Blue-White Sonic-Pro S4 User Manual

SONIC-PRO

Series S4

ProSeries

TWO-YEAR

WARRANTY

Ultrasonic Flow Meter

Installation and Operating Manual

ProSeries

by Blue-White Ind.

Industries, Ltd.

Page 1

Safety Precautions

Thank you for purchasing the Sonic-Pro series S4 ultrasonic flowmeter.

This instruction manual provides important information regarding the safe installation, operation and maintenance of the flowmeter. Please read it carefully before attempting to install or operate the meter. A copy of this manual should be kept by the operator. Extra copies of this manual are available from your supplier or directly from the manufacturer.

The following important symbols are used throughout this manual and on labeling affixed to the flowmeter:

CAUTION

risk of electric shock

Sonic-Pro

This symbol identifies a risk of electric shock where the possibility of injury or death is present.

CAUTION

risk of danger

CAUTION

risk of danger

QUESTIONS REGARDING THE SAFE USE OF THIS PRODUCT AND OTHER TECHNICAL ASSISTANCE MAY BE DIRECTED TO:

This symbol identifies a risk of injury or death is present.

In all cases, when this symbol is used on labeling affixed to the flowmeter, the documentation needs to be consulted to find out the nature of the potential HAZARD and any actions which have to be taken.

If the equipment is used in a manner not specified by this instruction manual, the protection provided by the equipment may be impaired.

Blue-White Industries

714-893-8529

techsupport @blue-white.com

ProSeries

by Blue-White Ind.

Industries, Ltd.

Sonic-Pro

Page 2

1.0 Product Overview

The Sonic-Pro series S4 Ultrasonic Flow Meter can measure fluid flow in water and many other clean fluids with sound speeds that are similar to water. The meter measures fluid flow using the Transit Time method. The S4 ultrasonic sound transducers do not touch the process fluid and there are no moving parts. This method of flow measurement is safe, nonintrusive and requires little to no maintenance.

The fluid being measured must be relatively “clean” to enable the sound waves to complete their circuit. The maximum amount of particles should not exceed . The 5% (50,000 ppm) meter cannot measure through air. Air bubbles and excessive turbulence will disrupt the sound beam.

The angle of the sound beam, as it travels through a material, is effected by the speed that sound travels through that material. As the sound speed changes, the angle changes. Sound travels through 68 F clean water at a speed of 1,481 meters per sec. The S4 ultrasonic sound transducers are factory positioned for a fluid sound speed of 1,500 m/sec +/- 100. They cannot be adjusted in the field.

Water that contains concentrations of other chemicals, or other chemicals entirely, may be acceptable provided the chemical does not change the sound speed (SOS) more than approximately +/- 100 meters per second and provided the fluid allows the sound beam to pass through unimpeded. Note that the speed that sound travels through the fluid is effected by changes in the fluid’s density.

The S4 includes a 6-button user interface that can be used to configure the meter. The optimum sound speed setpoint can be adjusted by the user within the range of 1,500 m/sec +/- 100 m/sec.

TRANSIT TIME MEASUREMENT PRINCIPLE

During operation in the Transit Time measurement method, a short ultrasonic signal burst passes first in one direction and then in the other between two transducers separated along the length of the pipe. When traveling in the same direction as fluid flow, the burst is carried along by the fluid and arrives earlier as a result. When traveling against fluid flow, the burst is held back by the fluid and arrives later. The SPU ( measures this Signal Processing Unit) difference in time-of-flight in the two directions. From this, the actual time-of-flights, the distance traveled in the fluid and the angle of the ultrasonic signal path, it calculates the fluid velocity.

ProSeries

by Blue-White Ind.

Industries, Ltd.

