Turbine Flow Meter

Installation/Operation Manual
February 2005 MNIT001

Table of Contents
Introduction ............................................................................................................................................................. 2
Installation ............................................................................................................................................................... 3
Turbine Flowmeter Maintenance ............................................................................................................................. 3
Magnetic Pickups .................................................................................................................................................... 5
Dimensions ............................................................................................................................................................. 7
Magnetic Pickup Enclosures ................................................................................................................................... 8
Turbine Flowmeter Cable Assemblies .................................................................................................................... 9
Repair Parts Kits ................................................................................................................................................... 10
General Specifications .......................................................................................................................................... 11
Turbine Flowmeter Sizing ..................................................................................................................................... 11
3-A Sanitary Meters/Internals ................................................................................................................................ 12
Flow Related Formulas ......................................................................................................................................... 13
WH Meter/4200/4300 Manual.................................................................................................................................14

FMC INVALCO
Issue/Rev. 2825 W. Washington
0.6 !(2/06) ! Stephenville, Texas 76401 ! Telephone: 254/968-2181 ! FAX 254/968-5709 ! Toll Free: 800/468-25261
Introduction

The INVALCO Turbine Flowmeter is a device used to measure the volumetric flow of a fluid. The flowmeter consists of
the body, a multiblade rotor (usually 6 to 10 blades depending on size), bearings and supports for the rotor. As a fluid
passes through the flowmeter the rotor spins. The speed of the rotor is directly proportional to the fluid velocity or flow
rate.
As the rotor spins, the balde tips pass through a magnetic field generated by permanent magnets in a pickup coil
mounted in close proximity to the rotor but separated from it and the process fluid by the wall of the flowmeter body.
Each time a blade passes the magnet, it generates a small alternating current in the pickup coil. (See Figure 7) The
pickup coil is attached to the pickup by two terminals or wires.
Each rotor blade passing through the magnetic pickup flux lines produce one alternating current cycle. Depending on
the flowmeter size, a certain number of pulses are produced for each volumetric unit of liquid passing through the turbine
flowmeter. This is known as the “K-Factor” of the turbine flowmeter. The variation of this factor over the specified flow
range is the Linearity or accuracy of the flowmeter.
Mechanical Installation

Turbine Flowmeters are affected by upstream and downstream piping configurations. Upstream piping has a
pronounced effect on flowmeter performance making it necessary to have ten (10) straight pipe diameters up-
stream of the turbine flowmeter and five (5) pipe diameters downstream of the turbine flowmeter. Flowmeters
should be installed with the arrow marked on the body pointing in the direction of flow.

Figure 1

Control valves should always be located downstream from the flowmeter. If a line is empty and a valve is opened, the
high velocity fluid stricking the flowmeter can cause severe damage. Air eliminators should be used in cases where
gases are flowing in the process stream. Air in the liquid will cause the flowmeter rotor to spin at a different rate than the
liquid giving incorrect readings.
Spools should be installed in the flowmeter position during start up to prevent damage to the flowmeter from solids
(welding slag, rust, scale, etc.) in the process liquid.
Note: Meter should be installed with ten diameters of straight pipe the same size as turbine meter bore
up and 5 straight pipe diameters downstream of meter.
Note: If valve is to be used, it must be downstream from the meter. This is necessary not only to keep the line
full for accuracy in batching applications, but to prevent damage caused by striking an empty meter with a
high velocity stream.
Note: Sleeved bearings used in INVALCO flowmeters are lubricated with the process fluid. Never spin
the flowmeter at high speeds with air. Always confirm that the flow line contains fluid at start up.
The life of the flowmeter can be extended by using a mesh filter in the flow line. Table I shows the recommended filter for
various sizes of flowmeters.

Table 1
Turbine Flowmeter Size Mesh Size Opening Size
1/2” 40 0.015
3/4” 40 0.015
1” 40 0.015
1-1/2” 18 0.0386
2” 14 0.051

