Xylem FM500 User Manual

Hybrid Ultrasonic Flowmeter

Installation and Operating Manual

Page 2

Table of Contents

Safety precautions.... .................................................4

1 Product overview ..............................................5

1.1 Operating principles . . . . . ...... ....... ....... ....... .......5

1.2 Transit Time operation . . ...................................5

1.3 Doppler operation . . . . . . ....... ....... ....... ..............6

1.4 Fluid requirements . . . . . . ...... ....... ....... ....... .......7

1.5 Pipe requirements. . . . . . ...................................7

1.5 Straight pipe length requirements ............................7

1.7 Standard model features and options. . . . . .....................8

1.8 Wiring compartment. . . . ...................................9

2 Quick Start Guide .... ....... ....... ............................10

3 Flowmeter SPU installation .. ....... ....... .....................16

3.1 Unpacking . . . . . ....... ....... ....... ....... ..............16

3.2 Select a mounting location . . . . . . ............................16

3.3 Wall mounting . . . . .... ....... ............................16

3.4 Panel mounting. . . . .... ....... ....... ....... ....... .......17

3.5 Pipe mounting. . ..................... ....... ....... .......17

3.6 Select a measurement method . . . . . . . . . . ....... ....... .......18

3.7 Electrical connections . . . ....... ....... ....... ....... .......18

3.8 Cable gland liquid tight connections . . . . . . ...... ....... .......19

4 Overview of Flowmeter Operation.... ............................20

4.1 Power on and self test . . . . . . . . . . . . . .........................21

4.2

4.3 Startup state . . . . . . .... ....... ....... ....... ..............22

4.4 Setup (configuration) mode. . . . . . ............................22

4.5 Transducer positioning state . . . . .............. ....... .......23

4.6 Zero calibration state . . . . . . . . . . ....... .....................24

4.7 Run mode . . . . . . . . .... ....... ............................25

4.8 Fault and warning codes ...................................25

5 Setup mode ............................................. .......27

5.1 Menu Navigation. . . . . . . ....... ....... ....... ..............27

5.2 Global configurations . . . . . . . . . . . . . . . . . .....................28

5.3 Manage configuration sets . . . . . . ....... ....... ..............30

5.4 Configuration edit menu. . . . .... ....... ....... ....... .......31

6 Transducer installation ...... ....... ....... ....... ....... .......40

6.1 Transducer piping system location . . . . . . . . . . .... ....... .......40

6.2 Transducer mounting mode for Doppler measurement . . . . . . . . . . . . 40

6.3 Transducer mounting mode for Transit Time measurement. . . . . . . . 40

6.4 Transducer separation distance . . . . . .................. .......41

6.5 Pipe surface preparation. . . . . . . . . . . . . . . .....................42

6.6 Doppler method transducer installation . . . . . . . . . . . . . . . . . . . . . . . 42

6.7 Transit Time transducer installation - V and W mount mode .......43

Description of operating states and controls . . . . . . . . . . . . . . . . ....21

