Micronics U1000-U User manual

Issue 1.5 Feb 17 Page 1
U1000-U
Ultrasonic Flowmeter
(Universal)
User Manual
Micronics Ltd, Knaves Beech Business Centre, Davies Way, Loudwater,
High Wycombe, Bucks HP10 9QR
Telephone: [phone] Facsimile: [phone] E-mail: [email protected]
www.micronicsflowmeters.com

Issue 1.5 Feb 17 Page 2
Table of Contents
1 General Description ..................................................................................................................................................... 3
2 Quick start procedure .................................................................................................................................................. 4
3 How does it work? ....................................................................................................................................................... 5
4 User interface............................................................................................................................................................... 6
4.1 Key switches........................................................................................................................................................ 6
5 Installing the U1000-U ................................................................................................................................................. 7
5.1 Preparation.......................................................................................................................................................... 8
5.2 Sensor separation................................................................................................................................................ 8
5.3 Adaptors for small pipes ................................................................................................................................... 10
5.4 Attaching the U1000 to the pipe....................................................................................................................... 11
5.5 U1000-U interface cable ................................................................................................................................... 12
5.6 Connecting the U1000-U to the Supply............................................................................................................. 12
5.7 Pulse Output connection................................................................................................................................... 13
5.8 Current Output (If fitted).................................................................................................................................. 13
5.9 Cable Screen...................................................................................................................................................... 13
6 Powering up for the first time.................................................................................................................................... 14
6.1 How to enter the Pipe ID................................................................................................................................... 15
6.2 Pulse output ...................................................................................................................................................... 16
6.2.1 Volumetric mode...................................................................................................................................... 16
6.2.2 Frequency mode....................................................................................................................................... 16
6.2.3 Low Flow Alarm ........................................................................................................................................ 16
6.2.4 Loss of Flow Reading Alarm...................................................................................................................... 16
6.3 4-20mA Current output (If fitted)..................................................................................................................... 17
7 Subsequent Power-ON Sequence .............................................................................................................................. 17
8 Password Controlled Menus ...................................................................................................................................... 17
8.1 General procedure for changing menu settings................................................................................................ 18
8.1.1 Selection menus ....................................................................................................................................... 18
8.1.2 Data entry menus ..................................................................................................................................... 18
8.2 User Password controlled menu structure ....................................................................................................... 19
9 Diagnostics Menu....................................................................................................................................................... 24
10 Relocation of guide rail.......................................................................................................................................... 25
11 Appendix I –U1000-U Specification ...................................................................................................................... 26
12 Appendix II –Default values .................................................................................................................................. 27
13 Appendix III –Error and Warning Messages.......................................................................................................... 28
13 Declaration of Conformity ………………………………………………………………………………………………………………..………………….29

Issue 1.5 Feb 17 Page 3
1 General Description
Fixed installation, clamp-on flowmeter
Easy to install
Requires the minimum of information to be entered by the user
Both the electronics and guide rail housings form an integral unit
Simple attachment to the pipe using the supplied jubilee clips.
Power to the unit is provided by an external 12 - 24V ac/dc power supply (7VA minimum).
Operates on steel, copper and plastic pipes with ID’s in the range 20mm (0.8”) to 110mm
(4.3”) and a maximum wall thickness of 9mm for metal pipes and 10.5mm for plastic.
Compact, rugged and reliable, the U1000-U has been designed to provide sustained
performance in industrial environments.
U1000-U standard features include:
2 line x 16 character LCD with backlight
4-key keypad
Isolated pulse output
Simplified guide rail and transducer assembly
Two sets of self- adhesive Gel pad acoustic couplant
Continuous signal monitoring
Password protected menu operation for secure use
Operates from external 12 to 24Vac or dc power supplies
Small pipe adaptors
Optional features
4-20mA current output
Typical applications
Hot water metering and flow measurement
Flow measurement for Heat Metering
Chilled water metering and flow measurement
Potable water metering and flow measurement
Process water metering and flow measurement
Ultra-pure water metering and flow measurement.

