GAS & STEAM

FLOW COMPUTER
MODEL 415

415-M-V3.2 June 2017

415-M-V3.2
 CONTENTS
List of Symbols

1. Introduction 7

1.1 Model Number Designation 9

2. Specification 10

3. Operation 14

3.1 Front Panel Operation 14

3.2 Flow Equations for Gases 16
3.2.1 Ideal Gas Law 22
3.2.2 General Gas 24
3.2.3 Natural Gas 25
3.3 Steam Measurement 26
3.4 Filtering 31
3.5 Non-Linearity Correction 33
3.5.1 Digital Input Linearity Correction 33
3.5.2 Analog Input Linearity Correction 35
3.6 The Output Pulse 37

4. Options 39

4.1 The 4-20mA Output Option 39

4.1.1 Load Specification 40
4.1.2 Calculation 40
4.2 The RS232/422/485 Interface Option 43
4.2.1 Hardware 43
4.2.2 Multipoint Communication 44
4.2.3 Communication Protocol 46
4.3 Data Logging 48
4.4 The Relay Output Option 49

415-M-V3.2
 5. Calibration 50

5.1 Programming Chart 52

5.2 Definitions 59

6. Input Circuits 62

6.1 Frequency Flow Input 62

6.2 Analog Inputs 67
6.3 Remote Switches (Model 415A Only) 70

7. Installation 71

7.1 General 71
7.2 Wiring Designations for the Mode 415 73
7.3 Ex 410 Enclosure Dimensions 75

Appendix 76

Properties of Selected Gases 76

Index 78

415-M-V3.2
 List of Symbols Used in this Manual

Symbol Description SI Units US Units

A Normalised signal from the

flowmeter which will be 0 at
4mA and 1 at 20mA.

G Specific Gravity for Gas.

hB Specific Enthalpy at Reference kJ/kg kJ/kg

Conditions.

hF Specific Enthalpy at Flow kJ/kg kJ/kg

Conditions.

KF K-factor (pulses/unit) for a pulses/m3 pulses/ft3

frequency flowmeter.

N Timebase Constant with which the

flowrate is displayed and is:
1 for units/second
60 for units/minute
3600 for units/hour
86400 for units/day

ᴘB Density at base conditions. kg/m3 lbs/ft3

ᴘF Density at flow conditions. kg/m3 lbs/ft3

ᴩB Pressure at base conditions. kPa (abs) psia

ᴘC Critical pressure of gas. kPa (abs) psia

415-M-V3.2
 Symbol Description SI Units US Units

PF Pressure at flow conditions. kPa (abs) psia

QE Energy value of steam. MJ/day BTU x 1000/day

MJ/hr BTU x 1000/hr
MJ/min BTU x 1000/min
MJ/sec BTU x 1000/sec

QM Mass Flowrate. kg/day lbs/day

kg/hr lbs/hr
kg/min lbs/min
kg/sec lbs/sec

QVB Volume Corrected Flowrate. m3/day ft3/day

m3/hr ft3/hr
m3/min ft3/min
m3/sec ft3/sec

Note: If the corrected flowrate is at standard base conditions,

then the flow will be in scm or scf (ie. standard cubic meters or
feet).

If the corrected flowrate is at normalised base conditions, then the

flow will be in Nm3 (ie. Normalised cubic meters).
SM Span (Mass Flowrate at 20mA). kg/day lbs/day
kg/hr lbs/hr
kg/min lbs/min
kg/sec lbs/sec

SV Span for a volumetric flowmeter m3/day ft3/day

(eg vortex). m3/hr ft3/hr
m3/min ft3/min
m3/sec ft3/sec

415-M-V3.2
 Symbol Description SI Units US Units

SVB Span (Volumetric Flowrate at m3/day ft3/day

20mA) and at base conditions. m3/hr ft3/hr
m3/min ft3/min
m3/sec ft3/sec

TB Temperature at base conditions. °K °R

(Kelvin) (Rankin)

TC Critical temperature of gas. °K °R

TF Temperature at flow conditions. °K °R

Specific Weight of Steam at dm3/kg dm3/kg

VB
Reference Conditions.

Specific Weight of Steam at Flow dm3/kg dm3/kg

VF
Conditions.

Zb Compressibility at base conditions.

ZF Compressibility at flow conditions.

415-M-V3.2
415-M-V3.2
 Introduction 7

1. INTRODUCTION
The Model 415 Gas Flow Computer incorporates compensation for gas
and vapours to the following equations:

1. Ideal Gas Law using temperature & pressure correction, but where
compressibility is ignored.

2. General Gases where compressibility is calculated using the

Redlich-Kwong1 equation.

3. Natural Gas using NX-192 equation for supercompressibility.

4. Steam Equations for both saturated and superheated steam. Mass

and energy flowrates are calculated using standard equations to
determine the specific weight and enthalpy of steam.

Inputs from a wide range of flowmeters are handled including vortex,

turbine, orifice plate, averaging pitot tubes, wedges, V-Cones and target
flowmeters. In addition, where two differential pressure transmitters are
used across an orifice (or similar device) to increase the measured
flowrange, both D.P. Transmitter inputs can be accepted into the Flow
Computer and scaled separately with automatic crossover.

Options include a 4-20mA re-transmission, high and low flow alarms and
an RS232/422/485 output. A unique feature available with the
RS232/422/485 output is the ability to print flowrates and totals at
programmable time intervals.
This enables the instrument to function as a data logger when used in
conjunction with a printer, or other storage device.

Two versions of the instrument are available, the Model 415R with direct
RTD input, and the 415A with a 4-20mA temperature input. Both accept a
4-20mA pressure input.

The Model 415 is designed to supersede the Models 405GS and 405ST.

1 Redlich & Kwong. "An equation of State". Chem Rev, vol 44, p233, 1949.
2 Par Research Project NX-19. "Extension of Range of Supercompressibility
Tables", American Gas Association, 1962.

415-M-V3.2
 8 Introduction

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

Communities 2014/30/EU, the LVD directive 2014/35/EU and the following
standards:

EN61326:2013 Electrical equipment for measurement, control

and laboratory use – EMC requirements : Residential,
Commercial & Light Industry Environment &
Industrial Environment.

EN61010:2010 Safety requirements for electrical equipment for

measurement, control, and laboratory use.

415-M-V3.2
 Introduction 9

1.1 MODEL NUMBER DESIGNATION

The Model number of an instrument describes which input and output

options are installed and the AC mains voltage rating.

Model 415 R. 1 0 E C

C for Conformal Coating

E for 220/240 VAC

A for 110/120 VAC
D for DC Power Only

Temperature Options
R for RTD input 0 for no option
A for 4-20mA 1 for 4-20mA output
2 for RS232/422/485
3 for Relay option
4 for 4-20mA and relays
5 for RS232/422/485 and
relays

Mounting
1 for panel mounting
2 for field mounting
3 for explosionproof

The Model number of the instrument is displayed on first entering

the Calibration Mode (see Section 5).

415-M-V3.2
 10 Specification

2. SPECIFICATION
General

Display: Alphanumeric LCD display with

backlighting and 2 lines x 20
characters/line.
Each character 5.5mm high.
Keyboard: Sealed membrane keyboard with four keys.
Transducer Supply: 8-24VDC field adjustable, 65mA maximum.
Power Requirements: 14 to 28.0 VDC, 300mA typical.
AC mains - Set internally to 95 - 135 VAC
or 190 - 260 VAC.
Operating Temperature: 0 to 55°C.
Facia: Watertight to IP65 or Nema 3S.
Dimensions: 144mm (5.7") wide x 72mm (2.8") high x
188mm (7.4") deep.
Depth behind Panel: 139mm (5.5") x 67mm (2.6").

Frequency Input

Frequency Range: Minimum: 0.25Hz on Rate.

0Hz on Total.
Maximum: 10KHz.
Input Circuits: Will accept most sine logic and proximity
switch inputs (see section 6.1).
K-factor Range: 0.1000 to 999,999.
Non-Linear Correction: Up to 10 correction points.

415-M-V3.2
 Specification 11

4-20mA Inputs

Inputs: Flow (2), pressure & temperature.

Input Impedance: 250 ohms.
Measurement Ranges: Pressure: 0kPa (abs) (0 psia) to 100,000 kPa
(10,000 psia).
Temp:-273°C (-459.4°F) to 1200°C (2192°F).
Accuracy: 0.05%.
Circuit: The 250 ohm resistors are connected to a
common signal ground (current sinking).
Span (Flow): 999,999.