5.1.1 Setup root menu . . . .... ............................27

5.1.2 Escaping from setup . . . . ....... .....................27

5.2.1 Communication settings . . . . . . . . . . . . . . . . . . ...........28

5.2.2 Master password ....... ....... ....... ....... .......29

5.2.3 Setting the date and time ............................29

5.2.4 Saving changes . . . . . . . . . . . ........... ....... .......29

5.3.1 Activate a configuration set . . . . . . . . .... ....... .......30

5.3.2 Open a saved configuration set . . . ...... ....... .......30

5.3.3 Create a new configuration set . . . . . . . . . ....... .......30

5.3.4 Delete a saved configuration set. . . . . . . . . . . . . . . . . . . . . . . 30

5.4.1 Editing data items. . . . . . . . . .........................31

5.4.1.1 . Editing numerical values . . . . . . . . . . . . . . .......31

5.4.1.2 . Entering passwords using the soft buttons .......32

5.4.1.3 . Units of measure ....... ....... ....... .......32

5.4.2 Transducer setup . . . . . . ....... ....... ..............33

5.4.3 Metering setup . . . . . . . . ............................34

5.4.4 Process control setup. . . . . . . . . . . . . . . . . . . . . . . . .

5.5.5 Reset working set to factory values . . . . . . . ...... .......39

5.4.6 Set password (for a single configuration set) . . . . . . .......39

5.4.7 Saving changes . ..................... ....... .......39

5.4.8 Escape without saving . . ....... ....... ....... .......39

.......37

Ultrasonic Flowmeter

6.8 Transit Time transducer installation - Z mount mode ...... .......44

6.9 Transducer acoustic mounting gaskets . . . .....................46

6.10 Transducer pipe mounting clamps ....... ....... ..............47

7 Run mode .................................................48

7.1 Primary and secondary display areas . . . . ....... ....... .......48

7.1.1 Flow rate measurement . . . . .........................49

7.1.2 Total flow measurement ....... ....... ....... .......50

7.2 Measurement status areas . . . . . . ....... ....... ....... .......50

7.2.1 Configuration and mode . ............. ....... .......50

7.2.2 Goodness of measurement . ..... ....... ....... .......50

7.2.3 Sound speed display .... ....... ....... ....... .......51

7.2.4 Measuring the fluid sound speed . ....... ....... .......51

7.3 Process control status areas . . . . . ....... ....... ....... .......52

7.4 Soft buttons . . . . ....... ....... ....... ....... ....... .......52

7.5 Output signals . ....... ....... ....... ....... ..............52

7.5.1 Analog signal output. . . . . . . . . . . .....................52

7.5.2 Digital pulse output . . . . ....... ....... ....... .......53

7.6 Data logging . . . ..........................................53

7.6.1 Periodic logging. ....... ....... ....... ....... .......53

7.6.2 Logging rate setpoints . . . . . . . . . ....... ..............53

7.6.3 Logging totalizer setpoints . . .... ....... ....... .......53

7.6.4 Local log data storage (SD flash memory card) . . . . .......54

7.6.4.1 . Inserting and removing the memory card . .......54

7.6.4.2 . Format of data on the memory card . . . . . . .......54

7.6.4.3 . Rotation and purging of log files. . ....... .......54

7.6.4.4 . Power loss . . . . . . . . .... .....................55

7.6.5 Remote access to log data ....... ....... ....... .......55

8 Process control....... ....... ....... ....... ....... ..............56

8.1 Process controlsScreen . . . . ..... ............................56

8.2 Batch dispensing ....... ....... ....... .....................57

8.2.1 Manual batch start type . ....... ....... ....... .......57

8.2.2 Auto batch start type . . . ....... ....... ....... .......58

8.2.3 Batch clear . . . . . . . .... ....... .....................59

8.2.4 Batch edit . . . . . ...................................59

8.3 Flow rate alarms ....... ....... ....... ....... ....... .......60

8.3.1 Basic operation . ....... ....... ....... ....... .......60

8.3.2 Clearing alarms .............. ....... ....... .......61

8.3.3 Editing alarms . . . ..... ....... ....... ....... .......61

8.3.4 More on clearing alarm conditions ....... ....... .......62

9 Sonic-Pro User PC Software .............................. .......63

9.1 Software installation. . . . ....... ....... ....... ..............63

9.2 Making connections. . . . . ...................................63

9.2.1 Ethernet Connection . . . . ............................63

9.2.2 Serial and USB connections . . . . . . . ..... ....... .......64

9.3 Retrieving log data . . . . . ....... ....... ....... ....... .......64

10 Indexes..................... ....... ....... ....... ....... .......66

10.1 Complete flowmeter model number system ....... ....... .......66

10.2 Additional transducers model number system. . . . . . .............66

10.3 Specifications . . ................................... .......67

10.4 Pipe dimensional data . . ....... ....... ....... ....... .......68

10.5 Sound speed data

10.6 Troubleshooting guide . . . ...... ....... ....... ....... .......71

.........................................70

Page 3

Ultrasonic Flowmeter

Page 4

Safety Precautions

Thank you for purchasing the 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

CAUTION

risk of danger

CAUTION

risk of danger

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

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

In all cases, when this s the documentation needs to be consulted to find out the nature of the

QUESTIONS REGARDING THE SAFE USE OF THIS PRODUCT, THE LINUX OPERATING SYSTEM SOURCE CODE AND OTHER TECHNICAL ASSISTANCE MAY BE DIRECTED TO THE PLACE OF PURCHASE.

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.

ymbol is used on labeling affixed to the flowmeter,

Ultrasonic Flowmeter

LABELING

1.1 Operating Principles

1.2 Transit Time Operation

Page 5

1.0 Product Overview

The Hybrid Ultrasonic Flow Meter can measure fluid flow in virtually any fluid in which sound waves can travel. The meter is considered “hybrid” because it can measure fluid flow using either the Doppler or Transit Time methods. The system includes a set of ultrasonic sound Transducers and a Signal Processing Unit (SPU). The transducers are clamped to the outside of the pipe wall and include no moving parts. The SPU controls and processes the transducer signals into useful flow measurement data. This method of flow measurement is safe, non-intrusive and very easy to service.

The Transit Time measuring method requires relatively “clean” fluid to enable the sound waves to complete their circuit. The meter may be operated in the Transit-Time mode when the fluid contains particles. To allow for changes in the fluid’s particle count, the Sonic-Pro monitors the signal gain and employs an Automatic Gain Control (AGC) algorithm that automatically adjusts the gain to maintain the optimum power level.

The speed at which sound travels in the fluid must be known. The factory will configure the meter for a known fluid during the initial configuration. The model 3 includes a 5button user interface that can be used to configure the meter. Many common fluids are listed in the software and can be selected directly from the menu. Provided the speed of sound in the fluid is known, custom “unknown” fluids can be input manually by the user. A list of various fluids and their sound speeds are provided in the index of this user manual.

0% to 10% (0 to 100,000 ppm) of

TRANSIT TIME MEASUREMENT PRINCIPLE

When operated 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 difference in time-of-flight in the two directions. From this, the

Unit) actual time-of-flights, the distance traveled in the fluid and the angle of the ultrasonic signal path, it calculates the fluid velocity.

As well as the V mounting method shown, the transducers could be on opposite sides of the pipe with no reflections in the path (Z mount).

Signal Processing

Ultrasonic Flowmeter

Page 6

1.3 Doppler Operation

The Doppler measurement method requires that particles be present in the flow stream to “reflect” the sound waves. The particles must be of sufficient size, volume and type to reflect the sound waves. For example; although orange juice may contain pulp that is of sufficient size and volume, the properties of the pulp do not allow the sound waves to reflect. Therefore, the meter will not operate in the Doppler mode with orange juice containing pulp.

The meter may be operated in the Doppler mode when the fluid contains (200 to 150,000 ppm) of sound reflection properties.

particles that are at least 50 micron in size and have sufficient

0.02% to 15%

DOPPLER MEASUREMENT PRINCIPLE

When operated in the signal passes from a transmitting transducer into a pipe carrying a moving fluid. The signal is reflected by particles in the fluid and is picked up by a receiving transducer on the opposite side of the pipe.

When using the Doppler method, the transducers are installed directly opposite each other along the pipe axis, one each side of the pipe, either with or against the flow of fluid. The ultrasonic signal is subject to a Doppler shift when it is reflected from the particles moving at (nominally) the same velocity as the fluid. Therefore, the frequency at the receiving transducer will be slightly different from the transmitted frequency. SPU (

Signal Processing Unit) measures this difference in frequency and calculates the

fluid velocity.

Note that the meter is actually measuring the velocity of the particles and not the actual fluid. For this reason, measurement error will occur if the particles do not move at the same velocity as the fluid, such as when the particles are heavier than the fluid or when the fluid is moving at such a low velocity that the particles drop out of suspension. Large “gulps” of air or particles will temporarily disrupt the flow measurement resulting in error.

