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U3000-4000_USER MANUAL.book

1. 42 U3000 U4000 User Manual Issue 2 0 6 Troubleshooting 6 1 Overview If you have a problem with your flow monitoring system it can be due to any of the following Faulty instrument Blank instrument display Loss of power supply to the instrument Internal power supply fuse ruptured Scrambled instrument display Reboot the instrument by temporarily disconnecting its power supply Incorrect setup A low or zero signal could be caused by incorrect set up such as e Incorrect site data entered into the instrument e Incorrect or non matching ultrasonic transducers selected for use e Incorrectly fitted transducers lack of couplant applied incorrect spacing insecure attachment e Poor connections between the probes and the instrument Application problem If you are certain that the instrument is healthy and suitably set up for the current site and the probes are properly assembled and fitted correctly there could be an application problem concerned with the site Check such conditions such as Poor pipe outer surface quality Uneven surface preventing good surface contact with the transducer e Flaking paint should be removed e Variable air gap in concrete covered pipes affecting the ultrasonic signal quality Poor internal pipe construction e Rough internal pipe walls affecting fluid flow see roughness factor Internal welds positioned in the transducer signal path affecting the signal quality The dr
2. Isolation Relay Contact Mode Alarm Functions Alarms Number of Channels Available 2 opto isolated MOSFET relay 1500V opto isolated from unit N O when switching condition is False Closed when switching condition is True The two relays can be configured to operate when apredefined MINimum or MAXimum flow rate is exceeded a specified VOLume is measured a signal Error condition occurs manual alarm test Supply Voltage Mains Input Voltage 86V to 264V a c Mains Input Frequency 47Hz to 63Hz Power Consumption 10 5W Alternative Input Supply 24Va c d c 1A max Operating Temperature Enclosure Material ABS and aluminium Dimensions 230mm x 180mm x 120mm Weight 1 2kg Protection IP65 Fixing Wall mountable Keypad No Keys 15 key tactile feedback membrane keypad Display Format 240 x 64 pixel graphic display high contrast black on white with backlight Viewing Angle Min 30 typically 40 Active Area 127mm W x 34mm H Overlay Standard English Optional overlays available 20 C to 50 C Storage Temperature 55 C to 75 C Operating Humidity Safety 90 RH MAX at 50 C BS EN 61010 1 2001 EMC BS EN 61326 1 2006 BS EN 61326 2 3 2006 Environmental BS EN 60068 1 1995 BS EN 60068 2 1 2007 BS EN 60068 2 2 2007 U3000 U4000 User Manual Issue 2 0
3. Log data to Memory 2 Press the Logger function key to access Logging interval 10 seconds the REAL TIME LOGGER screen Start date amp time dd mm yy hh mm ss Stop date amp time dd mm yy hh mm ss 3 Select Log data to and choose Memory to store the log to the instrument s internal MM DD HH MM SS memory Remaining time mm dd hh mm ss Memory Rollover Overwrite 4 Select Logging interval and enter the Graph Y axis max 50 required period e g 10 seconds Log Totals Total View log as text View log as graph START NOW Set Auto start Clear log Exit 5 Select Log Totals tolog either Totals Totals or Both as shown LOG TOTALS DD MM YY HH MM SS 6 Select Clear log if you want to discard Select item to log and press any existing logging data Total Total Both None 7 Select START NOW 8 This screen appears only if a log already exists for the QuickStart site It allows ERR Log not empty DD MM YY HH MM SS you to either delete or save the existing Dim mi log or cancel the START NOW request Press to confirm deletion Press A to save log and continue Press V to cancel U3000 U4000 User Manual 31 Issue 2 0 4 Data Logging amp Communications U4000 Monitoring the logged events as a table 1 The VIEW LOG AS TEXT screen displays the log events in date stamped VIEW LOG AS TEXT DD MM YY HH MM SS Logging to memory Dim mm chronological order Log Quickstart Date Time Flow Press key 5
4. Off On Permanently DD MM YY HH MM SS Note The default setting is On Permanently 3 1 3 Changing the user language If you want to change the user language at any time after the instrument has been put into operation 1 Select Setup Instrument fromthe MAIN MENU then press ENTER 2 Select Change Language from the SETUP INSTRUMENT screen then press ENTER 3 Select the required language from the list provided and press ENTER 4 The instrument returns to the MAIN MENU 3 1 4 Changing the date and time The correct date and time should have been set when the instrument was initially put into service To update the date time parameters 1 Set the required Date amp Time as described in Paragraph 3 1 1 SETUP INSTRUMENT Set Date amp Time Calibrate 4 20mA Pulse output Backlight Factory settings Change Language DD MM YY HH MM SS dd mm yy hh mm ss Off On Permanently SETUP INSTRUMENT Set Date amp Time Calibrate 4 20mA Pulse output Backlight Factory settings Change Language DD MM YY HH MM SS dd mm yy hh mm ss Off On Permanently U3000 U4000 User Manual Issue 2 0 17 3 Operating Procedures 3 2 Using the Quick Start Menu The Quick Start menu gathers various data for the site to be monitored and returns details of the transducer configuration that must be applied when mounting the transducers on the pipe Before you can use the U3000 U4000
5. RS232 Connection U4000 only An RS232 cable is supplied as part of the U4000 kit to allow communications with a PC or printer The RS232 cable can be inserted through one of the Alarms amp I O cable glands as shown in Figure 2 2 4 20mA Pulse and Alarm I O connections The 4 20mA pulse and alarm I O cables enter the bottom of the instrument via two cable glands and are connected internally to a terminal block Full details of the terminal connections are provided in Chapter 2 Installation and Chapter 7 Options Power supply Two cable glands on the bottom right hand side of the instrument are available for the power supply cable Two sizes of glands are provided to accept cables of different diameters 1 4 2 Keypad The instrument is configured and controlled via a 15 key tactile membrane keypad as shown in Figure 1 4 U3000 Keypad Scroll UP ENTER SELECT Scroll DOWN Scroll LEFT Scroll RIGHT Numerical keypad with dual function keys U4000 Keypad Scroll UP ENTER SELECT Scroll DOWN e Mcronics Scroll LEFT Scroll RIGHT Figure 1 4 U3000 U4000 Keypad U3000 U4000 User Manual 5 Issue 2 0 1 General Description Menus and the menu selection keys Note As a security measure once the instrument has been set up for the first time a password is required to gain subsequent access to the operating menus The U3000 U4000 menus are arranged hierarchally with the MAIN MENU being at t
6. WARNING Always isolate the supply to this instrument before removing the terminal cover LETHAL VOLTAGES This instrument must be installed by an electrically qualified technician aware of the potential shock hazards presented WARNING when working with mains powered equipment 1P65 Enclosure Protection Blanking plugs are fitted to the cable glands on leaving the manufacturer In order to preserve the enclosure s 1P65 rating ensure that the blanking plugs Caution remain fitted in any unused cable gland 2 2 Installing the U3000 U4000 instrument 2 2 1 Positioning the instrument The U3000 U4000 instrument should be installed as close as conveniently possible to the pipe mounted ultrasonic sensors Standard transducer cables are 5 metres in length with 3 metre cables being optionally available Where for operational reasons it is not possible to mount the instrument this close to the sensors bespoke cables of up to 100m can be provided consult Micronics Ltd for further information and availability A suitable mains supply must be available to power the instrument an optional 24V a c d c supply module is available The external supply must be suitably protected and connected via an identifiable isolator A 500mA fuse is fitted internally in the instrument s input supply line 2 2 2 Mounting the instrument Ideally the U3000 U4000 enclosure should be fixed to a wall using three M4 screws see Figure 2 3 1 Re
7. Diagnostics Exit 3 Select the value ofthe Damping factor as required to remove any unwanted DAMPING OPTION DD MM YY HH MM SS display fluctuations Increasing the value applies a greater smoothing affect seconds seconds 4 Press ENTER to apply the change seconds seconds seconds 100 seconds Key Point f the damping factor is set too high the value displayed may appear stable but might exhibit large step changes when the value is updated U3000 U4000 User Manual 23 Issue 2 0 3 Operating Procedures 2 nee ee pe 3 4 Outputs Both the U3000 and U4000 have configurable Current Pulse and Alarm outputs 3 4 1 Current output Note Where long cable runs are necessary or noise pickup is causing unstable flow readings the use of two core screened cable such as BELDEN 9501 060U500 or similar is recommended for use with the 4 20mA current output The cable screen should be connected to the RS232 GND terminal How to turn the 4 20mA output OFF ON 1 With the instrument operating in the FLOW READING mode press the 4 20mA function 4 29 mA OUTPUT DD MM YY HH MM SS key This will access the 4 20mA OUTPUT 4 20 mA O P is ON Dim mm Screen mA Output Reading 0 00 i Output Range 4 20 2 The ON OFF status of the 4 20mA output is Units l min shown on line 2 of the display Flow at max output 0 00 Flow at min output 0 00 3 To change the ON OFF status select Output mA for error 22 00 Outpu
8. ad ANE se Ale Box Dimensions 410mm x 205mm x 355mm Weight 7 5 kg Volumetric Weight 5 kg 54 U3000 U4000 User Manual Issue 2 0 aa CE Declaration of Conformity MicronicsS CE Declaration of Conformity Micronics Ltd Knaves Beech Business Centre Davies Way Loudwater High Wycombe Bucks HP10 9QR Ultrasonic Clamp on Flow Meter Ultraflow U3000 and U4000 Models This product is manufactured in accordance with the following Directives and Standards Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility Directive 2006 95 EC of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits BS EN 61010 1 2001 Safety requirement for electrical equipment for measurement control and laboratory use Part 1 General requirements BS EN61326 1 2006 Electrical equipment for measurement control and laboratory use EMC requirements Part 1 General requirements BS EN61326 2 3 2006 Electrical equipment for measurement control and laboratory use EMC requirements Part 2 3 Particular requirements Test configuration and performance criteria for transducers with integrated ore remote signal conditioning Included accessory battery charger not
9. change to Cancel Auto start To cancel the automatic logging session before it commences click the Cancel Auto Start Select Exit to return to the FLOW READING screen Monitoring the logged events This is described in detail in Paragraph 4 1 If you wish to view the logging progress at any time while you are operating in FLOW READING mode without interfering with the logging operation 1 Unit Log name Log data to Logging interval Start date amp time Stop date amp time Remaining time Memory Rollover Graph Y axis max Log Totals View log as text View log as graph START NOW Cancel Auto Start Clear log Exit l min Quickstart Memory 10 seconds dd mm yy hh mm ss dd mm yy hh mm ss MM DD HH MM SS mm dd hh mm ss Overwrite Press the Logger function key as described above to access the REAL TIME LOGGER screen 2 SelectView log as textorView log as graph as required Manually stopping the auto logging session Ws The logging session will stop automatically at the programmed Stop date amp time REAL TIME LOGGER DD MM YY HH MM SS Dim mm 2 If you wish to manually stop logging earlier Unit L min than programmed press the Logger Log name Quickstart function key to access the REAL TIME Log data to Memory LOGGER screen then select STOP NOW to Logging interval 10 seconds cease logging Start date amp time dd mm yy hh mm ss Stop date amp time dd mm yy hh mm ss 3 Select Exit t
10. secs 10 2 The ALARM SETTINGS screen should be Totaliser Run displayed as shown below Reset Total Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit 28 U3000 U4000 User Manual Issue 2 0 Alarm configuration 1 To reset Alarm 1 select Alarm1 Mode and press ENTER This will access the ALARM1 MODE menu screen shown below 2 Select Of f from the menu and press ENTER 3 This should de activate the alarm To re arm the alarm you must ensure that the activation condition is removed and then reconfigure the Alarm Mode as described above on page 27 3 Operating Procedures ALARM SETTINGS DD MM YY HH MM SS Alarmi Mode Alarmi Limit Alarm2 Mode Alarm2 Limit Exit Alarmi ON lt value gt lt value gt Alarm2 ON ALARM1 DD MM YY HH MM SS Off Low High Volume On Flow Error Alarm Test Frequency 3 5 How to Measure Totalised Flows manually The basic measurement indicated on the FLOW READING screen is the instantaneous flow rate which in some applications may vary over a period of time Average flow rates are therefore often required in order to get a better understanding of an application s true performance This is simply achieved by noting the total flow over a specific period for example 30 60 minutes and then calculating the average flow rate over that period of time 1 Pre