RTD Input (Model 415R)

Temperature
Measurement Range: -100°C (-148°F) to 200°C (392°F),
Note: a wider temperature range can be
handled via a 4-20mA input.
Accuracy: 0.1°C
RTD Type: Platinum PT100.
Linearity: The non-linearity of the RTD is internally
compensated for.

Pressure Input

Type: Absolute or Gauge.

Span: The absolute or gauge pressure at both 4mA
and 20mA is programmable.
Atmospheric: If a gauge pressure sensor is used the
atmospheric pressure can be programmed.

4-20mA Output

Function: The flowrate selected as the Default display

is output on the 4-20mA output.
Resolution: 10 bits.
Accuracy: Better than 0.1%.
Maximum Load: 500 ohms internally powered.
950 ohms from 24 VDC.
Isolation: Output is isolated.

415-M-V3.2
 12 Specification

Relay Output

Function: High and low flowrate alarms based on the

flowrate selected as the default display.
Maximum Switching Power: 1250VA.
Maximum Switching Voltage: 250 VAC, 30VDC.
Maximum Switching Current: 5 Amps.

RS232/422/485 Option

Type: Both RS232 & RS422/485 are provided.

Function: Printer and computer protocols are
programmable.
Output: Output is on request or at a programmable
time interval.
Baudrate: 300 to 9600.
Data Bits: 7 or 8.
Parity: None, Odd, Even.

Pulse Output

Function: The pulse output is scaled and outputs one

pulse each time the Default total
increments by one digit.
Pulse Width: 10mSec (negative going pulse).
Duty Cycle: Maximum of 49 pulses per second.
Output: An open collector transistor will sink 100mA
maximum.

Ideal Gas

Display: Corrected Volume (m3 or ft3).

Mass (kg or lbs).
Temperature Range: -273°C (-450°F) to 800°C (1472°F).
(RTD has a more limited range.)
Pressure Range: 0 kPa abs (0 psia) to 100,000 kPa (10,000
psia).

415-M-V3.2
 Specification 13

General Gas

Gases: Handles most gases for which the critical

temperature, pressure and SG are known.
Compressibility: Calculated using Redlich-Kwong equation.
Display: Corrected Volume (m3 or ft3).
Mass (kg or lbs).
Temperature Range: -273°C (-450°F) to 800°C (1472°F).
(RTD has a more limited range.)
Pressure Range: 0 kPa abs (0 psia) to 100,000 kPa (10,000
psia).

Natural Gas

Calculations: Uses NX-19 equation to calculate

supercompressibility Fpv.
Displays: Corrected Volume (m3 or ft3).
Mass (kg or lbs).
Temperature Range: -40°C (-40°F) to 115°C (240°F).
Pressure Range: 101.325 kPa (14.69 psia) to 34,380 kPa
(4985 psia).
SG Range: 0.554 to 1.000.
Carbon Dioxide: 0 to 15% mole.
Nitrogen: 0 to 15% mole.

Steam

Displays: Mass (kg or lbs)

Energy (MJ or BTU x 1000).
Calculations: Uses 1967 IFC Formulation equations to
calculate specific weight and enthalpy of
steam.
Steam Type: Saturated and Superheated.
Temperature Range: 20°C (68°F) to 800°C (1472°F).
(RTD has a more limited range.)
Pressure Range: 1 kPa (abs) (1 psia) to 100,000 kPa (10,000
psia).

415-M-V3.2
 14 Operation

3. OPERATION
The Model 415 uses a low power CMOS microprocessor to perform
all measurement and control functions.

The instrument is fully programmable with all operating parameters

and calculation constants user programmable (see Section 5 entitled
Calibration for information on programming). All parameters and
constants are stored in a non-volatile memory which retains data
without battery backup for a minimum of 10 years.

3.1 FRONT PANEL OPERATION

The alphanumeric display provides a clear indication of which parameter

is displayed and the engineering units.

During Calibration, the value which is to be normally displayed can

be programmed as the DEFAULT display. For example, if Mass is
required and is programmed as the DEFAULT display, then pressing
the RATE key will show the Mass flowrate, and pressing the TOTAL
key will show the Mass total.

The scaled pulse out, 4-20mA output option and high/low alarm option are
also based on the DEFAULT display selection. For example, the 4-20mA
output would be a re-transmission of the Mass flowrate, if the DEFAULT
display is set to Mass.

The DISPLAY key can be used to step through the data which can be displayed,
as follows:

Gas Flow
Corrected Volume (Rate & Total)
Mass (Rate & Total)
Temperature & Pressure

415-M-V3.2
 Operation 15

Steam
Mass (Rate & Total)
Energy (Rate & Total)
Temperature & Pressure
Specific Weight & Enthalpy

If any value other than the default display values are selected, they will
remain displayed for 5 seconds, after which the display will automatically
revert to the default values.

Totals are displayed with a maximum of 8 digits, including decimals.

For example, if two decimals are programmed, the maximum total is
999,999.99, after which the totals roll over to zero and continue
counting.

For large flowrates, totals can be integrated at 1/1000 of the flowrate

by programming the Total Units function at x 1000. The units of
measure will then be displayed as follows:

SI Units
Rate Total
cm/h kcm
scm/h kscm
Nm3 kNm3
kg/h tonne
MJ/h GJ

US Units
Rate Total
cft/h kcft
scft/h kscft
lbs/h klbs
BTU x 1000/h MBTU

(Note: k = x 1000, M = x 1,000,000, G = x 1,000,000,000).

The RESET key can be used to reset the totals whenever one of the totals
is displayed. Both totals will be reset at the same time. The RESET
switch can be disabled during calibration to prevent front panel resetting.

415-M-V3.2
 16 Operation

3.2 FLOW EQUATIONS FOR GASES

This section applies only to gas flow measurement and, if the Model 415 is to
be used for steam measurement, the reader can skip this section and go to
section 3.3.

The Model 415 will accept inputs from a wide range of flowmeters with
the flowrate calculated by the equations defined below. Both mass flow
and volume corrected flow to a base temperature and pressure are
calculated and displayed in either SI (metric) or US units. For an
explanation of the symbols used in the equations see the list at the
beginning of this manual.

Two basic formulae are common to all equations:

Molecular Weight of Gas
1. Specific Gravity, G = Molecular Weight of Air

Molecular Weight of Gas

= .....(1)
28.9625

2. Density of a Gas, ᴘ , at base conditions:

In SI Units
3.4834 G P B
rB = ZB T B
kg/m3 .....(2)

In US Units
2.6988 G P B
rB = ZB T B
lbs/ft3 .....(3)

Standard Conditions

Standard conditions are defined as:

15°C (288.15°K) and 101.325 kPa

or 59°F (518.67°R) and 14.69595 psia.

415-M-V3.2
 Operation 17

Normalised Conditions (SI Units only)

Normalised conditions are defined as:

0°C (273.15°K) and 101.325 kPa.

A. Volumetric Flowmeters With Frequency Output.

eg. Vortex, turbine or positive displacement flowmeters.
N. frequency(Hz) P F T B ZB
Q VB = KF . P .T
B F
. ZF ......(4)

QM =r B . Q VB ......(5)

B. Volumetric Flowmeters With 4-20mA Output.

eg. Vortex, turbine or positive displacement flowmeters with
frequency to current convertors.

TB TB ZB
Q VB = S V . TF . TF . ZF. .A

Q M= r B .Q VB

C. Differential Pressure Flowmeters With 4-20mA Output And A Square

Law Relationship.
eg. Orifice Plates, Averaging Pitot Tubes, Target Flowmeters, etc.

PF TB ZB
Q VB = S VB . PB
. TF . ZF
. A ......(7)

Q M= rB Q VB

415-M-V3.2
 18 Operation

D. Differential Pressure Flowmeters With 4-20mA Output And With A

Linear Flow Relationship.
eg. D.P. transmitters with a square root extractor or VA meters.

PF TB ZB
Q VB = S VB . PB
. TF
. ZF
.A ......(8)

Q M = r B . Q VB

Note that the pressure and temperature are still square rooted, even
though the flow signal A is not. This is because the output from the D.
P. transmitter is not truly volumetric, but will be affected by a change in
density of the gas being measured. Therefore, the equations
relating to differential pressure will apply.

E. Dual Differential Pressure Flowmeters With 4-20mA Output.

To increase the range over which flow can be measured, two D.

P. transmitters with different spans can be connected across a
common orifice or other differential pressure device.

Equations 5 & 6 or 7 & 8 above would be used depending upon

whether the D. P. transmitters have square root extractors. Separate
scaling using these equations is then programmed for each
transmitter.

At lower flowrates, transmitter 2 will be used as a basis of

measurement and at higher flowrates, transmitter 1 will be used.
The crossover point will occur when the input on transmitter 2
exceeds 20mA.