2 Issue/Rev. 0.6 (2/06)

Installation (con’t)
Electrical Installation (Figure 2)
Thread the magnetic pickup into the mounting boss
located on the top of the flowmeter. If the pickup does
not have wire leads included, connect the signal cable
to the pickup by threading on the keyed connector.
Note: Hand Tighten Only. Use of tools to tighten
the pickup can damage the flowmeter and pickup.
Figure 2
Issue/Rev. 0.6 (2/06)
Turbine Meter Maintenance
Removal of Flowmeter Internals
Cartridge Type Sizes 3/4 Inch through 2” (Figure 3)
The cartridge type turbine flowmeter utilizes internals as-
sembled into a single part, eliminating the need for the three
part internals kit.
Note: This type of internals is not interchangeable with any
other body type.
1) Remove the magnetic pickup.
2) Identify the upstream end of the meter by locating
the two grooves visible from the outside of one end.
3) Remove the retaining ring from the end of the flow
meter identified by the grooves.
4) Slide the internals out of the flowmeter. It may be
necessary to push the internals out by gently applying
pressure to the opposite end.
5) Inspect the internal bore of the flowmeter for defects.
The internal surface of the flowmeter should be
smooth. If the surface is damaged, the flowmeter
body should be replaced.
6) Inspect the internals kit for damage or wear. If it ap-
pears to be damaged, replace it with a new
internals kit.
Figure 3
Replacement of Flowmeter Internals
Cartridge Type Sizes 3/4 Inch through 2 Inch
1) Identify the upstream end of the turbine flowmeter by
locating the two grooves visible from the outside of one
end.
2) Identify the upstream end of the turbine flowmeter inter-
nals by locating the end with a cone recessed between
two supports forming a “V”.
3) Insert the end opposite of the recessed cone into the
groooves located in the upstream end of the turbine flow
meter body.
4) Slide the flowmeter internals into the turbine flowmeter
body until it seats firmly against the downstream end.
5) Insert the retaining ring into the upstream end of the tur-
bine flowmeter, pushing it far enough into the flowmeter
body to engage the retaining ring slot directly above the
turbine flowmeter internals.
3
Removal and Replacement of Flowmeter Internals Size
4 Inch (Shipped Before April 1990) and Size 3 Inch
Shipped Before January 1989
1) Locate the flow direction arrow on the turbine flow
meter body, or the words “Inlet” or “Outlet” stamped
near the ends. Set the flowmeter body on end with
the outlet map.
2) Assemble the rear support assembly, giving atten-
tion to aligning the grooves in the pinion bolt with the
slots in the cage.
3) Install the lock washer and nut. The threads on the
pinion bolt should only extend halfway through the nut,
(about 2-1/2 turns).
4) Insert three vanes with the tapered bottom edges match-
ing the sloping bottom of the grooves in the pinion bolt.
5) Locate the three wide and shallow grooves running in a
length-wise direction in the turbine flowmeter body.
6) Insert the support assembly into the body, bearing end
first, with the vanes sliding down the shallow grooves.
The assembly will come to rest against a shoulder.
7) Rotate the entire support assembly about 60 degrees,
so that the vanes are no longer lines up with the ac-
cess grooves in the body.
8) Tighten the nut slowly, working the assembly back
and forth so the vanes will seat properly. Tighten the
nut secruely.
9) Turn the body over and slip the rotor onto the rear
bearing just installed.
10) Assemble and install the front support in the same
manner. It may be necessary to pull or push on the
pinion bolt to work the assembly in far enough to read
the shoulder, before rotating. The pinion bolt is pulled
back, the vanes are forced outward.
The rear pinion bolt can be identified by the 1/2 inch diam-
eter carbide bearing which protrudes 1-7/32 inches.
The rear pinion body, or cage, can be identified as follows:
4 inch flowmeter front and rear cages are identical.
3 inch (shipped before January 1989) front cage overall
length is 2-21/32 inches and the slots begin 3/8 inches from
the open end.
Rear cage overall length is 2-15/16 inches and the slots
begin a little over 3/4 inch from the open end.
Figure 5
4 Issue/Rev. 0.6 (2/06)
Removal of Flowmeter Internals
Size 4 Inch (Figure 5)
1) Remove the internals by retracting the set screw and rap-
the sliding vane, if necessary, to relieve the locking pres-
sure.
2) If spirolox rings are installed, remove them before attempt
ing to remove the supports.
3) Remove the rotor support fromt he flowmeter.
4) Remove the rotor from the flowmeter.
5) Repeat steps 1 through 3 to remove the second support.
Replacement of Flowmeter Internals
Size 4 Inch (Figure 5)
1) If your flowmeter body is grooved for spirolox rings, it is
recommended that the rings be installed.
Note: Lock rings are provided to absorb shock and
should be replaced when replacing the internals.
2) Advance the sliding vane with the set screw until the whole
support assembly fits closely in the bore of the flowmeter
body.
3) Position the support assembly against the shoulder in the
flowmeter body and tighten the set screw.
4) Install a spirolox ring if a groove has been provided for.
5) Meter bodies shipped after December 1, 1970 have three
grooves machined in each end. The sliding vane has an
“ear”, detail “B”, to engage one of these grooves. The front
support assembly should be positioned so that the sliding
vane engages the upper-left-hand groove. The sliding vane
on the rear support should engage the upper-right-hand
groove. Both sliding vanes should be in line.
6) For installation in older bodies (prior to December 1, 1970),
which are not grooved, the sliding vane can be turned
upside down (Figure 5) so the ear is buried in the support.
Magnetic Pickups

Flow in the turbine flowmeter is sensed by a non-wetted sensor called a variable reluctance magnetic pickup. The
magnetic pickup is an assembly consisting of a permanent magnet and a coil bobbin on which several hundred turns of
wire are wound (Figure 6). This combination produces a magnetic field at the top of the pickup. The pickup is placed in
close proximity to the rotor blades, but is separated from it and the process fluid by the wall of the flowmeter housing. As
the rotor turns, the blades disrupt the magnetic field of the pikcup and generate a sine wave voltage signal across the
terminals of the magnetic pickup coil. Each time a rotor blade passes through the magnetic field, one alternating current
(AC) cycle is generated (Figure 7). The number of pulses produced by a turbine flowmeter per gallon of water is known
as the “K-Factor”.

