Micronics Ultraflo 2000 Operating Manual

ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

ULTRAFLO 2000 FLOW

& HEATMETER

Operating Manual

Micronics Limited, Unit B3 Knaves Beech Business Centre, Davies Way, High Wycombe, Bucks HP10 9QR UK.

Tel: [phone] Fax: [phone] e-mail [e-mail] www.micronicsltd.co.uk

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

CONTENTS

SYSTEM IDENTIFICATION

E1:High Flow 16

INTRODUCTION

E3:Hot Fault 16

HARDWARE

Electronics Housing 4
Transducers 4
Transducer Connections 4 W1:Check Data 16
Transducer Hardware 5 W2:Timing Poor 16
Transducer Mounting 5 W3:Signals Poor 16
Transducer Cables 6 W4:Ma (1) OVER 16
Keypad 6 W5:Ma (2) OVER 16
W6:Pulse At Max 17

MAIN MENU

Power up 7
Quick Start 8 Application Notes 17
View/Edit Site Data 10 Select a Metering Position 17
Set-up Sensors 11 Mounting The Transducers 18
Calibrate 4-20mA 12 Liquid Conditions 19
Read Flow 12 Propagation Velocity 19
Maximum Flow 19

FUNCTIONS

Display 13 Flow Range 19
Set-up 4-20mA 13
Pulses/Set Point 14
CutOff M/S 15
Set Zero Flow 15
Reset Total Flow 15
Reset Total Energy 15
Damping 15
Cal Factor 16
Diagnostics 16
Save And Exit 16

WARNING - users should ensure or note that:
a) The Ultraflo 2000 is not certified for use in hazardous areas.
b) The local site safety regulations are complied with.
c) Work is carried out in accordance with The Health & Safety at Work Act 1974.

3
4 E2:No Flow Sig 16

E4:Cold Fault 16

Application Temperature 19

ERROR MESSAGES

WARNING MESSAGES

APPLICATION INFORMATION

SPECIFICATION
HEATMETER INSTRUCTIONS
CE MARKING Guidance Notes
WARRANTY

20
21
22
22

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

F

F

FIGURE 1 - SYSTEM IDENTIFICATION

UP

4-20mA(1)

OUTPUT

4-20mA(2)

OUTPUT

PT100 TEMPERATURE
SENSORS
(if supplied)

The following information is requi red by Micronics when
placing an order.

EXAMPLE

POWER VOLTAGE................................ 24v DC

PIPE OD............................................... 60

PIPE MATERIAL ................................... STEEL

APPLICATION TEMP............................ 60°C

LIQUID ................................................ WATER

TRANSDUCER CABLE LENGTH......... 50 METRES

MAX FLOW IN UNITS........................... 150L/MIN

MAX ENERGY RATE

(HEATMETER ONLY) .......................1000KW

TEMPERATURE DIFFERENTIAL

(HEATMETER ONLY)........................... 25°C

TEMPERATURE PROBE CABLE

LENGTH (HEATMETER ONLY)............ 50 METRES

Example Order Code 24-60-S-60-W-50-150L/mi n

FLOW SENSORS ASSEMBLY

FLOW

RETURN

DOWN

ULTRAFLO

MICRONICS

u

24VDC

IN

u

2000

Figure 1

RELAY

OR

PULSE

OUTPUT

110/240V

SUPPLY

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

U

U
S

INTRODUCTION

The Ultraflo 2000 is a “Clamp-on” liquid flow meter
that uses the Transit Time method of
measurement to read flow. Using two PT100
temperature probes to measure temperature it
can also be used as a Heat/Energy meter.

The Ultraflo is able to m eas ure the flow of liquid in
any pipe from 13mm to 5000mm, providing the
pipe is flooded and the correct transducers are
used. Units are supplied according to application
data provided by the customer.

The instrument displays volumetric flow rate in

3

/hr, m3/min, m3/sec, g/min, USg/hr, l/m in, l/sec

m
and linear velocity in metres and feet per second.
The total volume of flow will be displayed, up to a
maximum 12-digit number. When supplied as a
Heatmeter, kW, kCal/hr, MJ/hr, MJ/min and
MJ/sec can be displayed, as well as the
temperature differential.

The flowmeter is supplied with electronics,
sensors and all mounting hardware. The
Heatmeter version will also be supplied with
PT100 temperature probes.

HARDWARE

Electronics Housing
An ABS housing with an opaque door contains the
master PCB. The housing is designed for wall
mounting using the brack ets provided (see Figure
2 for m ounting pattern) . Drilling f urther f ixing holes
in the Housing rem ove the IP67 protection rating
and CE approval.

Mounting the housing into position does not
require the rem oval of the electronics or the front
display panel.

Figure 2

DO NOT PROVIDE POWER to the instrument
until the service compartment cover has been
replaced.

The electronics are factory set for a particular
supply voltage. Should it be necessary to change
the settings for the power supply see page 7,
Power up.