11. 2 3 24V Supply An alternative 24V a c d c power supply module is available as a factory distributor fitted option This supply is protected by a resettable solid state fuse located on the U3000 U4000 motherboard If this fuse opens it can be reset by isolating the 24V supply Power failure The instrument will automatically power up and become operational when the input power is applied In the event of a power failure the instrument s configuration parameters are stored in non volatile memory which then allows the instrument to return to normal operation immediately power is restored On the U4000 a real time clock RTC records the date time of any power disruptions and time stamps any such occurrence in the output log All data logging ceases while power is unavailable 1 4 4 Expansion modules U4000 only The U4000 motherboard contains a standard plug in communications module which provides RS232 and USB functions An expansion slot is available which can be used to extend the functionality of the U4000 to include a Heat Meter or a range of process control interface options through a plug in expansion module Details of available plug in modules and other optional equipment are given in Chapter 7 6 U3000 U4000 User Manual Issue 2 0 2 Installation 2 1 Safety Precautions and Warnings LETHAL VOLTAGES You may be exposed to potentially lethal mains voltages when the terminal cover of this instrument is removed
12. 5 Adjusting the damping factor oona W D gt 15 16 16 17 17 17 18 21 21 21 ee 22 23 U3000 U4000 User Manual Issue 2 0 ent a eo fe 3 4 3 5 Outputs 3 4 1 Current output 3 4 2 Pulse output 3 4 3 Alarm outputs How to Measure Totalised Flows manually 4 Data Logging amp Communications U4000 4 1 4 2 4 3 44 4 5 46 4 7 48 How To Set Up The Basic Logging Application To Memory How To Set Up Automatic Timed Logging Mode How To Log Directly To A PC How To Log Directly To Both Memory and PC How To Download Logged Data To A PG Working With Portagraph Il Printing 4 7 1 How to print logged data using the RS232 printer Operation with the Calec ST Energy Totaliser 4 8 1 Pulse output 4 8 2 Connecting the U3000 U4000 to the Calec ST Energy Totaliser 4 8 3 Configuring the U3000 U4000 4 8 4 Configuring the Calec ST Energy Totaliser 5 Maintenance amp Repair 6 Troubleshooting 6 1 6 2 6 3 6 4 Overview General Troubleshooting Procedure Warning and Status Messages Diagnostics Display 7 Options 7 1 7 2 Options Common To Both The U3000 U4006 71 1 High temperature transducers 7 1 2 Large pipe diameter transducers 7 1 3 Guide rail options 7 1 4 Extended signal cable options 71 5 High temperature interface cable U4000 Options Only 7 2 1 Heat meter 7 2 2 MODBUS Appendix A Specification 24 24 26 27 29 31 31 33 35 35 35 36 36 36 38
13. Logging interval andenterthe Start date amp time dd mm yy hh mm ss required period e g 10 seconds Stop date amp time dd mm yy hh mm ss 5 Select Log Totals tolog either Totals MM DD HH MM Totals or Both 32 mm dd hh mm ss Remaining time 6 SelectStart date amp time and enter the Memory Rollover Overwrite date and time you wish logging to Graph Y axis max 50 commence Note this must be in the future Log Totals Total View log as text 7 SelectStop date amp time and enter the View log as graph date and time you wish logging to cease START NOW Note this must be later than the start time Set Auto start Clear log Exit U3000 U4000 User Manual 33 Issue 2 0 aad ne ae PES 4 Data Logging amp Communications U4000 8 If the instrument is to be left unattended for a long logging period of time the logged data could possibly fill the memory Select the Memory Rollover option to either Stop or Overwrite This determines what happens to the stored data if the memory becomes full Similarly select Clear log if you want to ensure that maximum memory is available Note if you select to clear all logs you will lose all the currently held log data 9 Select Set auto start This enables the auto logging application DD MM YY HH MM SS Dim mm REAL TIME LOGGER Logging to Memory 10 11 If Set Auto start is enabled with valid start and stop times then this entry will
14. Operating Procedures micronics With the system running in FLOW READING mode 1 Press the Options key to access the FLOW READING OPTION screen shown FLOW READING OPTION DD MM YY HH MM SS 2 Scroll down and select Roughness Data review factor then press ENTER Zero Cutoff m s 0 010 Set zero flo m s 0 000 3 Change the roughness factor according to none ue 10 the pipe material and condition as Totaliser Run described above Reset Total 4 Press ENTER to apply the change Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit 3 3 5 Adjusting the damping factor By averaging out the flow rate over several seconds the Damping factor can be used to smooth out rapid changes in flow rate to prevent wild fluctuations in the displayed flow value It has a range of 10 to 100 seconds with a default setting of 10 With the system running in FLOW READING mode 1 Press the Options key to access the FLOW READING OPTION screen shown FLOW READING OPTION DD MM YY HH MM SS 2 Scroll down and select Damping secs Data review and press ENTER This will open the Zero Cutoff m s 0 010 DAMPING OPTION screen Set zero flow m s 0 000 Damping secs 10 Totaliser 3 Run Reset Total Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value
15. code to disable the password control and gain access to any of the menus Note Once disabled the password control feature is re enabled if no keys are pressed for five minutes Attaching and connecting the transducers 16 Fit the designated sensors to the pipe using the guide rail as described in Paragraph 2 3 3 The separation distance must be set to within 0 5mm Taking a flow reading 17 Once the transducers have been fitted and connected press the ENTER key 18 This will take you from the SENSOR SEPARATION screen to the FLOW READING screen via the signal checking screen shown here 19 Check that the indicated signal strength on the left of the screen shows at least 2 bars ideally 3 or 4 If less than 2 bars are shown it indicates there could be a problem with the transducer spacing alignment or connections or an application problem Flow monitoring Please wait Checking signals 2K OR KK K K K K K K K K K K K K K K K K K K K K K K K K K K K K K KK K K KKK XX KK K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K KKK FLOW READING DD MM YY HH MM SS Dim mm n 0 000 Total 0 00 litres Total 0 00 litres The FLOW READING screen is the one most used during normal monitoring operation lt shows the instantaneous fluid flow together with totalised values when enabled In this mode you can select the flow rate measurement units by pressing keys 7 litres 8 Gallons
16. either direction ASet zero flow offset adjustment is provided to compensate for any inherent differences between the two sensors noise pick up internal pipe conditions etc It can be used to zero the flow indication under no flow conditions Key Point If you have adjusted the Zero Cutoff point to anywhere above 0 you P must reset it to 0 before you can observe and adjust the Set zero flow offset as its value is very small Once the Set zero flow offset has been cancelled you can then reapply the Zero Cutoff if required 1 Stop the liquid flow 2 With the instrument in FLOW READING mode press the Velocity function key and observe the reading m s Any reading other than 0 000 indicates an offset error and in practice this will typically be in the range 0 005m s possibly higher on smaller diameter pipes If a greater figure is shown it is worth cancelling the offset to obtain a more accurate result Continue as follows 3 Press the Options key to access the FLOW READING OPTION screen shown FLOW READING OPTION DD MM YY HH MM SS 4 Select Set zero flow m s and press Data review ENTER Zero Cutoff m s 0 010 Set zero flo m s 0 000 5 Press ENTER on the subsequent screen to DDE A 10 accept the change which will return you to Totaliser Run the screen shown Reset Total 6 Scroll down to select Exit and press ENTER to return to the FLOW READING screen Key Point n order to cancel any applied
17. imperial ruler inches is etched on the top side plate and a metric millimetres ruler is etched on the bottom side plate as shown in Figure 2 4 Once the guide rail assembly is fully assembled the transducers are locked into position by tightening two thumb screws which are themselves then secured by M5 locking nuts 11 U3000 U4000 User Manual Issue 2 0 2 Installation 2 3 4 Attaching the guide rail to the pipe 1 Remove the two nylon flags from the guide rail 2 Position the guide rail horizontally on the pipe at 45 to the horizontal and secure in position using the stainless steel banding as shown in Figure 2 5 Note In the following procedure the guide rail is installed with the rectangular opening facing towards the upstream end of the pipe 2 3 5 Fitting the transducers Figure 2 5 1 Attach the nylon flags to the two transducers as shown in Figure 2 6 2 Using a syringe applicator apply a 3mm bead of acoustic couplant to the base of both transducers 3 Insert the downstream transducer cable blue through the right hand guide rail end plate and up through the rectangular opening at the T left hand side of the guide rail Figure 2 6 as shown in Figure 2 7 Note When carrying out the following steps handle the transducer assembly with care to avoid smearing the couplant on the pipe whilst attaching the transducer to the guide rail 4 Connect the dow
18. m3 h Selectable Volume Units litres m3 Total Volume Fluid Condition Pipe Materials 12 Digits forward and reverse Clean liquids or oils that have less than 3 by volume of particulate content Applications include river water sea water potable water demineralised water glycol water mix hydraulic systems and diesel oil Any sonic conducting medium such as Carbon Steel Stainless Steel Copper UPVC PVDF Concrete Galvanised Steel Mild Steel Glass Brass Including Lined Pipes Epoxy Rubber Steel Plastic Pipe Dimension outside diameter Min 13mm Max 5000mm with D sensor set Pipe Wall Thickness imm 75mm Pipe Lining Applicable pipe linings include Rubber Glass Concrete Epoxy Steel Pipe Lining Thickness Omm 25mm Pipe Wall Temperature Range Standard sensor operating temperature is 20 C to 135 C Optional high temperature sensor operating temperature is 20 C to 200 C U3000 U4000 User Manual Issue 2 0 51 Standard Temperature Range 20 C to 135 C A ST standard 13 mm 115 mm pipe O D B ST standard 50 mm 2000 mm pipe O D Protection IP54 standard IP67 optional High Temperature Temperature Range 20 C to 200 C A HT High Temp 13 mm 115mm pipe O D B HT High Temp 50 mm 2000mm pipe O D Optional Data Logged Temperature Range 20 C to 80 C 0 5M
19. manufactured by Micronics complies with EN61204 3 the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s Signature Printed Name Michael Farnon Title Managing Director Date 25th January 2010 Registered Office Micronics Limited Knaves Beech Business Centre Davies Way Loudwater Buckinghamshire HP10 9GR Web site waw micronicsltd co uk Tel 44 1628 810456 Fex 44 1 531540 Drectors E J Fanon M A Feman Registration No 1289680 V AT Registration No 303 6190 91 U3000 U4000 User Manual 55 Issue 2 0 aad pneas pl e 56 U3000 U4000 User Manual Issue 2 0
20. mm ss 4 Note that the logged data will remain stored Memory Rollover Overwrite in the instrument s memory and can be Graph Y axis max 50 accessed at any time as described above Log Totals Total View log as text View log as graph STOP NOW Set Auto start Clear log Exit 4 2 HowTo Set Up Automatic Timed Logging Mode This procedure shows you how to set up an auto logging session under timed start stop control The logged data is saved to the instrument s memory and can be downloaded to a PC at a later time Starting point This procedure assumes that the instrument has been correctly installed and is operating in the FLOW READING mode Also that the instrument s date and time are correctly set Setting up starting and cancelling auto logging enter 00 in the seconds field rather than leave it blank otherwise an error message P Key Point When entering the Start and Stop times in this procedure you must is displayed 1 With the U4000 instrument operating in FLOW READING mode check that the indicated flow units are the same as those you want to appear on the logger output e g 1 min 2 Press the Logger function key to access the REAL TIME LOGGER screen REAL TIME LOGGER DD MM YY HH MM SS Logging to Memory Dim mm 3 SelectLog data to and choose Memory Unit l min This will store the log to the internal Log name Quickstart memory Log data to Memory Logging interval 10 seconds 4 Select