415-M-V3.2
 Operation 19

Example 1

Flow is to be measured across an orifice in the range of 0 -

2000 scm/hr. Because flow needs to be measured over a 10:1
range, two transmitters are spanned as follows:

Transmitter 2 0 - 600 scm/hr

Transmitter 1 0 - 2000 scm/hr

Hence, above 600 scm/hr, transmitter 2 is used and below

600 scm/hr, transmitter 1 is used. Since D. P. transmitters
are accurate over a 3:1 range, then the system will provide
reliable readings between 200 to 2000 scm/hr, which is a
10:1 turndown.

Both transmitters will be individually scaled to equations 5 & 6

or 7 & 8, as appropriate.

PROGRAMMING THE FLOW COMPUTER

For equations 4 to 8 to work correctly, a number of parameters

need to be programmed:

KF K-factor (for frequency producing flowmeters)

SVB (or SM) Span (for analog flowmeters)
TB Base temperature
PB Base pressure
G Specific Gravity of Gas

The flow computer will measure the flow input A (normalised

between 0 and 1), the temperature, TF, and pressure, PB.
Depending on the gas equation selected, the compressibility factors
and density are then calculated. Other parameters must also be
programmed and these are fully detailed in section 5.

415-M-V3.2
 20 Operation

PROGRAMMING THE SPAN AS MASS

It is also possible to enter the span of an analog flowmeter in

mass(instead of volume) at a nominal flowrate. The flow
computer willthen automatically calculate the Span, SVB, for
corrected volume flow as:
S
S VB = rMB ......(9)

Example 2

If a flowmeter produces 1000 kg/h at 30°C and 220 kPa, and

the specific gravity is 1.52 then from equation (2)
3.4834 x 1.52 x 220
r= 1 x (30 + 273.2)

= 3.84 kg/m 3 (assuming ZB = 1)

Therefore, from equation (9)

1000
S VB = 3.84

= 260 m 3 /hr

If the span is programmed as mass SM = 1000 kg/hr, with the

base temperature programmed to 30°C and the base pressure
programmed to 220 kPa, then the3flow computer will display
both mass (kg/hr) and volume (m /hr) corrected to a base
condition of 30°C and 220 kPa.

415-M-V3.2
 Operation 21

Example 3

If the mass flow is defined at non- standard base conditions

and it is required to display the corrected volume at standard
conditions, then it is first necessary to convert the mass to an
equivalent mass at standard conditions.

Using example 2 for a differential pressure device, the

corresponding mass at 15°C and 101.325 kPa can be determined
from equation 7 as:
P1 TB ZB
S M1 = S MB . PB
. T1
. Z1

where SM1 = the new span at 15°C and 101.325

kPa and with the input A = 1

Therefore, the new span SM1, with ZB = Z1= 1, is:

101.325 30 + 273.2
S M1 = 1000 x 220 x 15 + 273.2

= 696.1 kg/hr

Hence, the span would be programmed as 696.1 kg/hr, the

base temperature as 15°C and the base pressure as 101.325
kPa. The corrected volume will now be displayed at
standard conditions.

415-M-V3.2
 22 Operation

3.2.1 Ideal Gas Law

If the effects of compressibility on a gas can be ignored, then ZB and ZF can be

set to 1.00 in equations 1 to 8. This can make calculations much simpler,
particularly when the properties of a gas are not known or, over small
ranges of pressure and temperature, where the effects of compressibility are
often negligible.

Example 4

A vortex meter is used to measure oxygen in a 2" pipe at 25° C 3

and 200 kPa (abs). The flowmeter produces 9500 pulses/m
and the flowrange is 100 to 1000 m 3/h. Determine the flow
parameters which need to be programmed into the instrument
for it to display the flowrate and total flow as both mass and
corrected volume to Standard Conditions.

From the table, the Molecular Weight of oxygen is 31.9988.

From equation (1)
31.9988
G= 28.9625
= 1.105

According to ISO5024, Standard Conditions are 15° C (59° F) and

101.325 kPa (14.69595 psia). Hence, the following
are programmed into the instrument:

Scaling Factor (K-factor) = 9500 pulse/m3

Specific Gravity G = 1.105
Base Temperature = 15 °C
Base Pressure = 101.325 kPa
Timebase of Rate = Hours

Other parameters can be programmed as required.

The instrument will now display the corrected volume and

mass flowrates of the gas.

415-M-V3.2
 Operation 23

Example 5

The same vortex meter installation, as detailed in Example 4, also

has a 4-20mA output. The meter produces 20mA at 1000 m3/h
and 4mA at 0 m3/h. Determine the flow parameters which need
to be programmed for mass flow and corrected volume to
standard conditions.

With the instrument set for a linear 4-20mA input signal,

the following parameters are programmed:

Span (SV) = 1000 m3/h

Specific Gravity G = 1.105
Base Temperature = 15 °C
Base Pressure = 101.325 kPa
Timebase of Rate = Hours

415-M-V3.2
 24 Operation

3.2.2 General Gas

For general gases, the compressibility is calculated using the

Redlich-Kwong equation. In order to calculate the compressibility of a
gas, it is necessary to know the critical temperature and pressure. From
these parameters, the compressibility factors ZB and ZF are calculated for
a gas.

A list of common gases with specific gravity and critical temperatures

& pressures is given in the appendix to this manual.

The equations 1 to 9 are then used to calculate both corrected volume and
mass flow.

Example 6

It is required to measure Hydrogen via an orifice plate

using compressibility. Find the critical temperature and
pressure which need to be programmed and the specific
weight.

From the table, in the appendix,

T C = -239.9 C

P c = 1296.9 kPa

415-M-V3.2
 Operation 25

3.2.3 Natural Gas

In the gas industry, compressibility is referred to by a factor, FPV, termed

the supercompressibility factor where:

Z ......(10)
F PV = ZFB
FPV is calculated in the flow computer using the NX-19 equation Z for natural
gas and (FPV)2 is substituted into equations 4 to 8 in place of B
ZF

In order to calculate FPV, the following must be programmed within the

following ranges:

Specific Gravity G: 0.554 to 1.000

Carbon Dioxide mol%: 0 to 15%
Nitrogen mol%: 0 to 15%

Also, the temperature and pressure must be within the following ranges:

Temperature -40 to 115°C

(-40 to 240°F)
Pressure 0 to 34,372 kPa
(0 to 5000 psia)

415-M-V3.2
 26 Operation

3.3 STEAM MEASUREMENT

The Model 415 incorporates equations to handle both saturated and

superheated steam over the following range:

Pressure 0 kPa abs (0 psia) to 100,000 kPa abs (10,000 psia)

Temperature 100°C (212°F) to 800°C (1472°F).

When measuring saturated steam, it is possible to delete either the

pressure or temperature sensor since, on the saturation line, there is a
corresponding pressure for all temperatures. For superheated steam, it is
necessary to use both the pressure and temperature sensors.

Both the mass flow (in kg/hr or lbs/hr) and the heat content (enthalpy)
are calculated internally based o n the 1967 IFC Formulation (ASME)
Equations.
The equations use the pressure and temperature readings to determine:

- v, the specific volume of steam in dm3/kg or,

- h, the specific enthalpy of steam in kJ/kg.

A. Volumetric Flowmeters With Frequency Output.

eg. Vortex, Steam turbines, etc.

Mass Flow
N. frequency (Hz) 1
SI Units : Q M(SI) = 1000 . KF
. nF ......(11)

N. frequency 1
US Units : Q M(US) = 62.435 . KF
. nF ......(12)

(Note: for US units KF is in pulses/ft3.)

415-M-V3.2
 Operation 27

Energy Flow
QM(SI) x h
SI Units : Q E(SI) = 1000
......(13)

Q M(US) x h
US Units : Q E(US) = 0.42992 1000
......(14)

B. Volumetric Flowmeters With 4-20mA Output.

eg. Vortex or Steam turbines with frequency to current convertors.

Mass Flow
SV
SI Units : Q M(SI) = 1000 x nF xA ......(15)

......(16)
SV
US Units : Q M(US) = 62.447 x nF xA

Energy Flow

Equations 13 & 14 are used.

C. Differential Pressure Flowmeters With 4-20mA Output And A Square

Law Relationship.
eg. Orifice Plates, Averaging Pitot tubes, target flowmeters, etc.

Mass Flow
nB
QM = SM . nF . A ......(17)

Energy Flow

Equations 13 & 14 are used.

415-M-V3.2
 28 Operation

D. Differential Pressure Flowmeters With 4-20mA Output And With A

Linear Flow Relationship.
eg. D. P. transmitters with a square root extractor or VA meters.

