Badger Meter iSonic 4000 Operating instructions

UF_iS4000_BA_02_1811

®

Badger Meter Europa GmbH

iSonic 4000

INSTALLATION AND

OPERATION MANUAL

November 2018

Content

UF_iS4000_BA_02_1811

Basic safety recommendations ............................................................................ 1

System description ............................................................................................... 2

Installation .............................................................................................................. 5

Installation with the sensor EchoPod DL-10 ............................................................... 5

Power connections ................................................................................................ 7

Auxiliary power .......................................................................................................... 7

Configuring input/output (I/O) ..................................................................................... 8

In- and output cable connection ....................................................................... 9

Programming ....................................................................................................... 10

Main Menu ............................................................................................................... 12

Meter Setup ................................................................................................... 12

Measurement................................................................................................. 13

Input and outputs ........................................................................................... 18

Clear total ...................................................................................................... 21

Communications ............................................................................................ 22

Miscellaneous ................................................................................................ 23

Info ................................................................................................................ 23

PIN ................................................................................................................ 24

Login ............................................................................................................. 24

Troubleshooting .................................................................................................. 25

Control LED ............................................................................................................. 25

Replace meter’s electronics ..................................................................................... 26

Technical data ...................................................................................................... 27

Program structure ............................................................................................... 29

Flow meter ModBus

®

register table 2017-06-29, Version “2.00” ..................... 35

iSonic conversation table ......................................................................................... 41

Rights ...................................................................................................................... 41

Wiring the iSonic 4000 meter to an ORION

®

cellular LTE endpoint .............. 42

Return of goods for repair ................................................................................ 43

Basic safety recommendations Page 1/43

UF_iS4000_BA_02_1811

Basic safety recommendations

Before installing or using this product, please read this instruction manual thoroughly.

Only qualified personnel should install and/or repair this product. If a fault appears,

contact your distributor.

Installation

Do not place any unit on an unstable surface that may allow it to fall.

Never place the units above a radiator or heating unit.

Route all cabling away from potential hazards.

Isolate from the mains before removing any covers.

Power connection

Use only the type of power source suitable for electronic equipment. If in doubt, contact

your distributor. Ensure that any power cables are of a sufficiently high current rating.

All units must be earthed to eliminate risk of electric shock.

Failure to properly earth a unit may cause damage to that unit or data stored within it.

Protection class

The device has protection class IP 67 and needs to be protected against dripping water,

water, oils, etc.

Setup & operation

Adjust only those controls that are covered by the operating instructions. Improper

adjustment of other controls may result in damage, incorrect operation or loss of data.

Cleaning

Switch off all units and isolate from mains before cleaning.

Clean using a damp cloth. Do not use liquid or aerosol cleaners.

Repair of faults

Disconnect all units from power supply and have it repaired by a qualified service person if

any of the following occurs:

• If any power cord or plug is damaged or frayed

• If a unit does not operate normally when operating instructions are followed

• If a unit exposed to rain/water or if any liquid has been spilled into it

• If a unit has been dropped or damaged

• If a unit shows a change in performance, indicating a need for service.

RoHs

Our products are RoHs compliant.

Battery disposal

The batteries contained in our products need to be disposed of as per your

local legislation acc. to EU directive 2006/66/EG.

Failure to adhere to these safety instructions

may result in damage to the product or

serious bodily injury.

System description Page 2/43

UF_iS4000_BA_02_1811

System description

Ultrasonic flow meter iSonic4000 is designated for flow measurements in open

channels and partially filled pipes and volume measurements of liquids in tanks. It is

possible to connect one level sensor (ultrasonic, pressure...) with 4-20 mA output to

the unit. Flows are consequently calculated from measured levels using pre-

programmed formulas for various primary flow elements (flumes, weirs) or from Q/h

table. Menu also enables the calculation of flow rateas in partially filled pipes and

angular open channels using Manning equation

• iSonic 4000 is IP67 device in robust wall mounted metal case, with large

graphic display.

• iSonic 4000 menu is operated with 3 x front panel high endurance buttons.

• iSonic 4000 is powered from external power AC 92 - 275V / 50..60Hz,

alternatively from external power 9-36 V (max 9 W), only possible with DC

version.

• User can be connected to iSonic 4000 via USB or Ethernet interface with

software Flow Meter Tool, which can be used for parameters setup and also for

datalogger download.

• iSonic 4000 have internal datalogger with 2 MB capacity for approximately

130 000 logged lines. It is possible to download logged data with software Flow

Meter Tool and save in *.csv, format to PC.

• Interfaces USB, Ethernet, ADE, RS232, ModBus RS485 / RS422 galvanic

isolated are mounted on board.

• The iSonic 4000 unit have 1 analog output 0/4..20mA and 2 galvanic isolated

pulse outputs.

Nameplate

Look at the device nameplate to ensure that the device is delivered according to

your order. Check for the correct supply voltage printed on the nameplate.

System description Page 3/43

UF_iS4000_BA_02_1811

System settings

Flow meter tool settings

Settings control panel

System description Page 4/43

UF_iS4000_BA_02_1811

Driver details

Installation Page 5/43

UF_iS4000_BA_02_1811

Installation

Installation instructions given in the following are to be observed in order

to guarantee a perfect functioning and a safe operation of the meter.

Installation with the sensor EchoPod DL-10

Installation of the sensor:

Screw the sensor into the stainless steel mounting bracket while using the

gaskets.

Sensor must be installed maximum 125 cm above the flume bottom (minimal

measured level) with a minimum of 5 cm distance above the maximal

measured level.

EchoPod DL-10 connection to the 4-20 mA input terminal (on the bottom side of

display board):

Viton Gasket

Sensor EchoPod

Max

125 cm

Min

5 cm

Installation Page 6/43

UF_iS4000_BA_02_1811

Mounting position of the iSonic ultrasonic sensor for manhole flume

Size

Max.

flow

Max.

water level

V-Mt

H-Mt

DN/Inch

l/sec

mm

100/4“

5

148

600

146

150/6“

16

227

600

197

200/8“

35

312

600

248

250/10“

63

395

700

298

300/12“

94

457

700

349

Mounting position of the iSonic’s ultrasonic sensor for parshall flume

Size

Max.

flow

V-Mt

H-Mt

DN/Inch

l/s

mm

75/3

54

780

305

150/6“

114

780

406

230/9“

284

970

572

305/12“

598

contact

factory

contact

factory

455/18“

94

contact

factory

contact

factory

Sensor

MT

V

H

3Power connections Page 7/43

UF_iS4000_BA_02_1811

Power connections

Caution: For the 2 x M20 cable inlets only use flexible electric cables.

Use separate cable inlets for auxiliary power, signal and input/output

cables.

Auxiliary power

Warning: Do not connect meter under impressed mains voltage.

Take national applicable rules into account

Observe type plate (mains voltage and frequency)

Equipment shall be installed with an external means for disconnecting

it from each operating energy supply source. The disconnecting

means shall disconnect all current-carrying conductors.

1. Slightly loosen the lower cover screws and both upper cover screws

completely. Open cover to the lower side.

2. Push auxiliary power cable through the upper cable inlet.

3. Connection as shown in the picture.

4. In the following close connection cover again firmly.

Power supply 92-275 VAC (50/60 Hz) Recommended cable size min. 0,75 mm²

Power supply 9-36 VDC (max. 9 W) Recommended cable size min. 0,75 mm²

3Power connections Page 8/43

UF_iS4000_BA_02_1811

RS-Interface

Dig. Out- and Input

Analog Output

Solid State Relay

RS-Interface

DIP switch

Display

Sensor input

Configuring input/output (I/O)

Input/Output Description Terminal

Analog output*

0 - 20 mA

4 - 20 mA RL < 800 Ohm

0 - 10 mA

7 (+)

8 (-)

9 (GND)

Digital output

1*

Open collector max. 10 kHz

• Passive max. 32 VDC, <100 Hz 100 mA, >100 Hz 20 mA

• Active 24 VDC, 20 mA

(can be powered by analog output if not used)

3 (-)

4 (+)

2*

Open collector max. 10 kHz

• Passive max. 32 VDC, <100 Hz 100 mA, >100 Hz 20 mA

• Active 24 VDC, 20 mA

(can be powered by analog output if not used)

1 (-)

2 (+)

3

Solid State Relais max. 230 VAC, 500 mA, max 1 Hz

(Function is linked with Output 2)

S1 and

S2

Digital input* 5 - 30 VDC 5 (-) and 6 (+)

RS interfaces*

RS232, RS485 and RS422 with ModBus

®

RTU.

Mode can be configured by DIP switches also termination

ON or OFF. I

n case of the RS485 the A wire has to be

connected to Y terminal and the B wire has to be

connected to Z terminal.

422 232 485

A RxD

B

Z TxD B

Y A

G (GND)

USB USB Device CDC (Host Mass Storage) Micro USB

Ethernet* Ethernet Interface connection RJ45 socket

* all marked in- and outputs are according to safety data TNV-1 IEC 60950-1

Auxiliary power

USB

Ethernet

3Power connections Page 9/43

UF_iS4000_BA_02_1811

In- and output cable connection

For the normal I/Os use shielded cables. Connect the shield of the cable

to one of the grounding screw. Recommended cable LiYCY size min.

0,14 mm².

Solid State Output

In case the second cable gland is used for the normal I/Os, use one

cable and cable gland for the power supply and solid state relay.

Recommended cable size min. 0,75 mm².

Caution: Use separate cable inlets for cables connected to the solid

state relay output and cables connected to the other

input/outputs.

In multiphase nets solid state relay should handle only the

same phase which is used for powering the meter

Programming Page 10/43

UF_iS4000_BA_02_1811

Programming

First screen – open channel

Volume designation

Volume value

Volume unit

Water level designation

Water level value

Length unit

Flow designation

Volumetric flow value

Volumetric flow unit

Icons

First screen – tank

Volume designation

Volume value

Volume unit

Water level designation

Water level value

Length unit

Icons

Second screen

Tag

Application version

Actual date & time

Current designation

Current value

Current unit

Programming is accomplished by using the three functional buttons ▲, ► and

Exit/Save.

You can move from the measuring mode to the programming mode by pressing

once the button Exit/Save

With the ▲ button you move downwards in the list. With the ► or Exit/Save button

you enter the menu or you move to the next submenu. The scrollbar on the upper

right shows at what position you are in the list. Go back from a submenu to the

upper menu press Exit/Save.

To select parameters or values from a list in a menu point, press key ▲ until the

requested parameter or value is displayed and confirm with key Exit/Save. The

current number in the list is marked by a ▪ on the left side. For example ▪

Pars.Flume2"

To change a parameter, enter the menu by pressing the button ► and the first

character flashes. Press the key ▲ to change the figure. Once you have changed

the desired figure, move to the next figure with the key ►. Confirm the new value

with key Exit/Save.

*Meaning of symbols on the display

menu header

scrollbar

indication of a submenu

submenu

Meter Setup

Main Menu

Programming Page 11/43

UF_iS4000_BA_02_1811

You get access to the individual menus through three programmable access levels:

Administrator, service and user level.

Access rights of the individual menu items are shown in the following with three

symbols:

For programming the access levels, see the chapter “passwords”. No passwords

were set at the factory.

Minor battery power

(Real Time

Clock)

W

Sensor warming

Device error

0

Sensor not connected

No keyword active

M

Sensor measuring

USB active

S

Simulation active

Administrator

Service

User

Programming Page 12/43

UF_iS4000_BA_02_1811

Main Menu

The following menu items are available to you in the main menu:

• Meter setup

• Measurements

• Inputs and outputs

• Totalizer reset

• Communication

• Miscellaneous

• Information

• Pin

Meter Setup

Application

Sellection between Tank and Open Channel measurement

Sensor

Interval

Setup of time measurement interval (s)– default

value is 1 second, bigger interval (e.g. 300

seconds) is set when unit is powered from

battery

WarmUpTime

Powering time of sensor (s) before

measurement, – for bigger intervals as 1

second, is set when unit is powered from

battery

LowerRangeValue

The minimal level value of used sensor =4 mA

in selected level units

UpperRangeValue

The maximal level value of used sensor =20

mA in selected level units

Offset

Level offset in selected level units, depends of

sensor mounting position.

Tank

Open Channel

Programming Page 13/43

UF_iS4000_BA_02_1811

Measurement

Length

Length units let you select among the units mentioned below.

Lengths values are automatically converted into the selected unit.

DecimalPlaces – set of the decimal places of the Length values

Flow Rate

Flow rate units let you select among the units mentioned below. Flow

rate values are automatically converted into the selected unit.

Volume

Volume units let you select among the units mentioned below.

Volume values are automatically converted into the selected unit.

Unit

L/s

Liter/Second

gal/s

Gallons/Sec.

L/min

Liter/Minute

g/min

Gallons/Min.

L/h

Liter/Hour

gal/h

Gallons/Hour

m³/s

Cubic meters/Sec.

MG/D

MegaGallon/Day

m³/min

Cubic meters/Min.

IG/s

UKG/Sec.

m³/h

Cubic meters/Hour

IG/min

UKG/Min.

ft³/s

Cubic Feet/Sec.

IG/h

UKG/Hour

ft³/min

Cubic Feet/Min.

Bbl/min

Barrel/Min.

ft³/h

Cubic Feet/Hour.

DecimalPlaces

– set of the decimal places of the Flow Rate values

Unit

ft

Feet

m

Meter

in

Inch

cm

Centimeter

mm

Milimeter

Unit

L

Liters

MG

MegaGallons

hL

HectoLiter

IG

Imperial Gallons

m³

Cubic Meters

bbl

Barrel

Ft³

Cubic Feet

Aft

Acre Feet

gal

U.S. Gallons

DecimalPlaces – set of the decimal places of the volume values

Programming Page 14/43

UF_iS4000_BA_02_1811

Equation

selection

Table

Q/hTable – is possible only from software

Flow Meter Tool

Exponential Eq

Exponential function Q= K h

exp

Contract.Weir

Contracted Weir

Suppress.Weir

Suppressed Weir

CipolettiWeir

Cipoletti Weir

VNotchWeir30°

V Notch Weir 30°

VNotchWeir45°

V Notch Weir 45°

VNotchWeir60°

V Notch Weir 60°

VNotchWeir90°

V NotchWeir 90°

ManningRect.

Manning Rectangle Flume

ManningPipe

Manning Pipe

Pars.Flume1"

Parschall Flume 1"

Pars.Flume2"

Parschall Flume 2"

Pars.Flume3"

Parschall Flume 3"

Pars.Flume6"

Parschall Flume 6"

Pars.Flume9"

Parschall Flume 9"

Par.Flume12"

Parschall Flume 12"

Par.Flume18"

Parschall Flume 18"

Par.Flume24"

Parschall Flume 24"

Par.Flume36"

Parschall Flume 36"

Par.Flume48"

Parschall Flume 48"

Par.Flume60"

Parschall Flume 60"

Manh.Flume4"

Manhole Flume 4"

Manh.Flume6"

Manhole Flume 6"

Manh.Flume8"

Manhole Flume8"

Manh.Flume10"

Manhole Flume10"

Manh.Flume12"

Manhole Flume12"

Programming Page 15/43

UF_iS4000_BA_02_1811

Equation Params

Open channel calculation

Volumetric flow is calculated from actual water level; actual water level is limited

by “Maximum water level”

Exponential Equation (general Parshall or Manhole flume)

Equation Q=K.Q

exp

Q – Volumetric flow [m³/s]

K – Coefficient [

]

h – Water level [m]

exp – Exponent [-]

Exponent value in for equation (Q= K h

exp

)

Exponent

Coefficient value in for equation (Q= K h

exp

)

Coefficient

Measured profile width (Weirs, Manning

equation)

Width

Rectangular profile slopes angle (Manning

equation)

Angle

Measured pipe Radius (Manning equation)

Radius

Water Surface Slope (Manning equation)

WaterSurfaceSlope

Surface Roughness coefficient (Manning

equation)

SurfaceRoughness

Maximum Water Level

MaximumWaterLevel

Flow Rate Upper Range Value

UpperRangeValue

Maximum

Water Level /SetDefaultVal. )

Set of the Maximum Water Level for the selected primary element

– the value

is possible

to edit further.

