Micronics U1000 User manual

Micronics U1000 User Manual
Issue 2.0 Page 1
Micronics U1000
Ultrasonic Flowmeter
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

Micronics U1000 User Manual
Issue 2.0 Page 2
Table of Contents
1 General Description ........................................................................................................................3
2 How does it work? ..........................................................................................................................4
3 User interface..................................................................................................................................5
3.1 Key switches............................................................................................................................ 5
4 Installing the U1000........................................................................................................................5
4.1 Preparation .............................................................................................................................6
4.2 Attaching the U1000 to the pipe ............................................................................................ 7
4.3 Adaptors for small pipes .........................................................................................................8
4.4 U1000 interface cable.............................................................................................................9
4.5 Connecting the U1000 to the Supply......................................................................................9
4.6 Pulse Output connection ........................................................................................................9
4.7 Current Output (When fitted)..............................................................................................10
4.8 Cable Screen..........................................................................................................................10
5 Powering up for the first time.......................................................................................................10
5.1 How to enter the Pipe ID ......................................................................................................11
5.2 Pulse output..........................................................................................................................12
5.2.1 Volumetric mode ..........................................................................................................12
5.2.2 Frequency mode ...........................................................................................................12
5.3 4-20mA Current output (When fitted)..................................................................................12
6 Subsequent Power-ON Sequence.................................................................................................12
7 Password Controlled Menus.........................................................................................................13
7.1 General procedure for changing menu settings ...................................................................13
7.1.1 Selection menus............................................................................................................13
7.1.2 Data entry menus..........................................................................................................14
7.2 User Password controlled menu structure...........................................................................14
8 Diagnostics Menu..........................................................................................................................19
9 Relocation of guide rail .................................................................................................................20
10 Appendix I –U1000 Specification .............................................................................................21
11 Appendix II –Default values .....................................................................................................22
12 Appendix III –Error and Warning Messages.............................................................................23
12.1 System errors ........................................................................................................................23
12.2 Errors.....................................................................................................................................23
12.3 Warnings ...............................................................................................................................23
13 Declaration of Conformity ……………………………………………………………………………………………………….. 25

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1 General Description
The U1000 is a fixed installation, clamp-on flowmeter that is easy to install and requires the
minimum of information to be entered by the user. Unlike other clamp-on flowmeters, the
U1000 transducer separation distance is factory preset to a nominal pipe size. Both the
electronics and guide rail housings form an integral unit that is attached to the pipe using the
supplied jubilee clips. Power to the unit is provided by an external 12 - 24V ac/dc power
supply. The U1000 is intended to operate on steel and plastic pipes with ID’s in the range
20mm (0.8”) to 110mm (4”).
Compact, rugged and reliable, the U1000 has been designed to provide sustained
performance in industrial environments.
U1000 standard features include:
2 line x 16 character LCD with backlight
4-key keypad
Isolated pulse output
Simplified factory configured guide rail and transducer assembly
Continuous signal monitoring
Password protected menu operation for secure use
Operates from external 12 to 24Vac or dc power supplies
Optional features
4-20mA current output
Small pipe adaptors
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.

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2 How does it work?
The U1000 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 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 Figure1. 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

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3 User interface
Figure 2 illustrates the U1000 user interface comprising:-
One 2 line x 16 character LCD with backlight
Four tactile key switches
Two LED’s
3.1 Key switches
4-20mA LED is illuminated when the 4-20mA output is ON
Pulse LED is illuminated when the Pulse output is ON
4 Installing the U1000
Figure 3 Location of Transducers
Figure 2 U1000 User Interface
Selection key. Allows the user to select between options on the
display.
Used to decrement the value of each digit in numeric entry fields.
Used to increment the value of each digit in numeric entry fields.
Used to enter the selection displayed or terminate the data
entry. Pressing this key will take the user to another menu or to
the Flow Reading screen.
Λ
>

V
Possible Air
Possible
sludge
Guide
rail
Uniform Flow Profile
Distorted Flow Profile
Flow
Flow
Valid transducer location
20 x Diameter
10 x Diameter
45°

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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 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 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 by ensuring
there is a 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.
4.1 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 by degreasing it and removing any loose material or flaking paint in 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.

