FIELD MOUNTED

RATE TOTALISER
MODEL 202

June 1998
CONTENTS
1. Introduction 3
1.1 Model Number Designation 4
1.2 Operation 6
1.3 Intrinsic Safety Considerations 7

2. Specification 9

3. Programming 11
3.1 Program Steps 12
3.2 Calculation of Rate and Total 15
3.3 Total Conversion 16
3.4 Filtering 17
3.5 Example 19

4. Versions 20
4.1 Battery Powered Version 20
4.2 4-20mA Output Version 21
4.3 DC Power Version 24

5. Flowmeter Input 26

6. Intrinsic Safety Connections 30

7. Installation 34
7.1 Wall Mounting 34
7.2 Removing the Front Panel 35
7.3 The Main Electronics 37
7.4 Wiring 38
7.5 Terminal Designations 39

Index 40
 Introduction 3

1. INTRODUCTION
The Model 202 Rate-Totaliser is designed to accept frequency or pulse
inputs from a wide range of flowmeters and to display flowrate, a resetable
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:

1. A Battery Powered version.
2. A Loop Powered version with 4-20mA output.
3. A DC Powered version with high and low flow alarms.

The Model 202 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. An optional
bracket is also available for mounting on a 2" pipe.

This instrument conforms to the EMC-Directive of the Council of European

Communities 89/336/EEC and the following standards:

Generic Emission Standard EN 50081-1 Residential, Commercial & Light

Industry Environment.

Generic Emission Standard EN 50081-2 Industrial Environment.

Generic Immunity Standard EN 50082-1 Residential, Commercial & Light

Industry Environment

Generic Immunity Standard EN 50082-2 Industrial Environment.

In order to comply with these standards, the wiring instructions in Section

7.4 must be followed.
4 Introduction

1.1 MODEL NUMBER DESIGNATION

Model 202i. 2 0

i Denotes Version
Intrinsically Safe 0 Battery Powered (Lithium Batteries)
Version 1L Loop Powered with 4-20mA
output and lithium batteries
3L DC Powered with alarm Outputs and
lithium backup batteries

Mounting Options
0 No holes drilled for cable entries
2 Wall Mount (stand
4 Turbine Adapter
6 2" Pipe Mount (Galvanised)
 Introduction 5

The Model 202

6 Introduction

1.2 OPERATION

The Model 202 Rate Totaliser will display:

Rate
Resetable Total
Accumulated
Total.

Both the Rate and Resetable Total are continuously displayed while the
Accumulated Total is only displayed when the ACCUM TOTAL key is
pressed. The Resetable Total can be reset at any time by pressing the
RESET key.

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.
 Introduction 7

1.3 INTRINSIC SAFETY CONSIDERATIONS

At the date this manual was issued (see front page), two versions of the
Model 202 were certified for use in hazardous areas to both CENELEC
and Australian Standards.

The versions which have certification are:

Model 202i.x0
Model 202i.x1L

CENELEC Approval: Kema No Ex-94.C.8425X.

SAA Approval: Ex 2003x.
Type of Protection: Ex ia.
Group: IIB.
Temperature Class: T4 at ambient temperature of 60°C.

When installing in hazardous areas, the instrument must be installed

according to the guidelines given in section 6 and in accordance with
standards for wiring and installation in hazardous areas.

Flowmeter Inputs

Entity Parameters on the flowmeter input enable connection to a

wide range of approved sensors.

Input Parameters are:

Ui = 24V
Ii = 20mA
Pi = 320mW

Output Parameters are:

Uo = 10.0V
lo = 9.0mA

Maximum allowed external capacitance is 60uF.

Maximum allowed external inductance is 1.5H.
8 Introduction

4-20mA Output

The output can be connected to I S circuits with the following

maximum values:

Ui = 28V
Ii = 93mA
Pi = 653mW.
 Specification 9

2. SPECIFICATION
General

Display: LCD, which is continuously powered.

Resetable Total: 7 digits with l0mm (0.4") high digits.
Resetable from front panel.
Accumulated Total: Displayed when the Accumulated Total
button is pressed.
Rate: 4 digits with 8.5mm (0.33") high digits.
K-factor: The pulses per unit of measure (e.g.
pulses/gallon) is programmable in the
range 0.2 to 29,999.
Decimal Points: Decimal Point positions are fully
programmable for both rate and total.
Timebase: Rate can be displayed in units per second,
minute, hour or day.
Frequency Range: 0.25Hz to 5KHz.
Signal Type: Switch settable for Sinewave (40mV P-P
minimum), Open Collector, Reed Switch or
Pulse.

Battery Powered Version

Type: Two lithium battery packs.

Battery Life: Battery life is dependant on the
percentage of time that the instrument is
totalising flow.

Time Totalising Typical Battery

Life
10% of time 5 years
50% of time 3 years
Continuously 2 years
10 Specification

Loop Powered 4-20mA Output Version

Scale: The 4mA and 20mA points are

programmable.
Accuracy: 0.5% of range.
Update Time: 0.5 second.
Connection: Two wire.
Voltage Drop: 16 volts maximum.
Supply Backup: Lithium battery.

DC Power/Alarm Version

Outputs: Two open collector outputs suitable for

driving DC solenoids or external relays.
The outputs provide high and low flow
alarms and the alarm points are fully
programmable.
Switching Power: 200mA. 30VDC maximum.
DC Power Input: 12-28 Volt at 8mA maximum.
Supply Backup: Lithium battery.

Physical

Temperature: Operating Temperature: -20°C to 60°C.

Dimensions: 97mm (3.8") high x 150mm (5.9") wide
x 41mm (1.6") deep (cable glands not
included).
Protection: Sealed to Nema 4x or IP67 standards.
Cable Entry: By cable glands.
Mounting: Universal Mounting Bracket supplied as
standard.
Pipe Mounting: A galvanised metal bracket is available
which enables the Model 202 to be
attached to a 2" vertical or horizontal
pipe.
Turbine Meter
Adapter: An optional mounting stem is available
for mounting the Model 202 directly on
turbine flowmeters which have a 1" NPT
boss or 1" BSP boss.
 Programming 11

3. PROGRAMMING
The Model 202 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 the wrong side up.
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.

The PROGRAM switch is used to step through the program (CAL

sequences) and the 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.
12 Programming

3.1 PROGRAM STEPS

Step Comment

CAL 1 Scaling Factor - whole numbers.

CAL 2 Scaling Factor - digits after the decimal point.

The Scaling Factor is the pulses per unit of

Measure (e.g. pulses/litre, pulses/gallon, etc).
The Scaling Factor can be programmed in
the range of 0.2 – 29,999.

See section 3.2

.
CAL 3 Frequency Divider.

This determines the frequency where:

1 = 0.25 - 500Hz.
10 = 0.25-5KHz.

CAL 4 Decimal Point for Rate Display.

The flowrate can be displayed with 0, 1, 2

or 3 decimal point places.

CAL 5 Timebase for Rate.

The Rate can be displayed in units per

second, minute, hour or day.
0 = second
I = minute
2 = hour
3 = day.

See. section 3.2

 Programming 13

Step Comment

CAL 6 Filter.
Fluctuations in the flowrate can be filtered
out so that the Rate and 4-20mA
transmission are held steady. The filter
value is programmed between 1 - 99 where
"1" represents no filtering and 99 is
maximum.

See section 3.4.

CAL 7 Decimal Point for Total Display.

The totals can be displayed with 0, 1 or 2
decimal points.

CAL 8 Total Conversion Factor - whole numbers.

CAL 9 Conversion Factor - digits after 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

Unit, e.g. litres.

See section 3.3.

CAL 10 Low Alarm - whole numbers.

CAL 11 Low Alarm - digits after 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.
14 Programming

Step Comment

CAL 10 & 11 Program the flowrate below which

the low alarm relay will close. The value can be
programmed in the range 0 to 49,999.9999.

CAL 12 High Alarm - whole numbers.

CAL 13 High Alarm - digits after the decimal point.

CAL 12 & 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.

CAL 14 4mA Re-transmission - whole numbers.

CAL 15 4mA Re-transmission - digits after the decimal point.

CAL 14 to CAL 15 represent the flowrate at

which 4mA will be output (only displayed on the
Loop Powered Version).

CAL 16 20mA Re-transmission - whole numbers.

CAL 17 20mA Re-transmission - digits after the decimal point.

CAL 16 & 17 are the flowrates at which the

output will reach 20mA.

CAL 18 Identification Number.

Not currently used.

CAL 19 Communication Parameter.

Not currently used.

 Programming 15

3.2 CALCULATION OF RATE AND TOTAL

The flowrate, R, is calculated as follows:

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.
16 Programming

3.3 TOTAL CONVERSION

The Total Conversion feature enables the rate to be displayed in one

engineering unit (e.g. gallons/minute) and the totals to be displayed in
another engineering unit (e.g. barrels).

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 resetable 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 totalise 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
Litres/ Kilolitres 1000
ml/ Litres 1000
Mgallons/ Acre-feet 0.32587

* Units per second, minute, hour or day. The timebase is programmed

separately during Programming.
 Programming 17

3.4 FILTERING

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.

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.
18 Programming

A 90% 99%
1 0 0
2 1 2
4 2 4
6 3 6
10 5 11
15 8 17
20 11 22
25 14 28
35 20 40
45 25 51
60 34 69
75 43 86
90 52 103
99 57 113

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

Note that if CAL 6 is set to 01 there is no filtering of the input

signal.
 Programming 19

3.5 EXAMPLE

A flowmeter produces 20.538 pulses per litre and has a maximum output
frequency on 200Hz. It is required to display the flowrate in litres/min with 1
decimal point and the total in litres with no decimals. A 4-20mA output is
installed and 4mA is to represent 0 litres/m and 20mA is to represent 500
litres/m. The instrument is then programmed as follows.

CAL01 00020 Scaling Factor (Whole Numbers)

CAL02 5380 Scaling Factor (Decimals)
03 1 Frequency Divider
04 1 Rate decimal position
05 1 Timebase
06 01 Filter disabled
07 0 Total decimal position
08 0001 Total Conversion (set to 1.0000)
09 0000 Total Conversion (decimals)
10 00000 Low Alarm (not installed)
11 0000 Low Alarm (not installed)
12 00000 High Alarm (not installed)
13 0000 High Alarm (not installed)
14 00000 4mA Output (Whole Numbers)
15 0000 4mA Output (Decimals)
16 00500 20mA Output (Whole Numbers)
17 0000 20mA Output (Decimals)
20 Versions

4. VERSIONS
4.1 BATTERY POWERED VERSION
The battery powered version of the Model 202 is designed for operation in
the field without external power sources. Lithium batteries provide
sufficient power to operate the instruments for up to 5 years and the
operator is warned of a low power condition by a message on the LCD
display.

New batteries can be purchased via Contrec 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 this may result in
loss of setup parameters.
 Versions 21

4.2 4-20mA OUTPUT VERSION

The 4-20mA output provides a two wire re-transmission 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 4-20mA loop and uses
lithium batteries for backup if the 4-20mA loop is interrupted.

Specification

Digital to Analog Converter: 10 bit.

Accuracy: 0.5% of Span.
Voltage Drop across terminals 8 & 7: 16 Volts maximum.
Response (4mA to 20mA): 0.5 Second.
Maximum Voltage across Output: 28 VDC.

Since the 4-20mA output is designed to provide power to the Model 202, it
is not isolated from the input. Hence, all sensors must be self powering
(such as reed switches & coils). If external power is required to power the
sensor leg. Namur switches, Hall Effect sensors or opto-sensors), the
power supply delivering the external power must be isolated from the
4-20mA loop supply.
22 Versions

Typical Connection

Connection to a Sensor Requiring External Power

 Versions 23

Isolation via 4-20mA Output

24 Versions

4.3 DC POWER VERSION

The DC Power version will operate from an external power source

between 12-28VDC and draws no more than 8mA. This enables the
instrument to be powered from AC mains adapters and eliminates the
need to run mains voltages in the field.

The instrument uses lithium batteries for backup if the DC power is

interrupted.

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 Outputs

Maximum Current (sink): 200mA

Maximum Voltage: 30VDC.
Saturation Voltage: 2.0VDC across Outputs when in
the "on" state.
Isolation: Both outputs are separately isolated.
 Versions 25

Connections
26 Flowmeter Input

5. FLOWMETER INPUT
The Model 202 has an input conditioning circuit which will accept signals
from most pulse or frequency producing flowmeters. A 6 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.

The following pages give examples of interconnection to various signal

outputs, and a circuit diagram of the input is also provided.

For pulse or logic type signals, the input switching threshold is 1.3 volts.
Hence, 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 40mV P-P.

All inputs are protected for over voltage up to 25 volts.

 Flowmeter Input 27

S6 must be open
except with an
external DC supply

The Frequency Input Circuit

28 Flowmeter Input

1. Squarewave, CMOS, or Pulse

2. Open-Collector

3. Reed Switch – Battery Powered

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.
 Flowmeter Input 29

4. Reed Switch – External DC Power

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

5. Coils

6. NAMUR Proximity Switch

Note: If a 4-20Ma output is installed, the supply to the Proximity Switch

must be isolated, as detailed in Section 4.2.
30 Intrinsic Safety Connections

6. INTRINSIC SAFETY
CONNECTIONS
When installing the Model 202i 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 4-20mA output must, therefore, only be connected as shown
on the following page, to barriers with the specified parameters.

The Model 2021 will connect directly to a turbine flowmeter 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

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 202 seen on the
input are negligibly small and the maximum voltage and current produced
by the Model 202 on its inputs (terminals 1 to 4) are:

Uo = 10.0 volts (open circuit)

lo = 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 202 without certification.
 Intrinsic Safety Connections 31

The Model 202 has two pulse inputs, a high impedance balanced input for
coils and a pulse input for other devices. It is not allowable to connect to
both inputs at the same time.

Connection to certified Namur Proximity Switches is permitted as shown

on the following page, with the following maximum input parameters:

Ui = 24V
Ii = 20mA
Pi = 120mW .
32 Intrinsic Safety Connections
Intrinsic Safety Connections 33
34 Installation

7. INSTALLATION
7.1 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).
 Installation 35

7.2 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.

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.
36 Installation
 Installation 37

7.3 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.

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.

The Main Electronics

38 Installation

7.4 WIRING

When connecting the Model 202, it is good practice to use shielded cable.
The shield should be connected to earth near the instrument. The other
end of the shield should not be connected.

In order to comply with the requirements for Electromagnetic Compatibility,

as per EMC-Directive 89/336/EEC of the Council of the European
Community, this wiring practice is mandatory.
 Installation 39

7.5 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 (-)
40 Index
NOTES