21. or contaminants Connectors may be cleaned with a general purpose cleaner if necessary 3 Avoid the use of excessive grease ultrasonic couplant on the sensors as this may impair the performance of the equipment Excessive grease couplant can be removed from the sensors and guide rails using an absorbent paper towel and a general purpose solvent cleaner 4 We recommend that the ultrasonic couplant is replaced on the sensors every 6 months especially on pipes where the application is too hot to touch If the signal level drops below 30 this is also an indication that the sensors need re greasing Regularly check all cables parts for damage Replacement parts are available from Micronics Ensure the person who services your instrument is qualified to do so If in doubt return the instrument to Micronics with a detailed report of the nature of any problem 7 Take suitable precautions when using any materials to clean the sensors 8 The instrument and sensors should be calibrated at least once every 12 months Contact Micronics or your local service agent for details 9 When returning product to Micronics make sure it is clean and please notify Micronics if the instrument has been in contact with any hazardous substances 10 If the instrument was supplied with dust or dirt caps make sure they are re fitted when the instrument is not in use U3000 U4000 User Manual 41 Issue 2 0 5 Maintenance amp Repair a 2 Ane se Ale
22. pressed for the cursor to Set Auto start move automatically Clear log Exit 5 If you want to change the value of the Y axis to improve the resolution of the graph VIEW LOG AS GRAPH DD MM YY HH MM SS press the UP DOWN scroll keys The ES 0 Dim mm maximum values will then increase Log Quickstart decrease as appropriate Point XXX XXX 6 To exit the VIEW LOG AS GRAPH screen Value xx xx and return to the REAL TIME LOGGER dd mm yy ee screen press ENTER Monitoring the logged events at a later time If you wish to monitor the logging progress at any time while you are operating in FLOW READING mode without interfering with the logging operation 1 Press the Logger function key as described above to switch to the REAL TIME LOGGER screen 2 Select View log as textorView log as graph as required 32 U3000 U4000 User Manual Issue 2 0 4 Data Logging amp Communications U4000 Stop logging 1 Fromthe FLOW READING screen press the Logger function key to access the REAL TIME LOGGER DD MM YY Bh MNS REAL TIME LOGGER screen RAS mm Unit L min 2 Select STOP NOW to cease logging Log name Quickstart Note that the START NOW and STOP NOW Log data to Memory options toggle depending on which was last Logging interval 10 seconds selected Start date amp time dd mm yy hh mm ss Stop date amp time dd mm yy hh mm ss 3 Select Exit to return to the FLOW READING screen MM DD HH MM SS Remaining time mm dd hh
23. results of the transit time calculations to compute the fluid flow velocity Once the flow velocity is known the volumetric flow can be easily calculated for a given pipe diameter The system can be set up to operate in one of four modes determined mainly by the pipe diameter and the type of transducer set in use The diagram in Figure 1 1 illustrates the importance of applying the correct separation distance between the transducers to obtain the strongest and therefore most reliable signal 1 3 Supplied Hardware The supplied U3000 U4000 components are shown in Figure 1 2 Mounting clamps x2 r a Steel bands x2 U3000 4000 Instrument High Temperature Interface Cables x2 tm Guide Rail Transducer Transducers Cables x2 Sensors Ax2 or Bx2 Figure 1 2 Standard U3000 U4000 equipment U3000 U4000Standard equipment Instrument with backlit graphic display Transducer cables x2 5 metres long Transducers A ST x2 U3000 U4000A for use with pipes ranging 13mm 115mm Transducers B ST x2 U3000 U4000B for use with pipes ranging 50mm 2000mm USB cable and RS232 C cable U4000 Guide rail for use with A or B transducers Steel bands used to secure the transducer guide rails to the pipe e Acoustic couplant e User documentation U3000 U4000 User Manual 3 Issue 2 0 1 General Description Real ge pe U3000 U4000 Optional equipment High temperat
24. system you need to obtain the following details this information is required when setting up the Quick Start menu The pipe outside diameter e The pipe wall thickness and material The pipe lining thickness and material if any The type of fluid contained in the pipe being monitored The fluid temperature Entering the site data 1 Select Quick Start fromthe MAIN MENU and press ENTER You will then be presented with a series of screens in which to enter the data mentioned above 2 Select the dimension units millimetres or inches used to measure the pipe then DIMENSION UNIT DD MM YY HH MM SS ENTER press Select the dimension units mm Inches 3 Enter the pipe outside diameter dimension then press ENTER OUTSIDE DIAMETER DD MM YY HH MM SS Dimensions Pipe outside diameter 4 Enter the pipe wall thickness dimension then press ENTER PIPE WALL THICKNESS DD MM YY HH MM SS Dimensions Pipe outside diameter Pipe wall thickness 5 If the pipe has a lining enter the lining thickness PIPE LINING THICKNESS DD MM YY HH MM SS If nothing is entered the instrument automatically assumes there is no lining Dimensions 6 Press ENTER to continue Pipe outside diameter Pipe wall thickness Pipe lining thickness 18 U3000 U4000 User Manual Issue 2 0 ad micronics 10 11 12 13 14 Select the pipe wall material from the list provided then press ENT
25. the maximum flow rate is Fmax l min and the minimum flow rate Fin is 0 l min as shown max 0 16mA scale 0 20mA scale 4 20mA scale z LL Finin I mA U3000 U4000 User Manual 25 Issue 2 0 3 Operating Procedures 2 AMERS pe To calculate the flow rate l min for a measured current I mA then 0 20mA 0 16mA 4 20mA x F _F x F En 4 x F F Flow rate max Fin nar nin p Flowrate ne ni yp Flow sate ae tt F 3 4 2 Pulse output Pulse output configuration Two parameters can be configured from the PULSE OUTPUT menu Volume of fluid per pulse Pulse width 1 With the instrument operating in the FLOW READING mode press the Pulse function PULSE OUTPUT DD MM YY HH MM SS key to access the PULSE OUTPUT screen 5e output is ON Dim mm Flow units litres Ensure that the Output is Of f Output Off Vol per pulse 10 00 Select Vol per pulse and press ENTER Pulse width ms i 10 Enter the required value In the example Exit shown a pulse is produced every 10 litres of flow Note The Vol per pulse can only be changed if the Pulse Output is Off 5 Select a Pulse width in ms to suit the particular application e g electro mechanical counter Refer to the manufacturer s data sheet for the minimum pulse width 6 Select Exit and press ENTER to return to the FLOW READING screen How to turn the pulse output OFF ON 1 With t
26. this mode the logged data can be output to the instrument s memory to a PC via the RS232 or USB serial interfaces or simultaneously to both memory and PC When logging to memory only the logged data can be downloaded to the PC at a later time Both the flow rate and Totals can be logged with up to 96K logging events stored internally 1 4 1 Connections LCD Display Keypad Coaxial cables to probes Small amp Large Blue Downstream Glands for power Red Upstream Cable glands for connection Alarms amp I O connections Figure 1 3 Instrument details Transducer connections The transducer probes are connected to two coaxial sockets located on the bottom left hand of the instrument The silk screen above these connectors show a red and blue triangle and a direction of flow symbol For a positive flow reading it is important that the upstream transducer is connected to the RED socket and the downstream transducer to the BLUE one It is safe to connect or disconnect the cable while the instrument is switched on 4 U3000 U4000 User Manual Issue 2 0 1 General Description USB connection U4000 only A USB cable is supplied as part of the U4000 kit and can be connected between the U4000 instrument and a PC to download logged data The USB connector located on the top left hand side of the flowmeter as shown in Figure 2 2 uses a Bulgin screwed type connector to preserve the enclosure s IP 65 rating
27. until all logged data is output or until the key is pressed SETUP RS232 USB DD MM YY HH MM SS i 2a i D i i l RS232 The printer will continue printing until its ata is being downloaded on Ra23 print buffer is empty which may take a few This screen will clear minutes when download is completed Press to cancel Download 4 8 Operation with the Calec ST Energy Totaliser The U3000 U4000 can be operated with the Calec ST Energy Totaliser which allows accumulated Energy measurement to be made In this configuration one Pt100 or Pt500 temperature sensor is fitted to the output pipe hot side and another to the return pipe cold side The temperature difference AT Thot Tcold measured by the Calec ST Energy Totaliser together with the pulse input from the U3000 U4000 allows the Calec ST Energy Totaliser to calculate and display the accumulated Energy absorbed by the heating system 4 8 1 Pulse output When working with the Calec ST Energy Totaliser the U3000 U4000 normal pulse output is not used Instead a pulse whose frequency is proportional to the flow rate is independently generated and output on ALARM1 or ALARM2 outputs This gives a more stable reading than the pulse packets that would normally be output 4 8 2 Connecting the U3000 U4000 to the Calec ST Energy Totaliser Connect the U3000 U4000 to the Calec ST Energy Totaliser as follows 1 Connect ALARM1 or ALARM2 to the Calec s Pulse input 1
28. 0 2 Connect ALARM1 or ALARM2 to the Calec s Pulse input 11 4 8 3 Configuring the U3000 U4000 Configure the U3000 U4000 frequency pulse output using the following procedure 1 From the FLOW READING screen press the Opt ions key to select the FLOW FLOW READING OPTION DD MM YY HH MM SS READING OPTIONS menu shown Data review Zero Cutoff m s 0 010 Note You may need to enter the password Set zero flow m s 0 000 first Damping secs 10 2 Scroll down to Alarm Settings and Totaliser Run press ENTER to select the ALARM Reset Total SETTINGS menu shown below Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit 38 U3000 U4000 User Manual Issue 2 0 ad 4 Data Logging amp Communications U4000 micronics 3 Select Alarm 1 Mode and press ENTER to select the ALARM1 MODE menu shown below 4 Scroll down to Frequency and press ENTER 5 This return to the ALARM SETTINGS menu which will indicate Frequency on the Alarm 1 Mode field as shown below 6 Select Exit to return to the FLOW READING OPTIONS menu 7 Scroll down to select Max Pulse Freq Hz and press ENTER 8 Enter either 10Hz or 200Hz and press ENTER 9 Select Flow at Max Frequency and press ENTER 10 Enter the maximum flow rate corresponding to 10Hz or 200Hz and press ENTER 11 The Calculated Pulse Value sho
29. 0 User Manual 45 Issue 2 0 6 Troubleshooting ERR mA out gt Max aad ent et gt ek Interpretation The actual flow is higher than the maximum set on the mA range Response Re scale the 4 20mA output to be able to cope with the higher flow see Paragraph 3 4 1 Calibration 20mA Error NOTE The 4 20mA output is calibrated before the instrument leaves the factory and should not require further adjustment Interpretation You have adjusted the DAC outside its accepted range when calibrating the 20mA signal output Response Re calibrate the 4 20mA output see Paragraph 3 4 1 Calibration 4mA Error ERR Log not empty ERR Log memory full NOTE The 4 20mA output is calibrated before the instrument leaves the factory and should not require further adjustment Interpretation You have adjusted the DAC outside its accepted range when calibrating the 4mA signal output Response Re calibrate the 4 20mA output see Paragraph 3 4 1 Interpretation When using QuickStart and manually starting a log this message is displayed to warn you that a log already exists The screen will offer the option to cancel the logging or save the log to another site Response Attempt to save the existing log then re start logging If logging still fails to start and the error message remains then either all the sites are in use or all the Logger memory is full Check for any unwanted log files and delete