Mass Flow
nB
QM = SM . nF .A ......(18)

Energy Flow

Equations 13 & 14 are used.

Note that the Specific Weight (density) is still square rooted even
though the flow signal A is not. This is because the output from the
D.P. transmitter is not truly volumetric, but will be affected by a
change in the steam density. Therefore, the gas equations relating to
differential pressure must apply.

E. Dual Differential Pressure Flowmeters With 4-20mA Output.

To increase the range over which flow can be measured, two D.

P. transmitters with different spans can be connected across a
common orifice or other differential pressure flowmeter.

Equations 17 or 18 would be used depending on whether the D.

P. transmitters have square root extractors. Separate spans are
then programmed for each transmitter and at lower flowrates
transmitter 2 will be used. At higher flowrates, where the
output of transmitter 2 exceeds 20mA, transmitter 1 will be used.

415-M-V3.2
 Operation 29

PROGRAMMING THE FLOW COMPUTER

For equations 11 to 18 to work, a number of parameters need to

be programmed. These include:

KF K-factor (for frequency producing flowmeters).

SM Span (for analog flowmeters).
nB Base specific weight at which the span is determined.

The flowmeter will measure the flow input A (normalised between

0 and 1) and the temperature TF and pressure PF. The
temperature and pressure are used to calculate the specific
weight,n, and enthalpy, h,from internal equations. Other
parameters must also be programmed and these are fully detailed
in section 5.

Example 7

A vortex flowmeter has a K-factor of 68.32 pulses/ft3, and it

is required to measure saturated steam in lbs/hour. What
are the main parameters to be programmed?

The instrument should be programmed for steam

measurement from a frequency meter. Because the steam
is saturated, it is only necessary to use either a temperature
or pressure sensor. Because of cost, a temperature probe
is used. The main parameters to program are simply:

Units US Units
K-factor = 68.32
Timebase hours

415-M-V3.2
 30 Operation

Example 8

A differential pressure transmitter across an orifice is designed

to output 20mA at 10,000 kgs/hour at a reference pressure of
1300 kPa (abs) and specific weight of 216.05 dm3/kg. The
flowrate is required in kg/hour and the calorific value in
MJ/hour. What are the main parameters to be programmed?

From the steam tables at 1300 kPa (abs) and a specific weight
of 216.05 dm3/kg, the temperature can be calculated as 350°C,
and is in a superheated state. Hence, steam measurement via
a 4-20mA input with square law relationship is selected and
the following key parameters are programmed:

Units SI Units
Span 10,000
Base Temperature 350°C
Base Pressure 1300 kPa
Timebase hours
Steam Superheated

415-M-V3.2
 Operation 31

3.4 FILTERING

Frequency fluctuations caused by pulsating flow through a flowmeter, often

make 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.
Rate

Filtered Response

Unfiltered Response

Time

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, A, is the filter constant
which is programmed during the Calibration routine. The times for the
display value to reach 90% and 99% of full swing are given in seconds, for
different values of A.

415-M-V3.2
 32 Operation

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 A is set to 1 there is no filtering of the input signal.

415-M-V3.2
 Operation 33

3.5 NON-LINEARITY CORRECTION

3.5.1 Digital Input Linearity Correction

Non-linearity correction enables the instrument to correct for

known non-linearities if the flowmeter. This feature is not
selectable for analog flow inputs.

Up to 10 frequencies and scaling factors can be programmed. Data on

the flowmeter non-linearity can usually be supplied by the flowmeter
manufacturer in the form of a Calibration Certificate, and is the result of
individual tests on a flowmeter over a range of flowrates. The
Certificate will list a number of flowrates or frequencies with the
measured K-factor (eg. pulses per gallon or litre) at each flowrate.

The following diagram graphs the change in scaling factor with frequency for
a hypothetical flowmeter. The heavy black line represents the actual scaling
factor of the flowmeter, while the light black line is the approximation used
in the instrument.

S c a l i n g F a c t or

Fact 4

Fact 5 Fact 1
Fact 3

Fact 2

Fact 6

Frequency

Freq Freq Freq Freq Freq Freq Max

6 5 4 3 2 1 Frequency

Linear Interpolation is used between points on the curve, except for

Factor 1 which maintains a constant value between Frequency 1 and the
maximum input frequency.

415-M-V3.2
 34 Operation

During Calibration, the program requires the user to input a frequency and
the Scaling Factor (K-factor of the flowmeter) at up to 10 points on the
curve.
Generally these points will correspond to those shown on the Certificate.

If any frequency is set to 0Hz (Frequency 6 in the preceding example), then

the program will require no further correction points to be programmed.
Hence, the user can program any number of correction points up to a
maximum of 10. Note that if all 10 correction points are required, then
Frequency 10 will automatically be assigned the value of 0Hz.

415-M-V3.2
 Operation 35

3.5.2 Analog Input Linearity Correction

For single analog flow inputs, an input table can be programmed to correct
for any non-linearities between the flow signal and the actual flowrate.
This feature is very useful when using the flow computer with some types of
VA flowmeters or laminar flow tubes which may exhibit slight non-linear
characteristics.

Up to 20 points can be programmed, and linear interpolation is then

used between points in the curve. The table works by inputting a
normalised flow input signal A, into the table and produces a corrected
output AC. The table ranges between 0 and 1.0000 so that, at a 4mA
input, both A and AC equal 0 and at 20mA both values must also
equal 1.0000.

The user programs the table starting with 1.0000 and programs
corresponding values of A and AC. As soon as A is programmed as 0.0000,
no further input to the table is possible and the program will correct over
the number points that were programmed. A maximum of 20 points can
be programmed.

At the base temperature and pressure, the flow equation, with non-
linearity correction is defined as:

Q = Span . A C

Note: The square root relationship for conventional differential

pressure flow devices is handled separately and not by the
correction described in this section.

415-M-V3.2
 36 Operation

Example

A flowmeter has been tested and the following relationship

between the input and the flowrate has been determined at the
nominal temperature & pressure as follows:

Input Flowrate Normalised Inputs for

table
Inches D.P Output lbs/hr Input (A) Output (AC)
wg mA
52.2007 20.000 7075.89 1.0000 1.0000
39.3894 5306.92 0.7546 0.7500
33.3231 4422.43 0.6384 0.6250
26.7444 3537.94 0.5123 0.5000
20.1656 2653.45 0.3863 0.3750
12.9913 1768.97 0.2489 0.2500
5.5400 884.48 0.1061 0.1250
1.0388 269.06 0.0199 0.0380
0.0000 4.0000 0 0.0000 0.0000

Inches wg Inches wg
where A= Inches wg at 20mA
= 52.2007

flowrate flowrate
AC = flowrate at 20mA
= 7075.85

The values of A and AC are input into the table during

Calibration and the span would be programmed as 7075.89
such that

Q = 7075.89 x A C

415-M-V3.2
 Operation 37

3.6 THE OUTPUT PULSE

An OUTPUT PULSE is available on terminal 10 for driving remote counters

and produces a pulse each time the Total of the Default display increments
by one digit. For example, if the Default Total has a resolution of 0.01
kilograms, a pulse is produced each 0.01 kilograms.

The pulse is a current sinking pulse of approximately 10mSec produced by

an open collector transistor and can sink up to 100mA. The maximum
pulse rate is limited to 49 pulses per second and the resolution on the
accumulated total must be set so that the accumulated total increments at
less than 49 counts per second.

Note that due to the uneven pulse output spacing on this output, the pulse
output cannot be used to drive rate indicators.

415-M-V3.2
 38 Operation

Connection of Output Pulse is as follows:

Relay or
Impulse Counter

Model 415

10

5.6 ohms
33V
Zener

12
DC Supply

Driving an External Relay or Impulse Counter

Model 415
DC Supply 11
Out (8-24V)
External Load
Resistor 10K
Logic Input
5.6 ohms 10

33V Level Shifter

Zener
2

Driving a Logic Input such as a PLC or Electronic Counter

415-M-V3.2
 Options 39

4. OPTIONS NB. Version 3 Models Only

4.1 THE 4-20mA OUTPUT OPTION

The 4-20mA output option provides an analog output of the Default

flowrate as a 4-20mA current. The output will be the corrected volume,
mass or energy, depending on which parameter is programmed as the
default displayed. All output signals are electrically isolated from the
instrument power supply and signal inputs to ensure minimum interference.

Either 2 wire current transmission is available with the loop powered

internally, or 3 wire transmission from an external loop supply.

A block diagram of the output is shown below and various methods

of interconnection are outlined on the following pages.

NB. Diagram refers to Version 3 Models Only

Version 3 models can be defined by having plug-off green

terminals.