Issue 1.5 Feb 17 Page 4
2 Quick start procedure
The following procedure details the steps required to set up the heat meter. See the sections referred to
if you are unsure about how to install the instrument.
1. Establish a suitable location for the flow meter on a straight length of pipe clear of bends and valves
or similar obstructions.(See Sections 5 and 5.1)
2. Determine the pipe internal diameter and material.
3. Either use the table in the manual, or power up the instrument to determine the correct separation
code. (See Sections 5.2 or 6)
4. Set the sensors to the correct separation by adjusting the sensor holding screws so the sensor can
slide in the slot. (See Section 5.2)
5. Select any adaptors needed for pipes with an outside diameter of less than 60mm, inside diameter
will typically be less than 50mm. (See Section 5.3)
6. Apply the Gel pads or couplant to the sensors and mount the guide rail on the pipe using the banding
provided, then remove the sensor holding screws. (See Section 5.4)
7. Wire the electronics up to a 12 to 24V ac or dc power supply (7VA minimum per instrument) via the
Blue and Brown wires. (See Section 5.6)
8. Plug in the flow sensors and DO NOT clip the electronics assembly on to the guide rail at this stage.
9. Power up the instrument and check that flow readings can be obtained(See Sections 6 and 7)
10. Once good readings have been obtained any further changes, such as selecting different units, can be
made via the User Menu. (See Section 8)
11. When happy with set up and readings, clip the electronic assembly to the guide rail.

Issue 1.5 Feb 17 Page 5
3 How does it work?
The U1000-U is a clamp-on, ultrasonic flowmeter that uses a multiple slope transit time algorithm to
provide accurate flow measurements.
An ultrasonic beam of a given frequency is generated by applying a repetitive voltage pulse to the
transducer crystals. This transmission goes first from the Downstream (blue) transducer to the
Upstream transducer (red) as shown in the upper half of Figure 1. The transmission is then made in
the reverse direction, being sent from the Upstream transducer (red) to the Downstream transducer
(blue) as shown in the lower half of Figure 1. The speed at which the ultrasound is transmitted through
the liquid is accelerated slightly by the velocity of the liquid through the pipe. The subsequent time
difference T1 –T2 is directly proportional to the liquid flow velocity.
Figure 1 Principle of Transit-Time operation

Issue 1.5 Feb 17 Page 6
4 User interface
Figure 2 illustrates the U1000-U user interface comprising:-
One 2 line x 16 character LCD with backlight
Four tactile key switches
Two LED’s
4.1 Key switches
4-20mA LED is illuminated when the 4-20mA output is ON
Pulse LED is illuminated when the Pulse output or Frequency output are enabled, and
then flashesto indicatedactive pulse activity. It is also illuminated if an alarm is enabled
and active.
Figure 2 U1000-U User Interface
Selection key. Allows the user to select between options on the
display.
Used to increment the value of each digit in numeric entry fields.
Used to decrement the value of each digit in numeric entry fields.
Used to enter the selection displayed or terminate the data entry.
Pressing thiskey will take the user toanother menu or to the Flow
Reading screen.
>
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Issue 1.5 Feb 17 Page 7
5 Installing the U1000-U
Figure 3 Location of Transducers
In many applications an even flow velocity profile over a full 360° is unattainable due, for example, to
the presence of air turbulence at the top of the flow and also possibly sludge at the bottom of the pipe.
Experience has shown that the most consistently accurate results are achieved when the transducer
guide rails are mounted at 45°with respect to the top of the pipe.
The U1000-U equipment expects a uniform flow profile as a distorted flow will produce unpredictable
measurement errors. Flow profile distortions can result from upstream disturbance such as bends,
tees, valves, pumps and other similar obstructions. To ensure a uniform profile the transducers must
be mounted far enough away from any cause of distortion such that it no longer has an effect.
To obtain the most accurate results the condition of both the liquid and the pipe must be suitable to
allow ultrasound transmission along the predetermined path. It is important that liquid flows uniformly
within the length of pipe being monitored, and that the flow profile is not distorted by any upstream or
downstream obstructions. This is best achieved byensuring there isa straight length of pipe upstream
of the transducers of at least 20 times the pipe diameter, and 10 times the pipe diameter on the
downstream side, as shown in Figure 3. Flow Measurements can be made on shorter lengths of
straight pipe, down to 10 diameters upstream and 5 diameters downstream, but when the transducers
are mounted this close to any obstruction the resulting errors can be unpredictable.
Key Point: Do not expect to obtain accurate results if the transducers are positioned close to any
obstruction that distorts the uniformity of the flow profile.
Micronics Ltd accepts no responsibility or liability if product has not been installed in accordance with
the installation instructions applicable to the product.
Possible Air
Possible
sludge
Guide
rail
Uniform Flow Profile
Distorted Flow Profile
Flow
Flow
Valid transducer location
20 x Diameter
10 x Diameter
45°

