HyQuest Solutions TB340A User manual

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 1 Issue 7 : 28 Apr, 2017
QUALITY SYSTEM
ISO: 9001
CERTIFIED
INSTRUCTION MANUAL
TB340A TBRG Calibrator
(TBRG AUTOMATED LABORATORY CALIBRATOR)
HYQUEST SOLUTIONS PTY LTD
48-50 Scrivener St, Warwick Farm, NSW 2170, AUSTRALIA
Phone: [phone] Fax: [phone]
Email: [email protected]
Web: www.hyquestsolutions.com.au

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 2 Issue 7 : 28 Apr, 2017
AMENDMENTS
Issue
Description
By
Date
0.01
Draft version 1.
SG
29-1-16
1
Initial Release
SG
11-7-16
2
Updated Dimensions and Weight in Specifications
SL
11-8-16
3
Section 4.2.4 –Highest rate nozzle should be fitted to position #5
SL
12-12-16
4
Updated transit bracket photos, added Configure PLC section 4.7.4
and expanded the Calibration procedure section 4.9
SL
21-2-17
5
Updated unpacking and installation photos
SL
27-2-17
6
Added sample Certificate of Calibration to Reports section 4.6.3
Changes to PDF & Printing section 4.7.3
Added items to Troubleshooting list
SL
11-4-17
7
Corrected the Dispense Accuracy in the Specification
SL
28-4-17

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 3 Issue 7 : 28 Apr, 2017
TABLE OF CONTENTS
1INTRODUCTION ........................................................................... 5
2SPECIFICATIONS .......................................................................... 6
2.1 Mechanical Specifications.........................................................................6
2.2 Electrical Specifications ..........................................................................6
3INSTALLATION ............................................................................ 7
3.1 Setting up the TBRG Calibrator Rig..............................................................7
3.1.1 Turning the TBRG Calibrator On.......................................................... 10
3.2 Setting up the PC ................................................................................ 11
3.2.1 Install the Software ........................................................................ 11
3.2.2 Connecting the PC to the TBRG Calibrator ............................................. 11
3.2.3 Running the Software for the First Time................................................ 12
4OPERATION .............................................................................. 13
4.1 Preparing a TBRG on a station ................................................................. 13
4.1.1 Connecting the Reed Switch Inputs ...................................................... 14
4.2 Preparing a Test Series.......................................................................... 15
4.2.1 Opening the Setup Window................................................................ 15
4.2.2 Tipping Bucket Rain Gauge ................................................................ 16
4.2.3 Test Options ................................................................................. 17
4.2.4 Nozzles ....................................................................................... 18
4.2.5 Tests .......................................................................................... 19
4.3 Performing a Wetting Cycle .................................................................... 20
4.4 Starting a Test.................................................................................... 20
4.5 Monitoring a Test Series......................................................................... 21
4.5.1 Units List ..................................................................................... 22
4.5.2 Unit Details .................................................................................. 23
4.5.3 Test Overview and Control ................................................................ 24
4.5.4 Current Test ................................................................................. 25
4.5.5 Test History.................................................................................. 26
4.6 Reporting.......................................................................................... 27
4.6.1 Unit List ...................................................................................... 28
4.6.2 Test Data Table ............................................................................. 29
4.6.3 Staged Test Data for Report .............................................................. 30
4.6.4 Test Details .................................................................................. 32
4.7 Program Options ................................................................................. 33
4.7.1 Reports ....................................................................................... 34
4.7.2 Communications............................................................................. 35
4.7.3 PDF & Printing ............................................................................... 36
4.7.4 Configure PLC ............................................................................... 37
4.8 Model Management .............................................................................. 38
4.8.1 Model ......................................................................................... 39
4.8.2 Bucket ........................................................................................ 40
4.8.3 Catch Size .................................................................................... 41
4.8.4 Theoretical and Practical Values ......................................................... 41
4.8.5 Tolerances.................................................................................... 42
4.9 Calibrating a Load Cell .......................................................................... 45
5TROUBLESHOOTING / FAQ............................................................ 49

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 4 Issue 7 : 28 Apr, 2017
TABLE OF FIGURES
Figure 1-1 TBRG Calibrator overview...................................................................5
Figure 3-1 Power switch in cabinet of TBRG Calibrator ........................................... 10
Figure 3-2 Device Manager in Control Panel (Windows 7) ......................................... 11
Figure 3-3 USB to RS-485 adapter in Device Manger ............................................... 12
Figure 4-1 Reed switch connections .................................................................. 14
Figure 4-2 Test setup selection........................................................................ 15
Figure 4-3 Tipping bucket rain gauge options in test setup ....................................... 16
Figure 4-4 Test options in test setup ................................................................. 17
Figure 4-5 Nozzle setup in test setup ................................................................ 18
Figure 4-6 Test process setup in test setup ......................................................... 19
Figure 4-7 Main testing screen ........................................................................ 21
Figure 4-8 Unit list in main testing screen........................................................... 22
Figure 4-9 Unit details in main testing screen ...................................................... 23
Figure 4-10 Test overview and control in main testing screen ................................... 24
Figure 4-11 Current test in main testing screen .................................................... 25
Figure 4-12 Test history in main testing screen..................................................... 26
Figure 4-13 Reporting screen .......................................................................... 27
Figure 4-14 Unit list in reporting...................................................................... 28
Figure 4-15 Filter for unit list in reporting .......................................................... 28
Figure 4-16 Test data table in reporting ............................................................. 29
Figure 4-17 Staged test data in reporting............................................................ 30
Figure 4-18 Test details in reporting ................................................................. 32
Figure 4-19 Program options dialog................................................................... 33
Figure 4-20 Report plain text header in program options ......................................... 34
Figure 4-21 Report image header in program options.............................................. 34
Figure 4-22 Communications in program options ................................................... 35
Figure 4-23 Print and auto-print in program options............................................... 36
Figure 4-24 PDF and auto-PDF in program options ................................................. 36
Figure 4-25 Configure PLC in program Options...................................................... 37
Figure 4-26 Model management dialog ............................................................... 38
Figure 4-27 Model list in model management ....................................................... 39
Figure 4-28 Bucket list in model management ...................................................... 40
Figure 4-29 Catch size in model management ...................................................... 41
Figure 4-30 Theoretical and practical values in model management............................ 41
Figure 4-31 Tolerances in model management...................................................... 42
Figure 4-32 Adding a new tolerance in model management ...................................... 43
Figure 4-33 Editing a tolerance in model management............................................ 44
Figure 4-34 Load cell calibration dialog.............................................................. 45
Figure 4-35 Load cell calibration dialog 2 and 3 –Selecting Station and Nozzle............... 46
Figure 4-36 Load cell calibration dialog 4 and 5 –Nozzle Rate ................................... 46
Figure 4-37 Load cell calibration dialog 6 - Taring container..................................... 46
Figure 4-38 Load cell calibration dialog 7 - Container to collect water......................... 47
Figure 4-39 Load cell calibration dialog 8 and 9 - Filling and Draining .......................... 47
Figure 4-40 Load cell calibration dialog 10 –Weigh the water collected ....................... 48
Figure 4-41 Load cell calibration dialog 11 –Repeated process 5 times –then test........... 48
Figure 5-1 Switches on the relay module ............................................................ 49

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 5 Issue 7 : 28 Apr, 2017
1INTRODUCTION
The TB340A Calibrator is an automated lab-based testing system for tipping bucket rain
gauges (TBRGs). Developed using load-cell technology, it is designed to deliver 653 g of
water by mass rather than volume with high accuracy and repeatability. It consists of a
hardware and software element to provide a solution that can complete multiple tests at a
variety of rainfall rates, collect and analyse test data for comparison against specification
and generate the resulting report. All this is achieved with almost no required user
interaction.
The hardware element consists of a stand that can support simultaneous testing of two
tipping bucket rain gauges. All the elements required for testing are managed by a central
controller mounted in the cabinet of the stand. 5 solenoid valves can be used interchangeably
to provide up to 31 different dispense rates for testing. Through the use of MODBUS over
RS-485, multiple stands can be daisy chained together and connected to software running on
a PC, which manages the test procedure.
The software element is a PC application that has been developed to support the
automation of the TBRG testing process. A high level of flexibility allows for the testing of
third party TBRGs and is not limited to HyQuest Solutions products. The application will run
a planned test series, collecting and storing the TBRG tip count as it progresses. It will then
compare the test data to the specified performance of the TBRG before generating a report
on successful completion of a test.
Figure 1-1 TBRG Calibrator overview
MODBUS over RS-485
PC running TBRG Calibrator software
TBRG Calibrator rig