DC to DC
T erminal
Convertor
+15V 24
23

Digital to
22
Analog
Convertor

Opto-Isolation 0V 20

-15V 21

415-M-V3.2
 40 Options

4.1.1 Load Specification

Maximum load which the output can drive:

Internally powered loop: 500 ohms

Externally powered: R = (V-5)/.02
where V is the external loop voltage
R is the maximum load in ohms.

4.1.2 Calculation

Parameters relating to this option are programmed when calibrating

the instrument (see section 5) and provide for:

Defining the rate which is equivalent to 4mA

Defining the rate which is equivalent to 20mA
Selecting the output range as 4-20mA

By being independently able to set the output range, the instrument can
effectively be programmed to amplify the input signal. In driving chart
recorders, for example, this enables the output to zoom in on a particular
operating area, instead of having to display the full operating range of the
transducer.

For example, 4mA may be set as 0 kg/min and 20mA as 200 kg/min.
However, the user could set 4mA as representing 100 kg/min and 20mA as
representing 120 litres/min.

For rates or displayed values above and below the maximum and
minimum values the output will remain at its 20mA or 4mA level
respectively.

It should be noted that the output will be updated every 0.5 seconds in
unison with the display and, between updates, the output value is constant.

415-M-V3.2
 Options 41

NB. Diagram refers to Version 3 Models Only

Version 3 models can be defined by having plug-off green

terminals.

Terminal

+15V 24
Link
23
I(+)
I(-) LOAD
22
500 ohm
maximum

0V 20
-15 V 21
*
* For driving impedence loads over
500 ohms, terminate to terminal 21

Two Wire Transmission (Internal Supply)

415-M-V3.2
 42 Options

NB. Diagram refers to Version 3 Models Only

Version 3 models can be defined by having plug-off green

terminals.

Terminal
+15V 24
23
I(+)
I(-)
22

LOAD
0V 20

-15V 21
External supply of 23
to 30 VDC

Three Wire Transmission (External Supply)

415-M-V3.2
 Options 43

4.2 THE RS232/422/485 INTERFACE OPTION

With this option installed, the circuits for both the RS232 and RS422/485 are
provided as standard. They can be used to interface to both printers and
computers, and a number of standard protocols are built into the
instrument.

4.2.1 Hardware

The following diagram provides an overview of the RS232/RS422/RS485

communications hardware. All three interfaces are available on the rear
terminal strips and the user can select either one by making the appropriate
connections.

The RS232 interface is primarily used with printers or for simple communication
with a computer over a short distance. The RS422 and RS485 interfaces are
used for communication over a long distance or in applications requiring
multipoint communication.
24 (+)
RS422 Out
23 (-)

26 (+)
RS422 In
25 (-)

21 Data In
RS232
22 Data Out

27 CTS

20/2B G r o u n d

415-M-V3.2
 44 Options

4.2.2 Multipoint Communication

Multipoint Communication is a system whereby a number of instruments can

be addressed over a dual twisted pair interface. Up to 32 instruments can
be connected to a common bus using the RS422 and RS485 interfaces as
shown below.

To covert the RS422 interface to an RS485 interface, the RS422 (-) Data In
Terminal must be connected to the RS422 (-) Data Out Terminal and the
RS422 (+) Data In Terminal must be connected to the RS422 (+) Data Out
Terminal.
These connections will convert the RS422 4 wire interface to the RS485 2
wire interface, as shown in figure 2.

Each instrument can be programmed with a unique address which is used by

the Master Controller (eg. IBM/PC) to identify each instrument. The
Controller will send the address down the line and will alert the relevant
instrument. Subsequent software protocol will control the flow of data
between the Controller and the Instrument.

Load
120 ohms T wisted Pair

Load
Host 120 ohms
Computer

400 Series 400 Series

Instrument Instrument

Figure 1 RS422 Interface

415-M-V3.2
 Options 45

T wisted Pair

+ Load
120 ohms
Host
Computer -
Gnd

- + Gnd - + - + G n d- - +
In Out In Out
400 Series 400 Series
Instrument Instrument

Figure 2 RS485 Interface

415-M-V3.2
 46 Options

4.2.3 Communication Protocol

The Model 415 has a real time clock and enables the time and date to be set
and printed on tickets. The date format can be European
(days/months/years) or USA (months/days/hours), while the time is on a 24
hour clock.

Note that the clock will only retain its time for 3 days minimum if there is
no power connected to the instrument. After this period, the clock may
need to be reset.

Battery backup is provided. The battery will typically need replacing every
two years or more frequently if extended power downs are a feature of the
installation. Battery type is a CR2032 coin cell.
All new instruments are supplied with a ‘pullout battery life protection tab’
Please do not remove the tab until you are ready to install and apply
power to the instrument.

The baudrate, parity and wordlength can be programmed during calibration

and the user must ensure that these correspond to the setting on the
printer or computer with which the Model 415 is communicating.

The software protocols can be selected during Calibration to provide

standard interfaces to a number of printers and computers. Since other
interfaces will continue to be added, the user should consult the manual
"The RS232/422/485 Communications Option for the 400 Series, Version 2",
for the latest protocols and printer drivers.

Printer

A ticket is printed each time the RESET key is pressed or at defined

time intervals (see Data Logging). If the Reset key is used, the
instrument prints the ticket before resetting the totals.

Protocols are provided to drive the following printers:

1 Standard Computer Printer (Note that the printer must have an

RS232 Serial Interface).
2 EPSON CTM290 Slip Printer.
3 Contrec Model 624.
4 EPSON TM290-2 Slip Printer.
5 Contrec Model 632-2 Printer.
6 Syntest SP-210 Printer.
415-M-V3.2
 Options 47

A CTS input is provided, and will prevent the instrument from transmitting
any further characters to a printer if the printer buffer is full. The CTS input
is usually connected to the "Data Buffer Full" output from the printer.

If the printer buffer is large enough to handle the messages output from
the instrument, then this input need not be used and should be left
unconnected.

Computer

The instrument receives and transmits messages in ASCII, with all

command strings to the instrument terminated by a carriage return.
While replies from the instrument are terminated with a carriage return
and a line feed.

Xon/Xoff protocol is also supported, and the instrument will

automatically determine if the message sent by the host computer is
preceded by an Xoff character. If it does recognise an Xoff as the first
character of a command string, the instrument will automatically switch
to Xoff/Xon protocol, and begin & end all messages with Xoff and Xon
characters respectively. Xoff/Xon protocol is only available when the
RS232 interface is selected.

During Calibration, the instrument can be programmed to operate in a

full duplex or half duplex transmission mode. In full duplex mode, all
commands sent to the instrument will be echoed back to the host
computer. In half duplex, the commands are not echoed.

For more information on the computer interface please consult the manual
"The RS232/422/485 Communications Option for the 400 Series, Version 2".

415-M-V3.2
 48 Options

4.3 DATA LOGGING

The Model 415 can be programmed to output data to a printer, computer or

other storage device at the following intervals:

1 minute (Every minute on the minute)

10 minutes (On the hour, at 10 past...etc)
30 minutes (On the hour and half hour)
1 hour (On the hour)
6 hours (At 6:00, 12:00, 18:00 and 24:00)
12 hours (At 12:00 and 24:00)
24 hours (At 24:00)

The totals can be programmed to reset manually via the front panel,
or automatically after each print is initiated, or at 24:00 after the
print is initiated.

Note that if manual reset is selected, it is still possible to prevent front panel
reset by inhibiting this function in General Setup (in Calibration).

415-M-V3.2
 Options 49

4.4 THE RELAY OUTPUT OPTION

The Relay output option consists of two Form C relays which can be
preset during calibration to energise when the Default flowrate exceeds
or drops below the preset values.

The "low" relay is energised whenever the rate is below the preset value, and
the "high" relay is energised whenever the rate exceeds the preset value. The
preset values are programmed during calibration as described in section 5.

34 Normally Open

Relay 1
35 Norm ally Clos ed
Low Alarm

36 Common

31 Normally Open

Relay 2 32 Norm ally Clos ed

High Alarm

33 Common

415-M-V3.2
 50 Calibration

5. CALIBRATION
The Calibration routine enables the Setup Parameters to be programmed, as
well as enabling the input signals to be checked.

The calibration routine can be entered in two ways:

1 By connecting a wire link (or switch) to the rear terminal

strip across terminals 1 and 2 or,

2 By pressing the TOTAL key and, while still holding, pressing the
DISPLAY key. Both keys must then be held for approximately 6
seconds. This second method of access can be disabled during
the calibration so that it is only possible to enter the calibration
routine via the link across terminals 1 and 2.