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4.2 Attaching the U1000 to the pipe
Follow the four steps shown in Figure 4 below to attach the U1000 to the pipe.
Figure 4 simple steps to attaching the U1000 on the pipe
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.
The grease provided in the syringe is applied to
the centre of the sensors as shown above.
Clamp guide rail and sensor assembly to pipe,
using the supplied banding key, and release
sensor locking screws.
Connect power and sensors to the electronics
assembly. Sensor leads can be connected either
way round.
Click electronic assembly onto guide rails and
sensor assembly

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4.3 Adaptors for small pipes
Figure 5 Pipe Adaptors
Guide rails for small pipes are supplied with adaptors. The diagrams above shows 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

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4.4 U1000 interface cable
The U1000 interface cable supplied is a 6-core cable and is shown in Figure 6.
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.
4.5 Connecting the U1000 to the Supply
The U1000 will operate within the voltage range 12 - 24V ac/dc. 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.
4.6 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.
Power
Pulse
4-20mA
Figure 6. U1000 Interface Cable
12/24V Input
12/24V Return
Pulse Output
Pulse Return
4-20mA Output (+) (When fitted)
4-20mA Return (-) (When fitted)
Un-insulated screen

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4.7 Current Output (When 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 6.
The alarm current due to a flow outside the range specified or due to a loss of signal is set at
3.5mA.
4.8 Cable Screen
For full immunity to electrical interference the screen of the cable should be connected to
Earth.
5 Powering up for the first time
Powering up for the first time will initiate the sequence shown in Figure 7:
1. The Micronics startup screen is displayed for 5 seconds
2. The user enters the pipe ID (refer to section 5.1)
3. The U1000 checks for a valid signal
4. If a valid signal is found, signal strength and flow magnitude are displayed. 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.
Figure 7 Initial Power-on sequence

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5.1 How to enter the Pipe ID
Figure 8 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 the sequence 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
key to enter the Pipe ID numerical value.
If any of the parameters need to be changed from the default values, for example different
units are required, then the menu system must be activated via the password (see section
7).
V

Figure 8 Enter Pipe ID Screen (Metric)
>
>
>
Λ
V

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5.2 Pulse output
Pulse output can be set up to operate in two modes, namely volumetric and frequency.
5.2.1 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.
5.2.2 Frequency mode
In Frequency mode, the pulse output frequency is proportional to the flow rate within a
specified frequency range of 0 –200Hz.
5.3 4-20mA Current output (When fitted)
The default 4-20mA output setting will be 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 7.
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.
6 Subsequent Power-ON Sequence
If the power supply is cycled OFF then ON after the pipe ID has been entered, 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 7.

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7 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
7.1 General procedure for changing menu settings
7.1.1 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 9.
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.
>

Figure 9 Flow Units menu
Flow Units:
l/min | l/s

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7.1.2 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 10. 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)
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.
7.2 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 7.1.2. to enter
the password.
The flow chart shown in Fig.9 shows the user password menu structure. To skip over any
menu item that should remain unchanged, simply press the key.
>
>
>



Figure 10 Example of a Data entry screen
Flow @ 20mA:
1000.0
V
Λ
Λ

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Figure 11 Main Menu
Sig: 87% *
246.3 l/min
Enter Password:
*****
ERROR:
Invalid 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:
Totals
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

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Figure 12 Setup Menu
Select Dimensions:
mm | inches
Enter Pipe ID:
050.0 mm
Enter Pipe ID:
2.000 inches
Select Reading:
Flow | Vel
Select Reading:
Flow | Vel
System Units:
litres | m3
System Units:
Impgal | USgal
Flow Units
m3/min | m3/hr
Flow Units
l/min | l/s
Flow Units
gal/min | gal/hr
Flow Units
USgal/min | USgal/hr
Range 20 –110mm
050.0 mm
SETUP MENU
Inches &
Invalid
&
mm &
Invalid &