30. 38 38 38 40 41 43 43 44 45 48 49 49 49 49 49 49 49 4g 4g 4g 51 U3000 U4000 User Manual Issue 2 0 1 General Description 1 1 Introduction This manual describes the operation of the U3000 U4000 flowmeter The flowmeter is designed to work with clamp on transducers to enable the flow of a liquid within a closed pipe to be measured accurately without needing to insert any mechanical parts through the pipe wall or protrude into the flow system Using ultrasonic transit time techniques the U3000 U4000 is controlled by a micro processor system which contains a wide range of data that enables it to be used with pipes having an outside diameter ranging from 13mm up to 2000mm and constructed of almost any material The instrument will also operate over a wide range of fluid temperatures The basic features of the U3000 and U4000 are identical However the standard U4000 can also perform data logging has RS232 and USB communications interfaces U3000 U4000 standard features Large easy to read graphic display with backlight Simple to follow dual function keypad Simple Quick Start set up procedure e Continuous signal monitoring Isolated pulse output Isolated current output 4 20mA 0 20mA or 0 16mA Password protected menu operation for secure use e Signal diagnostics e Multi function alarm outputs Operates from Mains 24Va c or 24Vd c U4000 additional st
31. 50 Glycol water 30 Lubricating oil Diesel Freon Other m s FLUID TEMPERATURE DD MM YY Enter Fluid Temperature C 25 00 F 77 00 Continue HH MM SS HH MM SS HH MM SS HH MM SS U3000 U4000 User Manual Issue 2 0 19 3 Operating Procedures 15 The SENSOR SEPARATION screen now displays a summary of the entered parameters and informs you of the type of sensor to be used the mode of operation and the distance to set up between the sensors In this example it recommends type A ST A standard sensors operating in the Reflex mode spaced at 44 64mm apart Take a note of these details SENSOR SEPARATION DD MM YY HH MM SS Site Quickstart Pipe 76 00 mm Wall 1 50 Sensors A ST Reflex Temperature 25 00 C 77 00 F Set sensor separation to 44 64 mm Press to continue AV to select sens Key Point The above example shows the spacing required using a type A probe set as supplied with the model U3000 U4000A Note Do not press ENTER until the transducers are fitted and connected to the instrument Password Control After data has been entered for the first time the U3000 U4000 password control feature is enabled when you exit from Quick start to the FLOW READING screen This prevents unauthorised tampering of the set up data Once enabled a password control box is displayed if any key is pressed and you must then enter a 5 digit password
32. Barrels or 9 m8 or change the display to show velocity by pressing key 4 20 U3000 U4000 User Manual Issue 2 0 3 Operating Procedures 3 3 Instrument Calibration The instrument is fully calibrated before it leaves the factory however the following adjustments are provided to allow you to further fine tune your instrument to suit local conditions and application where necessary Apart from the zero flow offset adjustment these are normally carried out only where the instrument is to be used at a permanent or semi permanent location 3 3 1 Adjusting the zero cut off This adjustment allows you to set a minimum flow rate m s below which the instrument will indicate 0 The default setting is 0 01 m s but you may adjust this value if required 1 With the instrument operating in FLOW READING mode press the Options key to FLOW READING OPTION DD MM YY HH MM SS access the FLOW READING OPTIONS Data review menu shown password required Zero Cutoff m s 0 010 2 Select Zero Cutoff m s and press Set zero flow m s 0 000 ENTER Damping secs 10 Totaliser Run 3 Enter the value for the Zero Cutoff e g Reset Total 0 06 m s then press ENTER 4 Scroll down to select Exit and press ENTER to return to the FLOW READING screen 3 3 2 Adjusting the set zero flow offset The U4000 instrument operates by comparing the time taken to send an ultrasonic signal between two transducers in
33. Check the following the pipe data has been entered correctly the fluid type has been entered correctly the correct transducer type has been selected the pipe diameter is within specifications of the selected transducers the pipe is completely full the pipe surface is not corroded or protective surface loose no particles in the fluid Loss of power supply Confirm power supply availability note if using 24V power supply the internal fuse should reset when power is removed Turn instrument OFF ON If the display is still scrambled hung up return the instrument for repair Note any active messages Refer to the message table in this chapter to interpret the message and view suggested response Ensure that the transducer cables are connected orrectly Ensure that sufficient acoustic couplant has been applied to the transducers If triple reflex mode is selected try selecting double or single reflex instead Figure 6 1 Troubleshooting chart 44 U3000 U4000 User Manual Issue 2 0 6 Troubleshooting 6 3 Warning and Status Messages FLOW RATE ERRORS ERR No flow signal Interpretation This message appears when the transducers cannot send or receive signals to each other Response Firstly check that all cables are connected transducers are on the pipe correctly with sufficient couplant on the face This condition could also be due to a partially em
34. ER If the material is not listed select Other and enter the propagation rate of the pipe wall material in metres sec Contact Micronics if this is not known If a lining thickness value was entered earlier this screen is displayed to request that you enter the lining material type If no lining thickness was entered this screen will be bypassed Select the lining material from the list provided then press ENTER If the material is not listed select Other and enter the propagation rate of the lining material in metres sec Contact Micronics if this is not known Select the fluid type from the list provided and press ENTER If the liquid is not listed select Other and enter a propagation rate in metres second Contact Micronics if this is not known If you need to alter the fluid temperature from that shown select either C or F with the cursor and press the ENTER key Enter the new temperature value and press the ENTER key The new temperature should now be indicated in both C and F Select Continue and press ENTER 3 Operating Procedures PIPE WALL MATERIAL DD MM YY Select pipe wall material Mild Steel S less Steel 316 S less Steel 303 Plastic Cast Iron Ductile Iron Copper Brass Concrete Glass Other m s PIPE LINING MATERIAL DD MM YY Select pipe lining material Steel Rubber Glass Epoxy Concrete Other m s FLUID TYPE DD MM YY Select fluid type Water Glycol water
35. Hz D 1500 mm 5000 mm pipe O D Standard All measurement parameters and flow reading Optional Totalised values No data points Standard 98K data points may be affected by totaliser Optional 196K data points may be affected by totaliser Time Stamping All data points are date amp time stamped No Sites 1 non editable and 1 editable Logging Interval User programmable 5 secs to 1hr Operating Modes Logging stopped when memory full Logging continues on memory overflow with old date overwritten Logged Data Transfer Standard Supported Languages Serial Interface Logged data can be transferred to PC via RS232 or USB English French German Italian Spanish Portuguese Russian Norwegian Dutch Swedish RS232 and USB 2 0 Full Speed 12Mbits sec mode USB software driver provided Maximum Load Logged Data Can be output to PC or Printer Current Output No Channels 1 Format 4 20mA 0 20mA 0 16mA Resolution 0 1 of full scale Error Currents Any between 0 26mA Isolation 1500V Opto isolated from unit 620 Ohms Pulse Output TTL Number Available Isolation Pulse Repetition Rate Pulse Width Max Current Max Voltage 1 Opto isolated MOSFET relay 1500V opto isolated from unit User programmable from 1 to 250 ppm User programmable from 2ms to 500ms 500mA 48V O1 N U3000 U4000 User Manual Issue 2 0
36. Micronics U3000 4000 Ultrasonic Flowmeter User Manual LS Through measurement comes control Micronics Ltd Knaves Beech Business Centre Davies Way Loudwater High Wycombe Bucks HP10 9QR Telephone 44 0 1628 810456 Facsimile 44 0 1628 531540 E mail sales micronicsltd co uk www micronicsflowmeters com Issue 2 0 Table of Contents 1 General Description 1 1 Introduction 1 2 Principles of Operation 1 3 Supplied Hardware 1 4 U3000 U4000 Instrument 1 4 1 Connections 1 4 2 Keypad 143 Power supply 1 4 4 Expansion modules U4000 only 2 Installation 2 1 Safety Precautions and Warnings 2 2 Installing the U3000 U4000 instrument 2 2 1 Positioning the instrument 2 2 2 Mounting the instrument 2 2 3 Connecting the instrument 2 3 Installing The Ultrasonic Transducers 2 9 1 Transducer positioning 2 3 2 Preparation 2 3 3 Transducer attachment 2 3 4 Attaching the guide rail to the pipe 2 9 5 Fitting the transducers 2 4 Installing the USB Virtual Com Port U4000 only 3 Operating Procedures 3 1 Setting up the Instrument 9 1 1 Using the instrument for the first time 3 1 2 Enabling disabling the backlight 3 1 3 Changing the user language 3 1 4 Changing the date and time 3 2 Using the Quick Start Menu 3 3 Instrument Calibration 9 9 1 Adjusting the zero cut off 3 3 2 Adjusting the set zero flow offset 3 3 3 Adjusting the calibration factor 3 3 4 Adjusting the roughness factor 3 3
37. ames to download Clear log U3000 U4000 User Manual 35 Issue 2 0 4 Data Logging amp Communications U4000 Rale ge PES 4 If you want to view the log prior to downloading it you can do so using the View log as text or View log as graph options When you are ready to begin downloading the log select Download log From the DOWNLOAD LOG screen select USB or RS232 then select Send from the DOWNLOAD LOG DD MM YY HH MM SS i Dim mm subsequent confirmation screen a Select Serial port or printer amp press 7 The selected logged data is now USB downloaded to the PC RS232 Bluetooth Printer 8 Upon completion select Exit to return to ER the VIEW LOGGED DATA screen 9 Onthe VIEW LOGGED DATA screen you can now Clear the log if required or Exit directly back to the MAIN MENU Key Point When using the USB to download data make sure that the USB driver has been installed and the correct COM port has been set see Paragraph 2 4 4 6 Working With Portagraph Il Micronics Ltd supplies the Portagraph Il Downloading and Graphing software to make it easy for the user to downloading logged data to a PC This software application automatically connects to the U4000 via the RS232 or USB serial interface Logged data can then be downloaded and analysed using the Portagraph II graphing capability or exported to Microsoft Excel for more detailed graphing and analysis Portagraph II will automatically det
38. and press ENTER Exit Note In order for the above procedure to work the U4000 must be connected to the PC and the RS232 USB link already established 4 4 How To Log Directly To Both Memory and PC Logging simultaneously to both the unit s internal memory and to the PC or Printer can be set up as follows 1 From the REAL TIME LOGGER menu select Log data to and then select Both 2 Select START NOW to begin the logging session link has already been established If the RS232 protocol has not been configured you P Key Point This will only work if the U4000 is connected to the PC and the RS232 can access the RS232 set up screen by pressing the Comms button 4 5 How To Download Logged Data To A PC This procedure describes how to download stored data to a PC It assumes that the U4000 is already connected to the PC s serial port and that RS232 USB communication has been established as described in Paragraph 4 6 1 Access the MAIN MENU Note If this is done from the FLOW READING screen any logging currently taking place will be terminated 2 Select View Logged Data fromthe MAIN MENU VIEW LOGGED DATA DD MM YY HH MM SS Dim mm 3 Only two sites are available on the U4000 Choose from list of sites One non editable site name QuickStart View log as text and one editable site name default View log as graph EmptySite1 Select Choose from Graph Y axis max list of sites and select one of these Download log site n
39. andard features 98k stored data points Logging of Flows and Volume totals e RS232 and USB output The U4000 can accommodate a number of options that are not available on the U3000 These include Heat Meter MODBUS e Further options are being developed and will be released during 2010 Volumetric flow rates are displayed in I h l min l sec gal min gal h USgals min USgals h Barrel h Barrel day m s m min m3 h Linear velocity is displayed in metres or feet per second When operating in the Flow Reading mode the total volumes both positive and negative are displayed up to a maximum 12 digit number The flowmeter can be used to measure clean liquids or oils that have less than 3 by volume of particulate content Cloudy liquids such as river water and effluent can be measured along with cleaner liquids such as demineralised water Typical U3000 U4000 applications include e River water Seawater Potable water Demineralised water Treated water U3000 U4000 User Manual 1 Issue 2 0 17 General Description Both the U3000 and U4000 have A and B model options which refer to the transducer type provided Thus a U3000A will be supplied with type A transducers which are designed to work with pipe diameters between 13mm 115mm whereas a U4000B will be supplied with type B transducers which are designed to work with pipe diameters between 50mm 2000mm B