Page 3

Sonic-Pro

2.0 Flowmeter SPU Installation

2.1 Unpacking

2.2 Mounting Location

risk of danger

The Sonic-Pro Flowmeter is shipped with the following items:

! Sonic-Pro Flowmeter SPU (Signal Processing Unit) ! Sonic-Pro Inline Pipe Fitting ! Enclosure Mounting Hardware (not included in sensor mounted units)

2 mounting plates 4 mounting plate screws (10-32 x .50”) 2 wall mounting screws (#10 x 1.00”) 1 pipe mounting clamp (maximum pipe diameter 10”)

! Instruction Manual

The Sonic-Pro was designed to be installed and operated by qualified personnel only. Do not attempt to install or operate the meter if you are unsure. Seek qualified assistance. Please

note that warranty coverage does not include damage due to misuse or improper installation.

If remote mounting the SPU, select a mounting location that is within reach of the transducer

cables and power supply. The transducer cable must not be cut or modified. Note that the Sonic-Pro can accurately measure flow from either direction.

The SPU can be mounted on a wall or on a horizontal or vertical run of pipe. Although the Sonic-Pro is designed to withstand outdoor conditions. A cool, dry location, where the unit can be easily monitored is recommended. Special ventilation is not required.

CAUTION

Do not position the equipment so that it is difficult to disconnect the power supply cord.

2.3 Wall or Pipe Mounting

When the SPU is not mounted directly to the Inline Fitting, the SPU must be installed on a solid, secure surface such as a solid wall, panel, wall studs, etc. DO NOT install the meter

on drywall with anchor bolts.

8.00 in

[20.3 cm]

The SPU can be mounted on horizontal or vertical pipe. The pipe must be secure and of sufficient strength to support the weight of the SPU.

ProSeries

by Blue-White Ind.

Industries, Ltd.

Sonic-Pro

Page 4

3.0 Ultrasonic Transducer Installation

3.1 Pipe Fitting/ Transducer Installation

Minimum Straight Pipe Length Requirements

The Sonic-Pro’s sound wave beam is only affected by fluid that actually passes through the beam and therefore, the meter will not measure with high accuracy if the fluid velocity is not consistent across the entire pipe diameter. Flow disturbances such as pumps, elbows, tees, and valves in the flow stream can cause swirl patterns and vortices that will affect the measurement accuracy or disrupt flow measurement capability. Install the transducers on a straight run of pipe as far as possible from any disturbances. The distance required for high accuracy will depend on the type of disturbance.

Type of Disturbance

Flange

Reducer

90 Elbow

Two 90 Elbows - 1 Direction

Two 90 Elbows - 2 Directions

Gate valve or Pump

Upstream from Transducers

5 x Nominal Pipe Size

7 x Nominal Pipe Size 5 x Nominal Pipe Size

10 x Nominal Pipe Size 5 x Nominal Pipe Size

15 x Nominal Pipe Size 5 x Nominal Pipe Size

20 x Nominal Pipe Size 5 x Nominal Pipe Size

25 x Nominal Pipe Size 5 x Nominal Pipe Size

Straight Lengths of Pipe Required

Downstream from Transducers

5 x Nominal Pipe Size

Transducer Mounting Requirements

The meter can be mounted on horizontal or vertical runs of pipe.

Mounting anywhere around the diameter of vertical pipe is acceptable, however, the pipe must be completely full of fluid at all times.

Back pressure is required on downward flows to ensure a full pipe.

See the minimum straight length of pipe requirement chart above.

Related piping must be independently supported. The meter should not be allowed to support the weight of related piping.

Pipe must be full

Air could be trapped

Down flows

must have

back pressure

160° F (71° C)

150° F (65° C)

140° F (60° C)

130° F (54° C)

120° F (49° C)

110° F (43° C)

100° F (38° C)

TEMPERATURE F (C)

90° F (32° C)

80° F (27° C)

70° F (21° C)

L >= 5DL >= 10D

See minimum straight length requirements above

INLINE PIPE FITTING

TEMPERATURE VS PRESSURE

HDPE and 316SS Adapters

PVC Adapters

50 100

WORKING PRESSURE (PSI/g)

150

200 250

300

ProSeries

by Blue-White Ind.

Industries, Ltd.