Issue 1.5 Feb 17 Page 8
5.1 Preparation
1. Before attaching the transducers first ensure that the proposed location satisfies the distance
requirements shown in Figure 3 otherwise the resulting accuracy of the flow readings may be affected.
2. Prepare the pipe bydegreasing it and removingany loose material orflaking paintin order to obtain
the best possible surface. A smooth contact between pipe surface and the face of the transducers is
an important factor in achieving a good ultrasound signal strength and therefore maximum accuracy.
5.2 Sensor separation
The sensor must be positioned at the correct distance for the pipe size and type they will be used on.
The table below gives the typical separation code for a given pipe material and inside diameter, based
on a 4mm wall thickness. If the wall thickness is significantly different from this value then the
separation may need to be one code higher or lower. The instrument displays the required separation
after the pipe internal diameter and material are entered.
Pipe ID range
Pipe material
Separation
Plastic and
Copper
Steel
B1
20-24
---
A2
25-30
20-22
C1
31-36
23-28
B2
37-42
29-34
A3
43-48
35-40
C2
49-54
41-46
B3
55-60
47-52
D2
61-65
53-58
C3
66-71
59-64
B4
72-77
65-70
D3
78-83
71-76
C4
84-89
77-82
E3
90-95
83-88
D4
96-101
89-94
F3
102-107
95-100
E4
108-110
101-106
D5
---
107-110
Figure 4 Separation Table

Issue 1.5 Feb 17 Page 9
The diagram below shows how to adjust the separation of the sensors
Figure 5 Separation Setting
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.

Issue 1.5 Feb 17 Page 10
5.3 Adaptors for small pipes
Figure 6 Pipe Adaptors
Adaptors are supplied for use on small pipes. The diagrams above show how these are fitted around the pipe.
The top pipe adaptor clips into the ends of the guide rail.
Less than 40mm outside diameter
40 to 60mm outside diameter
Greater than 60mm outside diameter

Issue 1.5 Feb 17 Page 11
5.4 Attaching the U1000 to the pipe
After applying the Gel pads centrally on the sensors, then follow the four steps shown in Figure 7 below to
attach the U1000-U to the pipe
Figure 7 simple steps to attaching the U1000 on the pipe
Remove the RED protective overlay from the Gel pads.
Ensure there are no air bubbles between pad and sensor.
Clamp guide rail and sensor assembly to pipe,
using the supplied banding, release and remove
sensor locking screws.
Connect power and sensors to the electronics
assembly. Sensor leads can be connected either
way round.
Confirm the unit is working correctly before attaching
the electronic assembly onto guide rail assembly
assembly.

Issue 1.5 Feb 17 Page 12
The locking screws and washers should be kept in case it is necessary to change the location of the guide rail
and sensors. See the relocation section for the procedure to do this.
5.5 U1000-U interface cable
The U1000-U interface cable supplied is a 6-core cable and is shown in Figure 8.
The polarity of the wires is as follows:
The un-insulated wire is the connection to the screen of the cable and should be earthed for full immunity to
electrical noise.
5.6 Connecting the U1000-U to the Supply
The U1000-U will operate within the voltage range 12 - 24V ac/dc. Supply to have a minimum rating
of 7VA. Connect the external power supply to the Brown and Blue wires of the six core cable. For full
compliance with EMC regulation a 12V supply is recommended for domestic and light industrial
applications.
Power
Pulse
4-20mA (If fitted)
Figure 8. U1000-U Interface Cable
12/24V Input
12/24V Return
Pulse Output
Pulse Return
4-20mA Output (+)
4-20mA Return (-)
Un-insulated screen
(If fitted)
(If fitted)

Issue 1.5 Feb 17 Page 13
5.7 Pulse Output connection
The isolated pulse output is provided by a SPNO MOSFET Relay which has a maximum load current
of 500mA and maximum load voltage of 48V AC. The relay also provides 2500V isolation.
The pulse output is available at the White and Green wires. Electrically this is a volt free contact
closure.
5.8 Current Output (If fitted)
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 polarities are shown in Figure
8.
The alarm current due to a flow outside the range specified or due to a loss of signal is set at 3.5mA.
5.9 Cable Screen
For full immunity to electrical interference the screen of the cable should be connected to Earth.