40. ated us value If however this value is much greater than the calculated time then there is a problem with the set up Flow m s This displays flow velocity in m sec to 3 decimal places Signal strength This is the averaged value of Signal and should be a value between 800 and 1600 where 800 is approximately 50 and 1600 is approximately 100 Gain Gain values are typically in the range 600 to 850 Switches Typical Switches values are None and 10 On small pipes and when using the test block the value should be None A Switch value of 100 indicates poor sensor set up or poor connections UP DN time difference The difference in transit times between the upstream and downstream signals due to the fluid flow Fluid propagation rate This is the sound speed of the fluid calculated using the data entered by the user Sensor separation The same value as displayed in the setup screen 48 U3000 U4000 User Manual Issue 2 0 7 Options 7 4 Options Common To Both The U3000 U4000 The following options are common to both the U3000 and U4000 instruments 7 1 1 High temperature transducers Type A HT and type B HT transducers are available for operation over the temperature range 20 C to 200 C These high temperature transducers can be used over an identical pipe diameter ranges as the standard type A ST and type B ST transducers The probe dimensions guide rail fittings and cable connection a
41. cables may be required Current output a 4 20mA 0 16mA or 0 20mA monitoring signal is output at terminal mA and mA mA is the current output terminal and mA is the return terminal Pulse output an opto isolated pulse output is available at terminals PULSE and PULSE PULSE is the pulse output terminal and PULSE is the return terminal Alarm Outputs two programmable multifunction alarm outputs are available using MOSFET SPNO relays The relays are rated at 48V 500mA continuous load and are connected to terminals ALARM1 ALARM1 ALARM2 and ALARM2 respectively e RS232 Interface U4000 only an RS232 interface is provided to allow logged data to be downloaded to a PC or RS232 compatible printer The interface is connected to terminal TxD data transmitted from the U4000 RxD data received by the U4000 and GND signal ground e Expansion ports U4000 only terminals EXPI0 1 to EXPIO 8 are used for I O connections to a number of optional expansion boards that may be fitted to the U4000 expansion slot Details of the available options are provided in Chapter 7 1 Remove the terminal block cover Route the control and monitoring cables through the two smaller cable glands Cut the wires to length strip back the insulation by approximately 10mm and connect them into the required terminals as described above and identified in Figure 2 1 4 On completion tighten the cable glands to ensure the cables a
42. e default value is 9999 Volume limit values If VOL limit is selected the value entered in the ALARM SETTINGS menu must be in the range 3 999 999 999 99 to 3 999 999 999 99 This value will be in the units previous selected e g Litres m3 gals The default value should be 3 999 999 999 99 Alarm Test An Alarm Test should be made to ensure that data entered is within the specified ranges 1 Select Alarm Test and press ENTER in the Alarm1 MODE menu to test that Alarm1 can be activated 2 Select Alarm Test and press ENTER inthe Alarm2 MODE menu to test that Alarm2 can be activated Pulse Frequency When Frequency is selected a variable frequency pulse proportional to the flow rate can be output at the ALARM 1 or ALARM 2 outputs When this feature is used the Max Pulse freq Hz andFlow at Max Frequency must be set in the FLOW READING OPTION menu Refer to page 38 for operation with the Calec ST Energy Totaliser for full details Resetting an alarm When either Alarm1 or Alarm2 is activated the appropriate relay will be held in the closed position until The activation condition is removed or The Alarm is reset Both Alarm1 and Alarm2 can be reset by using one of the following procedure 1 Access the The ALARM SETTINGS menu by selecting Alarm Settings from the FLOW READING OPTION DD MM YY HH MM SS FLOW READING OPTION menu and press ENTER Data review Zero Cutoff m s 0 010 Set zero flow m s 0 000 Damping
43. ect the unit s RS232 configuration baud rate data bits parity stop bits so there is no need for the user to specifically set this up For full details of Portagraph Il operation refer to the Portagraph II user manual 4 7 Printing Logged data can be printed using an RS232 compatible printer 4 7 4 How to print logged data using the RS232 printer This procedure shows you how to set up and use the RS232 printer to print logged data Setting up an RS232 connection 1 Connect the U4000 instrument to the printer using the printer cable supplied This cable is fitted with a 9 way D Type plug terminated as follows Pin 1 N C No connection Pin 2 TxD data from U4000 to printer Pin 3 RxD data from printer to U4000 Pin 4 N C Pin 5 Signal ground Pin 6 N C Pin 7 N C Pin 8 N C Pin 9 N C 36 U3000 U4000 User Manual Issue 2 0 4 Data Logging amp Communications U4000 2 Select Setup RS232 USB from the MAIN MENU This will access the SETUP SETUP RS232 USB DD MM YY HH MM SS Dim mm RS232 USB screen shown here Wandehakang Xon Xoff 3 Set the RS232 parameters to comply with Baud Rate 1200 those for the printer Data Bits 8 Stop Bits 1 The parameters shown here are for the Parity None Seiko DPU 414 Thermal Printer New Fine CR LF _ Printer test 4 Ensure that the printer has sufficient paper Exit is switched ON and ON LINE 5 To check that the U4000 printer i
44. g Procedures Set date time Language Backlight QUICK START Enter data Attach sensors FLOW READING How to adjust the Zero Flow Offset Paragraph 3 3 2 How to adjust the Calibration Factor Paragraph 3 3 3 How to adjust the Roughness Factor Paragraph 3 3 4 How to adjust the Damping Factor Paragraph 3 3 5 How to measure totalised flows Paragraph 3 5 4 20mA ON OFF Paragraph 3 4 1 4 20mA Calibration Paragraph 3 4 1 Pulse ON OFF Paragraph 3 4 2 7 5 Pulse calibration Paragraph 3 4 2 How to set up basic manual logging Paragraph 4 1 Alarm outputs Paragraph 3 4 3 How to set up auto timed logging Paragraph 4 2 i How to set up logging live to a PC Paragraph 4 3 How to Log directly to both Memory and PC Paragraph 4 4 RS232 set up Paragraph 4 7 1 USB set up Paragraph 2 4 How to download saved data to a PC Paragraph 4 5 How to print data Paragraph 4 7 How to use with Calec ST Energy Totaliser Paragraph 4 8 U3000 U4000 User Manual 15 Issue 2 0 3 Operating Procedures 3 1 Setting up the Instrument The procedures outlined below apply to both the U3000 and U4000 unless otherwise indicated Key Point When the instrument used for the first time the operator has free access P to all the set up and operating menus until the instrument is put into FLOW READING operation where upon all the menus become pas
45. he instrument operating in the FLOW READING mode press the Pulse function PULSE OUTPUT DD MM YY HH MM SS key to access the PULSE OUTPUT menu Pulse output is ON Daim Mm Flow units litres 2 Select Output and press ENTER Output Of f Vol l i Select On and press ENTER Pe a S T 99 A Pulse output is ON message will appear Exit in the second line of the display 5 Select Exit and press ENTER to return to the FLOW READING screen 26 U3000 U4000 User Manual Issue 2 0 ae 3 Operating Procedures Bam gop a 3 4 3 Alarm outputs Both the U3000 and U4000 models contain two programmable alarm outputs that are interfaced by opto isolated relays The relay contacts are rated at a 48V maximum voltage across the open contacts and 500mA maximum continuous current through the closed contacts The two alarm outputs can be individually configured to operate in one of four modes Activate at a predefined Low or High flow rate Activate when a specified Volume is measured Activate if a signal error is detected either due to poor signal strength or complete signal loss Alarm Test mode e Pulse Frequency output Alarm settings selection 1 To access the The ALARM SETTINGS menu select Alarm Settings from the FLOW READING OPTION DD MM YY HH MM SS FLOW READING OPTION menu and press 5 ENTER Data review Zero Cutoff m s 0 010 2 The ALARM SETTINGS screen should be Set zero flow m s 0 000 di
46. he top level Menu navigation is achieved by three keys located on the right hand side of the keypad which are used to scroll UP and DOWN a menu list and SELECT a menu item When scrolling through a menu an arrow shaped cursor moves up and down the left hand side of the screen to indicate the active menu choice which can then be selected by pressing the ENTER SELECT key Some menus have more options than can be shown on the screen at the same time in which case the overflowed choices can be brought into view by continuing to scroll DOWN past the bottom visible item Menus generally loop around if you scroll beyond the first or last items If you select Exit on any menu it usually takes you back one level in the menu hierarchy but in some cases it may go directly to the Flow Reading screen Some screens require you to move the cursor left and right along the display as well as up and down This is achieved using keys 5 scroll LEFT and 6 scroll RIGHT Dual function numerical keypad The block of keys shown in the centre of the keypad in Figure 1 4 are dual function keys They can be used to enter straight forward numerical data select the displayed flow units or provide quick access to frequently required control menus 1 4 3 Power supply Mains supply As standard the instrument is designed to work with a mains supply of 86 236V and 50 60Hz A 500mA mains supply fuse is located adjacent to the mains power connection see Figure
47. hown separately in the Total field Calculating the average flow To calculate the average flow wait for the allotted monitoring period to expire then divide the indicated total flow by the time taken This will give you the average flow in m s galls hour or whatever units you select Note that in a bi directional flow situation you must calculate the difference between the indicated positive and negative flow totals before carrying out the average flow rate calculation How to stop the totaliser temporarily If you want to stop the totaliser temporarily for operational reasons set the Totaliser option to Stall in the FLOW READING OPTIONS screen as described above This will stop the totaliser operation without affecting its current values 30 U3000 U4000 User Manual Issue 2 0 4 Data Logging amp Communications U4000 4 1 How To Set Up The Basic Logging Application To Memory This procedure shows you how to set up a basic logging session under manual start stop control The logged data is saved to the instrument s memory and can be downloaded to a PC at a later time Either Flow Rate or Flow Rate and Totals can be logged to Memory RS232 or both Setting up and starting the logging 1 With the U4000 operating in FLOW READING mode check that the indicated REAL TIME LOGGER DD MM YY HH MM SS flow units are the same as those you want ae to Memory s eae Dims mm to appear on the logger output Log name Quickstart e g 1 min
48. ht pipe down to 10 diameters upstream and 5 diameters downstream but when the transducers are positioned this close to any obstruction the resulting errors can be unpredictable Key Point Do not expect to obtain accurate results if the transducers are positioned close to any obstructions that distort the uniformity of the flow profile 2 3 2 Preparation Before you attach the transducers you should first ensure that the proposed location satisfies the distance requirements shown in Figure 2 3 otherwise the resulting accuracy of the flow readings may be affected Prepare the pipe by degreasing it and removing any loose material or flaking paint in order to obtain the best possible surface A smooth contact between pipe surface and the face of the transducers is an important factor in achieving a good ultrasound signal strength and therefore maximum accuracy 2 3 3 Transducer attachment Thumb screw ry DANGER Nvion FI a POE MEMON COMMA n oe AE CE me Transducer Upstream Downstream Cable Connector transducer transducer Rectangular opening amp Stainless steel bands Figure 2 4 Transducer attachment completed assembly The type A or B transducers are fixed to the pipe using the adjustable guide rail assembly shown in Figure 2 4 The guide rail itself is secured to the pipe using two wrap around steel bands or by chain optional For user convenience an