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 6 Issue 7 : 28 Apr, 2017
2SPECIFICATIONS
2.1 Mechanical Specifications
Overall Dimension (1 rig)
Weight
Packed Dimension in Crate
Packed Weight in Crate
Construction
Body
Solenoid Valves
Vessel
Operating Temperature
Humidity
IP Rating
Load Cell SWL
Max. Input Water Pressure
Max. Dispense Rate
Dispensed Mass
Dispense Accuracy
2.2 Electrical Specifications
Input Voltage
Fuse
Communication
PC Requirements
Operating System
Memory
Display
1900mm (H) × 700 mm (W) × 600mm (D)
50 kg
1840 mm (W) x 900mm (D) x 700 mm (H)
135kg
Aluminium
Brass
Polycarbonate
-25°C to 50 °C
10 % to 90 %
IP51
3 kg (each)
100 psi
4 × 300 mm/hr
1 × 1000 mm/hr
653 g
±0.3 %F.S. (±2 g)
110/230 VAC, 50/60 Hz (auto-select) 2.5
Amp (5 × 20 mm, fast blow) MODBUS over
RS-485 (2-wire)
Microsoft Windows Vista
Microsoft Windows 7
Microsoft Window 8/8.1
1 GB (Minimum)
2 GB (Recommended)
1024 × 768 (Minimum)

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 7 Issue 7 : 28 Apr, 2017
3INSTALLATION
3.1 Setting up the TBRG Calibrator Rig
Unpacking
Your Rain Gauge Calibrator has been shipped in a wooden crate for protection during
transit, please take extreme care when opening the crate so as not to damage the unit.
Once the Calibrator has been removed from the crate, place upright on a flat level surface,
preferably at the final location where the Calibrator will be used.
The Calibrator has been fitted with two transit brackets to help protect the load cells during
transit. These can now be moved by undoing the 2 x Philips head screws and 10mm bolt as
shown. (Slide the transit bracket up and re-secure for future use.)
3.Loosen 10mm bolt
holding load cell
transit bracket.
2.Loosen 2 x Philips
head screws into
load cell.
1.Remove transit
foam.
4.Slide transit
bracket up and
retighten 2 x Philips
head screws and
10mm bolt.
IMPORTANT : Do not apply too much
downward pressure to Philips head screws
as this may damage the load cells.
Attach the two 12volt
solenoid valves to the back of
the calibrator support legs
using the supplied brackets,
if they are not already fitted.

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 8 Issue 7 : 28 Apr, 2017
Setup and levelling
Select a site to install the TB340A taking the following points into consideration.
(A) 110V - 240V AC mains power supply.
(B) Access to a clean filtered water source.
(C) Close to an appropriate water drain.
(D) A flat level surface.
After selecting an appropriate area place the TB340 in position and level using the 6
Adjustable feet to ensure the mounting plates are level in both planes.
Levelling feet.
Spirit level to adjust
in the 2nd plane.
Mounting plates.
Spirit level to adjust
in one plane.

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 9 Issue 7 : 28 Apr, 2017
Connect a clean and filtered water supply to the manifold using 1/4’’ nylon tube
Connect to appropriate drain outlets.
Pour a small amount of water down the drain holes located in the mounting plates to ensure
the water is making its way into the drain before running the system in automatic mode.
Manifold.
Drain outlets.

HyQuest Solutions Pty Ltd
TBRG Calibrator TB340A © Copyright Page - 10 Issue 7 : 28 Apr, 2017
3.1.1 Turning the TBRG Calibrator On
In addition to plugging power into the device, there is a switch in the cabinet of the TBRG
Calibrator. Switch this to the ON (I) position after the rig is plugged in and power will be
applied to the rest of the board.
Figure 3-1 Power switch in cabinet of TBRG Calibrator
When power is applied, the LED on the CR-800 main controller will come on for a short
period (about 30 secs) before changing to a flash once every 15 seconds. (Relay #8 will also
click on and off the same number of times as the Modbus Address 1 flash = address 1) The
power can also be checked by moving one of the switches on the relay out module (front of
cabinet, left side) to the ON position. The LED should come on and a clicking sound should
be heard. Return the switch to the AUTO position once testing is complete. Only do this
while water is switched off to the system.