The key switch actions during Calibration are as follows:

RATE will change a flashing digit, to the next digit.

TOTAL will increment a flashing digit or change a

parameter selection.

RESET will reset a flashing digit to zero.

DISPLAY (Program) will step through the program sequences.

Note that the arrows in the Rate and Total key switches indicate that
these switches can be used to change and increment digits respectively.

In stepping through the program sequence, the Parameter Description is

always shown. When a value or parameter can be changed, it is always
shown as flashing, and the LED's in the switch panels are lit if that key
switch can be used to change a value.

415-M-V3.2
 Calibration 51

On first entering the Calibration routine, the display will show the Model
number followed by:

SELECT
(GENERAL SETUP)

There are six main menu items as follows:

1. GENERAL SETUP
2. GAS PARAMETERS
3. FLOW PARAMETERS
4. OPTIONS
5. TEST
6. EXIT

The user can toggle between these menus using the" " key. To enter a
menu, the DISPLAY key is then pressed.

In the following flowcharts, the options which can be selected using the
or keys are shown in brackets ( ), and values to be entered are shown as
xxxx's. The flowcharts show the program flow during the Calibration and a
List of Definitions is given immediately after the flowchart. This list covers
those terms which are not explained elsewhere in the text.

To exit Calibration, step through the Setup program until the end, and
press the DISPLAY switch when Exit is displayed, (ensure the calibration link
is removed).

Floating Point Numbers

Values such as the SPAN or Pressure are programmed in floating point

format.
This enables numbers as low as 0.00001 and as high as 999999 to
be programmed with 6 digit accuracy.

To enter a value of, say, 101.325 when the display shows 0.0000, the
key would be pressed 9 times until 000.000 is displayed. Once the correct
position is reached, the and keys can then be used as normal to
enter data.

415-M-V3.2
 52 Calibration

5.1 PROGRAMMING CHART

SELECT
CALIBRATION
(GENERAL SETUP)

DISPLAY CONTRAST
ADJUST

FLOW UNITS
(SI UNITS, US UNITS)

TOTAL UNITS
(UNITS X 1000
X 1)

FLOW TIMEBASE
(DAYS, HOURS, MINUTES, SECONDS)

FRONT ACCESS
(ENABLE, DISABLE)

FRONT RESET
(ENABLE, DISABLE)

RESET TOTALS NOW?

(PRESS RESET)

SELECT
(EXIT)

415-M-V3.2
 Calibration 53

SELECT
(GAS PARAMETERS)

GAS EQUATION
(STEAM, IDEAL GAS, GENERAL GAS, NATURAL GAS)

STEAM TYPE
(SATURATED, SUPERHEATED)

SAT STEAM INPUT BASE TEMP CRITICAL TEMP BASE

(PRESSURE, ±XXX.XX ±XXX.XX TEMPERATURE
TEMPERATURE) ±XXX.XX

DEFAULT DISPLAY BASE PRESSURE CRITICAL BASE PRESSURE

(MASS, ENERGY) XXXXX PRESSURE XXXXX
XXXXX

BASE TEMP1 SPECIFIC GRAVITY BASE TEMP SPECIFIC GRAVITY

+XXX.XX X.XXX ±XXX.XX X.XXX

BASE PRESSURE1 DEFAULT DISPLAY BASE PRESSURE MOLE % N2

XXXXX (CORRECTED XXXXX XX.XX
VOLUME, MASS)

SELECT SELECT SPECIFIC MOLE % CO2

(EXIT) (EXIT) GRAVITY XX.XX
X.XXX

DEFAULT DISPLAY DEFAULT DISPLAY

(CORRECTED (CORRECTED
VOLUME, MASS) VOLUME, MASS)

SELECT SELECT
(EXIT) (EXIT)
Only required for differential pressure flowmeters. With volumetric flowmeters, there is no need to enter base temperature &
pressure and these values can be left at the default values.

Temperatures are entered as °C or °F rather than °K or °R.

415-M-V3.2
 54 Calibration

SELECT
(FLOW PARAMETERS)

FLOW INPUT TYPE

(FREQUENCY, ANALOG)

FLOW SIGNAL TYPE FLOW SIGNAL TYPE

(LINEAR, NON-LINEAR) (DIFFERENTIAL, VOLUMETRIC)

K-FACTOR UP TO 10 FLOW CORRECTION

XXXXX.XXX FREQUENCIES & (LINEAR, SQUARE ROOT, NON-LINEAR)
K-FACTORS
CAN BE
ENTERED
UP TO 20 INPUT
NO SENSORS & OUTPUT
(2, 1) POINTS CAN BE
PROGRAMMED

FLOW SPAN1 FLOW SPAN1

(MASS, VOLUME) (MASS, VOLUME)

LOW SPAN (at 20mA) SPAN (at 20mA) SPAN (at 20mA)
XXXX XXXX XXXX

CUTOFF (Low) FLOW CUTOFF FLOW CUTOFF

XX.X% XX.X% XX.X%

HIGH SPAN (at 20mA)

XXXX

1
For Steam measurement, the Span defaults to mass.

415-M-V3.2
 Calibration 55

FILTER FACTOR
XX

FLOWRATE DECIMAL
XXX.XX

TOTAL DECIMAL
XXX.XX

TEMP at 4mA 415A ONLY

±XXX.XX

TEMP at 20mA 415A ONLY

±XXX.XX

TEMP OFFSET
415R ONLY
±X.XX

PRESSURE INPUT
(ABSOLUTE, GAUGE)

PRESSURE at 4mA ATMOSPHERIC PRESSURE

XXXXX XXXXX

PRESSURE at 20mA PRESSURE at 4mA

XXXXX XXXX

PRESSURE at 20mA
XXXX

SELECT
(EXIT)

415-M-V3.2
 56 Calibration

SELECT
(OPTIONS)

OUTPUT TYPE
(4-20mA)

OUTPUT at 4mA IF
XXXXX 4-20mA
OUTPUT OPTION
IS INSTALLED
OUTPUT at 20mA
XXXXX

DATE FORMAT
(dd/mm/yy), mm/dd/yy)

DATE XX/XX/XX
TIME XX:XX

IF
BAUDRATE
RS232/RS422/RS485
(300 - 9600)
OPTION IS
INSTALLED

WORD LENGTH
(7, 8)

PARITY
(NONE, ODD, EVEN)

SIGNAL TYPE
(RS232, RS422, RS485)

415-M-V3.2
 Calibration 57

IDENTIFICATION NO
XX

TYPE OF COMMS
(PRINTER, COMPUTER)

PRINTER ECHO
(STANDARD 80 COLUMN) (FULL DUPLEX, HALF DUPLEX)
(EPSON CTM 290)
(MODEL 624)

PRINT METHOD
(ON RESET, TIME INTERVAL)
IF
RS232/RS422/RS485
OPTION IS
INSTALLED
PRINT INTERVAL
(1, 10, 30 MINUTES,
1, 6, 12, 24 HOURS)

RESET TYPE
(FRONT PANEL RESET)
(RESET AT 24:00 HOURS)
(RESET EACH PRINT)

HIGH ALARM SETPOINT

XXXXX

IF
ALARM OPTION
LOW ALARM SETPOINT IS INSTALLED
XXXXX

SELECT
(EXIT)

415-M-V3.2
 58 Calibration

SELECT
(TEST)

FREQUENCY INPUT IF FREQUENCY INPUT

XXX.X Hz IS SELECTED

LOW FLOW IF TWO 4-20mA FLOW

XXX.X mA INPUTS

HIGH FLOW IF ONE OR TWO

XX.X mA 4-20mA FLOW INPUTS

PRESSURE INPUT
XX.X mA

TEMPERATURE INPUT IF MODEL 415R, THE

±XXX.XX RTD TEMPERATURE IS
DISPLAYED

TEMPERATURE INPUT IF MODEL 415A

XX.XmA

DATE: XX/XX/XX
TIME: XX:XX

SELECT
(EXIT)

415-M-V3.2
 Calibration 59

5.2 DEFINITIONS

GENERAL SETUP

Display Contrast It is possible to adjust the contrast of

the display using the key to give
optimum viewability.

Total Units Enables totals to be integrated at 1/1000 of

the flowrate by programming x 1000. For
example, if the flowrate is in scm/h the
total will be kscm/h (scm x 1000).

Timebase Timebase selection will determine whether

the rate of flow is displayed in kg/day,
kg/hour...etc.

Front Access If enabled, access to the Calibration routine

is possible via the front panel (via the Total
and Display keys). If disabled, access to the
Calibration routine is only possible by
connecting a link between terminals 1 and 2.

