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

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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

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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

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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

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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)

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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.

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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.

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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.

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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.

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3.2 Setting up the PC
3.2.1 Install the Software
The software application will be provided either on a medium (CD or USB) supplied with the
rig or is available for digital download. If the application has not been provided, please
contact HyQuest Solutions to receive a copy.
Installation of the software application will require administrator rights on the PC it will run
on. If you do not have administrator rights, please contact your IT administrator for help
with installation.
Run the application installer and follow the on-screen prompts. The installer will copy the
necessary files to disk to allow it to run. The application does not require administrator
rights to run normally.
3.2.2 Connecting the PC to the TBRG Calibrator
A USB to RS-485 adapter is used to connect the PC to the TBRG Calibrators. Only one is
required to connect multiple calibrators.
To install the USB to RS-485 adapter, simply plug the USB connector into any available USB
port. The device should be automatically detected and the drivers will be installed. (If the
drivers cannot be found automatically, we have provided a copy on the HyQuest Solutions
website on the TB340A Calibrator page in the Software Upgrades tab.)
To check that it has installed correctly, open the Device Manager from Control Panel on the
PC.
Figure 3-2 Device Manager in Control Panel (Windows 7)

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Under Ports (COM & LPT), a device named USB Serial Port should be visible in the list. This
can be double checked by removing the adapter while the Device Manager is displayed.
When disconnected, the list will update and the device should be missing.
Figure 3-3 USB to RS-485 adapter in Device Manger
Make note of the COM port for the USB adapter (COM5 in Figure 3-3). This will be needed to
tell the software where the TBRG Calibrator is connected.
If you do not see a device for the USB adapter, please contact your IT administrator for
assistance.
3.2.3 Running the Software for the First Time
The first time the application is run, the Program Options (see 4.7 Program Options) will be
displayed automatically. It is recommended that options for reporting (see 4.7.1 Reports),
printing and PDFs (see 4.7.3 PDF & Printing) are set up at this time if the details are known.
Select the Communications tab (see 4.7.2 Communications) and set the COM port to that
identified in 3.2.2 Connecting the PC to the TBRG Calibrator. The port status should change
to Open.
With the Program Options closed, the marker next to the address on the main testing screen
(see 4.5 Monitoring a Test Series, 4.5.1 Units List) should be green to indicate successful
communication to the TBRG Calibrator/s.
Before testing can begin, the load cells need to be calibrated to ensure the required
accuracy is delivered. See 4.9 Calibrating a Load Cell for details on calibrating.
Once calibration is complete, the system is ready to begin testing. See 4.2 Preparing a Test
Series, 4.4 Starting a Test and 4.5 Monitoring a Test Series for details on how to run a test.
USB to RS-485 adapter
connected and disconnected.

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Loosen two socket screws to
remove funnel assemblies.
4OPERATION
4.1 Preparing a TBRG on a station
Place your Rain Gauge base on the supplied PVC mounting plate. (Please note this
calibration rig has been designed to suit HyQuest Solutions model TB3 TB4 TB6 Rain Gauges.
A custom adaptor may be necessary to suit other manufacturer’s Rain Gauges)
Insert the syphon body into the collector funnel. (Please note this calibration rig has been
designed to suit HyQuest Solutions model TB3 TB4 TB6 Rain Gauges. A custom Syphon
adaptor may be necessary to suit other manufacturer’s Rain Gauges)
Removable funnel assembly.
The supplied funnel assemblies
are removable, this allows the
Rain Gauge to be calibrated
with the standard collector
fitted.
Rain Gauge base.
Grey PVC Mounting plate.

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4.1.1 Connecting the Reed Switch Inputs
The connection to the tip counter inputs is made up of 4 separate wires. Each pair of wires
is identified by colour (blue and white)
One pair of wires is designed to connect to one reed switch so two reed switches can be
monitored with two pairs of wires. If only testing one reed switch, only one pair of wires is
used, the other pair can be left disconnected. It does not matter which pair is used.
Please refer to the manual of the tipping bucket rain gauge (TBRG) on test to the wiring
connections for each reed switch.
Connect the alligator clips either directly to the terminal or with the use of extensions if the
terminal is not accessible. Ensure that the clips are not in contact with each other.
Figure 4-1 Reed switch connections

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4.2 Preparing a Test Series
Before a test series can begin, it needs to be set up to match the requirements of the
tipping bucket rain gauge (TBRG) being tested. The setup is performed in the software to
allow for reporting and traceability.
4.2.1 Opening the Setup Window
To begin, when presented with the main testing screen (see 4.5 Monitoring a Test Series),
select Setup to open the setup page for that station. A window will be displayed and will
have the station address at the top of the window. In this example, “01 Left”. The following
sections will describe how each of the settings affects the test.
Once these setting have been set by the user, they will be remembered from test to test
and when the application is closed. Only when a new test has different settings to previous
one will a change need to be made. For example, only the serial number would need to be
changed when testing two rain gauges of the same model and bucket size.
OK When pressed, the changes that were made in the window are applied to the
station and the main screen is updated with the new information.
Cancel When Cancel or the cross in the top right is pressed, the dialog is closed and the
changes made are not remembered. The main testing screen will have the setup as
it was when the Setup window was opened.
Figure 4-2 Test setup selection

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4.2.2 Tipping Bucket Rain Gauge
Correctly selecting the model and bucket size for the TBRG that is going to be tested is
critical for the test process to be completed successfully. These two items are used to
determine the pass / fail conditions of a test as set up in the model management page (see
4.8 Model Management). These items, as well as the serial number, are used for result
storage and traceability. It is up to the user to ensure these items are correctly entered
before the test begins.
Figure 4-3 Tipping bucket rain gauge options in test setup
Model The manufacturing model of the TBRG that is going to be tested. If the model
of the TBRG isn’t in the list, it can be added through the model management
page (see 4.8 Model Management, 4.8.1 Model). This must be selected before
the bucket size, the list of appropriate bucket sizes will be loaded for that
model.
Bucket Size The bucket size of the TBRG that is going to be tested. If the bucket size for
the selected model is not in the list, it can be added through the model
management page (see 4.8 Model Management, 4.8.2 Bucket).
Serial # The serial number of the TBRG that is going to be tested. This is used, with
the model, for reporting (see 4.9 Calibrating a Load Cell).

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4.2.3 Test Options
The test options allow the user to customise the test depending on their requirements.
Some of these options can be used together while others can only be used independently.
Figure 4-4 Test options in test setup
Test both reed switches In all tests, two reed switch inputs are monitored for tip counts
and both values are logged. When checked, a comparison of the two tip
counts is made at the end of the test and if they are found to be more than
2 tips apart, the test will fail. When unchecked, no comparison is made
between the two tip counts; the count with the highest value is used for
determining pass / fail specifications.
Run In When checked, the system will continue to cycle through the test list (see
4.5.3 Test Overview and Control) until the tip count entered in the
corresponding Tips box is exceeded. The current test will complete before
finishing. While the test count data is displayed in the test history on the
main page (see 4.5.5 Test History), none of the test data is logged into the
database, it is for indication only. The run in feature is an independent
feature, and items that can’t be used at the same time will be disabled
when the run in feature is selected.
Tips (Run In) This becomes available when the Run In feature is selected. The user can
then enter the number of tips that need to be counted before the run in
test is complete.
Wetting Cycle When checked, a wetting cycle is performed before a test series is started.
A wetting cycle is performed by briefly opening each nozzle to remove any
air that may be trapped in the nozzle and then running for a random time
between 30 and 60 seconds to wet the surfaces of the funnel and bucket.
(See also, 4.3 Performing a Wetting Cycle.)
Auto-Print When checked, a report will be printed upon a completion of a test. The
printer that the report will be sent to can be selected in the options page
(see 4.7 Program Options, 4.7.3 PDF & Printing) and is separate to the
operating system default printer. If a test fails, no report will be generated
unless the option is selected in the Tools-Options-PDF & Printing section.
Auto-PDF When checked, a PDF report will be generated and saved to a default
location as specified in the options page (see 4.7 Program Options, 4.7.3
PDF & Printing) upon completion of a test. If a test fails, no report will be
generated unless the option is selected in the Tools-Options-PDF & Printing
section.

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4.2.4 Nozzles
The nozzles table is a representation of the nozzles that are or will be installed into the
vessel for the upcoming tests. This information is used primarily in reporting but is also used
by the Tests (see 4.2.5 Tests) below for defining rates.
Figure 4-5 Nozzle setup in test setup
#The nozzle number is the position of the nozzles as indicated in the image
to the right. As changes are made to each nozzle, the image to the right
will highlight the nozzle that the changes affect. This field cannot be
edited.
Rate (mm/hr) Enter the rate of the nozzle that is installed or is going to be installed at
the highlighted location. It may be helpful to enter the data first then
install the nozzle as the image will highlight where it needs to be installed.
Serial # Enter the serial number of the nozzle that is installed or is going to be
installed at the highlighted location. If no serial number is entered and the
nozzle is used in a test, it will be highlighted orange. This does not prevent
a test from running but provides an indicator in case it has been forgotten.
If no serial number is provided, no serial number will be placed on any
reports generated for tests that use that nozzle.
IMPORTANT : The highest rate nozzle being used, should always be
fitted into the Nozzle #5 position (at the right rear) –this position has a
larger valve which is capable of handing the higher rates!

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4.2.5 Tests
The tests table represents what nozzles will be used and the number of cycles (iterations)
that will be completed to form a test. Each row in the table is an individual test and the
table is considered a test series.
Test series can be saved and loaded to disk. This is helpful when a series is used often and
can be loaded on to many stations, saving time from entering the list into each station.
Figure 4-6 Test process setup in test setup
#1, #2, #3, #4, #5 Each column corresponds to the nozzle number in the nozzle table
above (see 4.2.4 Nozzles). For an individual test, a checked box indicates that
nozzle will be used in that test (for example, test 1 will use nozzle 2, test 2
will use nozzle 1 and test 3 will use nozzle 5).
More than one nozzle can be used in an individual test. The effect is the rates
of all the checked nozzles are added together (for example, if test 1 had
nozzle 2 and nozzle 5 checked, it would have a rate of 400 mm/hr). In
reporting, all the nozzles used in a test are listed.
Rate The rate is calculated from the nozzle table above (see 4.2.4 Nozzles) and
adds all the nozzles used from the boxes that were checked. This field cannot
be edited.
Iterations This is the number of times the vessel will complete fill / drain cycle on that
test. The iterations of the test are performed consecutively before moving to
the next test.
These arrows allow the order of the tests to be changed. A test series will
start at the top of the test list and process each test down the list. If a test is
in the wrong location, the arrows can be used to move the selected test up or
down.
Add/Remove This will add a new test to the bottom of the test list or remove the selected
test from the test list.
These will allow the user to save / load a test series to disk. When pressed, a
window will open for the user to specify the file they want to save / load.

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4.3 Performing a Wetting Cycle
Before a test has begun, or at any time a test is not running, a manual wetting cycle can be
run. To do so, press the Wet Only button and the system will begin a wetting cycle. You can
then abort a cycle by pressing the Abort button. Once aborted, starting the cycle will start
it from the beginning.
A wetting cycle is performed by briefly opening each nozzle to remove any air that may be
trapped in the nozzle and then running for a random time between 30 and 60 seconds to wet
the surfaces of the funnel and bucket.
This is also a test option that is run at the start of a test procedure. See 4.2.3 Test Options.
4.4 Starting a Test
When a test has been set up, the information will be displayed in the main testing screen
(see 4.5 Monitoring a Test Series). Here it can be checked for correctness before the test
begins. The user can then press the Start button to begin the test series.
Once the test is started, the button will then become an Abort button. When pressed, the
whole test series will be aborted and will need to be started again.
*** Note that if a test series is manually aborted before all of the tests in a run have
completed, the results of the those tests are lost and ARE NOT stored in the database.