Having completed the procedure f or mounting the
electronics, connecting all cables and checking

the power supply, the power can now be applied.
The Ultraflo 2000 is now ready for program ming.
A full programming procedure is described on
page 7.

Before programming the instrument, it is
necessary to attach the transducers to the pipe
wall such that they can be finally locked in the
correct position based on exact data pr ovided by
the instrument.

TRANSDUCERS

Each instrument uses two identical transducers,
which transmit and receive the ultrasonic waves.
They are clamped to the pipe surface using the
mounting hardware supplied, as described on
pages 5, 6.

The standard transducers are made from a Peek
material with an aluminium plate supporting the
stud, used to lock the sensor in position. A flying
armoured lead is attached between the sensor
block and the tuning circuit.

Figure 3

– 1MHz Sensors with TNC Coaxial

Connector

Transducers are supplied according to the pipe
size and flow velocity, and are available to meet
an operating temperature range from –20°C up to
+200°C.

Transducer Connections

Transducers are c onnected to the electronics from
the tuning circuit by TNC connectors. All other
output and input connections are made through
metal glands to the clearly marked terminals.

1 2 3 4 5 6 7 8 9 10 11 12 13
+ - + - + - + + - +

MA1 MA2 HOT COLD RELAY

Coax sensor connectors

Coax cable

NC COM NO

24V

+

F

220VAC

14 15 16 17 18

110VAC

F

24VDC

S

Only one current output can be used with the flow
meter, but both can be used when the Heatmeter
option is supplied. Connections 5-10 c an only be
used when the PT100 temperature probes are
supplied with the Heatmeter.

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

Transducer Hardware

Transducer alignment guide rails, chains and
couplant are supplied with all units in order to
ensure that the transducers are accur ately aligned
with respect to the pipe axis.

A single guide rail assembly is supplied for
mounting the transduc ers in Reflex m ode and two
guide rails are provided for m ounting in Diagonal
mode.

Figure 4

– 1MHz Reflex Mounting Assembly

Figure 5

- Diagonal Beam Mounting Hardware

Transducer Mounting

The two different methods of mounting the
transducers are shown on pages 5 & 6. When
ordering the Ultraflo 2000 specific application
information should have been given. This
information determ ines the correct har dware to be
supplied with each instrument.

Reflex Mode

Reflex mode is a def ault setting on all applic ations
up to 215mm. Above this the instrument will
default to Diagonal mode. It is possible to change
these default settings if required (s ee page 11 Set
up sensors).

Before attempting to attach the transducers it is
imperative to ensure that the cor rect position has
been chosen to site the trans ducers and that the
pipe surface conditions are suitable. Go to page
17 and carefully follow all instructions for the

selecting and preparing the transducer mounting
site.

At this point program the instr ument to determine
the separation distance. When you have this
information from the instrument follow the set up
procedure below.

Procedure
a) Insert the transducers into the guide rail

so the tails come out of either end.

b) By turning the locking nut centre

clockwise, withdraw the transducers up
into the guide rail.

c) Apply a bead of coupling grease to each

transducer. See page 19, figure 15.

d) Attach both lengths of chain to the quick

links provided and offer the guide rail up
to the pipe wall at 45°.

e) Wrap the chain around the pipe and

connect to the ‘J’ bolt. Complete the same
for both ends of the guide rail then tighten
the locking nuts on the ‘J’ bolt. This will
secure the complete assembly to the pipe.

f) By turning the centre of the locking

assembly anti-clockwise lower one block
onto the pipe. Now adjust the second
block to required separ ation distance and
repeat the procedure. The separation
distance is measured f rom the front edge
of each block and not the centre of the
locking nut.

g) If the instrument now reads a negative

flow swapping the TNC connectors on the
instrument can change this.

h) Now lock the transducers in position by

tightening the nut on locking assembly.

“DO NOT USE EXCESS PRESSURE”.
Note: When m oving the transducers into position
ensure that they are withdrawn into the guide rail
as far as possible. T his ensures that the couplant
will not be removed from the transducer face
before it is screwed down into position.

Figure 6

ZERO

SEPARATION
DISTANCE

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

(D)

All transducers are m ounted in Reflex or Diagonal
mode as described on page 5 and 6. The guide
rail assemblies are held in position using chains.

Diagonal Beam Mode

Diagonal beam mounting means the two
transducer blocks ar e mounted on opposite sides
of the pipe as shown in f igure 7. This is the default
setting for all applications above 215mm.

