switching Power 200mA, 30 VDC Maximum Voltage Input 12-28 VDC at 8mA Maximum Memory Backup Long life battery

Model Number Designation

Model 505T Mounting
2 Weatherproof Wall Mount Enc. 3 Explosion-proof MMT Enc. 4 Weatherproof MMT Enc. 7 Weatherproof MMT Enc. with Swivel

Power/Options
0 Lithium Battery Powered 1 Loop Powered 4-20mA 3 DC Powered with Alarms 4 DC Powered with input frequency retransmission

Physical Specifications
Operating Temperature 0F to 160F (-20C to 70C) Mounting Meter mount standard, optional wall mounting kit available Enclosure Polycarbonate, meets Nema 4X and IP67 standards; Optional Explosion-proof Cls. 1, Div. 1, Grp C&D Approvals Battery operated version/Intrinsically safe to Class 1, Div. 1 Grp C&D; CSA/FM approval applied for; CENELEC Approval: KEMA
2

Operation
The Model 505 Rate Totalizer will display: Rate Resettable Total Accumulated Total Both the Rate and Resettable Total are continuously displayed while the Accumulated Total is only displayed when the ACCUM TOTAL key is pressed. The Resettable Total can be reset at any time by pressing the RESET key.
Issue/Rev. 0.2 (1/99)

The instrument also has a test mode which can be entered by simultaneously pressing all three front panel keys. The tests are as follows: Lo Test - By pressing the ACCUM TOTAL key, the low alarm output (if installed) will go low. If a 4-20mA option is installed, the output will go to 4mA. Hi Test - By pressing the RESET key, the high alarm output (if installed) will go low. If a 4-20mA option is installed, the output will go to 20mA. Display Test - By pressing the PROGRAM key, all segments of the display will show. To exit the test mode, press the ACCUM TOTAL key and while still holding, simultaneously press the RESET and PROGRAM keys.

Program Steps
Step CAL 1 Comment Scaling Factor - Whole numbers (K-Factor) The Scaling Factor is the pulses per unit of measure (i.e. pulses/gallon, pulses/barrel etc.). The Scaling Factor can be programmed in the range of 0.2 to 29,999. Scaling Factor - Digits to the right of the decimal point. Frequency Divider This calibrates the Model 505 to a specific frequency range where: 1 = .25 to 500 Hz 2 = .25 to 5KHz Decimal Point Placement for Rate Display The flowrate can be displayed with 0, 1, 2, or 3 decimal places. Enter number of places. Timebase for Rate The Rate can be displayed in units per second, minute, hour, or day. Enter: 0 = second 1 = minute 2 = hour 3 = day Filter Fluctuations in the flowrate can be filtered out so that the Rate and 4-20mA transmission (if used) are held steady. The filter value is programmed between 1-99 where 1 represents no filtering and 99 is maximum. Decimal Point for Total Display The totals can be displayed with 0, 1, or 2 decimal places. Total Conversion Factor - Whole Numbers Total Conversion Factor - Digits to the right of the decimal point. The Total Conversion Factor enables the rate to be displayed in one engineering unit and the totals to be displayed in another engineering unit. Set to 1.000 if totals and rate are in the same engineering unit. Low Alarm - Whole Numbers

Intrinsic Safety Considerations

At the date this manual was issued, two versions of the Model 505 were certified for use in hazardous areas to both CENELEC and Australian Standards. The versions which have certification are: Model 505i.20 Model 505i.40 Model 505i.21 Model 505i.41 CENELEC Approval: Kema SAA Approval: Ex 2003x Type of Protection: Ex ia Group: IIB Temperature Class: T4 at ambient temp. or 60C When installing in hazardous areas, the instrument must be installed according to the guidelines given in the Intrinsic Safety Connections Section and in accordance with standards for wiring and installation in hazardous areas. CSA/FM approval has been applied for and will be offered as the standard configuration when available.