Figure 6

Issue/Rev. 0.6 (2/06) 5

Magnetic Pickups

Standard Magnetic Pickup Extended Temperature Wire Lead Low Drag

Stock No. 64908265
Temp. Range: -65° to 225°F
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S
Magnetic Pickup
Stock No. 64919755
Temp. Range: -450° to 450°F
Hermetically Sealed
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S
Magnetic Pickup Kit
Stock No. 49020839
Use with all meter mounted readout
devices.
Temp. Range: -65° to 225°F
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Signal Connection: 7” Wire Leads
Magnetic PIckup
Stock No. 64920774
For special applications
Temp. Range: -65° to 225°F
Coil Resistance: 975 OHMS
Coil Inductance: 400 mH
Housing: Stainless Steel
Mating Connector: 10SL-4S

RF (Radio Frequency) Pickup Kit

NEMA 6 Watertight
Magnetic Pickup
Stock No. 64920920
Molded 15’ thermo-plastic rubber
cable and connector, ozone and
ultraviolet resistant, excellent heat
aging/abrasion resistance. Suit-
able for outdoor applications and
installations that require hose
down cleaning of meter.
Temp. Range: -65° to 225°F
Housing: Stainless Steel
Pre-Amp Magnetic
Pickup Kit
Stock No. 49016811
Temp. Range: -40° to 180°F
Housing: Stainless Steel
Output: Square Wave
Supply Voltage: 5 to 26 VDC
Output Impedence: 2.2K OHMS
Load Current: 15mA (NOM)
Output Voltage: 90% Supply
Mating Connector: 10SL-3P
Non Magnetic
Stock No. 49020795
Temp. Range: -40° to 212°F Continuous
250F Intermittant
Housing: Plastic
Output: Square Wave
Supply Voltage: 5-26 VDC
Load Current: 20mA (NOM)
Output Voltage: 5 VDC Regulated
Mating Connector: 10 SL-3P
This pickup must be used with the 1/2” Turbine Meter to
achieve stated accuracy over the 10:1 range of the meter.
Not Pictured
Special Extended High Temp. Magnetic Pickup
Stock No. 64917721
Temp. Range: -450° to 800°F Continuous
+1000°F Intermittent
Housing: Stainless Steel
Supplied with 3’ Stainless Steel Shielded Overbraid Cable
with connector
Mating Connector: 10 SL-4P
Requires Turbine Flow Meter Modification.

6 Issue/Rev. 0.6 (2/06)

Dimensions

Issue/Rev. 0.6 (2/06) 7

Magnetic Pickup Enclosures
Magnetic pickup assemblies may require an enclosure to assure protection against the environment. Three types of enclosures
are available. These are:

WAK-2 Weatherproof Adapter

This kit provides an enclosure for the magnetic pickup to
protect it from physical damage, weather, hose down or high
humidity environments. A one inch (1”) NPT outlet is pro-
vided at the top for the adapter for a conduit connection. The
adapter is provided with a factory installed cable clamp de-
signed to squeeze the cable for weather-proofing. When
conduit is used, the cable clamp is removed.
EAK-2 Explosion-proof Adapter
This kit provides an explosion-proof enclosure for the
magnetic pickup. The enclosure is rated Class I, Divi-
sion I, Group D. The enclosure is provided with a one
and a quarter inch (1-1/4”) NPT connection for conduit.

EAK-2AX-P Explosion-proof Adapter with Terminal Block (Figure 10)

This kit provides an explosion-proof enclosure with a 3 point terminal strip. The enclosure is provided with either a
two wire lead magnetic pickup, a pre-amp magnetic pikcup (requires a 5 to 32 volts DC external power) or an RF
pickup (requires 5 to 26 volts DC external power).

Model EAK-2BX-P Explosion-

proof adapter with RF or
Transmission Signal Pre-amp
type pickup. 8” cable with
mating connector and termi-
nal strip.

Model EAK-2AX-P Explosion-

proof adapter with wire lead
magnetic pickup and 3 point
terminal strip.

8 Issue/Rev. 0.6 (2/06)

Turbine Flowmeter Cable Assemblies
Turbine flowmeter cables are 18 gauge shielded, heavy duty neoprene-jacketed complete with mating connector
for magnetic pickup and terminated for interconnection to a readout or junction box.

Length Part No.

8” 81001471
15’ 81001483
25’ 81001484
50’ 81001479
Standard Turbine Meter Cable
Assembly

Standard Cable Assembly (Figure 11)

The standard cable is made up of two conductor cables with a 10Sl-4S connector for mating with the standard
magnetic pickup or the low drag magnetic pickup. Maximum Temperature: +225°F

Length Part No.

8” 81001471
15’ 81001483
25’ 81001484
50’ 81001479
High Temperature
Turbine Meter
Cable Assembly

High Temperature Cable Assembly (Figure 12)

The high temperature cable is made up of two conductor cable with a high temperature version of the 10SL-4S
connector for mating with the extended temperature magnetic pickup. Maximum temperature: +450°F

Length Part No.