Page 5

Sonic-Pro

4.0 Wiring Installation

4.1 Electrical Connections

4.2 Cable Gland Liquid-Tight Connections

The meter must be powered by 15 to 28 volts DC. Depending on the model ordered, an AC/DC plug-in transformer may have been be supplied for this purpose. See the diagram below for wiring of output signals, communications signals and process control relays.

The transducer cable length is factory fixed. Do not attempt to modify the length of these cables. Various cable lengths are available from the factory. Contact the factory if you need assistance.

Shielded cable is recommended for signal output connections.

The Sonic-Pro SPU wiring compartment is equipped with:

Ÿ Three liquid-tight cable gland connectors for cable diameter from .200 to .394 inches (5.1

to 10.0 mm).

Ÿ Two liquid-tight cable gland connectors cable for diameters from .118 to .255 inches (3.0 to

6.5 mm).

Ÿ One communications cable liquid-tight cable gland grommet for cable diameters from .190

to .205 inches. It is provided for any one of the following cable types:

Ethernet Cable

RS-232 serial cable

Note that the blank grommet plug should be used when the communications cable grommet is not required.

4.3 Wiring Compartment

Back-up Battery Compartment (4 D cells -

not included)

Communications Cable Grommet

Optional Communications Circuitry

Wiring Terminals Main PCB

Transducer A Transducer B

USB Connection

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Communications Circuitry Input Socket

Touchpad Connection

Sonic-Pro

4.4 Wiring Terminals

The terminal blocks are plug type capable of accepting 14 to 30 AWG wire.

FUNCTION TERM PIN # DESCRIPTION

POWER INPUT:

Primary power

Chassis Ground

POWER INPUT:

Battery Back-up power

PULSE FREQUENCY OUTPUT:

Open Collector

PADDLEWHEEL SENSOR INPUT:

AC Sine wave

RELAY ‘A’ OUTPUT

RELAY ‘B’ OUTPUT

Chassis Ground

ANALOG OUTPUT:

4-20 mA

TRANSDUCER INPUT:

Transducer A

TRANSDUCER INPUT:

Transducer B

RATING

(+) 15-28 Vdc

(-) 15-28 Vdc

Ground

(+) Positive

(-) Negative

(+) Positive

(-) Negative

(+) Positive

(-) Negative

Normally Open

Common

Normally Closed

Normally Open

Common

Normally Closed

Ground

(+) Positive

(-) Negative

(+) Red

(-) Black

Green or Bare

(+) Red

(-) Black

Green or Bare

15-28Vdc, 400mA max

4 D cell size batteries (Alkaline batteries only are acceptable)

Type: Open collector w/ internal 1 K pull-up to 5V. Can be pulled up to 30V @ 10mA (3K pull-up)

Duty Cycle: 50%+/-5% Frequency Range: 0-1000 Hz Resolution: 1 Hz Accuracy: 0.5% F.S.

Blue-White model FC sensor. 100mVp-p, 10 to 350Hz

Type: FORM C Load capacity: 30V, 100mA max (ext. supplied)

Current output: 4-20 mADC, isolated. Max Load Impedance: 1K ohm Power: Internal Resolution: 12 bits Accuracy: Less than 0.1% F.S. Update Rate: 1.0 s

Page 6

Analog Out (+)

Chassis

Analog Out (-)

V Bat (+)

V Bat (-)

5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 3 2 13 2 1131211

Battery

T1 T2 T3 T4

WARNING

INPUT POWER LIMITS

DC INPUT

15~28 Vdc-15W

ANYBUS COMMUNICATIONS

DC (-)

DC PWR

POWER INPUTS

DC (+)

4-20 mA

Relay B (n/c)

Relay B (n/o)

Relay B (com)

Relay A (n/c)

Relay A (com)

Chassis

Relay B

USER INTERFACE

CONNECTIONS

Relay A

Relay A (n/o)

Pulse In (-)

Paddle

Pulse Out (-)

Pulse Out (+)

Pulse In (+)

Pulse

RED (+)

GRN

BLK (-)

Transducer A

TRANSDUCER

INPUTS

RED (+)

GRN

BLK (-)

Transducer B

USB

TOUCHPAD

INPUT

ProSeries

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Page 7

Sonic-Pro

5.0 Operation

5.1 Power On

5.1.1 Battery Powered operation

1. If power is present on Terminal T1 pins 1 & 2, the meter is always powered on.

2. If power is removed from Terminal T1 pins 1 & 2, and 4 D-Cell batteries are installed on Terminal T1 pins 4 & 5, the meter will stay on (battery back-up). Under these conditions, the meter can be turned on/off by pressing and holding the front panel ENTER button for three seconds.