CAL 2 CAL 3

CAL 4

CAL 5

CAL 6

Programming Overview
The Model 505 is fully programmable with all parameters being stored in memory. The Program Mode can be entered in one of two ways: 1. By removing the lower cover strip (i.e. the dark grey strip along the bottom of the enclosure) and replacing it after rotating 180. This brings a small magnet on the inside of the cover strip in contact with a reed switch inside the instrument. The program key is then pressed to enter the Program Mode. 2. By removing the front section of the enclosure which contains the main processor board and batteries. Once removed, the PROGRAM key is pressed to enter the Program Mode.
Issue/Rev. 0.2 (1/99)

CAL 7

CAL 8 CAL 9

CAL 10

Operation (cont)

The PROGRAM switch is used to step through the program (CAL sequences) and the A and keys on the front panel are used to change and increment the flashing digits. Up to nineteen CAL steps are accessible, depending on which options are installed. The CAL number is displayed on the lower display and the parameter is displayed on the upper display.

Program Steps (cont)

Step CAL 11 Comment Low Alarm - Digits to the right of the decimal point. CAL 10 to CAL 13 are displayed regardless of whether the high and low alarms are installed. If the high and low alarms are not installed, these parameters can be ignored. High Alarm - Whole numbers High Alarm - Digits to the right of the decimal point. CAL 12 and 13 program the flowrate above which the high alarm relay will close. The value can be programmed in the range 0 to 49,999.9999. 4mA Output Value - Whole numbers 4mA Output Value - Digits to the right of the decimal point. CAL 14 and 15 represent the flowrate at which 4mA will be output (only displayed on the Loop Powered version.) 20mA Output Value - Whole numbers 20mA Output Value - Digits to the right of the decimal point. CAL 16 and 17 represent the flow rate at which the output will reach 20mA. Identification Number Not currently used. Communication Parameter Not currently used.

CAL 12 CAL 13

CAL 14 CAL 15

The Scaling Factor is always programmed in the unit relating to Rate, and the Total Conversion constant is a division factor which can be used to convert the totals to the different unit. The Total Conversion factor affects the resettable and accumulated totals and is limited between 0.01 and 2000. For example: If the Rate is required in gallons per minute: 1. The Scaling Factor would be programmed as pulses per gallon. 2. The timebase would be programmed as minutes. If the Totals are required in barrels: 3. The Total Conversion Factor is programmed as 42 (there are 42 gallons in a barrel). All totals will now totalize in barrels. Some common units are given below together with the Total Conversion constant which should be programmed. Rate* Totals TOTCON Gallons (US)/ Barrels (oil) 42.000 Liters/ Kiloliters 1000 ml/ Liters 1000 Mgallons/ Acre-feet 0.32587 * Units per second, minute, hour or day. The timebase is programmed separately during Programming.

CAL 16 CAL 17

CAL 18 CAL 19

Filtering (Dampening)
Frequency fluctuations caused by pulsating flow through a flowmeter, often makes the Rate impossible to read with any precision. The Flow Computer has a digital filter which will average out these fluctuations and enable the Rate to be read to four digit accuracy. The ability to select a suitable filtering level means that highly accurate and stable readings can be obtained without excessive lag. When the Rate is retransmitted via the 4-20mA output, the filtering will also average out any fluctuations on the output. The diagram below shows a pulsating signal input together with the effect of filtering.

Calculation of Rate and Total

The flowrate, R, is calculated as follows: R=

fxH S

where: f is the input frequency in Hz. H is the timebase of rate and is 1 for seconds, 60 for minutes, 3600 for hours and 86,400 for days. S is the Scaling Factor. The Scaling Factor, S, is equal to the K-Factor of the flowmeter expressed in pulses per unit volume. The user programs the Scaling Factor and selects the timebase during the Programming procedure.

Total Conversion
The Total Conversion feature enables the rate to be displayed in one engineering unit (i.e. gallons/minute) and the totals to be displayed in another engineering unit (i.e. barrels).
4 Issue/Rev. 0.2 (1/99)

As a guideline to the degree of filtering to be used, the following table shows the response to a step change in input. The value, CAL 6, is the filter constant which is programmed during the Programming routine. The times for the display value to reach 90% and 99% of full swing are given in seconds, for different values of CAL 6.
CAL 6 Value 1 2 4 6 10 15 20 25 35 45 60 75 90 99 90% 0 1 2 3 5 8 11 14 20 25 34 43 52 57 99% 0 2 4 6 11 17 22 28 40 51 69 86 103 113

