Badger Meter MultySonic 8000 User manual

Badger Meter Europa GmbH
MultySonic 8000
INSTRUCTION MANUAL
July 2010
UF_Multy8000_BA_02_1007
®

Contents Page
UF_Multy8000_BA_02_1007
1. Description.........................................................................................................................1
1.1. Measurement principle.............................................................................................1
1.2. Applicable standards................................................................................................1
1.3. Measurement accuracy............................................................................................1
1.4. Specialised applications...........................................................................................1
2. Specifications ....................................................................................................................2
2.1. Sensors....................................................................................................................2
2.2. Evaluation unit .........................................................................................................2
2.2.1. Acoustic path................................................................................................2
2.2.2. Analogue inputs for water level sensors.......................................................2
2.2.3. Display with touch screen.............................................................................2
2.2.4. Analogue outputs..........................................................................................3
2.3. Cable for ultrasonic transducers..............................................................................3
2.4. Safety standards and EMC guidelines.....................................................................4
2.5. Interface specifications ............................................................................................4
2.5.1. Analogue inputs............................................................................................4
2.5.2. Analogue outputs..........................................................................................4
2.5.3. Relay outputs................................................................................................5
2.5.4. Pulse outputs................................................................................................5
2.5.5. LAN interface (Ethernet)...............................................................................5
2.5.6. USB interface ...............................................................................................5
2.5.7. RS232 interface............................................................................................5
3. Flow calculation.................................................................................................................6
3.1. Calculation algorithms..............................................................................................6
3.1.1. In “Partially filled/filled conduits, open channel” mode..................................6
3.1.2. Crossing paths............................................................................................10
3.1.3. In “Full conduit” mode.................................................................................10
3.2. Water level measurement......................................................................................10
4. Installation of the electronic unit ...................................................................................11
4.1. Electrical connection..............................................................................................11
4.2. Power supply (AC).................................................................................................11
4.3. Ultrasonic board.....................................................................................................12
4.4. Connecting the ultrasonic transducers...................................................................13
4.4.1. Connection in explosive areas....................................................................14
4.5. I/O board................................................................................................................14
4.6. Connection of water level measuring devices to the analogue inputs...................16
4.7. Connection to the analogue outputs......................................................................16
4.8. Connection to the digital outputs............................................................................17
4.9. Using several I/O boards .......................................................................................17
4.10. Access to MultySonic 8000 via Ethernet................................................................17
4.11. Use of USB memory sticks ....................................................................................17
4.11.1.Transferring a new parameter file...............................................................18
4.11.2.Activating a transferred parameter file........................................................18
4.11.3.Downloading an active parameter file from MultySonic 8000 to.....................
USB memory stick......................................................................................18
4.11.4.Reading out the data logger.......................................................................19
4.11.5.Performing updates and upgrades.............................................................19
4.12. Installation and removal of electronic boards / reconfiguration of boards..............19
5. Programming and operation...........................................................................................24
5.1. Operation...............................................................................................................24

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UF_Multy8000_BA_02_1007
5.1.1. The sections menu.....................................................................................24
5.1.1.1. Section status.............................................................................24
5.1.1.2. Section alarm .............................................................................25
5.1.2. The input/output menu................................................................................25
5.1.3. The scan menu...........................................................................................25
5.1.4. The paths menu..........................................................................................25
5.1.5. The maintenance menu..............................................................................27
5.1.5.1. Activating of parameter files.......................................................27
5.1.5.2. Reset..........................................................................................27
5.1.5.3. Switch off of MultySonic 8000....................................................27
5.2. Menu customisation...............................................................................................28
5.3. Using the LAN interface.........................................................................................28
5.4. Using the USB interface.........................................................................................28
6. User-defined settings......................................................................................................29
6.1. General information on software use.....................................................................29
6.1.1. Creating a new parameter file ....................................................................29
6.1.2. Loading a new parameter file.....................................................................29
6.1.3. Language selection ....................................................................................29
6.2. System configuration .............................................................................................29
6.2.1. Definition of existing hardware ...................................................................29
6.2.2. Number of sections.....................................................................................30
6.2.3. Flow meter ID.............................................................................................30
6.3. Section configuration .............................................................................................30
6.3.1. Section selection ........................................................................................33
6.3.2. Activation of individual acoustic paths to a section.....................................33
6.3.3. Geometric definition of your measuring site (drain)....................................33
6.3.3.1. Not activated ..............................................................................33
6.3.3.2. Open channel.............................................................................33
6.3.3.3. Partially filled and/or filled pipe compound.................................33
6.3.3.4. Filled pipe/filled compound.........................................................34
6.3.3.5. Round.........................................................................................34
6.3.3.6. Square........................................................................................34
6.3.3.7. Round with Spline Interpolation..................................................34
6.3.4. “Define sampling points” sampling point editor...........................................35
6.4. Path configuration..................................................................................................36
6.4.1. The expert menu ........................................................................................38
6.4.1.1. Auto window...............................................................................39
6.4.1.2. Sensor delay ..............................................................................39
6.4.1.3. Send sequence ..........................................................................39
6.4.1.4. Frequency ..................................................................................39
6.4.1.5. ADC............................................................................................39
6.4.1.6. Frequency Filter Low..................................................................39
6.4.1.7. Frequency Filter High.................................................................39
6.4.1.8. Automatic Gain Control (AGC)...................................................40
6.4.1.9. Signal min...................................................................................40
6.4.1.10. Signal max..................................................................................40
6.4.1.11. Manual gain................................................................................40
6.4.1.12. Maximum gain............................................................................40
6.4.1.13. Correlation quality ......................................................................41
6.4.1.14. Cal factor....................................................................................41
6.4.1.15. PATH XX samples......................................................................41
6.4.1.16. Activate cut off............................................................................41
6.4.1.17. Cutoff trigger...............................................................................41

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6.4.1.18. Samples before cut off ...............................................................42
6.4.1.19. Samples after cut off ..................................................................42
6.4.1.20. Cutoff filter..................................................................................42
6.5. Level measurement configuration..........................................................................42
6.6. Analogue ouput configuration................................................................................43
6.7. Digital output configuration ....................................................................................44
6.7.1. Counter pulses ...........................................................................................44
6.7.2. Section alarm..............................................................................................45
6.7.3. Constant values..........................................................................................45
6.7.4. Min-Alarm, Max-Alarm, Min-Max alarms....................................................45
Example 1: Setting Min-Alarm for Level.....................................................45
Example 2: Setting Min-Max-Alarm for flow ...............................................46
6.7.5. Min / Max frequency...................................................................................46
6.8. Basic settings configuration...................................................................................46
6.9. Medium configuration.............................................................................................47
6.10. Basic parameter configuration...............................................................................49
6.10.1.Minimal sensor surcharge ..........................................................................49
6.10.2.Low flow cut off...........................................................................................49
6.10.3.Low level cut off..........................................................................................49
6.10.4.Temperature offset.....................................................................................50
6.10.5.Damping.....................................................................................................50
6.10.6.Max. level ...................................................................................................50
6.10.7.Path substitution.........................................................................................50
6.10.8.Minimum number of functioning paths........................................................51
6.11. Dry weather flow configuration...............................................................................51
6.11.1.Using Manning-Strickler’s equation............................................................51
6.11.2.Using individual discharge curve................................................................52
6.12. Signal plausibility ...................................................................................................53
6.12.1.Min. and max. velocity................................................................................54
6.12.2.Min. signal quality.......................................................................................54
6.12.3.Min. and max. flow speed...........................................................................54
6.13. Creating the parameter file ....................................................................................55
7. Appendix ..........................................................................................................................56
7.1. Connection plans for the pulse outputs..................................................................56
7.2. Weighting of the paths with filled cross-sections in accordance with.....................57
ISO60041 (IEC41) .................................................................................................57
7.2.1. Weighting of the paths for filled round cross-sections....................................
(Gauss-Jacobi method)..............................................................................57
7.2.2. Weighting of the paths for filled, rectangular cross-sections..........................
(Gauss-Legendre method) .........................................................................58
7.3. Exerpt IEC41 – Calculation of Flow with weighing factors.....................................59
7.4. Access to MultySonic 8000 via Ethernet (LAN).....................................................62
7.4.1. Using Ethernet cable connection................................................................62
7.4.2. Access via http protocol – MultySonic 8000 integrated webserver ............62
7.4.3. Access via ftp-server..................................................................................63
7.4.3.1. Downloading data logger files....................................................64
7.4.3.2. Downloading / Uploading of parameter files...............................65
7.4.3.3. Activating parameter files via http ..............................................66
7.5. MultySonic 8000 network configuration.................................................................66
7.5.1. General.......................................................................................................66
7.5.2. Donwloading the file inittab.........................................................................66
7.5.3. Adjust the File Inittab..................................................................................68

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7.5.3.1. Change the IP address...............................................................68
7.5.3.2. Change the default gateway.......................................................68
7.5.3.3. Change subnet mask .................................................................69
7.5.4. Transferring file Inittab back to MultySonic 8000................................................69
7.5.5. Troubleshooting..................................................................................................69
7.6. Parametering of the RS232 interface.....................................................................70
7.6.1. General.......................................................................................................70
7.6.2. Data which can be transferred via RS232..................................................70
7.6.3. RS232 fixed settings...................................................................................70
7.6.4. ASCII Output String....................................................................................70
7.6.5. communication.par – Structure (1).............................................................71
7.6.6. Uploading parameter file communication.par to MultySonic 8000 .............75
7.6.7. Downloading parameter file communication.par from MultySonic 8000.....76
7.6.8. Downloading data files ...............................................................................76
7.7. MultySonic 8000 display (touchscreen) – Structure...............................................77
7.8. Handling of data logger files ..................................................................................78
7.8.1. Structure of Data Logger Files....................................................................78
7.8.2. Unpack Data Logger Files..........................................................................79
7.8.3. Handling of additional data logger files.......................................................80

Description Page 1 / 81
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1. Description
The MultySonic 8000 ultrasonic flow meter was developed specially for flow measurement of
fluids in pipes, drains and sewers with a width of 0.2m – 100m. Measurements can take
place in pressure pipes up to 100 bar and under highly variable levels.
1.1. Measurement principle
Measurement of the flow speed is carried out at several levels according to the
ultrasonic transit time method principle (time-of-flight). A big advantage of the
transit time method is the absolute determination of the mean flow rate between
two fixed sensors. This makes complicated and questionable calibrations
unnecessary.
1.2. Applicable standards
Partially filled pipes: ISO 6416
Fullfilled pipes: IEC41 / ASME PTC 18 (see chapter 7.3 for excerpt from
IEC41)
1.3. Measurement accuracy
To prevent errors caused by sound velocity measurement of the medium to be
measured, both the duration difference and the absolute duration of the ultrasound
signals are determined in the flow velocity calculation.
The achievable measuring precision depends on the number of measuring paths
used and the inflow conditions. The following table gives an overview of the
maximum measuring deviations depending on the number of measuring paths.
With shortened inflow routes the use of crossed paths is recommended, i.e. two
intersecting paths are installed on one path plane.
Accuracy in % of the current flow value under different conditions
6 (12) path, pressure pipe, 10D (<5D) inflow +/- 0.4 % of flow rate *
4 (8) path, pressure pipe, 10D (<5D) inflow +/- 0.5 % of flow rate *
2 (4) path, pressure pipe, 10D (<5D) inflow +/- 1.0 % of flow rate *
6 (12) path, partially filled pipe, 10D (<5D) inflow +/- 1.0 % of flow rate *
4 (8) path, partially filled pipe, 10D (<5D) inflow +/- 2.0 % of flow rate *
2 (4) path, partially filled pipe, 10D (<5D) inflow +/- 3.0 % of flow rate *
* For flow velocities >0,003m/s
1.4. Specialised applications
•MultySonic 8000 can be used in spaces and areas liable to contain explosive
atmospheres in compliance with the relevant regulations.
•The system can be converted to run on batteries.
•A variety of sensor forms and materials permit use under heavy mechanical
load and in aggressive media with pH values from 3.5 to 10.
2(4)-path installation in pressure pipe
4(8)-path installation in pressure pipe
6(12)-path installation in pressure pipe

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2. Specifications
2.1. Sensors
Temperature range Operating temperature
Ambient temperature 0 °C bis 50 °C
-18 °C bis 65 °C
Pressure range Depending on model See technical bulletins
Water quality pH
Solid materials 3.5 to 10 0 to 2000 ppm (duration)
Frequency range 200kHz-2MHz
Sensor power Approx. 90Vpp
2.2. Evaluation unit
2.2.1. Acoustic path
Up to 12 (16 if no I/O board required) paths distributed across up to 4
measuring points, depending on the number of ultrasonic boards (4 paths /
board)
•Standard range 0.2m to 40m
•Extended range (on request) Up to 150m
2.2.2. Analogue inputs for water level sensors
The system provides 4 analogue inputs per I/O board to which independent
water level sensors can be connected.
•Input range with 100Ωresistance : 4 mA to 20 mA
•Maximum resistance : 250Ω
•Maximum, relative voltage to earth : ±20V DC
•Maximum voltage : 240V rms
•Power supply for external sensors : + 24V DC max. 1A
2.2.3. Display with touch screen
•Graphic display with touch screen
•320 x 240 points
•Backlight
•Insensitive touch screen
Power supply Evaluation unit 100 tos 240 VAC
50 Hz tos 60 Hz, 1.8A
24 VDC (alternative)
Temperature range Ambient temperature -20°C to 60 °C
with heating -40°C to 60 °C
Dimensions
(w x h x d) 300 x 400 x 210 mm
Weight 9 kg
Protection class IP 67 (alternatively Eexd)
Power consumption See chapter 4.2

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2.2.4. Analogue outputs
The system provides the following outputs per I/O board (max. 2 I/O boards
per MultySonic 8000):
•8 x 4mA to 20mA active or passive
Max. load : 500 Ω10 V
Optional : 900 Ω19 V
Resolution : 0.005 mA (12bit)
Precision : ±0.02 mA or 0.1 % of full scale
Overvoltage protection : ±30 V DC
•2 relays
Breaking capacity : 0.5 A, 110 V DC
Break time : 40 ms
Insulation voltage : 2000 V AC
•2 frequency outputs
Frequency : max. 10kHz
•Type OC
Breaking capacity : 50mA, 30VDC
2.3. Cable for ultrasonic transducers
Double-shielded RG58 Triaxial cable for distances up to 100m.
Cable connections of more than 100m in length should be clarified in advance with
Badger Meter.
Cable length of two corresponding transducers should be equal in order to avoid
measurement errors caused by signal run times.

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2.4. Safety standards and EMC guidelines
The MultySonic 8000 has been developed and designed according to with the
following guidelines and standards.
Low-voltage guideline
EN 61010-1 Safety Requirements for Electrical Equipment
IEC 255_5 Insulation: 2 kV common mode, 1 kV Normal mode, >100 MΩ
Electromagnetic compatibility
EN 50082-2 (1995) Part 2 Industrial
IEC 77A Harmonics on power supply
EN 61000-4-11 Interruptions (100ms), dips and voltage variations +12 to –15% on supply
EN 61000-4-4 Fast transient/burst 2 kV common, 1 kV normal mode
EN 61000-4-5 High energy pulse/transient 2 kV common, 1 kV normal mode
EN 61000-4-12 Damped oscillatory waves 1 kV common, 0.5 kV normal mode
IEC 1000-4-6 Conducted disturbance, induced by radio frequency fields 150 kHz – 80 MHz
EN 61000-4-2 Electrostatic discharge 8 kV in air, 6 kV in contact
EN 61000-4-8 Power frequency magnetic fields 1000 Aeff/m
EN 61000-4-10 Damped oscillatory magnetic field 0.1 MHz and 1 MHz 30Ap/m
IEC 1000-4-3 Radiated electro-magnetic field 80-1000 MHz, field strength 10 V/m
Electro-magnetic emission
IEC 1000-3-2 Harmonic current emitted into power source
EN 50081-2 (1994) Part 2 Industrial electro-magnetic field radiated in bands 0.15 – 30 /
30 – 1000 MHz
Ex protection certificates
Special ultrasonic transducers with Ex certification are available. The
evaluation unit can also be delivered in a pressure-sealed housing. Please
see data sheets or ask your dealer.
2.5. Interface specifications
2.5.1. Analogue inputs
8x 4-20 mA standardised signals can be connected to the analogue inputs.
The potential difference of the signal terminals to the device earth must not
exceed 20 V.
The I/O board provides a maximum of 24 V max. 1 for passive water level
sensors.
The I/O board’s inputs and outputs can be switched actively or passively
with microswitches (see the chapter 4.5).
Input signals smaller than the start of the measurement range and larger
than 21mA are evaluated as defective.
2.5.2. Analogue outputs
The assigned variable is represented by a 4 -20 mA standard signal at the
active analogue outputs. The output can be assigned to the outflow, the
mean flow rate, the water temperature or various variables dependent on it.
The measuring ranges can be freely configured by entering the full
measuring scale.
If a variable is evaluated as defective, the analogue signal is reset to <3.6
mA. For values outside of the full measuring scale, the output takes the
relevant extreme value (3.84 or 20.5mA).

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2.5.3. Relay outputs
The existing relays (two per I/O board) can be assigned to the various
sections and variables. The relays have both an NC and an NO connection.
Functions such as the exceeding or falling short of outflow, water level or
outflow total limit values or malfunction alarm can be allocated to the relays.
For further information, see the chapter 6.7 (setting up digital outputs).
2.5.4. Pulse outputs
The existing pulse outputs (two per I/O board) can be assigned to the
various sections and variables. Functions such as metering pulse or
throughput can be allocated to the pulse outputs. For further information,
see the chapter 6.7.
For the possible electro-technical output circuits please see Appendix 7.1
Connection plans for the pulse outputs.
2.5.5. LAN interface (Ethernet)
The LAN interface permits the integration of MultySonic 8000 into Internet
or Intranet. The data logger memory and the MultySonic 8000 parameter
settings can also be accessed via the LAN interface and a ftp protocol.
MultySonic 8000 also has an integrated http server which contains various
information. For further information, see the chapter 7.4.
2.5.6. USB interface
The USB interface (Ver.1) permits the transfer of parameter data and data
logger data upload. Authorised updates can also be performed via the USB
interface. Compatible mass memory devices (memory stick, hard disk
drives) can be plugged for this. The MultySonic 8000 USB manager
comfortably guides the user through the operation. A list of compatible USB
mass memory devices is available from Badger Meter. For further
information, see the chapter 4.11.
2.5.7. RS232 interface
MultySonic 8000 provides a serial interface. See chapter 7.6 for set-up the
RS232 interface.

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3. Flow calculation
MultySonic 8000 can be configured with up to 16 acoustic paths and up to 2 water level
measurements per section (measuring point). Up to 4 sections can be realised with one
evaluation unit. The configuration of a section (measuring point) is defined with a parameter
set; the parameter names appear in italics.
The definition of a section (measuring point) includes in particular its geometric and hydraulic
description, the allocation of measuring card inputs and outputs for the section and the
calculation settings.
The definition of a measuring path contains in particular the sensor position, the path length,
the path angle and information on the sensor used.
3.1. Calculation algorithms
3.1.1. In “Partially filled/filled conduits, open channel” mode
Depending on the water level, the sensor position and possible individual
sensor pair malfunctions one of five different calculation processes is
automatically selected.
1. The outflow is set to 0 if the water level is below a certain value (user
input via parameter software, see chapter 6.10).
2. The outflow is determined via the Manning-Strickler equation if no path
is working below a defined water level.
3. If only one path is in operation the throughput is calculated according
to single path integration.
4. If several paths overflow, the outflow is calculated according to the
Mean Section, Mid Section or Smart Section method (user-defined).
Both calculation criteria are described in ISO6416.
5. When the pipe is full up MultySonic 8000 automatically calculates
according to the calculation model for filled pipes. The calculation
criterium for this is ISO60041 (IEC41).
1. The outflow is set to 0
If flow rates for low levels are not to be recorded, this can be set by
entering the “LowLevelCutOff” parameter.
2. Manning-Strickler equation
Outflow calculation according to the Manning-Strickler equation uses the
level measurement to calculate the outflow. Manning Strickler is used if no
path measurement works below a defined level.
vm = nman * rhy2/3 * Sman1/2 (equation 1)
vm: mean flow rate [m/s]
nman: Rate coefficient according to Strickler [m1/3 /s]
rhy: Hydraulic radius [m] is calculated by MultySonic 8000
Sman: energy drop (slope) [-]
The following figures must be parametered:
•Surface roughness coefficient nman
The surface roughness coefficient depends on the composition of the channel.
The following table gives an overview for typical surfaces.

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Channel types n man
Earth
Earth channels in firm material, smooth 60
Earth channels in firm sand with some clay or gravel 50
Earth channels with a floor of sand and gravel with rendered embankments 45–50
Earth channels made of fine 10/20/30 mm gravel 45
Earth channels made of medium-size 20/40/60 mm gravel 40
Earth channels made of rough 50/100/150 mm gravel 35
Earth channels made of large lumps of clay 30
Earth channels made with rough stones 25–30
Earth channels made of sand, clay or gravel, heavily overgrown 20–25
Rock
Medium rough rock excavation 25–30
Rock excavated with careful blasting 20–25
Very rough rock excavation, large irregularities 15–20
Masonry
Channels made of brickwork, bricks, also clinker bricks, well jointed 80
Rubble masonry 70–80
Brickwork channels (normal) 60
Normal (good) rubble masonry, hewn stones 60
Rough rubble masonry, stones only roughly hewn 50
Broken stone walls, rendered embankments with sand and gravel floor 45–50
Concrete
Smooth cement finish 100
Concete using steel forms 90–100
Smooth rendering 90–95
Smoothed concrete 90
Good formwork, smooth undamaged rendering, smooth concrete 80–90
Concrete produced with wood formwork, without rendering 65–70
Compressed concrete with smooth surface 60–65
Old concrete, uneven surfaces 60
Concrete shells with 150-200 kg cement per m3 , depending on age and type 50–60
Rough concrete lining 55
Uneven concrete surfaces 50
Wooden
New smooth channel 95
Planed, well-jointed boards 90
Unplaned boards 80
Older wooden channel 65–70
Metal
Smooth pipes with countersunk rivet heads 90–95
New cast iron pipes 90
Riveted pipes, rivet not countersunk, overlapped several times in the circumference 65–70
Natural
Natural riverbeds with firm floor, without irregularities 40
Natural riverbeds with moderate bed load 33–35
Natural riverbeds, weed-infested 30–35
Natural riverbeds with rubble and irregularities 30
Natural riverbeds, strong bed load 28
Wild streams with rough rubble (head-sized stones) with resting bed load 25–28
Wild streams with rough rubble, with moving bed load 19–22
Table 1: Roughness coefficients for different channel materials
•Sman
The energy drop (slope) can be calculated from the channel gradient.
Sman = h/l
h
l

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In practice both coefficients Sman and nman can be very precisely
calculated from the flow measurement at normal levels with ultrasound
measuring. Level and flow are stored in the MultySonic 8000 data logger
with sufficient levels and then both Manning Strickler coefficients for dry
weather flow are calculated with a curve fit, e.g. in Excel. Please ask your
dealer for making the curve fit. The transferability of coefficients thus
calculated on to the dry weather flow is very good at many measuring
points.
3. Single path interpolation
If just one single ultrasound path is in operation (or two intersecting paths),
the flow speed calculation is performed according to ISO 6416. For this a
calibration factor is calculated from the relative path height (path height
hp/total level h) from which the mean speed can be calculated.
4. Multiple path interpolation
If several paths or several intersecting paths are in operation the flow is
calculated according to a multiple path interpolation. Two flow equations
are available, the mean section method or the mid-section method. Both
models are described in detail in ISO 6416. The standard method is the
mid-section method. With this method MultySonic 8000 forms sub-
segments, calculates their mean speed and cross-sectional area and
integrates therefrom the total flow in cross-section.
With the mid-section method, a weighting factor kR must be entered which
takes into account friction on the channel floor. For extremely rough
channels the value become a minimum of 0.2, for “friction-free” channels
the value is 1. The table below shows reference values.
A weighting factor for the channel floor (kB, for standard values see the
table below) must also be entered for the mean section method and in
addition a weighting factor for the uppermost segment (kS). With the mean
section method the speed at the surface of the uppermost sub-segment is
calculated by interpolation. kS indicates how strongly this value is taken
into account in the calculation. A value between 0 (no influence) and 1
(complete influence) can be selected. A standard value is 0.1. The
influence of kS on the measurement result is especially small if several
segments are working (3 or more).
hp
h
Lowest sub-segment
2nd sub-segment
Uppermost (nth) sub-segment
... sub-segment
Ultrasound path

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Table 2: Roughness coefficients for calculation models mean-section and mid-section
5. Filled pipe in “Partly-filled pipe” mode
For this case the system can determine the flow with the same process as
in “Filled pipe” mode.
Channel types kR kB
Earth channels
Earth channels in solid material, smooth 0,58 0,48
Earth channels in firm sand with some clay or gravel 0,52 0,38
Earth channels with floor of sand and gravel with rendered embankments 0,52 0,38
Earth channels of fine 10/20/30 mm gravel 0,50 0,32
Earth channels of medium-sized 20/40/60 mm gravel 0,47 0,27
Earth channels of rough 50/100/150 mm gravel 0,44 0,22
Earth channels of large lumps of clay 0,41 0,16
Earth channels, made of rough stones 0,40 0,13
Earth channels of sand, clay or gravel, heavily overgrown 0,37 0,08
Rock channels
Medium rough rock excavation 0,40 0,13
Rock excavated with careful blasting 0,37 0,08
Very rough rock excavation, large irregularities 0,34 0,03
Masonry channels
Channels made of brickwork, bricks, also clinker bricks, well jointed 0,69 0,70
Rubble masonry 0,66 0,64
Channels made of brickwork (normal) 0,58 0,48
Normal (good) rubble masonry, hewn stones 0,58 0,48
Rough rubble masonry, stones only roughly hewn 0,52 0,38
Broken stone walls, rendered embankments with sand and gravel floor 0,51 0,34
Concrete channels
Smooth cement finish 0,80 0,91
Concrete using steel forms 0,78 0,86
Smooth rendering 0,76 0,82
Smoothed concrete 0,75 0,80
Good formwork, smooth undamaged rendering, smooth concrete 0,72 0,75
Concrete produced with wood formwork, without rendering 0,62 0,56
Compressed concrete with smooth surface 0,62 0,56
Old concrete, uneven surfaces 0,58 0,48
Concrete shells with 150-200 kg cement per m3 , depending on age and type 0,55 0,43
Rough concrete lining 0,55 0,43
Uneven concrete surfaces 0,52 0,38
Wooden channels
New smooth channel 0,78 0,86
Planed, well-jointed boards 0,75 0,80
Unplaned boards 0,69 0,70
Older wooden channel 0,62 0,56
Metal channels
Smooth pipe with countersunk rivet heads 0,76 0,82
New cast-iron pipes 0,75 0,80
Riveted pipes, rivet not countersunk, overlapped several times in the circumference 0,62 0,56
Natural watercourses
Natural riverbeds with firm floor, without irregularities 0,47 0,27
Natural riverbeds with moderate bed load 0,43 0,21
Natural riverbeds, weed-infested 0,43 0,20
Natural riverbeds with rubble and irregularities 0,41 0,16
Natural riverbeds, strong bed load 0,40 0,14
Wild streams with rough rubble (head-sized stones) with resting bed load 0,40 0,13
Wild streams with rough rubble, with moving bed load 0,36 0,07

Flow calculation Page 10 / 81
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3.1.2. Crossing paths
With shortened inflow routes we recommend the use of crossing paths (see
chapter 1.3 for achievable accuracies). Paths which are installed in one
section at the same path height are automatically recognised by MultySonic
8000 as crossing paths. The measured velocities of two crossing paths are
averaged. This reduces the influence of so called crossflow effects on the
accuracy.
Crossflows can arise with shortened inflow routes, e.g. when using
MultySonic 8000 behind a bend. This means that the flow vectors are not
yet parallel again to the channel or pipe axis after such disruptions. The
influence of these crossflows can be compensated by the use of
intersecting paths.
3.1.3. In “Full conduit” mode
In this mode your pipe/channel is always full and the flow is calculated from
the product of the average flow rate and the pipe cross-section. The
average flow rate arises from the measured individual rates, taking into
account a position-dependent weighting factor.
The optimum positions for the ultrasonic transducers are stated in the
IEC41 and suitable weighting factors are to be found in the chapter 7.2.
3.2. Water level measurement
Exact water level measurement is decisive for precise flow rate measurement in an
open channel or partially filled pipe. For safety reasons, up to two independent
water level measurements can therefore be allocated to each section.
In normal operation the average of the two level measurements is calculated. If
one of the level measurements should fail, the second measurement is used. In
this case an alarm relay can also be switched (see chapter 6 for parametering).

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4. Installation of the electronic unit
The measuring device should be fitted vertically on a wall or a mounting. To guarantee
stability the load bearing capacity should not be less than 30 kg.
The location should be chosen so that the evaluation unit is not more than 100m from the
measuring point, as the cables are limited in length (Badger Meter should be consulted about
larger distances). The converter cables can in principle be extended. We recommend a
RG58 (Triaxial) cable as an extension. The cable insulation must be suitable for the
operating location. When extending cables care must be taken that the insulated cable ends
are kept as short as possible and the earth and both inner conductors are polarised correctly.
We recommend the use of a suitable housing for the extension. Suitable housings should be
used if the cable extension is to take place in an area liable to contain explosive
atmospheres (Eex e or Eex d).
The evaluation unit must be within reach of power supply and data transfer cables.
The evaluation unit itself should be hung up outside the area liable to contain explosive
atmospheres. If this is not possible pressure-sealed housings are available for the evaluation
unit (please consult Badger Meter).
4.1. Electrical connection
The following connections must be provided depending on equipment and device
configuration.
•Power supply for the electronic part
•Sensor cable (required length can be stated with your order)
•Cable for water level sensors
•Cable for analogue outputs
•Cable for alarm contacts
•Cable for digital outputs
•Cable for interfaces (LAN / USB / RS232)
4.2. Power supply (AC)
The measuring device power consumption depends on the path length (see table).
Number of paths Approx. power consumption [VAC]
4 50
8 55
12 58
Table 3: Power consumption
Cables with a cross-section of at least AWG 16 or 0.75mm2 should be used for the
power supply. The power supply should be suitably protected with safety cut-outs
(min 1.8A). The power supply cables are connected via an angled rubber
connector (supplied).
WARNING! To avoid interference with the measuring signals from electromagnetic
radiation all, input and output cables should be laid in shielded cable channels, separated
in particular from power electronics cables.

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4.3. Ultrasonic board
The multiple-path ultrasound board permits the installation of up to four ultrasound
converter pairs, a total therefore of eight single ultrasound converters. MultySonic
8000 can be fitted with up to three ultrasound boards; it is therefore possible to
connect a maximum of 12 ultrasound board pairs to a MultySonic 8000. If more
than one ultrasound board is installed in MultySonic 8000, ultrasound paths 1 to 4
are located on the board installed furthest left (e.g. the board in expansion slot A),
paths 5 to 8 on the next board and finally paths 9 to 12. The ultrasound board has
six control LEDs in the upper aperture of the expansion slot. The uppermost LED
(orange) flashes during ultrasound measurement, the second LED (orange)
signals communication between the main computer and the ultrasound board.
After starting operation both LEDs flash alternately. The following four green LEDs
signal the adjacent supply voltages. During normal operation all four LEDs should
be illuminated.
When installing the ultrasound converter pairs there is an upstream sensor (code
U) and the downstream sensor (code D). The position results from the
arrangement in relation to the flow direction.
Power supply (AC) for connector
(included)
Control LEDs
Transducer connector terminals

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Numbe
r
Designation Numbe
r
Designation
1 + Path 3 UP (3U+) 15 + Path 1 UP (1U+)
2 - Path 3 UP (3U-) 16 - Path 1 UP (1U-)
3 Earth 17 Earth
4 + Path 3 DOWN (3D+) 18 + Path 1 DOWN (1D+)
5 - Path 3 DOWN (3D-) 19 - Path 1 DOWN (1D-)
6 Earth 20 Earth
7 + Path 4 UP (4U+) 21 + Path 2 UP (2U+)
8 - Path 4 UP (4U-) 22 - Path 2 UP (2U-)
9 Earth 23 Earth
10 + Path 4 DOWN (4D+) 24 + Path 2 DOWN (2D+)
11 - Path 4 DOWN (4D-) 25 - Path 2 DOWN (2D-)
12 Earth 26 Earth
13 Earth 27 Earth
14 Earth 28 Earth
With multiple path installations it is recommended that path 1 is installed as the
bottom path and the following paths then from bottom to top with subsequent
numbering.
If you install several ultrasonic boards, path 1-4 will be located on board 1 (slot A),
path 5-8 on board 2 (slot B), path 9-12 on board 3 (slot C) and (if applicable) path
13-16 on board 4 (slot D).
Please see chapter 6.3.2 to see how to allocate paths to different sites by
parameter software.
4.4. Connecting the ultrasonic transducers
Badger Meter supplies a variety of different sensors which are fitted in different
ways. Please observe the separate instructions provided when connecting
sensors.
Before the cables are connected, the sensors and cables should be checked as
follows:
1. Measurement of the sensor’s electrical resistance. A multimeter with a
measuring range of at least 30 MΩcan be used for this. The measurement
should be performed directly at the sensor contact or as close to the sensor as
possible. If one of the sensors has a resistance of less than 20 MΩit is
defective.
2. Checking the sensor extension cable for short circuits and continuity; a
multimeter can also be used for this. The wires should be checked individually
for short circuits. For the continuity check two wires each can short at one end.
UP
DOWN

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The RG58 cables must be stripped to approx. 25cm on the equipment side. The
braided shield can be shortened to some 2cm after the insulation. The MultySonic
8000 measuring transducer is supplied with special EMC cable screw connections.
The cable is fed into the housing so that the polyurethane insulation lies in the
cable screw connector rubber seal and the braided shield makes housing contact
with the EMC screw connection metal tongues. Both approx 25cm long free cable
inner conductors are now wound round the supplied ferrite ring four times and then
connected to the ultrasound board.
4.4.1. Connection in explosive areas
Work in areas liable to contain explosive atmospheres is to be carried out
exclusively by trained staff. Before starting work a check must be made that
no explosive atmospheres or fluids are present at the measuring point.
Approval should be obtained from the works security service.
Ultrasound converters which carry the designation are available for
installation in areas liable to contain explosive atmospheres. The
ultrasound converters are protected by encapsulation (EExm). It is
recommended that the transducer cable be fed out of the potentially
explosive area and the measuring transducer hung up outside the
potentially explosive area. If the sensor cables are too short they can be
extended within the potentially explosive area; the cable join should be
inside a protective housing with increased safety (EExe). During installation
works the power cable and the ultrasound board connector should be
disconnected from the measurement transducer.
4.5. I/O board
The I/O board offers a series of analogue and digital inputs and outputs. The I/O
board can be installed in any expansion slot (A-D). If required up to two I/O boards
can be mounted. Unlike the ultrasound board the I/O board has a third six-pole
connector (contacts 29-34) for both change-over relays.
If a factory-fitted I/O board is ordered, it is premounted in expansion slot D (further
I/O boards then in expansion slots C, B, A).
Connector 1 (below) -14 (above)
Connector 15 (below) –28 (above)
Connector 29 (below) –34 (above)

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Clamp n° Designation Numbe
r
Designation
15 + Analogue input 1 (4 - 20mA) 1 + Analogue input 5 (4 - 20mA)
16 - Analogue input 1 (4 - 20mA) 2 - Analogue input 5 (4 - 20mA)
17 + Analogue input 2 (4 - 20mA) 3 + Analogue input 6 (4 - 20mA)
18 - Analogue input 2 (4 - 20mA) 4 - Analogue input 6 (4 - 20mA)
19 + Analogue input 3 (4 - 20mA) 5 + Analogue input 7 (4 - 20mA)
20 - Analogue input 3 (4 - 20mA) 6 - Analogue input 7 (4 - 20mA)
21 + Analogue input 4 (4 - 20mA) 7 + Analogue input 8 (4 - 20mA)
22 - Analogue input 4 (4 - 20mA) 8 - Analogue input 8 (4 - 20mA)
23 + Analogue output 1 (4 - 20mA) 9 + Analogue output 3 (4 - 20mA)
24 - Analogue output 1 (4 - 20mA) 10 - Analogue output 3 (4 - 20mA)
25 + Analogue output 2 (4 - 20mA) 11 + Analogue output 4 (4 - 20mA)
26 - Analogue output 2 (4 - 20mA) 12 - Analogue output 4 (4 - 20mA)
27 + Digital output 1 (OC) 13 + Digital output 2 (OC)
28 - Digital output 1 (OC) 14 - Digital output 2 (OC)
Clamp n° Designation Numbe
r
Designation
29 Relay 1 NO 32 Relay 2 NO
30 Relay 1 Basis 33 Relay 2 Basis
31 Relay 1 NC 34 Relay 2 NC
The analogue inputs and outputs can be operated both actively (24VDC supply
from MultySonic 8000) and passively (external 24VDC supply). The I/O board is
delivered from the factory in active mode, i.e. MultySonic 8000 provides a 24VDC
power supply. There are small switches on the I/O board with which the
MultySonic 8000 auxiliary energy can be switched on (active) or off (passive).
WARNING! If MultySonic 8000 is operated actively, i.e. with 24VDC auxiliary
energy feed, no external auxiliary energy may be connected up. Double
auxiliary energy causes damage to MultySonic 8000 and to connected
peripherals. Please ensure that following maximum values are not exceed:
Relay: Umax=250V; Imax=1A
Transistor: Umax=100V; Imax=0.1A
If MultySonic 8000 is operated actively, i.e. with 24VDC auxiliary energy feed,
the galvanic separation between the inputs and outputs is cancelled out.
Please make sure that care is taken to provide a potential-free circuit when
using the inputs and outputs. If necessary the use of separators is
recommended.
Analogue outputs 1-4
(2 switches per output)
Analogue inputs1-8
(1 switch per output)
Digital outputs 1 and 2
(2 switches per output)