Front Reset If disabled, the front panel reset key

becomes inoperable during normal
operation.

GAS PARAMETERS

Default Display The flowrate and total which is normally

displayed (eg. Mass or Corrected Volume).

415-M-V3.2
 60 Calibration

Sat Steam Input With saturated steam it is only necessary to

use either a pressure or temperature sensor,
but not both. The user can program which
sensor is to be used in the system.

FLOW PARAMETERS

K-factor The pulses/m3 or pulses/ft3 produced by

a frequency type flowmeter.

Flow Signal Type Differential refers to all devices where

(Analog Input) the signal is pressure related, such as
orifice, pitot tubes, wedges or target
flowmeters.

Volumetric refers to flowmeters producing

a truly volumetric signal such as vortex,
turbine or positive displacement meters.

Flow Correction Square root applies to most

standard differential pressure devices
where there is a square law
relationship between flow and the
output signal.

Linear applies to D. P. transmitters with

square root extractors or to meters which
produce a linear flow signal, such as laminar
flow tubes or Gilflo meters.

Non-Linear applies if a custom non-

linearity correction curve is to be
programmed.

Flow Cutoff The flowrate, as a percentage of the SPAN

below which the flow is not displayed
or integrated.

415-M-V3.2
 Calibration 61

Flowrate Decimal The number of decimal points with which

the flowrate is displayed.

Total Decimal The number of decimal points with which

the total is displayed.

Temperature Offset This allows a small offset to be programmed

to correct for any offset error in the RTD. For
example, if during "TEST" the temperature
was read at 125.3°C when it was known that
the actual temperature was really 124.8°C,
then an offset of -0.7°C could be programmed
to correct for the error in the RTD.

Pressure Input Both absolute and gauge pressure systems

can be used with the Model 415.

Atmospheric Pressure If a gauge pressure sensor is used,

the atmospheric pressure must be
programmed since this will vary with
the altitude of the installation.

Note that the Absolute Pressure =

Atmospheric Pressure + Gauge Pressure. The
atmospheric pressure will default to 101.325
kPa (14.696 psia) which is the standard value
at sea level.

415-M-V3.2
 62 Input Circuits

6. INPUT CIRCUITS

The Model 415 has a regulated output which can be used to power sensors.
A trimpot on the rear of the instrument allows the voltage to be adjusted
in the range of 8-24 Volts and the output can supply a maximum of 50mA.

6.1 FREQUENCY FLOW INPUT

The Model 415 has an input conditioning card which will accept signals
from most pulse or frequency producing flowmeters. An 8 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 interconnections to various signal

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

415-M-V3.2
 Input Circuits 63

Switch Settings

The following switch settings are recommended for different input signal
types.

Input
Terminals Switch Settings
Input Signal Type CH1
+ - 1 2 3 4 5 6 7 8
A. Logic Signal, Not Not
9 8 off off off on off off
CMOS,Pulse used used
B. Open
Not Not
Collector or Reed 9 8 off off off on on off
used used
Switch
C. Namur
Not Not
Proximity (set DC 11 9 off on on on off off
used used
out to 8 volts)
D. Switch or
Not Not
Reed Switch with 9 8 off off off on on on
used used
debounce circuit
E. Coil (20m V Not Not
9 8 on off off off off off
P-P minimum) used used

General Specification

Switching Threshold: 2.5 Volts (except for input type c, e and f)

Maximum Input Voltage: 50V peak

Input Impedance
Input type a: 100K
Input types b & d: 10K
Input type c: 1K
Input type e: 100K

415-M-V3.2
 64 Input Circuits

+5V
10K

S7 INPUT COMPARATOR
1K 100K
Pulse Input
(9)
S3 S8

+
100R .01 1uF
+5V
(8)
Common 33K
S2
S5 S4

33K 1K2

The Frequency Input Circuits

415-M-V3.2
 Input Circuits 65

1. Squarewave, CMOS or TTL

Model 415
on
9
Common
8 1 8

eg. vortex, pre-amplifiers

or magnetic flowmeters

2. Open-Collector

Model 415

on
9
Common
8
1 8

eg. hall effect

sensors

3. Reed Switch

Model 415

on
9

1 8
8

eg. positive displacement

flowmeters with reed switch

415-M-V3.2
 66 Input Circuits

4. Coils

on Model 415
9

8 1 8

eg. millivolt signal

Use shielded from a turbine flowmeter
to case earth
cable (single input only)

5. Namur Proximity Switch

Model 415
on
+8V 11

9 1 8

eg. positive displacement

flowmeters with 2 wire
proximity switch outputs

6. Opto-Sensors

Resistor on
Model 415
11

1 8

9 eg. pre-amplifiers
Common and opto-sensors.
8

Note that the current

limiting resistor may be
required. See the flowmeter
manufacturer's data.

415-M-V3.2
 Input Circuits 67

6.2 ANALOG INPUTS

The Flow Computer can be supplied as:

* Model 415R Direct 4 wire Platinum RTD (PT100) for temperature

* Model 415A 4-20mA input for temperature.

Both versions have a 4-20mA pressure input.

THE RTD INPUT

Four wire RTD measurement is the most accurate form of measurement and
can be used for measurements with the RTD up to 100 meters from the
instrument. It is recommended to use shielded cable when interfacing to
RTD's.

Two or three wire RTD's can be used in place of 4 wire RTD's, but 4 wires
must be taken to the RTD and the signal and current wires joined as close to
the RTD as possible.

With direct RTD measurement, the program automatically corrects for

the non-linearity in the RTD.

MODEL 415R

R T D
T emperature Sensor
4 I (+)
I (-)
14
5
Signal (+)
Signal (-)
6

2
T wisted Pair
Cable

Shield

415-M-V3.2
 68 Input Circuits

When wiring the RTD, care must be taken to ensure the (+) of the Current
on terminal 4 is connected to the same side of the RTD as the (+) of the
signal on terminal 5. The RTD has no polarity and can be connected in
either direction.

4-20mA Inputs

Each 4-20mA has a 250 ohm input connected to the signal ground as
shown below. When the instrument is AC powered, there is sufficient
current from the DC output to power up to three current loops. If more
loops are to be powered,an external DC power source is required.

Powering from the Internal DC Supply

MODEL 415
Set Supply to 24V out
11
+
+ DP
P - 3
-
7

12

When using only one 4-20mA flow input, the signal must be connected
to terminal 3 as shown above

Shielding: When shielding the input signals, the shield should be connected
to the case earth and not connected at the transmitter end (ie.
Ground at one end only).

415-M-V3.2
 Input Circuits 69

Powering from an External Supply

12-24 VDC
- +
MODEL 415A

+ - Flow 1 (CH3) 3
DP Hig h Flo w

+ - Fl o w 2 ( C H1 ) 14 250
DP Low Flow ohm

250
+ - Temperature 4
T ohm
(CH0)

250

ohm
+ - Pressure 7
P
(CH2)
250
ohm

2
Signal Ground

The above diagram shows an installation with dual D. P. transmitters to

measure flow. When using only one 4-20mA flow input, the signal must be
connected to terminal 3 only.

415-M-V3.2
 70 Input Circuits

6.3 REMOTE SWITCHES (Model 415A Only)

Remote push-buttons can be connected to the Model 415A to duplicate

the switches on the front panel.

The switches are wired as follows:

2
RESET
5

DISPLAY
6

415-M-V3.2
 Installation 71

7. INSTALLATION
7.1 GENERAL

Terminal designations for the Model 415 Flow Computer are given on
the following pages. The cutout hole in the panel should be 5.5"
(139mm) wide x 2.6" (67mm) high. Two side clips are supplied to
secure the instrument into the panel.

A case earthing point is provided via an earth lug on the side of the case.
Note that this earthing point is for the case only and there is complete
electrical isolation between this point and all electronic circuits. For EMC
purposes, or when the instrument is connected to mains, this point must be
connected to a good earth using a multi-stranded, braided wire or strap. All
relay outputs are totally isolated from the case and from the internal
circuitry.

A Supply Output voltage is provided to power sensors. This output will provide
a regulated voltage of 8 to 24 volts and the voltage is adjustable by means of
the potentiometer on the rear panel. Maximum current is 65mA and the
instrument comes with the voltage factory set at 24 Volts. When the
instrument is powered from a DC power source, the maximum output voltage
on the Supply Output is the DC Input Voltage less 3.5 volts.

The instrument will operate from either 14-28 volts DC or from the mains.
The mains voltage is factory set to either 95-135 VAC (110 VAC nominal) or
190-260 VAC (220 VAC nominal). An internal mains transformer provides full
isolation between the mains and the electronic circuits.