Simplified Setup for Model 505

1. Insert screwdriver blade under end of dark gray strip at bottom of 505 and pry up. Remove strip and swap is end for end. Reinstall. 2. Press Program key. Unit will go into calibration mode. 3. See Chart below.
CAL 1 CAL 2 Enter Meter K-Factor. Press Program Key Does K-Factor have numbers after the decimal? decimal? If so, enter them. If not, enter 0000. Press Program key. Set to 10 for 2" and smaller meter. Set to 1 for 3" and larger meters. Do you want Flow Rate to be displayed with decimals? If no, enter 0. If yes, enter 1, 2, or 3 for number of decimal places to be shown. Press Program key. Will Rate to be in secs., min., hrs., or days? 0 - sec. 1 - min. 2 - hr. 3 - day Enter a number from 1 to 99 to smooth out flow rate reading fluctuations. 1 is minimum and 99 max. Press Program key. Do you want total to read out in decimals? If no, enter 0. If yes, enter 1 or 2 for the number decimal places desired. Press Program key. Do you want the total readout to be in gallons? If so, set to 1. If you want total to be in barrels, set to 42. Press Program key. Set to 0. Press Program key. Set to 0. Press Program key. Set to 0. Press Program key. Set to 0. Press Program key. Set to 0. Press Program key.

CAL 3 CAL 4

CAL 5

Table 1. Response to a step Input (in seconds).

CAL 6

Note that if CAL 6 is set to 01 there is no filtering of the input signal. Example: A flowmeter produces 208.538 pulses per Gallon and has a maximum output frequency on 1200Hz. It is required to display the flowrate in Gal/min with 1 decimal point and the total in Gallons with no decimals. A 4-20mA output is installed and 4mA is to represent 0 GPM and 20mA is to represent 500 GPM. The instrument is then programmed as follows:
CAL 1 CAL 2 CAL 3 CAL 4 CAL 5 CAL 6 CAL 7 CAL 8 CAL 9 CAL 10 CAL 11 CAL 12 CAL 13 CAL 14 CAL 15 CAL 16 CAL 17 208 5380 1 1 1 01 0 0001 0000 00000 0000 00000 0000 00000 0000 00500 0000 Scaling Factor (Whole Numbers) Scaling Factor (Decimals) Frequency Divider Rate Decimal Position Timebase Filter Disabled Total Decimal Position Total Conversion (set to 1.0000) Total Conversion (decimals) Low Alarm (not installed) Low Alarm (not installed) High Alarm (not installed) High Alarm (not installed) 4mA Output Value (Whole No.'s) 4mA Output Value (Decimals) 20mA Output Value (Whole No.'s) 20mA Output Value (Decimals)

CAL 7

CAL 8

CAL 9 CAL 10 CAL 11 CAL 12 CAL 13

4. Remove gray strip at bottom of 505. Swap it end for end. Reinstall. Unit will go into Operational Mode. Unit is ready.

Battery Powered Version

The battery powered version of the Model 505 is designed for operation in the field without external power sources. Lithium batteries provide sufficient power to operate the instruments for up to 3 years and the operator is warned of a low power condition by a message on the LCD display. New batteries can be purchased through INVALCO or our distributors and replaced in the field. There are two battery packs in each instrument and care must be taken to replace only one pack at a time so that there is always power connected to the memory. Failure to do so may result in loss of setup parameters.
5

Issue/Rev. 0.2 (1/99)

4-20mA Output Version

The 4-20mA output provides a two wire retransmission of the flowrate. Both the 4mA and 20mA points are fully programmable so that the output can span across the entire operating range or, alternatively, across a small section of the operating range. The response rate of the output is very fast, making the instrument suitable as a frequency to current converter in closed loop systems where a fast response is normally required. The instrument draws its operating power from the 420mA loop and uses a Lithium Battery for memory backup.

Typical Connection

8 + Magnetic Pick-up or Reed Switch

Model 505
7 -

Supply

Load Receiving Instrument

Specification:
Digital to Analog Converter 10 bit Accuracy 0.5% of Span Voltage Drop across terminals 7 & 8 16 VDC max. Response (4mA to 20mA) 0.5 seconds Maximum Voltage across Output 28 VDC Since the 4-20mA output is designed to provide power to the Model 505, it is not isolated from the input. Hence, all sensors must be self powering (such as reed switches and coils). If external power is required to power the sensor (i.e. Namur switches, Hall Effect sensors or opto-sensors), the power supply delivering the external power must be isolated from the 4-20mA loop supply.
+VDC 0 VDC 3 3 + Supply Load Receiving Instrument