3. If power is only present on the battery Terminal T1 pins 4 & 5, then the meter can be turned on/off by pressing and holding the front panel ENTER button for three seconds. Operating time is limited when powered by batteries only.

While the batteries pack is provided primarily as back-up power, the S4 meter can be operated solely with 4 D-cell batteries (not included). The meter can be configured to sleep

between measurements in order to conserve power. The approximate battery life is .....

Continuous Running

The following meter features are disabled during battery operation:

Ÿ Communications Module Ÿ Analog output Ÿ Pulse Frequency Output

10 / 10

128 Hr72 Hr 310 Hr 377 Hr 450 Hr

On / Sleep Time (seconds)

10 / 100 5 / 100 3 / 268

5.2 Run Screen

5.2.1 Fault Screen

When the S4 is factory ordered with a pipe fitting/transducer, the pipe fitting data and the default display feature parameters are pre-configured. When power is applied and there is water in the pipe fitting, the following RUN display screen will be displayed.

Transducer Separation

Distance

Flow Direction

Flow Rate Units

0.28”

U.S Gallons/Min

Total Units

Ÿ Press the ENTER button to enter the menu system. Ÿ Press the ESC button to clear the flow total to zero (if enabled in configuration). Ÿ Press the up arrow p to toggle the flow rate to linear Feet/Sec., Meters/sec and back to

the configured user units of measure.

There are three possible FAULT indicator screens.

Ÿ FAULT 11 - Transducers are not connected or there is no fluid in the pipe. Ÿ FAULT 12 - The allowable SOS (Speed Of Sound) error set-point has been exceeded. Ÿ FAULT 21 - The configuration data is not valid.

U.S Gallons

0.28”

U.S Gallons/Min XDCR Disc.

U.S Gallons

F-11

105

0”

1482

05469

Measurement Reliability

Battery Life

Measured Sound Speed

Flow rate

Flow Total

(press and hold ESC to clear)

Error Code

ProSeries

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Sonic-Pro

5.3 Menu Navigation

Page 8

The Configuration Menu

From the RUN mode, press and release the ENTER button to enter the CONFIGURATION menu. The following menu will be displayed:

5.3.1 Selecting and Entering Menus

5.3.2 Selecting Optional Items

Ÿ Press up arrow p or down arrow q to select menu items.

The selected item will be highlighted.

Ÿ Press right arrow u or ENTER to enter the selected menu.

Ÿ Press left arrow t to go back one menu.

Ÿ Notice the gray area. These menu items are hidden from

view. Press the up arrow p or down arrow q to display hidden menu items.

Ÿ Press up arrow p or down arrow q to select optional

configuration items. The selected item will be highlighted.

Ÿ Press left arrow t or ENTER to choose the selected

optional item and return to the menu heading.

Paddle Wheel

XDCR Settings

Meter Settings

Output Settings

Clock

Calibration

Global Config.

About

U.S. Gallons

Ounces U.S. Barrels Liq.

U.S. Barrels Oil

Cubic Feet

Acre Feet

Imperial Gallons

Cubic Meters

Liters

Milliliters

FR Custom V/Gal

5.3.3 Inputting Data

5.3.4 Save Configuration

Ÿ Press right arrow u or left arrow t to select a digit to

modify. Pressing the left arrow t will create additional numbers to the left.

Ÿ Press up arrow p to increase or down arrow q to

decrease the value.

Ÿ Press ENTER to confirm the modifications and return to

the menu heading.

Ÿ Press ESC to cancel the modifications and return to the

menu heading.