Issue 1.5 Feb 17 Page 14
6 Powering up for the first time
Powering up for the first time will initiate the sequence shown in Figure 9:
Figure 9 Initial power up screens
1. The start-up screen is displayed for 5 seconds
2. The user enters the pipe ID and then the material by scrolling through the available list. (Refer to
section 5.2)
3. The U1000-U checks for a valid signal
4. If a valid signal is found, signal strength and flow magnitude are displayed. The signal strength
should be at least 40% for reliable operation. The direction of flow when powered up will be set as
that for positive flow. The current output and pulse output will relate to the flow in this direction. If the
flow is reversed then the flow rate will still be displayed but the activity indication will change from an
asterisk to an exclamation mark. No pulses will be generated, and the current will go to the 3.5mA
alarm state if the flow is reversed.
If the flow value is displayed as “-----“ this indicates that there is no usable signal from the sensors.
The cause of this could be incorrect pipe data, no Gel pad on the sensors, sensor not in contact with
the pipe or very poor surface conditions on the inside of the pipe.

Issue 1.5 Feb 17 Page 15
6.1 How to enter the Pipe ID
Figure 10 shows the Enter Pipe ID screen after an initial power up.
Initially, the hundreds unit (050.0) will blink.
Press the
key to increment the hundreds digit (050.0) in thesequence 0, 1. Press
once to increment digit, or hold key down to automatically toggle
between 0 and 1.
Press the
key to decrement the hundreds digit in the sequence 1, 0. Press once
to decrement digit, or hold key down to automatically toggle between
1 and 0.
Press the
key to move to the tens digit (050.0). The tens digit should now blink.
Increment the tens digit in the sequence 0,1,2,3,4,5,6,7,8,9,0 using
the key. Press once to increment digit or hold down to scroll
through the numeric sequence. Decrement the tens digit in the
sequence 9,8,7,6,5,4,3,2,1,0,9 using the key. Press once to
increment digit or hold down to scroll through the numeric sequence.
Press the
key to move to the units digit (050.0). The units digit should now blink.
Increment or decrement the units digit in an identical manner to the
tens digit described above.
Press the
key to move to the decimal digit (050.0). The decimal digit should now
blink. Increment or decrement the decimal digit in an identical manner
to the tens digit described above.
Press the
Use
key to enter the Pipe ID numerical value, and move to the next screen
and
keys to scroll through the pipe materials and
then press
To select the material and complete the setup
procedure.
V


Figure 10 Enter Pipe ID Screen (Metric)
>
>
>
Λ
V
Pipe material
Steel
V
Λ

Issue 1.5 Feb 17 Page 16
If any of the parameters need to be changed from the default values, for example different units are
required, and then the menu system must be activated via the password (see section 8).
6.2 Pulse output
Pulse output can be set up to operate one of four modes, namely volumetric, frequency, Low Flow
Alarm and Loss of Flow (Signal) Alarm. The Alarm function allows the user to setthe alarm toNormally
Open or Normally Closed.
6.2.1 Volumetric mode
In Volumetric mode, each pulse output represents a measured volume of 10 litres (default value). In
Volumetric mode, with the Vol per Pulse set to 1 and the pulse width set to 25ms, the maximum
number of pulses that can be output (without storage) is 1/(0.025*2) = 20 pulses per second. If the
flow rate in the pipe is such that more than 20 pulses per second are generated, a Pulse Overflow
error may eventually occur if the stored number of pulses exceeds 1000. To avoid this, set the Vol
per Pulse to 10 litres.
6.2.2 Frequency mode
In Frequency mode, the pulse output frequency is proportional to the flow rate within a specified
frequency range of 0 –200Hz. The units of the flow rate are fixed as litres per second.
6.2.3 Low Flow Alarm
It is possible to use the pulse output as an alarm. The user can set a range between 0 and 9999 (no
decimal places), in the same units being used to measure flow. The Pulse LED will indicate the state
of the alarm. The default setting is normally open, but the user can select between N/O and N/C.
There is a 10% hysteresis on the switching of the output. Once turned on the flow rate must rise by
10% more than the set value to turn it on/off again.
If N/O and alarm not triggered -> Keypad LED off and contact open
If N/O and alarm triggered -> Keypad LED on and contact closed
If N/C and alarm not triggered -> Keypad LED on and contact closed
If N/C and alarm triggered -> Keypad LED off and contact open
6.2.4 Loss of Flow (Signal) Reading Alarm
If the flow reading (Signal) is lost, as indicated by the flow rate being displayed as “-----“, the alarm
will be triggered. The Pulse LED will indicate the state of the alarm. The default setting is normally
open, but the user can select between N/O and N/C.
If N/O and alarm not triggered -> Keypad LED off and contact open
If N/O and alarm triggered -> Keypad LED on and contact closed

Issue 1.5 Feb 17 Page 17
If N/C and alarm not triggered -> Keypad LED on and contact closed
If N/C and alarm triggered -> Keypad LED off and contact open
6.3 4-20mA Current output (If fitted)
The default 4-20mA output setting is ON, and the 4-20mA LED on the keypad will be illuminated. The
default flow for 20mA output will be automatically set depending on the pipe size. The default flow for
4mA is 0. This can be changed, see section 8.
If the flow reading is greater than that set as the 20mA value, or there is negative flow, or no flow
signal can be detected, then an alarm current of 3.5mA will generated.
Note: The 4-20mA current output is factory calibrated.
7 Subsequent Power-ON Sequence
If the power supply is cycled OFF/ON after the unit is in the flow reading screen all subsequent start-
ups will use the same configuration as was previously entered. If the configuration needs to be
changed for any reason, the user can make use of the password-controlled menu as described in
section 8.
8 Password Controlled Menus
The password controlled menu allows the user some flexibility to change the default settings:
User Password (71360):
Change the dimensions from mm to inches or vice-versa.
Change from Flow to Velocity Measurement
Change the system units litres/m3or Impgal/USgal
Change the flow units l/s, l/min or gal/s, gal/min or USgals/s, USgals/min
Change the default value for Flow at Maximum Current
Change the default setting for Flow at Minimum Current
Change the Pulse Output type
Change the Pulse output parameters
Press the key toget to the screenprompting for the password, which is entered using the method
shown in 8.1.2. To exit the password controlled menu navigate to the Exit screen and press the
key. If you wish to abandon enteringthe password then wait until the display returnsto the flow reading
screen.



Issue 1.5 Feb 17 Page 18
8.1 General procedure for changing menu settings
8.1.1 Selection menus
When a password controlled menu is selected the procedure for changing the default setting is the
same for all menus. For example, consider the Flow Units menu shown in Figure 11.
The default value ‘l/min’ will blink to indicate that this is the current setting. To change to ‘l/s’, press
the key. Now the ‘l/s’ units will blink to indicate that this is now the selected units. Press the
key to confirm the change.
8.1.2 Data entry menus
Menus containing a numeric value can be altered using the following procedure. For example,
consider changing the Flow at maximum current from the default setting 1000 litres as indicated in
Figure 12 to 1258 litres.
Press the
key twice to select the hundreds unit (1000.0) which will now blink
Press the
Press the key twice to increment the hundreds unit from 0 to 2
(1200.0)
Press the
key once to select the tens unit (1200.0) which will now blink
Press the
key five times to increment the hundreds unit from 0 to 5 (1250.0)
>

>
>
Figure 11 Flow Units menu
Flow Units:
l/min | l/s
Figure 12 Example of a Data entry screen
Flow @ 20mA:
1000.0
Λ
Λ

Issue 1.5 Feb 17 Page 19
Press the
key once to select units (1250.0) which will now blink
Press the
key twice to decrement the units from 0 to 8 (1258.0)
Press the
key to confirm the change
All numeric data menus can be changed in this way.
8.2 User Password controlled menu structure
Ensure that the instrument is in Flow Reading mode then press the key to go to the user
password menu. Enter 71360 using the procedure explained in section 8.1.2 to enter the password.
The flow chart shown in Figure 13 shows the user password menu structure. To skip over any menu
item that should remain unchanged, simply press the key.
>
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
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Issue 1.5 Feb 17 Page 20
Figure 13 Main Menu
Enter Password:
*****
71360 MENU
Invalid & OR No
input for 10 seconds
User Menu:
Pulse Output
User Menu:
Current Output
User Menu:
Calibration
User Menu:
Setup
User Menu:
Totaliser
Checking Signals
******
Sig: 87% *
246.3 l/min
Setup Menu
Totaliser Menu
Pulse Output Menu
Current Output Menu
User Menu:
Exit





v
v
v
v
v

Calibration Menu
v
Sig: 87% *
246.3 l/min