8” 81001485
15’ 81001494
25’ 81001507
50’ 81001510

Pre-Amplifier and RF Cable Assembly (Figure 13)

The pre-amp/RF cable is made up of three conductor cable with a 10SL-3S connector for mating with the pre-
amplifier or RF pickup. Maximum temperature: +225°F

Issue/Rev. 0.6 (2/06) 9

Repair Parts Kits
All INVALCO repair parts kits include all flowmeter internal components. The assembly is calibrated on water at
70°F, with a viscosity of 1 centistoke. Each repair kit has a K-factor guaranteed to be within +/-1 percent of the
original.

“W” Series - Tungsten Carbide Bearings Cartridge Internals

Meter Flow W2 W3 W4 W6 W9 WC-1/2% WC-1%
Size Range Stock No. Stock No. Stock No. Stock No. Stock No. Stock No. Stock No.
1/2” 0.6 to 6 81001901 81001901 - - - - -
3/4” 1.5 to 15 81001904 81001904 81001904 - 81003747 81014400 81004400
3/4” 3.2 to 23 81004044 81004044 81004044 - 81003749 - -
1” 6.5 to 65 81001905 81001905 81001905 81001905 81003735 81014401 81004401
1-1/2” 17.5 to 175 81001906 81001906 81001906 81001906 81003733 81014402 81004402
2” 33 to 330 81001907 81001907 81001907 81001907 81003731 81014403 81004403
3” 60 to 600 - 81004048 81004050 81004048 81004095 - -
3”* 60 to 600 - - 81004240 - - - -
4” 110 to 1100 - 81004049 81004051 81004049 81004096 - -
4”** 110 to 1100 - - 81004244 - - - -
6” 300 to 3000 - - 81014474 81003112 - - -
*3” Internal kit for turbine flowmeters purchased after January 1989.
**4” Internal kit for turbine flowmeters purchased after April 1990.

Cartridge
“WFP” Series -Rulon 641 Bearings Internals
Meter Flow W2 W3 W4 W6 W9 WC-1/2%
Size Range Stock No. Stock No. Stock No. Stock No. Stock No. Stock No.
1/2” 0.6 to 6 81001901 81001901 - - - -
3/4” 1.5 to 15 81001904 81001904 81001904 - 81003747 81014400
3/4” 3.2 to 23 81004044 81004044 81004044 - 81003749 -
1” 6.5 to 65 81001905 81001905 81001905 81001905 81003735 81014401
1-1/2” 17.5 to 175 81001906 81001906 81001906 81001906 81003733 81014402
2” 33 to 330 81001907 81001907 81001907 81001907 81003731 81014403
3” 60 to 600 - 81004048 81004050 81004048 81004095 -
3”* 60 to 600 - - 81004240 - - -
4” 110 to 1100 - 81004049 81004051 81004049 81004096 -
4”** 110 to 1100 - - 81004244 - - -
6” 300 to 3000 - - 81014474 81003112 - -
*3” Internal kit for turbine flowmeters purchased after January 1989.
**4” Internal kit for turbine flowmeters purchased after April 1990.

“WSP” Series -3A Sanitary Approved Carbide Bearings

Meter Flow W2
Size Range Stock No.
3/4” 1.5 to 15 81003845
1” 6.5 to 65 81003846
1-1/2” 17.5 to 175 81003847
2” 33 to 330 81003848