Connection to a Sensor requiring External Power

+VDC GND 3

Isolated Supply

RF or Half Effect Pick-up

8 +

Model 505
4 7 -

Supply

Load Receiving Instrument

RF or Half Effect Pick-up

Model
4

8 505 7

Issue/Rev. 0.2 (1/99)

DC Power Version
The DC Power version will operate from an external power source between 12-28 VDC and draws no more than 8mA. The instrument uses a Lithium battery for memory backup capable of maintaining memory for long periods. Open collector outputs are also provided for high and low flowrate alarms. They can sink up to 200mA and can be used to power external relays, lights or audible alarms. The outputs are internally protected against voltage spikes caused by relays and coils. Both outputs are separately isolated via opto isolators. The switching points can be programmed during the setup mode and the low flow alarm will switch on whenever the flowrate drops below the programmed flowrate. Similarly, the high alarm switches on whenever the flow exceeds the high setpoint. Specification for Alarm Output Maximum Current (sink) 200mA Maximum Voltage 30VDC Voltage across Output when in the On state 2.0VDC Isolation Both outputs are separately isolated. Typical Connections

Flowmeter Input
The Model 505 has an input conditioning circuit which will accept signals from most pulse or frequency producing flowmeters. A six position DIL switch on the rear panel enables the input circuit to be configured for different signal types. The input will interface directly to: Turbine Flowmeters Open Collector Outputs Reed Switches Logic Signals Two Wire Proximity Switches For pulse or logic type signals, the input switching threshold is 1.3 volts. Accordingly, the input signal must have a low voltage of less than 1.2 volts and a high voltage of greater than 1.4 volts. Separate input terminals are provided for the coil input so that high inductance values can be handled, while maintaining the intrinsic safety of the system. For a coil, the minimum input voltage is 20mV P-P. All inputs are protected for over voltage up to 25 volts. The following are examples of interconnection to various signal outputs, and a circuit diagram of the input is also provided.

Issue/Rev. 0.2 (1/99)

Flowmeter Input (cont)

1. Squarewave, CMOS or Pulse 4. Reed Switch - External DC Power with 10K ohm pullup resistor.
Switch Settings

Switch Settings

Switching Threshold Voltage is 1.3 volts.

Note: For a switch or reed input with contact bounce, S4 can switched on. This will eliminate the effect of switch bounce, while limiting the input frequency to 200Hz.

2. Open-Collector with 100K ohm internal pullup resistor.

5. Coils (Magnetic Pick-up)

Use shielded cable

e.g. Millivolt signal from turbine or paddlewheel (20V PP minimum)

3. Reed Switch - Battery Powered with 100K ohm internal pullup resistor.

6. Namur Proximity Switch

e.g. Positive displacement flowmeters with reed switch outputs.

Note: For a switch or reed input with contact bounce, S4 can be switched on. This will eliminate the effect of switch bounce, while limiting the input frequency to 200 Hz.
8

Note: If a 4-20mA output is installed, the supply to the Proximity Switch must be isolated, as detailed in the Version Section.
Issue/Rev. 0.2 (1/99)

Installation
Wall Mounting A wall mounting bracket is supplied with each instrument. The bracket should be attached to the wall using round head screws (do not use counter sunk screws). The bracket is mounted with the tray section at the bottom. The instrument is then attached to the bracket at the bottom with two screws (see diagram below).

The Main Electronics The front section of the housing contains the microprocessor, batteries and display. When replacing the Lithium battery packs, only one battery pack should be replaced at a time so that there is always one pack connected to power the memory. NiCad batteries should not require replacement, but they may need to be charged for a short period before they will provide effective backup to the memory. It is also possible to adjust the display contrast via a small potentiometer on the board. The DISPLAY CONTRAST control is shown below and this can be adjusted for optimum contrast. Adjacent to this control is a RESET switch which can be used to reset the microprocessor. Note that pressing this button will reset all Setup Parameters and set all totals to zero.

Removing the Front Panel

The front of the instrument is removed as follows: 1. Remove both the top and bottom cover strips (i.e. the dark plastic strips on the front) by levering a screwdriver under one end.

