GF U1000 V2 User manual

GF Piping Systems
User Manual
U1000 V2 Ultrasonic Flowmeter

Original instruction manual
Follow the instruction manual
The instruction manual is part of the product and is an important element of the safety
concept.
Read and follow the instruction manual.
Always keep the instruction manual available at the product.
Pass on the instruction manual to all subsequent users of the product.
Contents
1Intended use ..................................................................................................................... 3
2About this document ........................................................................................................ 3
2.1 Warnings ........................................................................................................................... 3
2.2 Other related documents ................................................................................................. 4
2.3 Abbreviations .................................................................................................................... 4
3Safety and responsibility .................................................................................................. 4
4Transport and storage...................................................................................................... 5
5Design and function.......................................................................................................... 5
5.1 Design................................................................................................................................ 5
5.2 Principle of operation ....................................................................................................... 5
5.3 User Interface ................................................................................................................... 6
6Technical specifications ................................................................................................... 7
6.1 Default values ................................................................................................................... 8
7Scope of delivery............................................................................................................... 9
8Installation ........................................................................................................................ 9
8.1 Positioning the transducers............................................................................................. 9
8.2 Preparation ......................................................................................................................10
8.3 Start-Up............................................................................................................................10
8.4 Adjusting the sensor distance.........................................................................................12
8.5 Mounting the U1000 V2 on the pipe ................................................................................14
8.5.1 Selecting the pipe adapter ..............................................................................................14
8.5.2 Apply sound-conductive paste ........................................................................................15
8.5.3 Mounting the guide rail ...................................................................................................15
8.5.4 Install the electronics module ........................................................................................16
8.6 Moving the guide rail .......................................................................................................16
8.7 Electrical connection of the U1000 V2............................................................................17
8.8 4-20 mA, Pulse option .....................................................................................................17

Intended use Instruction manual
2
8.8.1 Interface cable .................................................................................................................17
8.8.2 Pulse output.....................................................................................................................18
8.8.3 4-20 mA Output................................................................................................................18
8.9 Modbus option .................................................................................................................18
8.9.1 Interface cable .................................................................................................................18
8.9.2 Modbus connections........................................................................................................19
9Operation..........................................................................................................................19
9.1 Entering the pipe inside diameter ..................................................................................19
9.2 Setting the pulse output..................................................................................................21
9.3 Current output 4 - 20 mA ................................................................................................21
9.4 Modbus.............................................................................................................................21
9.5 Switching off and on again ..............................................................................................23
10 Password-protected menus ...........................................................................................23
10.1 Overview ...........................................................................................................................23
10.2 Opening a password-protected menu............................................................................23
10.3 Changing the selection menus .......................................................................................24
10.4 Changing the numerical values in data menus .............................................................24
10.5 Password-protected menu structure.............................................................................25
10.5.1 Overview ...........................................................................................................................25
10.5.2 Setup ................................................................................................................................26
10.5.3 Pulse output.....................................................................................................................29
10.5.4 Current output .................................................................................................................29
10.5.5 Calibration........................................................................................................................30
10.5.6 Total..................................................................................................................................30
11 Diagnosis..........................................................................................................................31
12 Maintenance.....................................................................................................................31
12.1 Maintenance plan ............................................................................................................32
13 Troubleshooting...............................................................................................................32
13.1 Flow errors and warnings...............................................................................................32
13.2 Error messages ...............................................................................................................32
13.3 Modbus Error Messages .................................................................................................34
14 Removal............................................................................................................................35
15 Disposal............................................................................................................................35

Instruction manual Intended use
3
1Intended use
The U1000 V2 ultrasound flowmeter is used to obtain an optimal measurement of the volume
flow and flow rate in steel and plastic pipes with outside diameter from 22 mm (0.86”) to 180
mm (7”).
Measurable pipe sizes are dependent on pipe material and inner pipe diameter.
Typical applications
Hot water metering and flow measurement
Flow measurement and heat measurement
Cold water metering and flow measurement
Tap water metering and flow measurement
Service water metering and flow measurement
High-purity water metering and flow measurement
2About this document
This document contains all the information necessary for installation, operation and
maintenance of the product.
2.1 Warnings
This instruction manual contains warning notices that alert you to the possibility of injuries or
damage to property. Always read and pay attention to these warnings!
Risk of fatal or serious injury!
There is a risk of fatal or serious physical injury if warnings are ignored!
Danger of minor physical injury!
Failure to pay attention to these warnings will lead to a risk of physical injury!
Risk of damage to property!
Failure to comply leads to a risk of damage to property (loss of time, loss of data, device
fault etc.)!
CAUTION
NOTICE
WARNING
CAUTION

Safety and responsibility Instruction manual
4
Other symbols
Symbol
Meaning
1.

Actions required in a numbered sequence.
Actions required

•
Listing of items on various levels
2.2 Other related documents
Georg Fischer industrial planning fundamentals
These documents are available through agents of GF Piping Systems or at www.gfps.com.
2.3 Abbreviations
Abbreviation
Description
ABS
Acrylonitrile-butadiene-styrene
DA
Double acting function
EMC
Electromagnetic Compatibility
FC
Fail safe to close function
FO
Fail safe to open function
LCD
Liquid crystal display
LED
Light-emitting diode
MOSFET
Metal oxide semiconductor field effect transistor
PB-INSTAFLEX
Polybutene plastic piping system
PE-ELGEF
Polyethylene plastic piping system
PP-PROGEF
Polypropylene plastic piping system
PVDF-SGEF
PVDF (polyvinylidene fluoride) plastic piping system
SPNO MOSFET
Single-pole normally open metal oxide semiconductor field effect transistor
VC-U-PVC
Polyvinyl chloride
3Safety and responsibility
Only use the product for the intended purpose, see Intended Use.
Do not use any damaged or faulty product. Sort out any damaged product immediately.
Make sure that the piping system has been installed professionally and that it is inspected
regularly.
Have the product and accessories installed only by persons who have the required
training, knowledge or experience.

Instruction manual Transport and storage
5
Regularly train personnel on all questions regarding the locally regulations applying to
occupational safety and environmental protection, especially for pressurised pipelines.
4Transport and storage
Protect the product against external forces during transport (impacts, knocks, vibrations
etc.).
Transport and / or store the product unopened in its original packaging.
Protect the product from dust, dirt, moisture as well as heat and ultraviolet radiation.
Ensure that the product is not damaged either by mechanical or thermal influences.
Before assembling, check the product for damage during transport.
5Design and function
5.1 Design
1
Power supply (AC/DC)
4
Guide rail
2
Pipe clamp
5
User interface
3
Electronics module
6
Pipe
The U1000 V2 consists of an electronics module (3) and a guide rail (4), which together form a
single unit which is fixed to the pipe (6) by pipe clamps (2).
The U1000 V2 is supplied with power through an external 12 –24 V power adapter (1).
5.2 Principle of operation
The U1000 V2 takes accurate flow measurements by determining the difference between the
transmission times of two ultrasound signals.

Design and function Instruction manual
6
A periodic voltage pulse acts on the transducer crystals and produces an ultrasound beam at
a certain frequency. The beam is first transmitted by the downstream transducer (blue) to the
upstream transducer (red).
The beam is then sent in the opposite direction, i.e. from the upstream transducer (red) to the
downstream transducer (blue). The time taken for the ultrasound to pass through the liquid in
this direction is slightly shortened by the speed at which the liquid flows through the pipe.
The resulting time difference T1 –T2 is directly proportional to the speed at which the liquid
flows through the pipe.
5.3 User Interface
1
LED 4 - 20 mA is lit when the current output is active
2
LED Pulse is lit when the pulse output is active
3
Button (selection button) switches backwards and forwards through the displayed
options
4
Button (reduce value) reduces the value incrementally in the digital input fields
5
Button (increase value) increases the value incrementally in the digital input fields
6
Button (confirm input) confirms the value displayed, ends data input, changes to
another menu or the flow values screen
7
LCD display with backlighting (2 rows x 16 characters)
Principle of
operation

Instruction manual Technical specifications
7
6Technical specifications
Data
Kv value
Measurement technology
Transmission time
Measurement channels
1
Resolution of time calculation
± 50 ps
Dynamics (turn-down ratio)
200:1
Flow rate
0.1m/s - 10m/s (0.3 ft/s - 32 ft/s)
Usable liquid types
High purity water, clean water with < 3 percent by volume
of particle content, or up to 30% ethylene glycol.
Accuracy
± 3 % of flow value with a flow rate of > 0.3 m/s
Repeatability
± 0.15 % of measured value
Selectable units of
measurement
Flow rate
m/s, ft/s
Volume flow
l/s, l/min, m3/min, m3/hr
gal/s, gal/min, USgal/s, USgal/min
Volume
l, m3, gals, USgals
Languages supported
English
Power input
12 –24 V (AC or DC)
Power consumption
7 VA max.
Cable
5 m shielded (6-wire)
Pulse output
Output
Opto-isolated MOSFET volt free contact (NO/NC)
Insulation
2500 V
Pulse width
Default value
50 ms
Programmable range
3 –99 ms
Pulse repeat rate
Up to 166 pulses/s (depending on pulse width)
Frequency based mode
200 Hz max. (Range 1-200)
Max. voltage/current load
48 V AC / 500 mA
Current output
Output
4 –20 mA
Resolution
0.1 % of total scale
Maximum load
620 Ω
Insulation
1500 V optically insulated
Alarm current
3.5 mA
Housing

Technical specifications Instruction manual
8
Data
Kv value
Material
Polycarbonate
Mounting
Pipe mountable
Protection class
IP54
Fire classification
UL94 V-0
Dimensions
250 mm x 48 mm x 90 mm
(electronics + guide rail)
Weight
0.5 kg
Ambient conditions
Pipe temperature
0 °C to +85 °C
Operating temperature
(electronics)
0 °C to +50 °C
Storage temperature
-10 °C to +60 °C
Humidity
90% relative humidity at < 50 °C
Display
LCD
2 lines x 16 characters
Viewing angle
30° min., 40° max.
Active area (W) x (H)
58 mm x 11 mm
Keypad
Format
Keypad with 4 buttons
6.1 Default values
The settings are configured at the factory for either metric or imperial dimensions and
weights.
Parameters
Metric dimensions
Imperial dimensions
Dimensions
mm
Inches
Volume flow
l/min
USgal/min
Pipe size
50 mm
2“
4 - 20 mA
On
On
Pulse output
Off
Off
Volume per pulse
10 l
10 US gallons
Pulse width
50 ms
50 ms
Damping
20 s
20 s
Calibration factor
1.000
1.000
Zero Cut-off
0.02 m/s
0.07 m/s

Instruction manual Scope of delivery
9
Parameters
Metric dimensions
Imperial dimensions
Zero offset
0.000 l/min
0.000 gal/min
7Scope of delivery
Component
Pcs.
U1000 V2 electronics module
1
Guide rail
1
Gel-Pads
4
Syringe with sound-conductive paste
1
Pipe clamps
2
Cable
1
Adapter for small pipes < 40 mm
1
Adapter for small pipes < 60 mm
1
8Installation
8.1 Positioning the transducers
The U1000 V2 requires an even and uniform flow profile, since distortions in the flow can
cause unpredictable measurement errors.
In many applications, however, it is not possible to have a uniform flow rate through 360°.
This may be, for example, because there are air bubbles inside the top of the pipe, or
turbulence in the pipe, or sludge at the bottom of the pipe.
Experience has shown that the most accurate results are obtained if the guide rail of the
transducers is not mounted vertically to the pipe, but turned at an angle of about 45° to the
right or left on the pipe.
Possible air gap
Turbulent flow profile
Laminar flow profile
Possible deposits
(sludge)
10x diameter
Possible sensor
position
20x diameter
Flow

Installation Instruction manual
10
Incorrect measurements
Measurements can be distorted if the transducers are positioned close to upstream pipe
components and fittings such as pipe bends, T-branches, valves, pumps and similar
obstacles.
To ensure that the U1000 V2 is positioned at a place that has an undistorted flow profile, the
transducers must be mounted sufficiently far from possible sources of distortion to prevent
these from having any effect on the measurement.
Install a straight section of pipe with length 20 times the diameter on the upstream side
of the transducer.
In exceptional cases, a pipe with length 10 times the diameter may be sufficient.
Install a pipe section with length 10 times the diameter on the downstream side of the
transducer.
In exceptional cases, a pipe with length 5 times the diameter may be sufficient.
8.2 Preparation
Before attaching the transducers, make sure that desired position meets the distance
requirements.
See Section 8.1 Positioning the transducers, Page 9.
Clean the pipe to remove any grease residues.
Remove any dirt and flaking paint in order to ensure an even surface.
Maximum accuracy
A smooth and even contact between pipe surface and transducer is an important factor for
obtaining a sufficiently strong ultrasound signal.
8.3 Start-Up
Connect the U1000 V2 to power supply
See section 8.7 Electrical connection of the
U1000 V2 for further details.
NOTICE
NOTICE

Instruction manual Installation
11
The U1000 V2 boots for the first time.
The GF start screen is displayed for 5 s.
The start-up wizard automatically starts.
Enter pipe id menu appears.
Select your pipe inside diameter and press
to acknowledge.
See Section 9.1 Entering the pipe inside
diameter, Page 19 for more details.
Select your pipe material and press to
acknowledge.
Select your instrument fluid and press
to acknowledge.
Select you media temperature:
- 'Cold' for temperature 2 °C to 40 °C
- 'Hot' for temperature 40 °C to 85 °C
Press to acknowledge.
The U1000 V2 shows you the correct
transducer distance for your application.
Press to acknowledge
Proceed with 8.4 Adjusting the sensor
distance
The U1000 V2 searches for a valid signal.
If a valid signal is detected, the signal strength
and flow are displayed.
The direction of flow at switch-on time is taken
as a positive flow value and the current and
pulse output refer to this flow direction.

Installation Instruction manual
12
If the flow direction is reversed, the volume
flow is still displayed. The activity indicator
changes from a star to an exclamation mark,
no more pulses are generated and the
4 –20 mA current output changes to a 3.5 mA
alarm status.
If the U1000 V2 does not detect a valid signal
'Sig: 00%' is shown.
In this case please make sure you followed the
steps in section 8.4 Adjusting the sensor
distance and 8.5 Mounting the U1000 V2 on the
pipe correctly.
See also section 13 Troubleshooting for further
advice.
8.4 Adjusting the sensor distance
Maximum accuracy
The two sensors must be placed at defined distance relative to each other, where the
distance depends on the pipe inside diameter and pipe material.
Define optimal sensor distance with entering your pipe credentials in the U1000 V2 start-
up wizard (see section 8.3 Start-Up). (E.g. B-4 for PVC-U pipe with 50 mm inside diameter)
Loosen the sensor mounting screws.
NOTICE

Instruction manual Installation
13
Move the sensors to the optimal position (see start-up wizard in section 8.3 Start-Up).
Tighten the sensor mounting screws.
NOTE. When the sensors have been moved to the correct setting and the guide rail is
attached to the pipe REMOVE the sensor holding screws, which will allow the spring loaded
transducers to make contact with the pipe.
NOTICE

Installation Instruction manual
14
8.5 Mounting the U1000 V2 on the pipe
8.5.1 Selecting the pipe adapter
Two adapters are available for attaching the measuring device to pipes with an outside
diameter of ≤60 mm.
If these adapters are not necessary, store them away for a possible later change of position.
Outside diameter less than 40 mm –top and bottom pipe adapters (black)
Outside diameter 40 mm –60 mm –top pipe adapter (black)
Outside diameter more than 60 mm
The adapters are placed on the pipe so that the top pipe adapter engages in the end pieces on
the guide rail.
NOTICE

Instruction manual Installation
15
8.5.2 Apply sound-conductive paste
Using the syringe, apply sound-conductive paste (3) to the sensor contact surfaces (1)
and (2).
8.5.3 Mounting the guide rail
Mount the guide rail (1) and pipe adapters if necessary (see section 8.5.1 Selecting the
pipe adapter) on the pipe (3) using the pipe clamps (2).
Loosen the mounting screws and remove along with the washers.
Store the mounting screws and washers away for future maintenance work or for a possible
change of position later.
NOTICE

Installation Instruction manual
16
8.5.4 Install the electronics module
Connect the power supply (1) to the electronics module (2).
Plug the cables of the two sensors into the sockets (3) and (4) on the electronics module.
The cables can be assigned as desired.
Set the electronics module (1) on the guide rail (2) and engage it in the clamp connections
at both ends.
8.6 Moving the guide rail
If it becomes necessary to change the position of the guide rail or the sensors:
Remove complete assembly from the pipe.
Undo the screw at the end of the guide rail and gently lift the same end as shown.
The opposite end of the electronics can now be released from the guide rail.
Disconnect the sensors.
Remove the original Gel pads from the sensors.

Instruction manual Installation
17
Push the sensor blocks into the guide rail so that the washers and locking screws can be
refitted.
Place replacement Gel pads down the centre of the sensor block.
Follow the procedure in section 8.5 for re-installing the guide rail on the pipe.
8.7 Electrical connection of the U1000 V2
The U1000 V2 operates in the voltage range 12 –24 V (AC/DC). The power supply must have a
minimum rating of 7 VA per instrument. To fully meet the requirements of EMC regulations,
a 12 V connection is recommended for domestic and light industrial applications.
For full immunity to electrical interference the screen of the power/pulse output cable and
modbus cable should be connected to Earth.
For safety, connecting the U1000 V2 to a power supply via a mains rated transformer is the
responsibility of the installer to conform to the regional voltage safety directives.
Connect the external power supply to the Brown and Blue wires of the six-core cable.
8.8 4-20 mA, Pulse option
Connect the external power supply to the Brown and Blue wires of the six-core cable.
Connect the White and Green wires to Pulse and the Red and Black wires to 4-20 mA
input.
8.8.1 Interface cable
The U1000 V2 6-wire interface cable
1
12 V / 24 V input (brown)
2
12 V / 24 V return conductor (blue)
3
Pulse + (white)
The SPNO MOSFET relay in the electronics module
supplies an insulated switching signal for a
switchable current of up to 500 mA and a voltage of up
to 48 VAC. This relay also provides 2500 V insulation.
Galvanically speaking, it is a volt free output.
4
Pulse - (green)
5
Output (+), 4 –20 mA (red)
NOTICE

Installation Instruction manual
18
6
Return conductor (-), 4 - 20
mA (black)
The 4 - 20 mA current output is an insulated current
source designed for loads of < 620 Ω.
The alarm current is triggered by flows outside the
specified range or by signal loss, and is set at 3.5 mA.
7
Non-insulated shielding
Electric shock due to short-current!
Before connecting the U1000 V2 to an external power supply, make sure that the power
supply is switched off.
8.8.2 Pulse output
The isolated pulse output is provided by a SPNO/SPNC MOSFET relay which has a maximum
load current of 500mA and maximum load voltage of 48V AC. The relay also provides 2500V
isolation, between the sensor’s electronics and the outside world.
The pulse output is available at the White and Green wires. Electrically this is a volt, or
potential free contact, and when selected as a low flow alarm is configurable NO/NC.
8.8.3 4-20 mA Output
The isolated 4-20mA is a current source and can drive into a maximum load of 620Ω.
The 4-20mA current output is available at the Red and Black wires.
The alarm current due to a flow outside the range specified or due to a loss of signal is set at
3.5mA.
8.9 Modbus option
8.9.1 Interface cable
1
Modbus –ve (brown)
2
Modbus ground (white)
3
Modbus +ve (black)
4
Modbus ground (white)
5
Modbus optional ground (uninsulated screen)
WARNING
CAUTION

Instruction manual Operation
19
8.9.2 Modbus connections
A lead is provided for the Modbus connections that plugs into the electronics assembly near
the power cable entry. The Brown is the -ve bus wire and the Black is the +ve bus wire. Both
White wires go to ground.
For reliable operation of a Modbus network the cable type and installation must comply with
requirements in the Modbus specification document “MODBUS over Serial Line Specification
& Implementation guide V1.0”.
9Operation
9.1 Entering the pipe inside diameter
Switch on the U1000 V2 for the first time.
The GF start screen is displayed for 5 s.
The hundreds digit (050.0) for the pipe inside diameter flashes.
Press the button.
The flashing hundreds digit (050.0) increases from 0 to 1.
Press the button.
The flashing hundreds digit (050.0) decreases from 1 to 0.
Press the button.
The tens digit (050.0) flashes.
Press the button.
The flashing tens digit (050,0) increases through the number sequence 0, 1, 2,
3, 4, 5, 6, 7, 8, 9 ,0.