10 Issue/Rev. 0.6 (2/06)

General Specifications
Response Time Performance Specifications
1/2” to 2” Linearity: +/- 0.5%
2-5 milliseconds for step change in flow rate WG Series: +/-1.0%
3” to 6” GT Series: +/-1.0%
10-25 milliseconds for step change in flow rate Repeatability
Within +/- 0.1% of indicated flow throughout the
Temperature Range of Pickups linear range.
Standard Pickup Maximum Overrange
-100° F to 248° F (-73° C to 120° C) To 125% of maximum flow rate for intermittent periods.
Hi-Temp Pickup
Standard Materials of Construction
-450° F to 450° F (-268° C to 268° C)
Body
Extended Temp Pickup
316 S.S.
-450° F to 800° F (-268° C to 426° C)
Rotor
Pre-Amp Pickup
CD4MCu
-40° F to 248° F (-40° C to 120° C)
Rotor Shaft
RF Zero Drag Pickup
Tungsten Carbide or 316 S.S.
-20° F to 160° F (-29° C to 71° C)
Bushings
Sanitary Options Available
Tungsten Carbide or High Performance Polymer
Frequency Output Over Linear Flow Range Thrust Ball
1/2” to 1-1/2” - 100 Hz to 1000 Hz 316 S.S. or Tungsten Carbide
2” - 100 Hz to 900 Hz Rotor Support Retainers
3” to 6” - 50 Hz to 500 Hz 302 S.S.
Voltage Output Rotor Supports
1/2” to 2” 316 S.S.
Approximately 100 MV @ 100 Hz to 1.5 Volts (rms) 1000Hz Temperature Rating of Bearing Structure
3” to 6” Tungsten Carbide
Approximately 80 MV @ 50 Hz to 800 MV (r.m.s.) 500 Hz -20° F to 300° F (-29° C to 149° C)
Pressure Rating High Performance Polymer
The working pressure of W Series Turbine Meters is -20° F to 250° F (-29° C to 121° C)
limited to a maximum of 7500 psig on 3/4” bore and to Extended Temperature
5000 psig on 1/2”, 1”, 1-1/2” and 2” bores. Flanged -200° F to 800° F (-130° C to 426° C)
meters are limited by flange rating.
Turbine Flowmeter Sizing
Flow Range Nominal K-Factor*
Meter GPM BPH P/GAL P/BBL Freq. Output
Size (Hertz)
1/2”*** 0.6 to 6.0 .86 to 8.6 10,500 441,000
1/2” 0.8 to 6.0 1.14 to 8.6 10,500 441,000 100-1,000
3/4” 1.5 to 15 2.1 to 21 4,605 193,410 150-1,000
3/4”** 3.2 to 23 4.6 to 46 1,875 78,750 100-1,000
1” 6.5 to 65 9.3 to 93 953 40,026 100-1,000
1-1/2” 17.5 to 175 25 to 250 341 14,322 100-1,000
2” 33 to 330 47.1 to 471 185 7,770 100-1,000
3” 60 to 600 85.7 to 857 50 2,100 100-1,000
4” 110 to 1100 157 to 1571 28 1,176 50-500
6” 300 to 3000 428 to 4286 10 420 50-500

*Actual K-Factor will be within +/- 1% of Nominal Value. Data based on water calibration at 25C.
**Extended range.
***RF Pickup is required when using a flow range below 0.8 GPM

Issue/Rev. 0.6 (2/06) 11

3-A Sanitary Meters/Internals
The INVALCO 3-A (28-03) Sanitary Turbine Flow meter is certified for use in the food and beverage industry where
3-A is required. The meter has been specially designed to have the same characteristics, flow ranges, and life as
all the Invalco industrial meters, and also meet or exceed the requirement of 3-A (28-03). The meter has a
maximum surface finish of 32ra on all internal parts; all components are manufactured out of 3-A approved
material, and can be cleaned in place to save time and money in disassembling cleaning and reassembling the
meter. The wear surfaces are made from FDA (3-A) approved carbide for superior wear resistance.

The meter can be cleaned as long as the following conditions are met:
! Caustic solutions that are acceptable with 316 stainless steel components
! Temperatures of less than 275ºF (135ºC) for less than a 60 minute duration
! Instantaneous flow Ranges of the fluids must never exceed the chart below.

Meter Size Flow Range (GPM)

3/4 1.5-15
1 6.5-65
1 1/2 17.5-175
2 33-330
3 60-600

! Air purging must be done with care not to create severe shock loading to the meter, and velocity through the
meter must not exceed the instantaneous published flow ranges of the meter.
! Radii at ends of meters and the thrust bearing pockets (see figure 14) must be periodically checked for
cleanliness and adjustments in cleaning may be required to clean these areas. If areas do not clean in place
the meter may need to be disassembled from the line and cleaned by hand or other method to insure proper
cleanliness is being achieved. If the meter is disassembled for cleaning or inspection, care must be
taken not to lose the thrust bearings located at either end of the shaft. All replacement internals utilize a
sanitary paste to ensure that the bearings remain in place during assembly.

12 Issue/Rev. 0.6 (2/06)

Flow Related Formulas
U.S. GPM = Imperial GPM x 1.200955
GPM = Hz x 60
K
Pounds Per Hour = 500 x S.G. x GPM
HZ = GPM x K
Pounds Per Gallon = S.G. x 8.33 (water)
60

BPH = GPM x 1.42857

K = Hz x 60
GPM
BPD = GPM x 34.286
GPM = GPD
BPM = GPM x 0.0238
1440

GPS = GPM x .01666

Pulses Per Liter = K
3.785
GPD = GPM x 1440.0
Pulses Per Barrel = K x 42
GPM = BPH x 0.7
Pulses per Cubic Meter = K
CFM = GPM x .13368
.003785

GPM = GPH x .01666

Pulses Per Pound = K
Pounds per Gallon
GPM = CC/MIN x .000264173
GPM = Pounds Per Hour
Specific Gravity = LBS/GAL
500 x S. G.
8.33
LPM (liters per min) = 3.785 x GPM