Valid &
Valid &
Vel &(m/s)
m3 &

Flow &

Litres &
Valid &
Flow &
Impgal &
USgal &
Vel &
(ft/s)

Range 0.79 –4.33
2.000 inches

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Figure 13 Pulse Output and Totaliser Menu
If the Total is turned on then the display will alternate between the flow reading and the total.
Either display can be held for 30seconds by pressing the key.
>
Select Totals
ON|OFF
On &
Reset + Total
NO |YES
Off &
TOTALISER MENU

Select Pulse:
ON | OFF
Volume per Pulse:
10.0 l
Pulse Width
25 ms
PULSE OUTPUT MENU
Valid &
Valid &
On &
Volume &
Max Pulse Freq:
200
Max Flow @ Freq:
9999.0
Valid &
Valid &
Test mode press V or Λto
generate a pulse
Invalid &
Valid &
Freq &
Pulse Type:
VOLUME | FREQ
Range 3 - 99
25 ms
Range 1 –200
200
Invalid &
Valid &
Off &
Valid &

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Figure 14 Current Output and Calibration Menu
Damping Time [s]:
20
Zero Cut-off:
0.10 m/s
Zero Offset
0.000 l/min
Range 0.00 –0.50
0.10 m/s
Done
71360
&
Zero Offset:
Averaging…9
^To Clear
V To Set
Valid &
Invalid & 


Calibrat. Factor:
1.000
Range 0.500–1.500
1.000
NO |YES
CALIBRATION MENU
Invalid & 
Valid &
Select 4-20mA:
ON | OFF
Flow @ 20mA
1000.0
Flow @ 4mA
0000.0
OFF &
ON &
CURRENT OUTPUT MENU
Valid &
Valid &

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8 Diagnostics Menu
The diagnostics menu provides some additional information about the flowmeter and its setup. The
menu can be accessed by pressing the key from the main flow-reading screen. The menu
shown below describes the various diagnostics items.
DIAGNOSTICS MENU
V
The Estimated TA (Time of Arrival) and Actual TA show the
theoretical and measured transit times. These values should
be within several per cent of each other.
The gain on line one is an indicator of the signal strength. A
good signal should have a gain of between 600 to 970. The
number in parentheses is the switch setting and should be x1.
The second line shows the current time differential between
the upstream and downstream signals.
The unit’s software version is shown on line 1.
Line 2 shows the unit’s serial number.
If the Frequency pulse option is enabled this screen displays
the current pulse output frequency. This is proportional to
the flow rate.
Press
To exit the Diagnostics menu
N. B. The key board is less responsive in the
Diagnostics Menu and longer key presses are
required.
Sig: 87% *
246.3 l/min
Est.TA 85.64
Act .TA 86.77
Gain 845 (x1)
DT 125 ns
Rev: 05.00.001
S/N: 12547
Pulse Frequency
124

>
>
>
>
>
Pipe Material
Metal
>
The selected pipe material
Figure 15 Diagnostics Menu

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9 Relocation of guide rail
If it is necessary to relocated the guide rail and sensor assembly use the following procedure
1. Remove complete assembly from the pipe
2. Insert a small screwdriver in the hole at the end of the guide rail moulding and lever
up the clip holding the electronics assembly by pressing down on the screwdriver as
shown below.
3. Repeat 2 on the other end and then pull off the electronics unit.
4. Disconnect the sensors
5. Remove the original grease from the sensors
6. Push the sensor blocks into the guide rail so that the washers and locking screws
can be refitted.
7. Place a bead of grease down the centre of the sensor block using the syringe
provided. See illustration on fitting the guide rail to the pipe for recommended bead
size.
8. Follow the original procedure for installing the guide rail on the pipe.