49. ippings in galvanised dipped pipes or other irregularities interfering with the signal path Incorrect probe location Transducers located too close to bends or valves disturbing the flow profile Transducers located too close to insertion probes disturbing the flow profile For horizontal pipework transducers should not be positioned on the top of the pipe Poor fluid conditions within the pipe Fluid contains bubbles high particle density or sludge Air in the top of the pipe Low fluid flow within the pipe e Pipe obstructions Malfunctioning valve not opening fully or closed inadvertently Liquid content problems e Multiple liquid contents do not comply accurately to expected sound speed criteria e Very hot pipe almost turns water to steam and therefore exhibits the wrong speed characteristics could be due to reduced pipe pressure e Flashover liquid turns into a gas because of lower than required pressure U3000 U4000 User Manual 43 Issue 2 0 6 Troubleshooting 6 2 General Troubleshooting Procedure aa micronics Ensure the temperature is set correctly Ensure transducers are positioned in accordance with the recommended distance from bends etc Ensure flow velocity gt 0 01m s Is the display blank Yes No Is the display scrambled or hung up Yes No Are any status messages shown Yes Problem probably due to non constant fluid flow
50. lume per pulse Imp The Volume per pulse value should be the same as that indicated in the U3000 U4000 Calculated Pulse Value Both of these values can be entered using the Calec s Inputs menu Refer to the Calec s User Manual for further details Example Consider the U3000 U4000 configured as follows for a 114mm stainless steel pipe Max Pulse Freq Hz 200Hz Flow at max Freq 20 0 l s Calculated Pulse Value 0 1 The U3000 U4000 reads a mean flow rate of 72 08 m3 h 1 Select Calec Inputs and program as follows F 200Hz Imp 0 1 2 Select Calec Instant then scroll to AT 36 78 P 3043 344 Q 72 023 K 1 149 The calculated value of P is given by P kx Q x AT 3043 7kW This verifies the correct U3000 U4000 with the Calec ST Energy Totaliser 40 U3000 U4000 User Manual Issue 2 0 5 Maintenance amp Repair This instrument does not contain any user serviceable parts The following notes are provided as a guide to general equipment care Do not disassemble this unit unless advised by Micronics Return the unit to an approved service agent or place of purchase for further advice WARNING 1 Ensure the unit is disconnected from the mains then wipe the exterior of the instrument with a clean damp cloth or paper towel Do not use a solvent based cleaning fluid on the instrument as it could damage the instrument surface 2 Ensure all cables and connectors are kept clean and free from grease
51. m s 0 010 wees fl m s 0 000 6 Change the calibration factor according to se aa 10 the error calculated in step 3 For example Totaliser Run if the instrument was reading 1 high then Reset Total increase the Calibration factor value by 0 010 Conversely if the reading is 1 Reset Total low then decrease the calibration factor to Calibration factor 0 990 Roughness factor Alarm Settings Press ENTER to apply the change Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit Select Roughness factor or Exit as required and press ENTER 3 3 4 Adjusting the roughness factor The roughness factor compensates for the condition of the internal pipe wall as a rough surface will cause turbulence and affects the flow profile of the liquid In most situations it is not possible to inspect the pipe internally and the true condition is not known In these circumstances experience has shown that the following values can be used Pipe Material Roughness Pipe Material Roughness Factor Factor Non ferrous metal 0 01 Welded steel pipes new 0 1 e Glass Long usage cleaned e Plastics e Lightly and evenly rusted e Light metal e Heavily encrusted Drawn steel pipes Cast iron pipes e Fine planed polished Bitumen lining surface New without lining e Plane surface e Rusted Encrusted e Rough planed surface 22 U3000 U4000 User Manual Issue 2 0 ae 3
52. move the U3000 U4000 terminal cover 2 Fix a screw into the wall at the required point to align with the mounting keyhole on the back of the enclosure Attach the enclosure to the wall using the keyhole screw mounting Align the enclosure then mark out the positions for the two remaining screw fixings through the slots near the bottom corners of the enclosure Then remove the enclosure and drill and plug the fixing points 5 Clear the site of any dust debris then mount the enclosure on the wall U3000 U4000 User Manual 7 Issue 2 0 2 Installation M4 Keyhole Mounting Details The instrument should be securely wall mounted using the three fixing points shown M4 Screw Slot Cable connections All power and control cables enter through cable glands located on the bottom of the instrument and connect to terminal blocks as shown Figure 2 1 U3000 U4000 Mounting and connection details U3000 U4000 User Manual Issue 2 0 2 Installation Baa gop a 2 2 3 Connecting the instrument All cables enter the instrument through the 4 cable glands provided and are connected to terminal blocks which are located behind a safety cover The terminal blocks use a spring loaded securing mechanism which is opened by lifting the orange tab situated on the top of the terminal connection Control amp monitoring cables Depending on the fitted options any of the following control and monitoring
53. mple applies to Windows XP Select Control Panel gt System to open the SYSTEM PROPERTIES window Click the Device Manager button to open the DEVICE MANAGER window Scroll down to the Ports region and you will find the new FDTI port installed e g USB Serial Port with a high port number Right click on the com port and select Properties From the PROPERTIES window select the Port Settings tab then click the Advanced button The ADVANCED SETTINGS window should open similar to that shown below Advanced Settings for COM8 COM Port Number USB Transfer Sizes Select lower settings to correct performance problems at low baud rates Select higher settings for faster performance Receive Bytes w Transmit Bytes BM Options Miscellaneous Options Select lower settings to correct response problems Serial E Latency Timer msec HIS Cancel If Power Off Event On Surprise Removal Minimum Read Timeout msec Set RTS On Close Minimum Write Timeout msec Disable Modem Ctrl At Startup Figure 2 12 Com Port configuration Inthe BM Options area change the Latency Timer value from 16 msec default to 1 msec Select OK to implement the change and then close the remaining windows that were opened Your computer should now be able to communicate with the U4000 instrument via the USB port in the same way as any other standard USB device 14 U3000 U4000 User Manual Issue 2 0 3 Operatin
54. ng cursor should appear under the Change Language first date number Enter the date sequence in dd mm yy order then press ENTER 4 Repeat this action to set the time 5 Select Exit then press ENTER to return to the MAIN MENU Note If you make a mistake when entering the data press the Delete key to move the cursor back to the number you wish to change then continue If you enter an invalid number an ERR Invalid Date or Time error message is displayed on the second line of the screen If this occurs repeat the set date time procedure 16 U3000 U4000 User Manual Issue 2 0 Rd Bam gop a 3 1 2 Enabling disabling the backlight The backlight can be selected to be either Disabled illuminated for 10 seconds 30 seconds or 1 minute every time a key is pressed or ON permanently To change the backlight operation 1 SelectSetup Instrument fromthe MAIN MENU and press ENTER 2 Select Backlight from the SETUP INSTRUMENT screen then press ENTER 3 Select the required backlight operation from the BACKLIGHT menu then press ENTER to return to the SETUP INSTRUMENT screen 4 Select Exit and press ENTER to return to the MAIN MENU 3 Operating Procedures SETUP INSTRUMENT Set Date amp Time Calibrate 4 20mA Pulse output Backlight Factory settings Change Language BACKLIGHT Disabled 10 seconds 30 seconds 1 minute ON Permanently DD MM YY HH MM SS dd mm yy hh mm ss
55. nstream cable to one of the transducers and lower the transducer and cable through the rectangular opening as shown in Figure 2 8 5 Align the slots in the side of the nylon flag with the edges on the top of the guide rail then carefully slide the transducer assembly to the middle of the guide rail 6 Tighten the thumb screw clockwise until the transducer is locked to the top of the guide rail to avoid the acoustic couplant from touching the pipe Figure 2 7 Figure 2 8 12 U3000 U4000 User Manual Issue 2 0 oa 2 Installation Relege ek 7 Connect the upstream signal cable red to the other transducer and lower the transducer assembly through the rectangular opening as shown in Figure 2 10 8 Position the upstream transducer at 0 on the ruler scale and lower the transducer onto the pipe by turning the thumb screw anti clockwise as shown in Figure 2 11 9 See Note below Align the face of the right hand downstream transducer at the calculated separation distance mark on the ruler scale then lower the transducer onto the pipe by turning the thumb screw anti Figure 2 9 clockwise until firm contact with the pipe is made Note The correct separation distance for the particular application can be found using the Quickstart menu as described in Paragraph 3 2 10 Finally lock the thumb screws in position by fitting the two M5 locknuts supplied 11 Ensure the tran
56. nterface is operational select Printer test fromthe SETUP RS232 USB menu If the RS232 interface is working correctly the following message will be printed Micronics Ltd lt unit serial number gt If nothing is printed check that the RS232 parameter settings are correct for the printer and that the U4000 TxD and RxD signals are compatible with the printer s RS232 interface A gender changer may be required to swap the TxD and RxD signals Printing logged data 1 Select View Logged Data from the MAIN MENU This will display the VIEW LOGGED VIEW LOGGED DATA DD MM YY HH MM SS Dim mm DATA eel oer shown Choose from list of sites 2 Select Choose from list of sites View log as text and select the site name for the log you View log as graph want to print Graph Y axis max Download log 3 When you are ready to begin printing the Clear log log select Download log 4 Fromthe DOWNLOAD LOG screen select RS232 This will open the SETUP RS232 DOWNLOAD LOG DD MM YY HH MM SS Dim mm USB screen shown below Select Serial port or printer amp press 4 USB RS232 Bluetooth Printer Exit 5 Select Send from the SETUP RS232 USB screen The printer should now start SETUP RS232 USB DD MM YY HH MM SS printing 6 The message screen will be displayed Send while printing takes place see next page Exit U3000 U4000 User Manual 37 Issue 2 0 4 Data Logging amp Communications U4000 7 Printing will continue
57. o return to the FLOW READING screen The logged data will remain stored in the instrument s memory and can be viewed at any time as described above Remaining time Memory Rollover Graph Y axis max Log Totals View log as text View log as graph STOP NOW Set Auto start Clear log Exit MM DD HH MM SS mm dd hh mm ss Overwrite 50 Total 34 U3000 U4000 User Manua Issue 2 0 4 Data Logging amp Communications U4000 micronics 4 3 HowTo Log Directly To A PC Instead of logging to the instrument s internal memory real time data logging to a PC can be REAL TIME LOGGER DD MM YY HH MM SS Dim mm accomplished as follows Unit l min 1 With the U4000 instrument operating in Log name Quickstart FLOW READING mode press the Logger Log data to RS232 function key to access the REAL TIME Logging interval 10 seconds LOGGER screen Start date amp time dd mm yy hh mm ss Stop date amp time dd mm yy hh mm ss 2 SelectLog data to and press ENTER MM DD HH MM SS 3 Select RS232 and press ENTER Remaining time gt nid KA mm ss 4 If necessary change the Logging interval Memory Rollover Overwrite Graph Y axis max 5 Select START NOW and press ENTER Real Log Totals time data logging to the PC will now View log as text commence at the specified logging interval View log as graph STOP NOW 6 To STOP logging to the PC select STOP Set Auto start NOW from the REAL TIME LOGGER menu Clear log
58. offset you must either read the flow via P Quick Start or switch the instrument OFF amp ON Any value that you trim out using the offset adjustment will be added subtracted from the flow reading across the whole range U3000 U4000 User Manual 21 Issue 2 0 3 Operating Procedures 3 3 3 Adjusting the calibration factor P Key Point USE THIS FACILITY WITH CARE amp ONLY WHERE NECESSARY The instrument is fully calibrated before leaving the factory and under normal cir cumstances does not require further calibration when used on site This facility can be used to correct the flow indication where unavoidable errors occur due to the lack of a straight pipe or where the sensors are forced to be fitted close to the pipe end valve junction etc Any adjustment must be made using a reference flowmeter fitted in the system With the system running 1 Stop Stall the totaliser facility and zero it Paragraph 3 5 2 Run the totaliser to measure the total flow over a 30 60 minute period and note the total flow indicated by the reference flow meter over the same period 3 Calculate the error between the U3000 U4000 instrument and reference meters If the error is greater than 1 calibrate the U3000 U4000 as detailed below 4 Press the Options key to access the FLOW READING OPTION screen shown FLOW READING OPTION DD MM YY HH MM SS 5 Scroll down and select Calibration Data review factor then press ENTER Zero Cutoff
59. oth sets of transducers use a common mounting system for pipe attachment Throughout this manual any reference to U3000 U4000 applies to both U3000A B and U4000A B model variants unless otherwise stated Note Type A and B probe sets are fully interchangeable and the alternative probe kit can be purchased separately if required to extend the usable range of the instrument 1 2 Principles of Operation Upstream Separation transducer Distance Reflex mode This is the mode most commonly used The two transducers U amp D are attached VMI OOO LEO to the pipe in line with each other and the D 4 signals passing between them are reflected Fi luid flow E N J by the opposite pipe wall Su rm The separation distance is calculated by Uilisiisisisiisisisishssisissitisissitisiishtitist tittisitistisitis tisitistttitishssitishititishitiishttitta the instrument in response to entered data VILLETTE MLL LLL LLL LLL concerning the pipe and fluid characteristics Separation Distanc Reflex mode double bounce 7 In this mode the separation distance is calculated to give a double bounce This is Fluid flow N 7 most likely to occur if the pipe diameter is gt NU No so small that the calculated reflex mode Y A separation distance would be impractical for the transducers in use Separation Distance Reflex mode triple bounce This illustration goes one step further to show Fl
60. output adjust the Scroll keys to obtain an output of exactly 20 00mA The DAC should indicate approximately 40000 6 Press ENTER when done DAC Value 40000 CALIBRATE 20mA DD MM YY HH MM SS Dim mm Adjust the output current to 20mA Use AV to set 5 6 to trim Press when done 4 20mA Signal scaling Note The 4 20mA can be set to represent a particular flow range It is also possible to enter a negative figure for the minimum output and this would enable a reverse flow to be monitored 7 With the instrument operating in the FLOW READING mode press the 4 20mA function vie pe peed a MERREN HH MM SS key This will he 4 20mA OUTPUT SEH 15 im mm EL is will access the OmA OUTPU mA dutou Reading ae Output Range 4 20 8 Select Flow at max output and press Units l min ENTER then enter a value of the flow Flow at max output 0 00 Flow at min output 0 00 rate that you want to associate with a Output mA for error 22 00 20 00mA output 9 Select Flow at min output and press ENTER then enter a value of the flow rate that you want to associate with a 4 00mA output This could be 0 10 Select Output mA for error and enter a value max of about 26mA that you want the 4 20mA output to produce in the event of an error e g if the flow rate is outside the set range 11 Upon completion press ENTER to return to the FLOW READING screen How to convert the measured current to flow rate Assume
61. pty pipe aerated liquid particulate content too high or when the condition of the pipe being measured is poor Flow signal is poor Interpretation This warning appears when the signal is lower than 25 Response This could be due to an application problem a poor quality pipe see also the conditions for No flow signal above Check for sufficient couplant ERR Zero cut off Interpretation You have entered an out of range value inthe Zero cutoff field in the Options menu Response Enter a valid number Totaliser beyond maximum Interpretation The totaliser has overflowed its maximum count The counter will roll over and restart from zero but this message alerts you to the fact Response Reset the totaliser as described in Paragraph 3 5 PULSE ERRORS Pulse Rate gt Max Interpretation The flow rate exceeds the capability of the pulse output i e too many pulses per second are required than can be achieved Response Narrow the pulse width time or increase the volume per pulse as described in Paragraph 3 4 2 ERR Pulse volume Interpretation You have entered an out of range value inthe Pulse volume error field inthe PULSE OUTPUT menu see Paragraph 3 4 2 Response Enter a valid number ERR Pulse width Interpretation You have entered an out of range value inthe Pulse width error field in the PULSE OUTPUT menu see Paragraph 3 4 2 Response Enter a valid number U3000 U400
62. re also identical to the standard A ST and B ST transducers 7 1 2 Large pipe diameter transducers Type D transducers are available for use with pipe diameters in the range 1500mm to 5000mm operating over the temperature range 20 C to 80 C The type D transducer kit is supplied in a separate case and includes the sensors together with ratchet straps and guide rails for attaching to the pipe 7 1 3 Guide rail options The standard method of securing the guide rail to the pipe is by stainless steel banding However optional end plates are available to allow fixing by chain 7 1 4 Extended signal cable options Normally the U3000 U4000 is supplied with 3m signal cable lengths However 1m and 5m lengths are available as options If required custom signal cables with lengths up to 100m can also be supplied Consult Micronics Ltd for further information and availability 7 1 5 High temperature interface cable Where the pipe temperature exceeds 80 C a pair of 0 5m RG174 high temperature interface cables are available to protect the standard transducer signal coaxial cables The high temperature interface cables have a maximum temperature rating of 200 C 7 2 U4000 Options Only 7 2 1 Heat meter This factory fitted option allows the U4000 to calculate the heat energy between an inlet and outlet pipe at different temperatures for a given flow rate When this option is specified two Pt100 thermocouples are supplied with the ins
63. re held securely USB Connection U4000 only USB Connector Figure 2 2 U4000 USB Connection A Mini USB connector is available at the left hand side of the enclosure to which the USB cable provided can be attached as shown in Figure 2 2 The free end of the USB cable can be plugged directly into any PC USB port U3000 U4000 User Manual 9 Issue 2 0 2 Installation 2 micronics Power connections LETHAL VOLTAGES Ensure the power cable is isolated from the mains supply Do not apply mains voltage with the terminal cover removed WARNING The instrument can be powered from a mains supply 86 264V a c 47 63Hz or from a 24V a c d c supply if it is fitted with a 24V supply module 1 Route the power cable through one of the two cable glands on the right hand side of the instrument below the power connection terminals using the gland most suitable for the cable diameter 2 Cut the wires to length strip back the insulation by approximately 10mm and connected to them into the correct power supply terminals identified in Figure 2 1 On completion tighten the cable glands to ensure the cables are held securely Refit the terminal block cover 2 3 Installing The Ultrasonic Transducers 2 3 1 Transducer positioning In many applications an even flow velocity profile over The U3000 U4000 equipment expects a uniform flow profile a full 360 is unattainable due for example to the as a distor
64. sducer signal cables are correctly connected to the U3000 U4000 instrument i e with the RED cable is connected to the upstream transducer connector and the BLUE cable to the downstream transducer connector Calculated 0 on ruler scale Figure 2 10 Figure 2 11 U3000 U4000 User Manual 13 Issue 2 0 2 Installation 2 4 Installing the USB Virtual Com Port U4000 only The USB connection requires a virtual com port to be installed on the computer The necessary driver can be provided by Micronics or downloaded from http www ftdichip com Drivers VCP htm de 11 12 13 14 15 Access the above url and download the driver for your particular operating system The download takes the form of a zip file Extract all the files from the zip file into a folder and note its location e g Desktop USBDriver Switch ON the U4000 instrument and connect it to the USB port on the PC A New device found message will appear and ask you for the location of the software installation files for the new device Use the Browse button to select the path to the unzipped driver files and then click OK Follow the on screen instructions to install the driver At the end of the driver installation routine you must carry out a minor configuration change to the newly installed virtual com port The way in which you gain access to the com port set up window will vary depending on your operating system The following exa
65. sor or Mode Interpretation The selected temperature is higher than the maximum allowed for the sensor type Response Select alternative sensors or change the temperature Mode Err Type Interpretation The selected sensors are invalid and the mode cannot be verified Response Select a valid sensor type and choose a mode that gives a non zero separation distance U3000 U4000 User Manual Issue 2 0 47 6 Troubleshooting AMERS pe 6 4 Diagnostics Display This feature is designed for advanced users and is intended to provide information that will aid the user to diagnose problems e g no signal strength When operating in the FLOW READING mode you can access a diagnostics screen by pressing the Options function key and then selecting Diagnostics fromthe FLOW READING OPTIONS screen This will display the operating values for the following parameters Calculated time us This is a value the instrument predicts will be the time in secs that it should take for the acoustic wave to propagate across a particular pipe size This value is ascertained from the data entered by the user i e Pipe size material sensor set etc Actual time us This is the value the instrument measures as the time taken for the acoustic wave to propagate across the pipe It is used to see if the signal is being taken from the burst at the correct time to get the strongest signal This value is normally a few us below the calcul
66. splayed as shown below Damping secs 10 This screen shows two parameters Mode Totaliser Run and Limit that can be individually set for Reset Total Alarm 1 and Alarm 2 Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit Alarm configuration 1 To setup Alarm 1 select Alarm1 Mode and press ENTER This will access the ALARM1 ALARM SETTINGS DD MM YY HH MM SS MODE menu screen shown below Alarm1 Mode Alarmi Level lt value gt Alarm2 Mode Alarm2 Level lt value gt Exit Alarmi ON Alarm2 ON 2 Scroll down the menu to the required alarm operating mode and press ENTER to select ALARM1 DD MM YY HH MM SS Off Low High Volume On Flow Error Alarm Test Frequency U3000 U4000 User Manual 27 Issue 2 0 3 Operating Procedures 3 This will return you to the ALARM SETTINGS menu ALARM SETTINGS DD MM YY HH MM SS 4 If the selected mode is Low High or Alarmi Mode Volume select Alarmi Level enter an Alarmi Level lt value gt appropriate value and press ENTER to set Alarm2 Mode the alarm operating point see below Alarm2 Level lt value gt Exit Alarmi ON Alarm2 ON High or Low limit values If High or Low limits are selected the value entered in the ALARM SETTINGS menu must be in the range 9999 to 9999 This value is in the units previously selected e g l min gal s Th
67. ss the Options key to access the FLOW READING OPTION screen shown FLOW READING OPTION DD MM YY HH MM SS 2 Ifthe Totaliser is indicating Run select it and change it to Stall Press ENTER Select Reset Total and press ENTER Data review Zero Cutoff m s Set zero flow m s Damping secs Totaliser Reset Total 0 010 Press ENTER on the subsequent screen to accept the reset 5 Press ENTER again to return to the FLOW READING OPTIONS menu Select Reset Total and press ENTER FLOW READING OPTION DD MM YY HH MM SS Press ENTER on the subsequent screen to accept the reset 8 Press ENTER again to return to the FLOW READING OPTIONS menu Zero Cutoff m s Set zero flow m s Damping secs 10 Totaliser Run Reset Total Reset Total 0 00 0 00 9 Note and record the current time 10 Select Totaliser and change it to Run Press ENTER Note the totalisers begin to count up as soon as Totaliser is set to Run U3000 U4000 User Manual 29 Issue 2 0 3 Operating Procedures 2 micronics 11 Scroll down and select Exit to return to the FLOW READING screen which will now FLOW READING DD MM YY HH MM SS indi Dim mm indicate the instantaneous flow together Sign with the totalised flow Mr l min Note that in some installations the measured flow can be in either direction Total 300 0 litres Where this is the case the upstream flow is Total 0 00 litres s