GPM = LPM
3.785

Issue/Rev. 0.6 (2/06) 13

Introduction Specifications
The Model 4200 Rate/Totalizer is designed to accept fre- Display
quency or pulse inputs from a wide range of flowmeters and Continuously powered LCD
to display flowrate and a re-settable total directly in engineer-
ing units. Scaled pulse output is standard. The Model 4200 Total
is fully programmable with K-Factors, linearization of multiple 6 digits, 0.5” (12.7mm) high, resettable from the front panel
K-Factors, decimal point positions, and timebase being pro- Rate
grammed via the front panel switches. The instrument is 6 digits, 0.5” (12.7mm) high
housed in a durable weatherproof polycarbonate enclosure
that can be mounted directly on a flowmeter, panel mounted Resolution
or wall mounted using a pivoting bracket. 16 bits (0.05% of span)
Model Number Designation Accuracy
Field Mounted Base Unit .01% of Total, +/- 1 count
4200 - x0 Battery (Lithium) Powered Version - Pulse Output K-Factor
4200 - x1 Loop Powered Version w/4-20mA Rate Output
Mounting Options Programmable, pulses per unit of measure, .001 to
1x Standard Weatherproof Wall Mount/Panel Mount 999.999
3x Standard Weatherproof Swivel Meter Mount Stem 1” FNPT Timebase
Rate displayed in units per second, minute, hour or day
Quick Setup
Frequency Range
The steps below are to be used only if you do not require 0.00 Hz to 4250 Hz
pulse or analog output. Input Signal
1. Press and hold the [Program] to enter the programming Sine wave (20mV P/P min), Pulse, Reed Switch, others
mode. Operating Temperature
2. Press [Program] to skip “Linear”. -40°F to 158°F (-40°C to 70°C)
3. In “Factor” mode. Mounting
a. Press [+] to increase number. Meter mount or panel/wall mount
b. Press [-] to decrease number. Enclosure
4. Press [Enter/Next] to move cursor left, press [K Weatherproof and corrosion resistant
Factor] to move cursor right.
5. Repeat steps 4 and 5 until entire K Factor is entered.
6. Press [Program] once to show F.dEc (Flow Rate Deci- Battery Operated Version
mal Point) mode.
Approvals
a. Press [+] to increase number.
Intrinsically safe to Class 1, Div. 1 Grp A,B,C&D; CUL/UL
b. Press [-] to decrease number.
pending
7. Press [Program] once to show t.dEc (Total Decimal
Battery Type
Point).
3.6 volt Lithium Battery pack
a. Press [+] to increase number.
Battery Life
b. Press [-] to decrease number.
5 years typical (Without utilizing the Scaled Pulse Output)
8. Press [Program] once to show tScale (Time Scale)
mode. Activating pulse out requires additional processing resources
that will increase battery drain and shorten battery life.
a. Press [+] or [-] to change time scale shown.
Connection
b. Sec = rate per second
Two wire connection to probe
c. 60 Sec = rate per minute
Output Type
d. Per hr = rate per hour
Open drain transistor to ground (Resistive closure to
e. 24 hr = rate per day.
ground)
9. Press [Program] once to “SPULSE” mode.
10. Press [Program] once to “ANALOG” mode.
11. Press [Program] once to “PASS” mode.
12. Press [Program] once to “ACCEPT” mode.
13. Press [Enter/Next] to exit programming mode.

14 Issue/Rev. 0.6 (2/06)

Operating Mode
The Model 4200 Rate Totalizer will display:
Total
Rate
Totals greater than 999,999 are viewable by pressing
the “Enter/Next” button. The roll over total screen dis-
plays a “r” in the left most position and then any digits
in excess of the six that are normally viewable.
K-factor is viewable by pressing the k-factor button on
the keypad, and pressing the k-factor button again will
return to the Totalizing display.
Software Version is viewable by pressing the “+” but-
ton on the keypad
Program Steps
1. Hold the “Program” button for 5 seconds. This will
put the 4200 into programming mode.
2. The first time that the 4200 is setup, the program
will take you directly to the K-factor entry screen. The
4200 will now prompt for using a single K-factor or to
linearize using multiple K-factors. Selecting “oFF” will
use a single K-factor (go to Step 3). Selecting “on” will
allow the input of multiple K-factors (go to Step 4).
Button operation:
“Program” = progress to next screen regardless of
where cursor is positioned
“Enter/Next” = move cursor left one position
“K-factor” = move cursor right one position
“+” = increments number where cursor is positioned
“-” = decrements number where cursor is positioned
“Reset” = replaces numbers with default and returns
the cursor to the right most position
3. Input the appropriate K-factor. Insertion of the
decimal position is the last step required to
input a new k-factor. After the last numerical
position is entered, the “+” and “-” buttons will
move the decimal position through the 3 posi-
tions. After placing the decimal in the correct
position, the “Enter/Next” button will progress
the screen. If linearization is required proceed
to Step 4. If linearization is not required pro-
ceed to Step 7.
Issue/Rev. 0.6 (2/06)
Button operation:
“Program” = progress to next screen regardless of
where cursor is positioned
“Enter/Next” = move cursor left one position
“K-factor” = move cursor right one position
“+” = increments number where cursor is positioned
“-” = decrements number where cursor is positioned
“Reset” = replaces numbers with default and returns
the cursor to the right most position
4. Input the 1st pulse rate (Hz) starting with the lowest.
Button operation:
“Program” = progress to next screen regardless of
where cursor is positioned
“Enter/Next” = move cursor left one position
“K-factor” = move cursor right one position
“+” = increments number where cursor is positioned
“-” = decrements number where cursor is positioned
“Reset” = replaces numbers with default and returns the
cursor to the right most position
5. Input the 1st k-factor matching the 1st pulse rate
entered in the previous step. Insertion of the deci-
mal position is the last step required to input a
new k-factor. The decimal position is limited to 3
positions. After the last numerical position is
entered, the “+” and “-” buttons will move the
decimal position through the 3 positions. After
placing the decimal in the correct position, the
“Enter/Next” button will progress the screen.
Button operation:
“Program” = progress to next screen regardless of where
cursor is positioned
“Enter/Next” = move cursor left one position
“K-factor” = move cursor right one position
“+” = increments number where cursor is positioned
“-” = decrements number where cursor is positioned
“Reset” = replaces numbers with default and returns the
cursor to the right most position
6. Repeat step 4 and 5 for as many different pulse
rate and k-factor combinations up to 10 entries. If
you have less than 10 combinations to enter, enter
“000000” in the next pulse rate prompt to finish
combination entry. If you have 10 combinations,
after you enter the last k-factor the 4200 will go to
the next screen.
15
7. Set how many decimal positions you want in
the flow rate display.
000000 = no decimal positions
00000.1 = one decimal position
0000.02 = two decimal positions
000.003 = three decimal positions
0000-.1 = flow rate x 10
0000.-2 = flow rate x 100
Button operation:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = increments amount of decimal positions
“-” = decrements amount of decimal positions
“Reset” = replaces default
8. Set how many decimal positions you want in
the total display.
000000 = no decimal positions
00000.1 = one decimal position
0000.02 = two decimal positions
000.003 = three decimal positions
Button operation:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = increments amount of decimal positions
“-” = decrements amount of decimal positions
“Reset” = replaces default
9. Set the time scale in which that the flow rate
will be displayed on the display.
SEc = unit of volume per second
60 SEc = unit of volume per minute
PEr hr = unit of volume per hour
24 hr. = unit of volume per day
Button operation:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = increments unit of time scale
“-” = decrements unit of time scale
“Reset” = replaces default
16
10. Select “on” for a scaled pulse output. Select
“oFF” if a scaled pulse output is not desired (go
to Step 13).
Button action:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = toggle between “oFF” and “on”
“-” = toggle between “oFF” and “on”
“Reset” = replaces default
11. Set the scale of the scaled pulse output.
_____1 = 1 pulse per 1 increment of least significant
digit in total LCD
____10 = 1 pulse per 10 increment of least significant
digit on total LCD
___100 = 1 pulse per 100 increment of least significant
digit on total LCD
__1000 = 1 pulse per 1000 increment of least significant
digit on total LCD
_10000 = 1 pulse per 10000 increment of least signifi-
cant digit on total LCD
100000 = 1 pulse per 100000 increment of least signifi-
cant digit on total LCD
Button operation:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = increments scale of pulse output
“-” = decrements scale of pulse output
“Reset” = replaces default
12. This option is not operable or available for the
battery powered 4200. Verify that “oFF” is dis-
played. To select “oFF” push the “+” or “-” key and
go to Step 13.
Button operation:
“Program” = progress to next screen
“Enter/Next” = progress to next screen
“K-factor” = no action
“+” = toggle between “oFF” and “on”
“-” = toggle between “oFF” and “on”
“Reset” = replaces default
Issue/Rev. 0.6 (2/06)
13. At this point the user has the option to establish a
password. Once a password has been set, the 4200 will
always prompt the user for a password, before pro-
gram changes can be made. When no password or the
wrong password is entered, the 4200 will go back to
the normal display. THE ESTABLISHMENT OF A
PASSWORD IS OPTIONAL. If locking the 4200 with a
password is not needed, enter “000000” and the 4200
will operate unlocked. **
Button operation:
“Program” = progress to next screen regardless of
where cursor is positioned
“Enter/Next” = move cursor left one position
“K-factor” = move cursor right one position
“+” = increments number where cursor is posi-
tioned
“-” = decrements number where cursor is posi-
tioned
“Reset” = replaces numbers with default and re-
turns the cursor to the right most position
** It is highly recommended that the
password function not be used unless it
is required. If a password is required
write down the password in the manual
and keep in a secure location. If you
forget the password you must con-
sult the factory for procedures on
how to reset the current password.
14. Now the 4200 will prompt for user to accept
the password. Display should read 000000 in RATE
area of LCD if no password is required
Button operation:
“Program” = return to password screen (step 14)
“Enter/Next” = accepts password and exits program
mode
“K-factor” = return to beginning of setup
“+” = return to password screen (step 14)
“-” = return to password screen (step 14)
“Reset” = return to password screen (step 14)
Calculation of Rate and Total
Gallons (US) to Barrels (oil)………42.00
Liters to Kiloliters ……………….1000.00
mL to Liters ……………………..1000.00
Mgallons to Acre-feet …………..0.32587
Issue/Rev. 0.6 (2/06)
Changing Batteries
New batteries can be purchased through INVALCO or
our distributors and replaced in the field.
WARNING - To prevent ignition of flammable or
combustible atmospheres, read, understand, and
adhere to the manufacturer’s live maintenance pro-
cedures.
Replace battery with an INVALCO battery assembly
ONLY. Battery assembly part number is P524017. The
model 4200 is designed to operate on one battery.
NEVER attempt to power the unit with two battery as-
semblies or with a non-INVALCO battery assembly.
There is one Lithium battery pack in each instrument and
care must be taken to replace so that there is always power
connected to the memory. Connect the new battery pack
into J3 or J4 before disconnecting the old battery. Failure to
not supply the board with continuous power will result in loss
of setup parameters and totals. Please dispose of old
batteries by sending them to an Approved Battery
Recycle Location.
Typical Connections
Flowmeter Input
The Model 4200 input circuit which will accept signals
from most pulse or frequency producing flowmeters.
The input will interface directly to:
Turbine Flowmeters
For flow meters with coils, the minimum input voltage is
20mV P-P. See the drawing below and sketches on the
next two pages for hook-up information.
1. Squarewave, CMOS or Pulse
2. Reed or Switch
5. Coils (Magnetic Pick-up)
Wiring
When connecting the 4200 it is good practice to use a
shielded cable. The shield should be connected to
earth at one end of the cable. The other end of the
shield should not be connected.
17
Input Signal Wiring Options The Circuit Board
Two-wire coil pickup
Terminal Designations
Input - (+TFM)
Input - (-TFM)