The DC Ground terminal 12 provides a common ground for the 14-28

Volt power input, the 8-24 Volt output and the pulse output.

It is good practice to use shielded cables for all signal connections to the
Model 415. Care must be taken to separate signal cables from power cables
so as to minimise interference.

Overall shields should be connected to the case earth at the instrument end
only.
This connection should be as short as possible and connected to the earthing
lug on the side of the case.

415-M-V3.2
 72 Installation

In order to comply with the requirements for Electromagnetic Compatibility

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

Although it is also possible to connect shields to the signal ground (terminal

2) this practice is not in accordance with EMC directives.

RC Networks for Interference Suppression

When driving highly inductive loads with the relay outputs, it is

recommended that RC suppression networks (often called "Snubbers") are
used for two reasons:

Ÿ To limit the amount of electrical noise caused by arcing

across the contacts which may, in extreme cases, cause the
microprocessor to act erratically.

Ÿ To protect the relay contacts against premature wear through

pitting.

RC suppression networks consist of a capacitor and series resistor and

are commonly available in the electrical industry. The values of R and
C are dependant entirely on the load. However, if the user is unsure
of the type of snubber to use, values of 0.25uF and 100 ohms will
usually suffice. Note that only mains rated, UL approved RC
suppression networks should be used.

The basic principle of operation is that the capacitor prevent a series of

sparks arcing across the contact as the contact breaks. The series resistor
limits the current through the contact when the contact first makes.

415-M-V3.2
 Installation 73

7.2 WIRING DESIGNATIONS FOR THE MODEL 415

Terminal Model 415R Model 415A

1 Calibration Link Calibration Link

2 Signal Ground Signal Ground
3 Flow 1 (4-20mA) Flow 1 (4-20mA)
4 PT100 I (+) Temperature (4-20mA)
5 PT100 Signal (+) Reset Switch
6 PT100 Signal (-) Display Switch
7 Pressure (4-20mA) Pressure (4-20mA)
8 Flow Common (-) Flow Common (-)
9 Flow Pulse Input (+) Flow Pulse Input (+)
10 Pulse Out Pulse Out
11 DC Power Out (8-24V) DC Power Out (8-24V)
12 DC Ground DC Ground
13 DC Power Input DC Power Input
14 PT100 I (-) Flow 2 (4-20mA)

Note: When using a single 4-20mA flowmeter, it is connected

to Terminal 3. The second 4-20mA flow input on
terminal 14 is only used when there are dual 4-20mA
inputs. In this case, terminal 3 becomes the High Flow
input and terminal 14 is used for the low flow.

Terminal Analog Flow Output (4-20mA) RS232/422/485

20 0 Volts RS232 Signal Ground

21 -15 Volts RS232 Data In
22 I(-) RS232 Data Out
23 I(+) RS422/485 (-) Data Out
24 +15V RS422/485 (+) Data Out
25 DC Ground RS422/485 (-) Data In
26 Not To Be Used RS422/485 (+) Data In
27 Not To Be Used RS232 CTS

2B Signal Ground

415-M-V3.2
 74 Installation

Terminal Relay Option

31 High - Normally Open

32 High - Normally Closed
33 High - Common
34 Low - Normally Open
35 Low - Normally Closed
36 Low - Common

415-M-V3.2
 Installation 75

7.3 EX 410 ENCLOSURE DIMENSIONS

(all dimensions in mm)

Mounting Holes (4) on rear
Metric thread M8
Ex 410 Enclosure with 5 Keys NPT thread 5/16 UNF

Door
115.0
Hinge 288

302 221

Bottom View

Mounting Holes Mounting Holes

4 x M8 4 x 5/16 UNF

Earth Point
70.0 70.0

71.5 71.5

130.0 130.0 Gland Holes

Gland Holes 3 x ¾“ NPT
3 x M20

Enclosure with 3 x M20 Gland holes Enclosure with 3 x ¾“ NPT Gland holes

Material: Cast Aluminium

Finish: Light beige powdercoat

415-M-V3.2
 76 Appendix

APPENDIX
PROPERTIES OF SELECTED GASES

Sp. Gravity Critical Temperature Critical Pressure

G °C °F kPa psia
Acetylene 0.8990 35.17 95.3 6140 890.6
Air 1.0000 -140.4 -220.8 3769 546.7
Ammonia 0.5880 -168.0 -270.4 11277 1637.7
Argon 1.3793 -122.3 -188.2 4873 706.9
Butane 2.0054 153.0 307.4 3648 529.1
Carbon Dioxide 1.5196 31.06 87.9 7376 1069.9
Carbon Monoxide 0.9671 -140.3 -220.5 3496 507.0
Chlorine 2.4482 143.8 290.9 7701 1116.9
Ethane 1.0382 32.28 90.1 4884 708.4
Ethylene 0.9686 9.28 48.7 5036 730.4
Helium 0.1381 -267.9 -450.2 228.99 33.21
Helium-4 0.1382 -267.9 -450.3 226.8 32.9
Hydrogen 0.0696 -239.9 -399.9 1296.9 188.1
Hydrogen Chloride 1.1898 51.44 124.6 8313 1205.7
Hydrogen Sulfide 1.1767 100.1 212.1 8751 1269.2
Methane 0.5539 -82.56 -116.6 4600 667.2
Neon 0.6969 -228.8 -379.8 2756 399.7
Nitrogen 0.9672 -146.9 -232.5 3394 492.3
Nitrous Oxide 1.5199 36.5 97.7 7265 1053.7
Oxygen 1.1048 -118.6 -181.4 5046 731.9
Propane 1.5226 96.67 206.0 4246 615.8

415-M-V3.2
 Appendix 77

Propylene 1.4529 91.83 197.3 4620 670.1

Sulphur Dioxide 2.2119 157.7 315.8 7883 1143.4
Xenon 4.5334 16.56 61.8 5836 846.5

415-M-V3.2
 78 Index

E K
Index Earthing Point, 71 K-factor Range, 10
External Supply, 69
4-20mA Inputs, 68 Ex 410 Enclosure, 75 L
4-20mA Output, 39
405GS, 7 F Laminar Flow Tubes, 35
405ST, 7 Linear Interpolation, 33
Filtering, 31 Logic Signals, 62
A Floating Point
Numbers, 51 M
Analog Inputs, 67 Flow Correction, 60
ASME, 26 Mass, 20
Flow Equations, 16
Atmospheric Model Number, 9
Flow Input, 62
Pressure, 61 Molecular Weight, 16
Flow Parameters, 51
Multipoint
Flow Signal Type, 60
B Fluctuations, 31
Communication, 44
Front Access, 59
Battery, 46 Front Reset, 59
N
Natural Gas, 25
C G Non-Linearity
Calibration Correction, 33
Gas Parameters, 51
Certificate, 33 NX-19, 7
Gases, 76
Calibration Routine, General Gas, 24
50
General Setup, 51
O
Coils, 66
Ground Terminal, Offset, 61
Compressibility, 24 71
Computer, 47 Open Collector, 62
Options, 51
Cutoff, 60 I Orifice Plates, 17, 27
D Ideal Gas Law, 22 Output Pulse, 37
IFC Formulation, 26 Output Voltage, 71
Data Logging, 48 Impulse Counter, 38
Date Format, 46 Input Circuits, 62 P
Decimal Points, 60 Installation, 71
Default Display, 14, 59 Pitot Tubes, 17, 27
Interference Power Requirements,
Density, 16 Suppression, 72 10
DIL Switch, 62 Isolation, 39, 71 Pressure Input, 11, 61
Dimensions, 10 Printer, 46
Display, 10
Display Contrast, 59
Dual Differential
Pressure, 18, 28
415-M-V3.2
 Index 79

Properties, 76 Temperature
Protocol, 46 Measurement Range,
Protocols, 43 11
Proximity Switches, 62 Temperature Offset, 61
Pulse Output, 12 Test, 51
Timebase, 59
R Transducer Supply, 10
Turbine, 17
Redlich-Kwong, 7
Reed Switches, 62 V
Relay Output, 49
Remote Switches, 70 VA Flowmeters, 35
RS232, 43 Vortex, 17, 27
RS232/422/485
Interface Option, 43 W
RS422, 43
Wiring Designations, 73
RTD Input, 67

S
Saturated, 26
Setup Parameters, 50
Shielding, 68
Snubbers, 72
Span, 19
Specific Enthalpy, 26
Specific Gravity, 16
Specific Volume, 26
Specification, 10
Standard Conditions,
16
Steam Measurement,
26
Steam Turbines, 27
Supercompressibility
Factor, 25
Superheated, 26
Symbols, 5

T
Target
Flowmeters, 17, 27

415-M-V3.2