Ÿ Press left arrow t to exit to the main menu.

Ÿ Press down arrow q to Highlight Save Config.

Ÿ Press right arrow u or ENTER to save the configuration

changes.

Ÿ Press ENTER to confirm the configuration changes have

been saved.

Ÿ Press up arrow p to RUN.

Ÿ Press right arrow u or ENTER to enter the RUN mode,

Enter Value

9.1000

Configuration

XDCR Settings

Save Config.

Configuration

XDCR Settings

Save Config.

Configuration

Configuration Saved!

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Page 9

Sonic-Pro

6.0 Configuration

The S4’s SPU can be used with a Paddle Wheel type sensor that outputs an AC Sine wave or an Ultrasonic type sensor.

6.1 Configure the SPU for a Paddle Wheel Sensor

6.2 Configure the SPU for an Ultrasonic Inline Pipe Fitting

Configuration

Paddle Wheel

When using an AC Sine wave Paddle Wheel type flow sensor and pipe fitting, the installer must input the pipe fitting K-factor. The K-Factor is the total number of pulses output by the sensor per gallon of fluid flow for a specific pipe fitting. The K-factor is different for each pipe fitting. See the paddle wheel sensor’s instruction manual for a list of pipe fitting K-factors.

Configuration

Run

Save Config

Paddle Wheel

K-Factor

Enter Value

0.0000

When using Ultrasonic Transducers (XDCR), if the SPU and the Ultrasonic Inline Pipe Fitting was shipped from the factory as a single model number, the SPU is pre-configured

with the proper model number and calibration constants shown on the calibration label attached to the pipe fitting. If the pipe fitting was sold separately, the SPU will need to be configured with the following data shown on the calibration label:

1. Measurement Units. The default value for all inline fittings is ENGLISH.

2. Model. The default value for all inline fittings is “C”.

3. Mount Method. The default value for all inline fittings is “V”.

4. Cable Length. Enter the length in feet. The available cable lengths are: 1 foot (SPU

mounted directly on the pipe fitting), 10, 25, 50 or 100 feet.

5. Flow Direction -> Direction. The default value for all inline fittings is “A -> B”.

6. Flow Direction -> Settings. Each flow direction has a unique SCALING and ZERO

VALUE number shown on the pipe fitting calibration label. Note that the ZERO number may be POSITIVE or NEGATIVE.

7. Pipe Outside Diameter. Shown on the pipe fitting calibration label. Do not use your

inlet/outlet pipe size.

8. Pipe Wall Thickness. Shown on the pipe fitting calibration label. Do not use your

nominal pipe size.

9. Pipe Material. Shown on the pipe fitting calibration label. Do not use your inlet/outlet pipe

material.

10. Fluid Type. Select WATER or CUSTOM.

11. Fluid SOS. If WATER is selected, it is not necessary to input a fluid SOS. If “CUSTOM”

fluid type is selected, the Speed of Sound (SOS) for the custom fluid must be entered manually. Note that the SOS must be within the pipe fitting’s SOS range.

Run

Save Config

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XDCR Settings

Meas. Units

Transducer

Pipe

Fluid Fluid Type

ENGLISH

Mount Method

Cable Length(ft)

Flow Direction

Pipe Outside Dia.

Pipe Wall Thick.

Pipe Material

Pipe SOS

Fluid SOS

METRIC

Model

I J

Enter Value

Direction

Settings

Enter Value

0.0000

Enter Value

0.0000

Enter Value

0.0000

Enter Value

0000

A -> B

B -> A

A -> B B -> A

Custom

HDPE

Custom

Water

Enter Value

0.0000 0.0000

Scaling(A->B)

Zero(A->B)

Scaling(B->A)

Zero(B->A)

Zero Value(B->A)

Sign(B->A)

Positive

Negative

Enter Value

Zero Value(A->B)

Sign(A->B)

Positive

Negative

Enter Value

0.0000

Enter Value

0.0000

+ 22 hidden pages

Blue-White Sonic-Pro S4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual