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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UF_Multy8000_BA_02_1007
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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UF_Multy8000_BA_02_1007
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
UF_Multy8000_BA_02_1007
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

Specifications Page 2 / 81
UF_Multy8000_BA_02_1007
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.