Hontzsch ExactSonic III User manual

_________________________________________________________________________________________
_____________________________________________________________________________________
1 von 49
U455_ExactSonicIII_B_e_230330
ExactSonic III
Portable Ultrasonic Flow Meter
Operating Instructions

_________________________________________________________________________________________
_________________________________________________________________________________________________
2 von 49
U455_ExactSonicIII_B_e_230330
Contents
1General Description.........................................................................................................................................4
1.1 Introduction.................................................................................................................................................4
2Principle of Operation......................................................................................................................................4
2.1 Reflex (V) Mode..........................................................................................................................................6
2.2 Double Reflex (W) Mode ............................................................................................................................6
2.3 Triple Reflex (WV) Mode ............................................................................................................................6
2.4 Quadruple Reflex (WW) Mode ...................................................................................................................6
2.5 Diagonal Mode............................................................................................................................................6
3Scope of Delivery.............................................................................................................................................7
3.1 ExactSonic III Instrument............................................................................................................................8
3.1.1 Connections........................................................................................................................................8
3.1.2 Keypad................................................................................................................................................9
4Installation......................................................................................................................................................11
4.1 Transducer Positioning.............................................................................................................................11
4.2 Attaching the Transducers........................................................................................................................12
4.2.1 Preparation........................................................................................................................................12
4.2.2 Assembling the Guide Rails..............................................................................................................12
4.2.3 Fitting the transducers ......................................................................................................................13
4.3 Connecting Outputs..................................................................................................................................14
4.4 Connecting the Power Supply...................................................................................................................15
4.4.1 Charging the Battery.........................................................................................................................15
4.4.2 Optimising Battery Life......................................................................................................................15
4.5 Initial use and adjustment of the instrument.............................................................................................16
4.5.1 Checking System Health...................................................................................................................16
4.5.2 Selecting a Language .......................................................................................................................16
4.5.3 Setting Date & Time..........................................................................................................................17
4.5.4 Enabling/Disabling the Backlight.......................................................................................................17
5Using the Quick Start Menu...........................................................................................................................18
5.1 Entering the Site Data...............................................................................................................................18
5.2 Attaching and Connecting the Transducers..............................................................................................20
5.3 Taking a Flow Reading.............................................................................................................................20
5.4 Flow Monitoring.........................................................................................................................................20
5.5 Total Flows................................................................................................................................................20
5.5.1 Calculating the Average Flow ...........................................................................................................21
5.5.2 Resetting Totals................................................................................................................................21
6Managing Named Sites .................................................................................................................................22
6.1 Selecting an Existing Site..........................................................................................................................22
6.2 Adding a New Site.....................................................................................................................................23
6.3 Changing a Site Name..............................................................................................................................23
6.4 Editing Site Data .......................................................................................................................................23
6.5 Calibration of the Instrument.....................................................................................................................24
6.5.1 Adjusting the Zero Cutoff..................................................................................................................24
6.5.2 Adjusting the Zero-Flow Offset (ZFO)...............................................................................................24
6.5.3 Adjusting the Calibration Vactor........................................................................................................24
6.5.4 Adjusting the Roughness Factor.......................................................................................................25
6.5.5 Adjusting the Damping Factor...........................................................................................................26
7Logging Functions .........................................................................................................................................26
7.1 Manual Logging.........................................................................................................................................26
7.2 Scheduling Logging...................................................................................................................................27
7.3 Stopping Logging......................................................................................................................................27
7.4 Copying Logged Data to a USB Memory Stick.........................................................................................27
7.5 Clearing Log Files von Protokolldateien ...................................................................................................28
7.6 Logger Status............................................................................................................................................28
8Outputs..........................................................................................................................................................29