Terminal Designations All Versions 1 Coil Input 2 Coil Input 3 Pulse Input (+) 4 Pulse Input (-) 4-20mA Output 7 4-20mA (-) 8 4-20mA (+) DC Power Versions 7 DC Power 0V 8 DC Power +12 to 28 VDC 9 Low Alarm (+) 10 Low Alarm (-) 11 High Alarm (+) 12 High Alarm (-)

2. Undo the seven screws retaining the front. Note that the screws should not be removed from the front panel as they are retained by O-rings. 3. Pull the front panel free from the housing. Replacing the front panel of the instrument is the reverse procedure. However, ensure that the front panel is aligned at both connector points before tightening the screws.
Issue/Rev. 0.2 (1/99)

Intrinsic Safety Connections

When installing the Model 505i in hazardous areas, the wiring and installation must comply with appropriate installation standards. The approval uses entity parameters on the input for connections to the flowmeter, and an associated apparatus type approval for the 4-20mA output. The 420mA output must, therefore, only be connected as shown on the following page, to barriers with the specified parameters. The Model 505i will connect directly to a turbine flowmeters or paddlewheel with a certified I S coil or other certified I S sensors which produce a pulse output, provided they do not exceed the following input parameters: Ui = 24V Ii = 20mA Pi = 320mW Intrinsically Safe Operation

The maximum allowed capacitance and inductance of the pulser or coil, including cabling is: Cext = 60uF Lext = 1.5H The internal capacitance and inductance of the Model 505 seen on the input are negligibly small and the maximum voltage and current produced by the Model 505 on its inputs (terminals 1 to 4) are: Uo = 10.0 volts (open circuit) Io = 9.0mA (short circuit) Devices such as reed switches, which can be classed as Simple Apparatus as defined in the CENELEC standard EN50020, can be connected to the Model 505 without certification.

Typical Wiring Diagram for 4-20mA Current Loop

Typical Wiring Diagram for Namur Proximity Detector

*Note: Base units, battery powered, are entity approved intrinsically safe without the need for barriers. Only when outside power is applied are certified I.S. Barriers needed.

10

Issue/Rev. 0.2 (1/99)

505 Settings for Cubic Meters/Day

If the K-Factor is above 29,999 pulses per cubic meter, then the time base can be shifted to allow the 505 to display rate in cubic meters per day. (M3/DAY and a corrected total for cubic meters (M3). Conversions: 1 gpm = 3.785 lpm 1 lpm = 1.44 M3/DAY 1 Day = 1440 Minutes Shifted K = K-Factor (P/G) / (1.44 * 3.785) = K-Factor / 5.4504 924 Enter the K-Factor in P/GAL: 244.12153 Equivalent K-Factor (P/L) = 169.5288 Shifted K-Factor = Set the 505 for Minutes Set Total Conversion to 1440 MIN/DAY The 505 will now display rate in M3/DAY and Total M3. The alarms and 4-20mA should be set in M3/DAY. Sample: 1 Meter

(CAL 01 & CAL 02) (CAL 05 = 1 FOR MINUTES) (CAL 08 = 1440)

K = 873 P/GAL

Shifted K-Factor = 160.1717 (CAL01 = 00160 and CAL 2 = 1717) Set the 505 for Minutes (CAL 05 = 1 for Minutes) Set Total Conversion to 1440 MIN/DAY (CAL 08 = 1440)

Issue/Rev. 0.2 (1/99)

11

Dimensions
Inches (mm)

Standard Weatherproof Meter Mount Connection (Wall Mount Enclosure - Ignore Mounting Stem)

Optional Swivel Mount Connection (Weatherproof Enclosure Only)

Explosion-proof Meter Mount Connection

Note: Dimensions - Inches to the nearest tenth (millimeters to the nearest whole mm), each independently dimensioned from respective engineering drawings.
The specifications contained herein are subject to change without notice and any user of said specifications should verify from the manufacturer that the specifications are currently in effect. Otherwise, the manufacturer assumes no responsibility for the use of specifications which may have been changed and are no longer in effect. FMC INVALCO Fluid Control P.O. Box 1377, Stephenville, TX 76401, Phone: 254/968-2181, FAX: 254/968-5709, Toll Free: 800/468-2526 Printed in U.S.A. 1/99 FMC INVALCO All rights reserved. Issue/Rev. 0.2 (1/99)

12

Issue/Rev. 0.2 (1/99)