Upper Range Value /Calculate

Is calculat

ing the maximal Flow Rate value for Maximal Water Level - the

value is possible to edit further

– this parameter is used also for outputs

(

Upper Range Value=100% - full range)

Programming Page 16/43

UF_iS4000_BA_02_1811

Predefined flume

Equation [m³/s, m]

Maximum water level [m]

Parshall flume 1”

0.230

Parshall flume 2”

0.260

Parshall flume 3”

0.667

Parshall flume 6”

0.724

Parshall flume 9”

0.876

Parshall flume 12”

0.925

Parshall flume 18”

0.925

Parshall flume 24”

0.925

Parshall flume 36”

0.925

Parshall flume 48”

0.925

Parshall flume 60”

0.925

Manhole flume 4”

0.149

Manhole flume 6”

0.227

Manhole flume 8”

0.313

Manhole flume 10”

0.396

Manhole flume 12”

0.457

Contracted rectangular weir

Equation

Q – Volumetric flow [m³/s]

1.84 – Coefficient [

]

L – Width [m]

h – Water level [m]

Suppressed rectangular weir

Equation

Q – Volumetric flow [m³/s]

1.84 – Coefficient [

]

L – Width [m]

h – Water level [m]

Cipoletti weir

Equation

Q – Volumetric flow [m³/s]

1.84 – Coefficient [

]

L – Width [m]

h – Water level [m]

Programming Page 17/43

UF_iS4000_BA_02_1811

V-notch weir 30°

Equation

Q – Volumetric flow [m³/s]

g – Standard gravity 9.80665 [m/s²]

h – Water level [m]

V-notch weir 45°

Equation

Q – Volumetric flow [m³/s]

g – Standard gravity 9.80665 [m/s²]

h – Water level [m]

V-notch weir 60°

Equation

Q – Volumetric flow [m³/s]

g – Standard gravity 9.80665 [m/s²]

h – Water level [m]

V-notch weir 90°

Equation

Q – Volumetric flow [m³/s]

g – Standard gravity 9.80665 [m/s²]

h – Water level [m]

Manning equation: Q = 1/n R

h

2/3

I

1/2

A R

h

=A/P

Manning rectangular

Equation

Q – Volumetric flow [m³/s]

n – Gauckler-Manning coefficient [

]

L – Width [m]

h – Water level [m]

α – Angle [°]

I – Water surface slope [m/m]

Manning pipe

Equation

where

Q – Volumetric flow [m³/s]

n – Gauckler-Manning coefficient [

]

L – Width [m]

h – Water level [m]

I – Water surface slope [m/m]

Programming Page 18/43

UF_iS4000_BA_02_1811

Material

n[ ]

Material

n[ ]

Glass , PVC

0.010

Earth channel - weedy

0.030

Cement, concrete-steel,

tl

0.011

Natural streams – clean

0.035

Brick

0.015

Floodplains - light brush

0.050

Earth, smooth

0.018

Natural channels, poor

d

0.060

Earth channel – clean

0.022

Floodplains - heavy brush

0.075

Gravel, firm

0.023

Floodplains – trees

0.15

Earth channel – gravelly

0.025

Input and outputs

Analog output

Range

This parameter establishes the range of the analog output

signal: 0 to 100% (= full scale). The following current ranges are

available to you:

Analog output active

Analog output passive

Note:

In case that an error message is displayed, the current is set

according the programing of the “Alarm Mode” below.

In case that you select bidirectional operation, you can signal

flow direction via digital outputs.

Alarm Mode

This parameter configures the behaviour of the analogue output

during alarm conditions. Three options exist for this parameter:

OFF, 3.5 mA and 23 mA.

OFF: Analogue signal is based on flow rate and always within

the configured range.

3.5 mA: During alarm conditions, the analogue signal will be

3.5.

23 mA: During alarm conditions, the analogue signal will be

23mA.

For example, if the analogue range is 4 to 20 mA and the alarm

mode is set to 23 mA, then during a full scale flow alarm

condition, the analogue output current will be 23 mA

.

Compensation

Correction of the current value output.

Current output

0 to 20 mA

4 to 20 mA

0 to 10 mA

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Badger Meter iSonic 4000 Operating instructions

Badger Meter iSonic 4000 Operating instructions

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