_________________________________________________________________________________________
_____________________________________________________________________________________
3 von 49
U455_ExactSonicIII_B_e_230330
8.1 Current Loop Setup / Analog Output.........................................................................................................29
8.1.1 Converting the Measured Current to Flow Rate ...............................................................................30
8.2 Digital Outputs ..........................................................................................................................................31
8.2.1 Pulse Output .....................................................................................................................................32
8.2.2 Volumetric Pulse...............................................................................................................................32
8.2.3 Alarm Output.....................................................................................................................................32
8.2.4 Frequency Output .............................................................................................................................34
9NiMh Power Screen.......................................................................................................................................34
9.1 Power Checklist........................................................................................................................................34
10 Primary Flow.............................................................................................................................................35
11 Maintenance and Repair...........................................................................................................................36
12 Troubleshooting........................................................................................................................................37
12.1 Overview...................................................................................................................................................37
12.2 General troubleshooting procedure ..........................................................................................................38
12.3 Warning and Status Messages.................................................................................................................39
12.4 Test Block.................................................................................................................................................43
12.5 Reset.........................................................................................................................................................44
12.6 Diagnostics ...............................................................................................................................................44
12.6.1 Advanced Diagnostics ..................................................................................................................45
13 Appendix...................................................................................................................................................46
13.1 Technical Data..........................................................................................................................................46
14 Declaration of conformity, Declaration of Incorporation............................................................................49

_________________________________________________________________________________________
_________________________________________________________________________________________________
4 von 49
U455_ExactSonicIII_B_e_230330
1General Description
1.1 Introduction
This manual describes the operation of the ExactSonic III portable flowmeter. The flowmeter is designed to
work with clamp-on transducers to enable the flow of a liquid within a closed pipe to be measured accu-
rately without needing to insert any mechanical parts through the pipe wall or protrude into the flow sys-
tem.
Using ultrasonic transit time techniques, the ExactSonic III is controlled by a microprocessor system which
contains a wide range of data enabling it to be used with pipes with an outside diameter ranging from
13 mm to 2000 mm and constructed of almost any material. The instrument will also operate over a wide
range of fluid temperatures.
Easy to operate, the ExactSonic III standard features are:
•large, easy to read graphic display with backlighting
•simple to follow duak function keypad
•simple ‘Quick Start’ set up procedure
•continuous signal monitoring
•3 isolated switched outputs for use in any combination as a
oPulse output (volume)
oFrequency output (flow)
oAlarm output (flow, volume, flow signal quality)
•current output with a selectable range between 0 and 24 mA (e.g. 4 … 20mA), including support for
an alarm current
•rechargeable battery
•battery management
•diagnostics
Volumetric flow rates are displayed in: l/s, l/min, l/h, m³/s, m³/min, m³/h, Ml/s, Ml/min, Ml/hr, Ml/day,
USgals/sec, USgals/min, USgals/h, USgals/day, Barrel/h, Barrel/day, ft3/sec, ft3/min, ft3/hr, MUSgal/hr),
MUSgal/day, Imp Gals/sec, Imp. Gal/m, Imp Gals/hr, Imp Gals/day, Barrels/hr, Barrels/day.
Flow velocity is displayed in metres or feet per second.
When operating in the 'Flow Reading' mode the integrated volume (or amount), is displayed as a 12-digit
number with correct sign.
The flowmeter can be used to measure liquids with less than 3% volume of solids content. An appli-cation
for cloudy liquids such as rivers and wastewater is also possible as well as for demineralised water.
Typical ExactSonic III applications are
•river water
•sea water
•potable water
•demineralised water
•treated water
2Principle of Operation
When ultrasound is transmitted through a liquid the speed at which the sound travels through the liquid is
accelerated slightly if it is transmitted in the same direction as the liquid flow and decelerated slightly if
transmitted against it. The difference in time taken by the sound to travel the same distance but in oppo-
site directions is therefore directly proportional to the flow velocity of the liquid.
The ExactSonic III system employs two ultrasonic transducers attached to the pipe carrying the liquid and

_________________________________________________________________________________________
_____________________________________________________________________________________
5 von 49
U455_ExactSonicIII_B_e_230330
compares the time taken to transmit an ultrasound signal in each direction. If the sound characteris-tics of
the fluid are known, the ExactSonic III microprocessor can use the results of the transit time calculations
to compute the fluid flow velocity. Once the flow velocity is known, the volumetric flow can be calculated
easily for a given pipe diameter. The ExactSonic II can be set up to operate in one of five modes deter-
mined mainly by the pipe diameter and the type of transducer set in use. The diagram below illustrates the
importance of applying the correct separation distance between the transducers to obtain the strongest
signal.
Reflex (V) mode
(single bounce)
Reflex (W) mode
(double bounce)
Reflex (WV) mode
(triple bounce)
Reflex (WW) mode
(quadruple bounce)
Diagonal mode
(without bounce)
Abbildung 2.1 Messmodi
Figure 2.1 Operationg Modes

_________________________________________________________________________________________
_________________________________________________________________________________________________
6 von 49
U455_ExactSonicIII_B_e_230330
2.1 Reflex (V) Mode
This is the most commonly used mode. The two transducers (U & D) are attached to the pipe in line with
each other and the signals passing between them are reflected by the opposite pipe wall.
The separation distance is calculated by the instrument in response to entered data concerning the pipe
and fluid characteristics.
2.2 Double Reflex (W) Mode
In this mode the separation distance is calculated to give a double bounce*. This is most likely to occur if
the pipe diameter is so small that the calculated reflex mode separation distance would be impractical
for the transducers in use.
2.3 Triple Reflex (WV) Mode
This mode goes one step further to show a triple bounce* situation. This would normally apply when work-
ing with very small pipes relative to the transducer range in use.
2.4 Quadruple Reflex (WW) Mode
This mode goes one step further again, to use a quadruple bounce*. Again this would normally apply when
working with very small pipes relative to the transducer range in use.
2.5 Diagonal Mode
This mode might be selected where relatively large pipes are concerned. In this mode the transducers are
located on opposite sides of the pipe but the separation distance is still critical in order for the signals to be
received correctly.
* In general, if should be noted that errors accumulate as the number of bounces increase. Units are cali-
brated using single reflex mode. Any inherent inaccuracy will be amplified by using higher order modes
such as triple or quadruple bounce. In addition to this, as the path length is longer, the signal will also be
more attenuated with higher order operating modes.

_________________________________________________________________________________________
_____________________________________________________________________________________
7 von 49
U455_ExactSonicIII_B_e_230330
3Scope of Delivery
The ExactSonic III equipment is supplied in a rugged IP67 carrying case fitted with a foam insert to give
added protection for transportation. The supplied components are shown below in figure 3.1.
Standard equipment
1ExactSonic III instrument with backlit graphic display
2. Power supply with UK/US/European adapters, 110/240VAC
3. Output signal cable (current loop & 3 digital outputs)
4. Transducer cables (2x) each 2 m long
5. Chains (2x), each 3.3 m long
6. Guide rails (2x) for use with A or B type transducers
7. Ultrasonic couplant
8. Tape measure
9. Transducer set „A“ for use on pipes with 13 mm to 115 mm outside diameter.
Transducer set „B“ for use on pipes with 50 mm to 2000 mm outside diameter.
10. Test block
11. Syringe (for the application of the couplant during installation)
12. Ruled separation bar (two pieces)
13. USB stick
Figure 3.1 Standard Equipment
1
2
3
4
4
5
5
6
6
7
8
9
9
10
11
12
11
13
11

_________________________________________________________________________________________
_________________________________________________________________________________________________
8 von 49
U455_ExactSonicIII_B_e_230330
3.1 ExactSonic III Instrument
The ExactSonic III is a microprocessor controlled instrument, operated through a menu system using an
inbuilt LCD and keypad. It can be used to display the instantaneous fluid flow rate or velocity, together
with totalised values.
The instrument can also provide a variable current or variable ‘pulse’ (volumetric or flow frequency) output
that is proportional to the detected flow rate. In addition to this, the instrument can also be used to signal
alarm conditions such as flow too high, too low or a volume being exceeded. This output can be calibrated
to suit a particular flow range and used with a range of external interface devices, such as those found in
building management systems or site monitoring systems. The three isolated outputs provided can be con-
figured as required in any order and with any functionality as just mentioned.
3.1.1 Connections
Figure 3.2 Front and top view
Top view
Output cable
connector
USB socket
Transducer cable
connectors
Output cable
connector
Transducer cable
connectors
USB socket
Front view
Battery charging point (power supply)