Doppler measurement method, a continuous-wave ultrasonic

The

Ultrasonic Flowmeter

Page 7

1.4 Fluid Requirements

1.5 Pipe Requirements

Doppler Operation

Must conduct sound

Must contain sound reflecting particles such

Must conduct sound

Must be relatively clean fluid

Transit Time Operation

as air bubbles, sand, etc.

Transit Time measurement requires relatively Doppler measurement requires 15% (200 to 150,000 ppm)

0.02% to

particles be

present in the flow stream to “reflect” the

“clean” fluid. Fluids containing from

10% (0 to 100,000 ppm) of particles

acceptable. sound waves.

Note: Do not attempt to measure very low flow velocities in the Doppler mode, the particles can fall out of suspension resulting in error or failure.

Pipe Material

Brass (Naval)

Copper

FRP (fiberglass Reinforced Plastic)

Iron (cast)

Iron (ductile)

Nylon

Polyethylene (HDPE)

Polyethylene (LDPE)

Polypropylene

PVC / CPVC

304 Stainless Steel

304L Stainless Steel

316 Stainless Steel

Steel (1% carbon hard)

Steel (carbon)

Titanium

Doppler Mode Pipe Size Range

2“ to 100” (63mm to 2500mm)

1“ to 100” (25mm to 2500mm)

2“ to 100” (63mm to 2500mm)

Pipe Size Ranges and Maximum Wall Thickness

Transit Time Mode Pipe Size Range

2“ to 100” (63mm to 2500mm)

1-1/2“ to 100” (40mm to 2500mm)

2“ to 100” (63mm to 2500mm)

Max Pipe Wall

.500” (13mm)

2.00” (50mm)

1.00” (25mm)

.500” (13mm)

2.00” (50mm)

.500” (13mm)

0% to

are

1.6 Straight Pipe Length Requirements

Note: The outside surface of the pipe must be clean and smooth. Insulation, coatings, rust and other surface imperfections should be removed before installing the transducers. The inside surface of the pipe must be smooth to properly reflect the sound wave.

Type of Disturbance

Flange

Reducer

90 Elbow

Two 90 Elbows - 1 Direction

Two 90 Elbows - 2 Directions

Gate valve

Pump

Note: The 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. 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.

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

Ultrasonic Flowmeter

Page 8

1.7 Standard Model Features and Options

STANDARD MODEL FEATURES

! Data logging to a standard SD Card. ! 4-20 mA output signal ! 0-1000 Hz digital frequency output signal ! LED status indicator lights

DISPLAY AND USER ACCESS MODEL DISTINCTIONS

Model 3 includes a full featured display with a 5

button touch pad. The start-up process and the zero calibration can be performed by pressing the proper buttons on the touch pad.

Note that the start-up process, the zero calibration, and all other functions can also be performed by the optional remote PC software application.

Model 2 includes a basic display with a 2 button touch pad. The start-up process and the zero calibration can be performed by removing the front cover plate and pressing the setup button located on the circuit board.

Note that the and all other functions can also be performed by the optional remote PC software application.

Model 1 has no display or touch pad. The start-up process and the zero calibration can be performed by removing the front cover plate and pressing the setup button located on the circuit board.

Note that the start-up process, the zero calibration, and all other functions can also be performed by the optional remote PC software application.

OPTIONAL COMMUNICATIONS PACKAGE WITH CUSTOM PC SOFTWARE

Any model can be equipped with a connector panel and custom PC software. When software, any model can perform the functions described in this manual including program editing and data logging downloads directly into the PC.

start-up process, the zero calibration,

Communications Package that includes circuitry,

connected to a computer running the

Model 3

Ultrasonic Flowmeter

OPTIONAL PROCESS CONTROL RELAY BOARD

Any model can be equipped with a Process Control Relay Package that includes three independently programmable 10 amp relays. However, relay programming requires the Model 3 programming features or the Communications Software package to function. Models 1 and 2 cannot access the relay functions unless connected to the communications Software.

Page 9

1.8 Wiring Compartment

WIRING COMPARTMENT

The wiring access door on the front of the flowmeter enclosure only must be removed to access the wiring terminal blocks, motherboard controls (a setup button and the measurement mode switch) and to view the status LEDs.

The meter is factory set for transit time operation.

There are no user serviceable items inside the rear enclosure.

FRONT COVER PLATE REMOVED

DOPPLER / TRANSIT TIME

MODE SELECT SWITCH

(factory set for transit time mode)

INDICATOR LIGHTS

GRN

RS485

INDICATOR

LIGHTS

SD CARD DATA LOG (REMOVE)

TRANSDUCER

INPUTS

Tx 1 Tx 2

BLK (-)

GRN

RED (+)

RS232

USB

COMMUNICATIONS

CONNECTOR PANEL

BLK (-)

RED (+)

BLK (-)

ETHERNET

WIRING COMPARTMENT LAYOUT

SETUP BUTTON

MODE SWITCH

COM

NC NO

PROCESS CONTROL RELAYS

(THREE EACH) 10A 250V AC

SETUP BUTTON (white)

FUSE

1A 250V (5x20mm)

slow blow

SIGNAL

OUTPUTS

NEG (-)

POS (+)

littlefuse 239001.XP

POWER INPUT

DC (-)

GRN

110~240Vac 50/60Hz-40W

DC (+)

NEG (-)

POS (+)

WARNING

INPUT POWER LIMITS

AC INPUT

DC INPUT

15~30 Vdc-40W

CAUTION

risk of electric shock

GRN

AC LINE

AC NTRL

INPUT POWER (green)

FAULT CONDITION (red)

INDICATOR LIGHTS

METER STATUS (yellow)

Ultrasonic Flowmeter

Page 10

Down flows

must have

back pressure

Pipe must be full

Air could be trapped

2.0 Quick Start Guide

Select doppler or transit time mode

Note that the meter is factory set for Transit-Time operation.

See section 3.6 for more information

Select the transducer mounting location

The flowmeter’s sound wave beam only measures fluid that actually passes through the beam, therefore, the fluid velocity must be consistent across the entire pipe diameter to ensure high accuracy. Flow disturbances such as pumps, elbows, tees, and valves in the flow stream can cause swirl patterns and vortices that will affect the measurement. Install the transducers on a straight run of pipe as far as possible from any disturbances. The distance required for accuracy will depend on the type of disturbance.

FRONT COVER PLATE REMOVED

Type of Disturbance

Flange

Reducer

90 Elbow

Two 90 Elbows - 1 Direction

Two 90 Elbows - 2 Directions

Gate valve

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

MINIMUM STRAIGHT PIPE LENGTHS

Flow Direction

10 x D

PIPE SYSTEM CONSIDERATIONS

MODE SELECT SWITCH

TRANSDUCER

INPUTS

Tx 1

BLK (-)

GRN

RED (+)

RS232

COMMUNICATIONS

CONNECTOR PANEL

USB

Tx 2

GRN

RED (+)

BLK (-)

RED (+)

RS485

GRN

ETHERNET

INDICATOR

LIGHTS

SD CARD DATA LOG (REMOVE)

MODE SWITCH

COM

NC NO

COM

NC NO

COM

NC NO

PROCESS CONTROL RELAYS

(THREE EACH) 10A 250V AC

SIGNAL

OUTPUTS

NEG (-)

POS (+)

SETUP BUTTON

WIRING COMPARTMENT LAYOUT

Straight Lengths of Pipe Required

Downstream from Transducers

5 x Nominal Pipe Size

5 x D

GRN

NEG (-)

POS (+)

FUSE

1A 250V (5 x 20)

POWER INPUT

DC (-)

DC (+)

GRN

WARNI NG

INPUT POWER

LIMITS

AC INPUT

110VAC - 240VAC

50/60 Hz

DC INPUT

15 to 30 VDC

CAUTION

risk of electric shock

AC LINE

AC NTRL

See section 6.1 for more information

Ultrasonic Flowmeter

Air bubbles may be present

Sediment may be present

Determine the transducer mounting mode

When operated in the Doppler mode, the transducers are always mounted directly opposite each other, 180 degrees around the pipe.

When operated in the Transit-Time mode, the front faces of the transducers must face each other and be positioned the correct distance apart. In V-mode, the transducers are on the same side of the pipe. In Zmode, the transducers are on the opposite side of the pipe, 180 degrees apart.

When factory configured, the appropriate Transit- Time mounting mode is pre-configured and printed on the serial label.

See section 6.2 for more information

All pipe types and sizes

Flow

“V” Mount Mode

Typically smaller pipe

sizes from 2” to 6”

Separation

Distance

Flow

TRANSIT TIME

DOPPLER

Typically larger pipe

sizes from 4” to 100”

Separation

Distance

“Z” Mount Mode

Flow

Page 11

Flow

Determine the 1st transducer location

The mounting surface must be clean, smooth and free of surface imperfections. Remove all insulation material, loose paint, etc. Clean the pipe thoroughly. Use sandpaper if necessary to remove surface imperfections. Be sure to locate the transducers on the side of horizontal runs of pipe. Do not mount the transducers over weld seams. Place a mark where the first transducer will be located.

See section 6.5 for more information

TRANSDUCER MOUNTING LOCATION

Horizontal

Ultrasonic Flowmeter

Page 12

Determine the 2nd transducer location

When operated in the Doppler mode, the transducers are always mounted directly opposite each other, 180 degrees around the pipe.

When operated in the Transit-Time mode, the factory configured separation distance and mounting mode is printed on the serial label. The currently active separation distance is also displayed on the run mode screen, the fault indicator screen, and when activating a new configuration.

If the meter has not been factory configured, or if a new configuration is required, the pipe outside diameter, pipe wall thickness, pipe material, fluid type and transducer mounting mode data must be input before proceeding.

All pipe types and sizes

DOPPLER

SERIAL LABEL

1 T 0.88 in.

FAULT

Attempting Correction...

[ £]

£££

“V” Mount Mode

Typically smaller pipe

sizes from 2” to 6”

Separation

Distance

F81

“Z” Mount Mode

Typically larger pipe

sizes from 4” to 100”

Separation

Distance

TRANSIT TIME

Separation Distance

1 T 0.88 in. [¢¢¢£]

U.S. Gallons / min

625.38

U.S. Gallons

4345625.38

SETUP SWAP CLEAR

RUN MODE SCREEN

Firmware Version, A01.00.00

Transducer Positioning …

Position the transducers

at a separation distance of:

0.884416 inches (”V” Mount)

Information Screen

1490

Once activated, the new separation distance will be displayed.

See section 6.6 for more information

FAULT INDICATOR SCREEN

Press DONE when this is complete

DONE

NEW CONFIGURATION

ACTIVATION SCREEN

Configure the meter if it has not been factory configured

Apply power to the meter. note that only the most basic configuration requirements are shown here.

1 T 0.88 in. [¢¢¢£] 1490

U.S. Gallons / min

U.S. Gallons

625.38

Manage Configuration Sets

Global Configuration

Setup Root Menu

4345625.38

SETUP SWAP CLEAR

1. Press Setup.

ENTER Ç ESC

2. Highlight Manage Configuration Sets and

press enter.

Manage Configuration Sets

ENTER Ç ESCÈ

4. Highlight the Configuration set to be edited and press enter.

Setup Root Menu

Manage Configuration Sets

ÊActivate a Configuration Set

Open a Saved Configuration Set

Create a New Configuration Set Delete a Saved Configuration Set

ENTER Ç ESC

3. Highlight Open a saved Configuration set and press enter.

Setup Root Menu

Open a Saved Configuration Set

Configuration Set #1

See section 5.0 for more information

Ultrasonic Flowmeter

Configure the meter (continued)

Configuration Set #1

Transducer Setup

Metering Setup Process Control Setup Reset Working Set to Fact. Defaults Set Password... Save Save As ... Save and Activate

Configuration Set #1

Transducer Setup

ÊTransducer

Measurement Units

Transducer

Pipe Liner Fluid

Page 13

Configuration Set #1

Transducer Setup

ÊTransducer

Model Number

Mount Method

Cable Length (Feet)

Configuration Set #1

Transducer Setup ÊTransducer

Mount Method

W Z

ENTER Ç

ESC

5. Highlight Transducer Setup and press enter.

Configuration Set #1

Transducer Setup

ÊTransducer

Model Number

Mount Method

Cable Length (Feet)

ENTER Ç ESC

9. Press escape.

Configuration Set #1

Transducer Setup ÊPipe

Outside Diameter

Wall Thickness

Pipe Material

Speed of Sound in Custom Material

ENTER Ç ESC

13. Highlight Wall Thickness and press

enter.

Configuration Set #1

Transducer Setup

ÊPipe

Outside Diameter

Wall Thickness

Pipe Material

Speed of Sound in Custom Material

ENTER Ç ESC

17. Press escape.

Configuration Set #1

Transducer Setup

Fluid

Fluid type

Speed of Sound in Fluid Type

ENTER Ç ESC

21. Press escape twice.

ENTER Ç ESC

6. Highlight Transducer and press enter.

Configuration Set #1

Transducer Setup

Measurement Units

Transducer

Pipe

Liner Fluid

ENTER Ç ESC

10. Highlight Pipe and press enter.

Configuration Set #1

Transducer Setup ÊPipe

Wall Thickness

0.218

ENTER Ç ESC

14. Input the actual wall thickness and press enter.

Configuration Set #1

Transducer Setup

Measurement Units

Transducer Pipe

Liner

Fluid

ENTER Ç ESC

18. Highlight Fluid and press enter.

Configuration Set #1

Transducer Setup Metering Setup

Process Control Setup Reset Working Set to Fact. Defaults Set Password... Save Save As ...

Save and Activate

ENTER Ç

22. Highlight Save and Activate and press enter.

ENTER Ç ESC

7. Highlight Mount Method and press enter.

Configuration Set #1

Transducer Setup ÊPipe

Outside Diameter

Wall Thickness Pipe Material

Speed of Sound in Custom Material

ENTER Ç ESC

11. Highlight Outside Diameter and press

enter.

Configuration Set #1

Transducer Setup

ÊPipe

Outside Diameter

Wall Thickness

Pipe Material

Speed of Sound in Custom Material

ENTER Ç ESC

15. Highlight Pipe Material and press

enter.

Configuration Set #1

Transducer Setup

Fluid

Fluid type

Speed of Sound in Fluid Type

ENTER Ç ESC

19. Highlight Fluid Type and press enter.

Information Screen

Firmware Version, A01.00.00

Transducer Positioning …

Position the transducers

at a separation distance of:

0.884416 inches (”V” Mount)

Press DONE when this is complete

ESC

DONE

23. Position the Transducers on the pipe and press Done.

ENTER Ç ESC

8. Highlight a Mount Method and press enter.

Configuration Set #1

Transducer Setup ÊPipe

Outside Diameter

2.625

ENTER Ç ESC

12. Input the actual outside diameter and press enter.

Configuration Set #3

Transducer Setup

ÊPipe

ÊPipe Material

PVC/CPVC

PVDF Stainless Steel 302/303 Stainless Steel 304 Stainless Steel 304L Stainless Steel 316

ENTER Ç ESCÈ

È È

16. Highlight the actual Pipe Material and press enter.

Configuration Set #1

Transducer Setup

Fluid

Fluid type

Water (Waste, Distilled)

Custom 1, 1, 1, Trichloroethane

1-Propanal Acetone (Dimethyl ketone, 2-Propanone) Alcohol (Ethyl alcohol, Ethanol)

ENTER Ç ESC

È È

20. Highlight the actual Fluid Type and press enter.

Ultrasonic Flowmeter

Page 14

Manage Configuration Sets

Create a New Configuration Set

Delete a Saved Configuration Set

Activate a Configuration Set

Open a Saved Configuration Set

Configuration Set #1

Configuration Set #2

Configuration Set #3

Configuration Set #4

Configuration Set #5

Global Configuration

Communications Settings

Master Password

Date and Time

Save Changes

Transducer Setup

Measurement Units

English (U.S. units)

Metric (SI units)

Transducer

Model Number

Mount Method

Cable Length (Feet)

Pipe

Outside Diameter

Wall Thickness Pipe Material

Speed of Sound in Custom material

Liner

Liner Wall Thickness Speed of Sound in Liner material

Fluid

Fluid Type

Speed of Sound in Custom Fluid

Metering Setup

Flow Rate

Volume Units Custom Unit Volume per U.S. Gallon

Ê Ê

Time Units Digits After Decimal Point

Totalizer

Volume Units

Custom Unit Volume per U.S. Gallon

Digits After Decimal Point

Ê Ê

Total Display Function

Display

Display Language

Flow Rate Averaging Display Update

Low Flow Cutoff

High Flow Cutoff

Scaling Offset

Signal Output

Analog Output

Pulse Output

Data Logging

Log Interval

Ê Ê

Log Rate Setpoint

Log Totalizer Setpoint

Setup Root Menu

Process Control Setup

Relay Channel #1

Assign Relay

Monitor Flow Rate

Monitor Flow Total

Disabled

Flow Rate Alarm Settings

High Trigger

High Release

Low Trigger

Ê Ê

Low Release Alarm Delay Time

Batch Dispense Settings

Default Batch Amount

Batch Start Mode

Relay Timer

Relay Channel #2

Relay Channel #3

Assign Relay

Monitor Flow Rate

Monitor Flow Total

Disabled

Flow Rate Alarm Settings

High Trigger

High Release

Low Trigger

Ê Ê

Low Release Alarm Delay Time

Batch Dispense Settings

Default Batch Amount

Batch Start Mode

Relay Timer

Assign Relay

Monitor Flow Rate

Monitor Flow Total

Disabled

Flow Rate Alarm Settings

High Trigger

High Release

Low Trigger

Ê Ê

Low Release Alarm Delay Time

Batch Dispense Settings

Default Batch Amount

Batch Start Mode

Relay Timer

Manual Batch Start

Auto (Proportional)

Manual Batch Start

Auto (Proportional)

Manual Batch Start

Auto (Proportional)

Ultrasonic Flowmeter

Page 15

Install the transducers

An acoustic coupling material must be placed between the transducer and the pipe surface at the point where the sound waves enter the pipe.

Draw a centerline on the pipe parallel to the pipe center. Place the first transducer onto the pipe. Locate the front arrow exactly over the first separation distance mark (A). Place the transducer straight and parallel to the centerline.

Secure the first transducer to the pipe using the pipe clamps. The arrows on the front and rear of the transducers must point toward the centerline.

TRANSDUCER

CENTERLINE

DOW 111 Silicone Grease

BLUE GASKET - Permenant

installations. Recommended

for metal pipes.

WHITE GASKET -

Temporary installations.

ACOUSTIC COUPLING MATERIAL INSTALLATION

FRONT VIEW

ARROW ON CENTERLINE

REAR VIEW

ARROW ON CENTERLINE

CENTERLINE

TRANSDUCER

BOTTOM VIEW

CENTERLINE

Locate the second transducer separation mark (B). Place the second transducer so that the front arrow is located exactly over the mark (B). Place the transducer straight and parallel to the centerline. Be sure that both transducers are facing each other and parallel to the pipe centerline.

Check that the separation distance is correct. Tighten the clamps equally.

See section 6.9 for more information

Restart the meter

Press the SETUP button. The meter will enter the SETUP ROOT MENU. Creation and modification of the five available Configuration Sets and the Global Configuration settings can be made from this menu. If no changes are to be made, press will re-start.

ESC. The meter

1 T 0.88 in.

U.S. Gallons / min

[¢¢¢£] 1490

625.38

U.S. Gallons

4345625.38

SETUP SWAP CLEAR

Separation

Distance

ACOUSTIC COUPLING

MOUNTING CLAMPS

Manage Configuration Sets

Global Configuration

ENTER Ç

Setup Root Menu

ESCÈ

Ultrasonic Flowmeter

Page 16

3.0 Flowmeter SPU Installation

3.1 Unpacking

3.2 Select a Mounting Location

The Flowmeter is shipped in a carrying case. Inside the carrying case you will find the following items:

Flowmeter SPU (Signal Processing Unit)

Transducer Set

Enclosure Mounting Hardware

2 mounting plates 4 mounting plate screws (10-32 x .50”) 4 panel mount screws (8-32 x 3.00”) 2 wall mounting screws (#10 x 1.00”) 1 panel mounting gasket 1 pipe mounting clamp (maximum pipe diameter 10”)

Transducer Mounting Kit

6 blue gaskets (single use) 2 white gaskets (multi use) 4 transducer mounting clamps

Paper Instruction Manual (English)

Instruction Manual (English, Spanish, German, French)

Note that additional clamps can be purchased and connected for larger pipe diameters.

The flowmeter 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.

Select a mounting location for the SPU t power supply. The standard transducer cable length is 10 feet and must not be cut or modified. Note that the flowmeter can accurately measure flow from either direction.

(maximum pipe diameter 10”)

hat is within reach of the transducer cables and

3.3 Wall Mounting

CAUTION

risk of danger

The SPU Although the meter where the unit can be easily monitored is recommended. Special ventilation is not required.

1) 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.

2) Measure and mark the distance between the keyhole slot centers as shown.

3) Drill two 5/32” diameter pilot holes. Install the enclosed #10 x 1.00” screws into the wall. Leave the screw heads away from the panel surface approximately 1/4”.

4) Hang the SPU enclosure on the screws.

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

can be mounted on a wall, on a horizontal or vertical run of pipe or in panel.

is designed to withstand outdoor conditions. A cool, dry location,

4.68 (119mm)

Ultrasonic Flowmeter

3.4 Panel Mounting

1) The SPU can be panel mounted.

Measure and cut an opening in the panel as shown.

2) Remove the two mounting plates from

the rear of the enclosure.

3) Install the gasket onto the rear of the

front panel of the SPU enclosure.

Page 17

7.90” (200mm)

10.40”

(264mm)

3.5 Pipe Mounting

4) Place the enclosure into the panel.

5) Re-install the two mounting plates as

shown.

6) Thread the four 8-32 x 3.00” machine

screws through each of the two outer tapped holes in the mounting plates. Tighten the screws to secure the enclosure to the panel.

1) 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.

2) Install the two mounting plates onto the

rear of the enclosure. For horizontal pipe mounting, install the mounting plates on the top and bottom plate cutouts. For vertical pipe mounting, install the mounting plates on the side plate cut-outs.

Mounting Plates

Gasket

8-32 x 3.00” Panel Screws

Panel

3) Thread the long mounting clamp

through the square cut-outs in the mounting plates as shown.

4) Wrap the clamp around the pipe and

tighten loosely. Be sure the pipe is seated in the pipe groove, then tighten securely.

Ultrasonic Flowmeter

Page 18

3.6 Select the Measurement Method

3.7 Electrical Connections

Open the front cover of the SPU. Position the Doppler/Transit-Time switch to the preferred operating mode (factory setting is transit time).

Operate the meter in the Transit Time mode (best accuracy) if the fluid contains little or no particles (up to 10% maximum).

Operate the meter in the Doppler mode if the fluid to be measured contains

more than 10% particles.

Doppler/Transti-Time Switch

The transducer connections are pre-wired at the factory. If a main AC input power cord selection was made when ordering, the power cord and main AC power input connection is factory wired. When powering the meter by DC, a power cable for this purpose should be installed in one of the cable gland liquid-tight connectors. See section 3.8 below. The meter will automatically adjust for any main power input that is within the power requirements range of 110 to 240 volts AC or 15 to 30 volts DC. See the diagram below for wiring of output signals, communications signals and process control relays.

CAUTION

risk of electric shock

CAUTION

risk of electric shock

The transducer cable length is fixed. Do not attempt to modify the length of the cables. Various cable lengths are available from the factory. Contact the factory if you need assistance. Shielded cable is recommended for signal output connections.

RS232

All high voltage connections in the front wiring compartment are considered “finger safe”. However,

disconnect electricity to the meter and use care when connecting high voltage wires to the plug-in type terminal blocks.

There are no user serviceable items inside the rear meter enclosure. If it becomes necessary to open the back cover, be sure to disconnect the main power supply before opening the back cover of the enclosure.

FUSE

1A 250V (5x20mm)

slow blow

littlefuse 239001.XP

POWER INPUT

DC (-)

DC (+)

NEG (-)

POS (+)

WARNING

INPUT POWER LIMITS

110~240Vac 50/60Hz-40W

15~30 Vdc-40W

GRN

AC INPUT

DC INPUT

CAUTION

risk of electric shock

TRANSDUCER

INPUTS

Tx 1 Tx 2

BLK (-)

GRN

RED (+)

COMMUNICATIONS

CONNECTOR PANEL

RED (+)

USB

RED (+)

BLK (-)

GRN

ETHERNET

RS485

INDICATOR

LIGHTS

SD CARD DATA LOG (REMOVE)

SETUP BUTTON

MODE SWITCH

COM

NC NO

COM

NC NO

COM

NC NO

PROCESS CONTROL RELAYS

(THREE EACH) 10A 250V AC

SIGNAL

OUTPUTS

GRN

NEG (-)

POS (+)

AC LINE

AC NTRL

Ultrasonic Flowmeter

WIRING CONNECTIONS

Power Input Terminal Block

Page 19

Flow Meter

12 345

Positive

(+)

15 to 30 VDC

40 WATTS MAX

Flow Meter

Current output (4-20 mA)

Maximum load 1000 ohms

Signal Output Terminal Block

Current

input

4-20mA receiver

Negative

(-)

Line

intput

110 to 240 VAC 50/60Hz

40 WATTS MAX

Neutral

POWER INPUT CONNECTIONS

Frequency output (0-1000 Hz)

Open Collector output, 50% duty cycle

Current

output

34 5

Ground

Digital Pulse Receiver

Frequency

SIGNAL OUTPUT CONNECTIONS

input

Flow Meter

(Open Collector output

50% duty cycle)

5-30 VDC

3.8 Cable Gland Liquid-Tight Connections

The SPU wiring compartment is equipped with: six large liquid-tight cable gland connectors, two small

liquid-tight cable gland connectors, and

a communications cable liquid-tight cable gland grommet and plug.

To ensure that the SPU enclosure remains water-tight, the following cable glands should be used:

The six large liquid-tight connectors can be used with any cable diameter from .200 to .394 inches (5.1 to 10.0 mm). They are provided for: 1 each for the power input cable 2 each for the transducer cables 3 each for the process control relay connection cables

The two small liquid-tight connectors can be used with any cable diameter from .118 to .255 inches (3.0 to 6.5 mm). They are provided for: 1 each for the 4-20 mA output signal cable 1 each for the pulse output signal cable

The communications cable grommet can be used with any cable diameter from .190 to .205 inches. It is provided for any one of the following cable types: USB cable Ethernet Cable RS-232 serial cable RS-485 serial cable

The blank grommet plug should be used when the not required.

communications cable grommet is

Ultrasonic Flowmeter

Page 20

4.0 Overview of Flowmeter Operation

4.1 Power On and Self-Test

4.2 Description of Operating States and Controls

On application of power, the power LED (green) on the motherboard comes on and the flowmeter performs self-test functions. The approximate duration of self-test is 10 seconds. The flowmeter indicates that it is in the Self-Test State as follows:

Model 1: the red and all four yellew LED indicator lights flash at 1 Hz.

INDICATOR LIGHTS IN

SELF-TEST STATE

Model 2: as for Model 1, plus the LCD shows the firmware version number and the text “Self-Test ...”.

Firmware Version, B01.00.00

Self-test …

Information Screen

Model 3: as for Model 2.

LCD DISPLAY

Below is a diagram of the flowmeter’s major operating states. The condition of the motherboard LEDs is pictured under the name of each state. Transitions are annotated with their causes, which may be user actions via the motherboard controls and timeouts (uppercase text), user actions using a display optionally fitted to the flowmeter, (italic text) or automatic transitions when a step is complete (in parentheses).

In the Self-Test state, the flowmeter checks the operation of internal circuitry, such as communication between the processor and its peripheral functions, Verify that all LEDs and the LCD display, if fitted, are working properly. Do not press any buttons during self-test.

Ultrasonic Flowmeter

If an error condition is detected during self-test, the flowmeter enters the Faulted State. Failure of the LEDs, LCD display, and the display touch-pad are not internally detectable.

If self-test completes without error, the flowmeter enters the Startup State. Note that

completion of self-test does not guarantee that the flowmeter is properly configured and able to make accurate measurements.

Power ON

(pass)

SELF-TEST

(fail)

FAULTED STATE

(complete)

ZERO CALIBRATION

(fail)

HOLD SETUP

FOR

3 SECONDS

TAP SETUP BUTTON or

“DONE” button

press

TRANSDUCER POSITIONING

STARTUP STATE

TAP SETUP BUTTON or

TIME OUT (5 minutes) or

press “ESC” button

SETUP MODE

TAP SETUP BUTTON or

Activate a

configuration

TAP SETUP

BUTTON

(fail)

TAP SETUP BUTTON or

FLIP DOPPLER / TT

MODE SWITCH

RUN MODE

(fail)

7 SECOND

TIME OUT

SONIC-PRO OPERATING STATES

Page 21

4.3 Startup State

When power is applied, the flowmeter enters the Startup state. In the Startup State, the flowmeter waits for up to 7 seconds for the Setup button to be pressed at which time the Setup mode is entered and changes to the configuration can be made. If the setup button is not pressed, the flowmeter will enter the Run Mode and attempt to start flow measurement. If the transducers are not installed on the pipe, a fault will occur. The location of the Setup button is as follows:

Model 1: a push-button switch on the controller motherboard.

Model 2: as for Model 1.

Model 3: as for Model 2, plus a SETUP soft

button appears on the display.

TRANSDUCER

INPUTS

Tx 1 Tx 2

BLK (-)

GRN

RED (+)

RS232

USB

COMMUNICATIONS

CONNECTOR PANEL

RED (+)

SETUP BUTTON (white)

INDICATOR

LIGHTS

SD CARD DATA LOG (REMOVE)

BLK (-)

GRN

RED (+)

BLK (-)

RS485

GRN

ETHERNET

COM

SETUP BUTTON

MODE SWITCH

PROCESS CONTROL RELAYS

(THREE EACH) 10A 250V AC

SIGNAL

OUTPUTS

NEG (-)

POS (+)

GRN

NEG (-)

POS (+)

FUSE

1A 250V (5 x 20)

POWER INPUT

DC (-)

DC (+)

GRN

WARN ING

INPUT POWER

LIMITS

AC INPUT

96VAC - 264VAC

50/60 Hz

DC INPUT

15 to 30 VDC

CAUTION

risk of electric shock

AC LINE

CIRCUIT BOARD LAYOUT

The flowmeter indicates that it is in the Startup State as follows:

Model 1: the Fault (red) LED is OFF and all yellow LEDs are at first ON and then turn OFF one by one, starting at LED1, at intervals of 1.5 seconds, so as to count down the 7 second pause.

AC NTRL

Model 2: as for Model 1, plus the display screen indicates:

Startup ... Tap Setup to enter Setup Mode Hold Setup for Zero Calibration Configuration set # (Searching for SD Card)

Below this, a “progress bar” counts off the 7 second delay.

Model 3: as for Model 2, plus the SETUP soft button is available.

MODEL 1

Information Screen

Firmware Version, A01.00.00

Startup …

Tap Setup to enter Setup

Hold Setup for Zero Calibration

Configuration Set #1 (Searching for SD Card)

[££££¢¢¢]

MODEL 2

Information Screen

Firmware Version, A01.00.00

Startup …

Tap Setup to enter Setup

Hold Setup for Zero Calibration

Configuration Set #1 (Searching for SD Card)

[££££¢¢¢]

SETUP

MODEL 3

Ultrasonic Flowmeter

Page 22

4.4 Setup (Configuration) Mode

From the Setup mode, a zero calibration can be performed or, if equipped with either the full function display (Model 3) or the optional Communications software, the Setup Root Menu system can be entered and the meter can be configured. be performed in the Setup Root Menu are fully described in section 5.0.

The Setup Mode can be entered in two ways:

1) Tap the SETUP button on the motherboard, the display touch-pad, or on the user PC Communications Software.

2) Flip the Doppler/Transit Time switch.

Note: the meter must be in the Startup State or in the Run Mode to enter the Setup Mode.

The flowmeter indicates that it is in the Setup Mode as follows:

Model 1: two outer yellow LEDs flash at 1

Hz.

Model 2: as for Model 1, plus the display screen indicates:

Setup Mode...

Firmware Version, A01.00.00

Setup …

The operations that can

SETUP MODE

Information Screen

MODEL 2

Setup Root Menu

Model 3: as for Model 2, plus the Setup Root Menu appears.

The flowmeter will remain in the Setup Mode until one of the following actions occur:

1) A Configuration Set is activated from the Setup Root Menu.

Either t required for this action.

2) The user “escapes” from this state. The user can escape to the Startup state by: a) Hold the SETUP button on the motherboard for three seconds. b) Tap the SETUP button on the motherboard once (resulting in entering the

c) Press the ESC button on the

Note that if the user escapes, the currently active configuration set will re-activate.

3) Five minutes passes without user action.

he full function display (Model 3) or the optional Communications software is

Transducer Positioning state) and tap again (resulting in entering the Startup state).

full function display (Model 3) or on the optional

Communications software.

Manage Configuration Sets

Global Configuration

ENTER Ç

MODEL 3

ESC

Ultrasonic Flowmeter

Page 23

4.5 Transducer Positioning State

In the Transducer Positioning State, the flowmeter waits for the transducers to be correctly positioned on the pipe.

When operated in the Transit Time measurement mode, the separation distance of the transducers is computed by the flowmeter from the information in the Transducer Setup branch of the Configuration Menu. The correct separation distance is dependent on the pipe OD, pipe wall thickness, pipe type and chosen mounting mode. If the Doppler measurement mode is selected (by the motherboard switch), the separation of the transducers (along the pipe axis) is always zero.

When factory configured, the separation distance and mounting mode is printed on the serial label. The separation distance will also be displayed on the LCD display or on the optional communications PC software, in either inches or millimeters depending on the Measurement Units chosen in Transducer Setup. If the meter has not been factory configured, or if a new configuration is required, the pipe OD, pipe wall thickness, pipe type, fluid type and chosen mounting mode configuration data must be input before proceeding. See section 5.3 for instructions on how to create or modify a configuration.

If the flowmeter has neither an LCD display nor a connected user PC Software application, then the Configuration information cannot be changed by the user so the separation of the transducers will not change from the factory setting.

The flowmeter indicates that it is in the Transducer Positioning State as follows:

Model 1: two center yellow LEDs flash at 1 Hz.

TRANSDUCER

POSITIONING STATE

Model 2: as for Model 1, plus the screen presents instructions to the user as shown.

Model 3: as for Model 2.

You must acknowledge that the transducers are correctly positioned by either pressing the SETUP button on the motherboard or the DONE soft button on the display, if fitted. The flowmeter will then return to the Startup state, see section 4.3 above, from which you can again enter Setup Mode or perform Zero Calibration or, by allowing the 7 second timeout to elapse, let the flowmeter enter Run Mode and begin flow measurement.

Firmware Version, A01.00.00

Transducer Positioning …

Position the transducers

at a separation distance of:

2.489416 inches (”W” Mount)

Press DONE when this is complete

DONE

Information Screen

Ultrasonic Flowmeter

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