If you encounter a difficult application or the
maximum flow velocity is outside of the default
operating range, when working in the Reflex
mode, it is poss ible to repr ogr am the instrument to
operate in Diagonal mode (see page 11, Set up
Sensors)

Diagonal Set up Procedure

a) Using whatever means available mark a

reference line around the circumference
of the pipe (reference line D). As shown
in figure 7.

b) Locate and mark two positions exactly

180° apart around this reference line.

c) On both of these positions draw a

reference line (E) perpendicular to line
(D), parallel to the pipe axis and
approximately 1 metre long. See figure 7.

d) Take each of the guide rails and load the

transducers as described previously on
page 5. Only one transducer goes in each
guide rail.

d) Attach the one guide rail to the pipe using

the chain provided, such that it is parallel
to the reference line (E) and position so
that the transducer face can be aligned
with reference line (D).

e) Program the flow meter and obtain the

separation distance.

f) From the intersection of the

circumference reference line (D) and the
second reference line (E) measure and
mark the separation distance XXX. Now
mount the second guide rail such that the
transducer face can be positioned on this
intersection ensuring that the guide rail is
parallel to the reference line (E). See
figure 7.

g) Screw down both of the transducers and

lock in position as previously described.

h) RG223 Coaxial Cable (50ohm), Different

lengths up to 200 metres available on
request.

Figure 7

SEPARATION

DISTANCE ‘xxx’ mm

Ref Line (E)

Chain

Ref Line (E)

Ref Line

HINT: DRAWING A TRUE CIRCUMFERENCE

AROUND A PIPE

An easy way to draw a perpendicular

circumference around a large pipe is to wrap a
length of mater ial such as chart paper around the
pipe, aligning the edges of the paper precisely at
the overlap. With the edge of the chart paper
being parallel, then either edge describes a
circumference around the pipe that is
perpendicular to the pipe axis.

BISECTING THE CIRCUMFERENCE
Mark the chart paper exactly where it overlaps.

Then after rem oving the paper from the pipe, fold
the measured length in half keeping the edges
parallel. The fold line now marks a distance
exactly half way around the pipe. Put the paper
back on the pipe and use the fold line to mark the
opposite side of the pipe.

Transducer Cables

The transducers are c onnected to the electronics

via 50ohm coaxial cables and TNC connectors.
The total length of the cable be up to a m axim um
of 200 mteres.

Keypad

All data is entered for set up and calibration via
the front panel keypad. Figure 9 shows the keypad
layout.

Keys

• To give a NO answer and scroll through listed

options, press SCROLL.

• To select options, store data and m ove on to

the next option, press ENTER.

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ULTRAFLO 2000 INSTALLATION & OPERATING INSTRUCTIONS

• If data has been incorrectly entered, press Y
until the display is clear, then re-enter the data
correctly.

Restart Key

The RESTART k ey can be pressed at any point in
the program and will take the ins trument back to
the opening display. Press SCROLL to enter the
password 2000 and reprogram the instrument. If
the instrument has already been measuring flow
and the SCROLL key is not pressed, it
automatically returns to flow mode.

Scroll Key

When the SCROLL key is pressed in flow mode
the display will read the following.

Signal 80%

0.00 mA

This displays the signal level of the instrument and
the current output status of the 4- 20mA. Both will
be displayed if a Heatmeter is supplied.

Press ENTER again and the following will be
displayed.

ERRORS PENDING

No errors

This will display all Error and W arning messages

(see page 16). To program the Ultraflo 2000,
accurate application data must be k eyed in via the
keypad. Data and instructions are requested via
the display and all questions must be answered
before the program will step through to the point
of measuring flow.

Once the unit has been program med the data c an
be reviewed and changed if necessary.

The instrument displays information in the

following 3 ways.

Flow in selected units.
l/min 0.00

l 0.00

Energy in selected units.
kW 0.00

kWh 0.00

Temperature differential.
H 50°C C 10°C

Diff 40°C

PROGRAMMING/MAIN MENU

Power Up
DO NOT PROVIDE POWER TO THE
INSTRUMENT UNTIL THE SERVICE
COMPARTMENT COVER HAS BEEN
REPLACED.

The power supply is factory set. To change from
110/220VAC to 24VDC the left hand switch needs
to be in the down position. The right hand switch is
only used when changing from 110VAC to
220VAC.

When power is applied to the Ultraflo 2000 it will
react in 2 distinctly differ ent ways depending upon
whether any application data has been
programmed into the EEROM.

All new meters received f rom the fact ory will have
had the EEROM memory wiped clean.

Apply power. Initial display will show
Micronics Ltd

ULTRAFLO 2000

Within 5 seconds the display will change to

DIMENSION

Millimetres

Application data can now be keyed in.

If the instrument has been used then application data
will be stored in the EEROM and the following will be
displayed. If SCROLL is not pressed within 5 seconds
after the initial display, the instrument will go directly to
flow mode.

Apply power. Initial display will show

Micronics Ltd

ULTRAFLO 2000

PRESS SCROLL within 5 seconds of initial start up
Display will then show

ENTER PASSWORD

Key in password 2000 (only required if the unit has
been previously used)

The flow information can be factored to suit the
users requirements by selecting CAL FACTOR
from the FUNCTIONS m enu. The Totalised Flow
data can also be reset to zero.

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