_________________________________________________________________________________________
_____________________________________________________________________________________
9 von 49
U455_ExactSonicIII_B_e_230330
Transducer cable connectors
The transducers are connected to two colour-coded miniature coaxial sockets located on the top of the
instrument. Using the red/blue connector cables provided, the upstream transducer should always be
connected to the RED socket and the downstream transducer to the BLUE one for a positive flow reading.
It is safe to connect or disconnect the cable while the instrument is switched on (see figure 3.2).
USB socket
USB memory sticks can be inserted here so that recorded logger data can be transferred (see figure 3.2).
Output cable connector
The current/’pulse’output cable should be connected to the 9-pin connector on the top of the flowmeter.
The 'tails' on the free end of the cable must be terminated to suit the intended application (see under 4.3).
Battery charger connection (power supply)
The supplied battery charger is connected tot he instrument by means oft he grey 2-pin connector at the
base of the unit as shown in figure 3.2. More info see under 4.4.
Note: The above connectors have different key-ways to prevent incorrect cable connection.
3.1.2 Keypad
The instrument is configured and controlled via a 16-key tactile membrane keypad as shown in figure 3.3.
ON/OFF Key
The ON/OFF key is shown on the top left of the keypad. When turned ON an initialisation screen is dis-
played on the LCD showing the instrument’s serial number and software revision.
Once this appears, the instrument can be started by pressing the ENTER key once –the initialization
screen is then re-placed by a MAIN MENU which provides access to the remaining functions.
Menus and the menu selection keys
The ExactSonic III menus are arranged hierarchically with the MAIN MENU being at the top level. Menu
navigation is achieved by three keys on the right hand side of the keypad which are used to scroll UP and
DOWN a menu list and SELECT a menu item. When scrolling through a menu an arrow-shaped cursor
moves up and down the left hand side of the screen to indicate the active menu choice which can then be
selected by pressing the ENTER (SELECT) key. Some menus have more options than can be shown on the
screen at the same time, in which case the 'overflowed' choices can be brought into view by continuing to
scroll DOWN past the bottom visible item. If you select Exit it usually results in taking you back one level in
Figure 3.3 Keypad
Numerical keypad
with dual function keys
ON/OFF
Scroll UP
Scroll DOWN
ENTER (Select)
Scroll LEFT
Scroll RIGHT

_________________________________________________________________________________________
_________________________________________________________________________________________________
10 von 49
U455_ExactSonicIII_B_e_230330
ExactSonic MAIN
↱ Quick start..
View / Edit Site Data..
Setup Instrument..
Data Logger..
Read Flow..
19-01-23 13:45:42
the menu hierarchy, but in some cases it may go directly to the FLOW READING screen. Some screens
require you to move the cursor left and right along the display as well as up and down. This is achieved
using keys 5 (scroll LEFT) and 6 (scroll RIGHT).
Dual Function Numerical Keypad
The block of keys shown in the centre of the keypad in figure 3.3 are dual function keys. They can be used
to enter straightforward numerical data, select the displayed flow units or provide quick access to fre-
quently required control menus.
Key
Use
0
Switch between READ FLOW and READ VELOCITY screens (via a short
press when reading flow or velocity), enter the SET ZERO FLOW screen
(long press when reading flow), or freeze and un-freeze diagnostic values
in the DIAGNOSTIC screen.
1
Display the LOGGER menu (see under 7).
2
Display the SYSTEM SETTING menu (see under 4.5.1).
3
Display the OUTPUT SETUP menu (see under 8)
4
Switch to READ VELOCITY from the READ FLOW display
5
No function –reserved for future use
6
No function –reserved for future use
7
Cycle through the available display units
8
Switch to READ FLOW from the READ VELOCITY display
9
No function –reserved for future use
Delete
+/-
No shortcut function: within text entries, deletes character to left of flash-
ing cursor. Deletes alarms when activated, or return to the MAIN MENU
from the SUMMARY screen
Diags
.
Display the DIAGNOSTICS screen (see under 12.6)
Main Menu
Figure 3.4 MAIN MENU