68. sword protected 3 1 1 Using the instrument for the first time Initial user language selection The first time you power up the instrument you will be asked to select a user language The selected language will then be the default when the instrument is next used If you want to change the language when the instrument is in use see below 1 On initial power up the start up screen will be displayed for 5 seconds showing the instrument s serial number and software vadoo revision 2 After 5 seconds the available language list mcr ONICS will be displayed Serial V 00 00 00 00 00 00 00 0000 3 Select the required language and press 37 Press el to da ENTER 4 The instrument will display the MAIN MENU The MAIN MENU screen The MAIN MENU screen is at the top of the menu hierarchy and is the starting point for all MAIN MENU DD MM YY HH MM SS the operations described in this chapter Under Quick start normal operating conditions this screen is View Edit Site Data accessed from the FLOW READING screen by Data Logger pressing the ENTER key Setup RS232 USB Setup Instrument Read flow Setting the date amp time 1 Select Setup Instrument fromthe MAIN MENU and press ENTER The SETUP SETUP INSTRUMENT DD MM YY HH MM SS oe selec NOUO now Pe Set Date amp Time dd mm yy hh mm ss Calibrate 4 20mA 2 SelectSet Date amp Time and press Pulse output Off ENTER Backlight ON Permanently Factory settings 3 A flashi
69. t Range and press ENTER 4 SelectOff to turn OFF the 4 20mA Output or select one of the output ranges to turn it 4 20 mA OUTPUT DD MM YY HH MM SS ON Dim mm Off 5 Press ENTER to return to the 4 20mA 4 20mA OUTPUT screen 0 20mA 0 16mA 4 20mA Signal calibration and ranging require further adjustment In the rare event that re calibration is necessary this AP Key Point The 4 20mA output has been calibrated in the factory and should not procedure should be carried out only by a trained engineer This procedure describes how to calibrate the 4 20mA output and scale it to operate over a defined flow rate range Signal calibration 1 Select Setup Instrument fromthe MAIN MENU then press ENTER to access the SETUP INSTRUMENT pen ec 1m SETUP INSTRUMENT Screen Set Date amp Time dd mm yy hh mm ss 2 SelectCalibrate 4 20mA and press Calibrate 4 20mA ENTER Pulse output Backlight Disabled Factory settings Change Language 24 U3000 U4000 User Manual Issue 2 0 ae 3 Operating Procedures micronics 3 Connect a calibrated ammeter to the 4 20mA output and adjust the UP DOWN CALIBRATE 4mA DD MM YY HH MM SS Dim mm Scroll keys Coarse and LEFT RIGHT Scroll keys 5 amp 6 fine until the output is aa e e a pu res sn k AA exactly 4 00mA f The DAC should indicate approximately DAC Value 3000 8000 4 Press ENTER when done Press when done With the meter still connected to the 4 20mA
70. ted flow will produce unpredictable measurement presence of air turbulence at the top of the flow and errors Flow profile distortions can result from upstream possibly sludge in the bottom of the pipe Experience disturbances such as bends tees valves pumps and other has shown that the most consistently accurate results similar obstructions To ensure a uniform profile the are achieved when the transducer guide rails are transducers must be mounted far enough away from any mounted at 45 with respect to the top of the pipe cause of distortion such that it no longer has an effect Air Uniform Flow Profile Possible sludge Flow Flow Figure 2 3 Locating the transducers To obtain the most accurate results the condition of both the liquid and the pipe wall must be suitable to allow the ultrasound transmission along its predetermined path It is important also that the liquid flows uniformly within the length of pipe being monitored and that the flow profile is not distorted by any upstream or downstream obstructions This is best achieved by ensuring there is a straight length of pipe upstream of the transducers of at least 20 times the pipe diameter and 10 times the pipe diameter on the downstream side as 10 U3000 U4000 User Manual Issue 2 0 2 Installation shown in Figure 2 3 Flow measurements can be made on shorter lengths of straig
71. them Interpretation This occurs when all the data logger memory locations are filled The effect on the logging process will depend on the setting of the Memory rollover field in the REAL TIME LOGGER screen which may be set to Stop or Overwrite Response Clear the logger memory as described in Paragraph 4 2 46 U3000 U4000 User Manual Issue 2 0 Rd Baa ge pe SET UP ERRORS 6 Troubleshooting ERR Pipe OD range Interpretation You have entered an out of range value for the pipe outside diameter dimension i e larger or smaller than the unit or sensor can be used on Response Enter a valid number ERR Wall thk range Interpretation You have entered an out of range value for the pipe wall thickness dimension accepted range is 1mm 75mm Response Enter a valid number ERR Lining thick range Interpretation You have entered an out of range value for the lining thickness dimension acceptable range is Omm 25mm Response Enter a valid number ERR Temperature range ERR Invalid Date or Time Interpretation You have entered an out of range value for the fluid Temperature Accepted temperature range 20 C to 300 C Response Enter a valid number Interpretation The entered Date or Time is invalid or when setting up timed data logging the Stop time is set earlier than the Start time Response Enter a valid Date and Time ERR Invalid Sen
72. to go to the top line of logged DD MM YY hh mm ee AA Lim data or key 6 to go to the bottom line DD MM YY hh mm XXX Xx l m 2 Press the ENTER key to return to the REAL DD MM YY hh mm xxx xx l m TIME LOGGER screen Then select Exit DD AR NES XXX XX to return to the FLOW READING screen Logging will continue to take place in the DD MM YY background Key Point There can be only one set of logged data per site If a new data log is started on a site it will clear the existing data Monitoring the logged events as a graphic 1 If you want to view the logging progress graphically rather than as text press the REAL TIME LOGGER DD MM YY HH MM SS Logger function key to get to the REAL o to Memory ET Dim mm TIME LOGGER screen Log name Quickstart 2 SelectGraph Y axis max and enter a Log data to Memory value slightly greater than the expected Logging interval 10 seconds maximum flow Start date amp time dd mm yy hh mm ss Stop date amp time dd mm yy hh mm ss 3 Select View log as graph This will open the VIEW LOG AS GRAPH screen MM DD HH MM SS shown below Remaining time mm dd hh mm ss Memory Rollover Overwrite 4 You can select the data at any point in time Graph Y axis max by scrolling along the time axis of the graph Log Totals using the LEFT RIGHT scroll keys 5 amp 6 View log as text The data values for the selected point are View log as graph then shown to the left of the graph Keep START NOW the scroll key
73. trument Contact Micronics Ltd Sales for further information and availability 7 2 2 MODBUS The U4000 MODBUS RTU option is fully compliant to the MODBUS specifications As standard they have an RS485 or RS232 port Contact Micronics Ltd Sales for further information and availability Note Other options are continually being developed for the U4000 Contact Micronics Ltd Sales for further information and availability U3000 U4000 User Manual 49 Issue 2 0 7 Options a 2 ANE se Ale 50 U3000 U4000 User Manual Issue 2 0 Appendix A Specification DSP Measurement Technique Transit time Timing Resolution 50 pico second continuous signal level indication on display Flow Velocity Range Minimum Velocity 0 1m s Max Velocity 20m s Bi directional Turn Down Ratio 200 1 Accuracy 0 5 to 3 of flow reading for flow rate gt 0 2m s and Pipe OD gt 75mm 3 of flow reading for flow rate gt 0 2m s and Pipe OD in range 13mm 75mm 6 of flow reading for flow rate lt 0 2m s Repeatability 0 5 of measured value or 0 02m s whichever is the greater Reynolds Number Correction Flow velocity corrected for Reynolds number over entire velocity range Response Time lt 500ms depending on pipe diameter Selectable Flow Units VELOCITY m sec ft sec VOLUME l s I min I h gal s gal min gal h USgals s USgals min USgals h Barrel h Barrel day m s m min
74. uid flow 7 a triple bounce situation This would normally gt yf Nf Ny apply when working with very small pipes d f CTI IA l elative to the transducer range in use Separation Distance Diagonal mode This mode might be selected by the instrument where relatively large pipes are concerned In this mode the transducers are located on opposite sides of the pipe but the separation distance is still critical in order Fluid flow for the signals to be received correctly a Q This mode might be used with the standard A amp B transducer sets but for really large N pipe installation the optional transducer set D Sd might be recommended Figure 1 1 Operating modes When ultrasound is transmitted through a liquid the speed at which the sound travels through the liquid is accelerated slightly if it is transmitted in the same direction as the liquid flow and decelerated slightly if 2 U3000 U4000 User Manual Issue 2 0 1 General Description transmitted against it The difference in time taken by the sound to travel the same distance but in opposite directions is therefore directly proportional to the flow velocity of the liquid The U3000 U4000 system employs two ultrasonic transducers attached to the pipe carrying the liquid and compares the time taken to transmit an ultrasound signal in each direction If the sound characteristics of the fluid are known the instrument s microprocessor can use the
75. uld indicate a value which must be used by the Imp value on the Calec This is a non editable value 12 Select Exit and press ENTER to return to the FLOW READING screen The message Frequency Pulse is ON should now be displayed on the status line of the display line 2 ALARM SETTINGS DD MM YY HH MM SS Alarmi Alarml Alarm2 Alarm2 Exit Mode Level Mode Level Off OFF ALARM1 MODE DD MM YY HH MM SS Off Low High Volume On Flow Error Alarm Test Frequency ALARM SETTINGS DD MM YY HH MM SS Alarmi Mode Alarmi Level Alarm2 Mode Alarm2 Level Exit Frequency Off FLOW READING OPTION DD MM YY HH MM SS Data review Zero Cutoff m s Set zero flow m s Damping secs Totaliser Reset Total 0 010 Reset Total Calibration factor Roughness factor Alarm Settings Max Pulse Freq Hz Flow at Max Frequency Calculated Pulse Value Diagnostics Exit U3000 U4000 User Manua 39 4 Data Logging amp Communications U4000 micronics Note ALARM 2 can be used instead of ALARM 1 The procedure is identical except that Alarm 2 Mode is selected and the frequency pulse output is connected to ALARM2 and ALARM2 4 8 4 Configuring the Calec ST Energy Totaliser Two parameters need to be entered to allow operation with the U3000 U4000 These are Maximum Input Frequency The Maximum Input Frequency should be the same as that set in the U3000 U4000 i e 10Hz or 200Hz Vo
76. ure transducer sets A HT and B HT 20 C to 200 C Transducer set D used for monitoring pipes of 1500mm to 5000mm diameter over a temperature range 20 C to 80 C This kit is supplied in a separate case and includes the sensors together with ratchet straps and guide rails for attaching to the pipe U4000 Optional equipment Heat Meter This option allows the U4000 to calculate the heat energy between an inlet and outlet pipe at different temperatures for a given flow rate It comprises a plug in board that performs the energy calculation This option requires two sets of Pt100 4 wire temperature probes Process Control Busses The first of these to be offered will be the MODBUS protocol using EIA RS 232 or EIA RS 485 physical layer 1 4 U3000 U4000 Instrument The U3000 U4000 is a microprocessor controlled instrument operated through a menu system using an inbuilt LCD display and keypad It can be used to display the instantaneous fluid flow rate or velocity together with totalised volumes The instrument can also provide an isolated current output or variable pulse output proportional to the measured flow rate which can be scaled to suit a particular flow range Finally two isolated alarm outputs are provided which can be configured in a number of ways For example to operate when the flow rate exceeds a specified maximum or minimum limit In addition the U4000 can function as a data logger When operating in

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