Grounded Switch Closure or Reed

3.6V DC

Powered Switch Closure or Reed Switch

3.6V DC Warnings
The 4200s are affected by EMF (Electric Magnetic
Fields); due to this the unit needs to be located in an
area with little affects from externally omitting EMF
Output Wiring Options devices. The turbine and pickup uses EMF in pulses
Scaled Pulse Connection to calculate rate. Interference in this field by other
devices will cause inaccuracies with the meter. Elec-
tric motors, spark driven engines, transformers, and
3.6V DC
other high current or high voltage devices create EMF
and should be kept as far away as feasible to lessen
their chances of effecting the meter.

Vibration can cause false readings or counted rate

when not in use. Portable units should be reset after
transport to re-zero the meter. Place meter in a loca-
tion where it is well grounded, free of vibration and
stable when metering.

Installation

Wall Mounting
A wall mounting bracket is supplied with each instrument.
The instrument is then attached to the bracket at
the bottom with knobs.
Removing the Front Panel:
The front panel of the instrument is removed as follows:
1. Loosen knobs and tilt unit down.
2. Undo the eight screws retaining the front panel.
3. Pull the front panel free from the housing.
Unit can then be tilted up to access internal components.

18 Issue/Rev. 0.6 (2/06)

Intrinsic Safety Connections
When installing the Model 4200 in hazardous areas, the wiring and installation must comply with appropriate installa-
tion standards. The Model 4200 will connect directly to turbine or paddlewheel flowmeters with a certified IS coil or
other certified IS sensors which produce a pulse output, provided they do not exceed the following input parameters:

Entity Parameters for TB3 Entity Parameters for TB2 Terminals 1 & 2
Vmax = 3.6 Vdc Voc = 3.6 Vmax = 3.6 Vdc
Imax = 72 mA Isc = 72 mA Imax = 72 mA
Ci = 12.34 uF Ca = 12.34 uF Ci = 12.34 uF
Li = 0 mH La = 0 mH Li = 0 mH

Control Drawing

i
i

i
i

i
i

Installation must be in accordance with the National Electric Code (NFPA 70, Article 504) and ANSI/ISA-RP12.6.

Selected intrinsically safe equipment must be listed and have entity parameters such that:
Vmax * Voc
Imax * Isc
Ci + Ccable * Ca
Li + Lcable * La

-or-

May be connected to simple apparatus that does not generate more than 1.5V, 100mA and 25mW. If cable
parameters are unknown, the following values can be used:
Cable Capacitance - 60pF/ft
Cable Inductance - 0.20uH/ft

Issue/Rev. 0.6 (2/06) 19

Dimensions
Wall Panel Mount

The 4200 Wall/Panel mounted version can be mounted with an offset utilizing the supplied bracket, or it can be mounted directly
to a panel or wall using the 4 tapped holes located on the back of the unit.
Direct Mount

The 4200-30 and 4200-31 are direct mounted. Care must be taken the follow these steps during installation:
1. Screw Pickup into TFM body, hand tight (do not over tighten).
2. Attach wires to Pickup.
3. Loosen screws on swivel (do not remove).
4. Hold totalizer body steady and screw swivel-neck onto TFM threaded adapter. Hand tighten (do not over tighten)
5. Adjust totalizer for required viewing position.
6. Retighten swivel neck screws.
Note: Dimensions - Inches to the nearest tenth (millimeters to the nearest whole mm), each independently dimensioned from respective engi-
neering drawings.

www.fmcinvalco.com

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
20Printed in U.S.A. ©2/04 FMC INVALCO All rights reserved. Issue/Rev. 0.1 (2/04) Issue/Rev. 0.6 (2/06)