Micronics U1000MKII-FM User manual

U1000MkII Pipe Mount
U1000MKII-FM: Clamp-on Ultrasonic Flow Meter
U1000MKII-HM: Clamp-on Ultrasonic Heat Meter
User Manual
Micronics Ltd, Knaves Beech Business Centre,
Davies Way, Loudwater, High Wycombe, Bucks HP10 9QR
Telephone: [phone] E-mail: [e-mail]
www.micronicsflowmeters.com

U1000MKII User Manual Micronics
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DOCUMENT AUTHORITY
Issue
3.4
Originator
Micronics Ltd
Checked
Approved
Date
13/12/2022

CONTENTS
1INTRODUCTION ................................................................................................................................................... 1
1.1 General Description............................................................................................................1
1.2 How Does It Work?.............................................................................................................2
1.3 Package Contents ..............................................................................................................3
1.4 Display................................................................................................................................4
2INSTALLATION....................................................................................................................................................5
2.1 Identify Suitable Location....................................................................................................5
2.1.1 Additional Considerations for Locating U1000MkII-HM................................................5
2.1.2 Clean the Pipe's Flow Sensor Contact Area ................................................................6
2.2 Connect Power and Signal Cables .....................................................................................6
2.2.1 Power Supply ..............................................................................................................6
2.2.2 Pulse Output Connection.............................................................................................7
2.2.3 Current Output.............................................................................................................7
2.3 Switch On...........................................................................................................................8
2.3.1 U1000MkII-FM.............................................................................................................8
2.3.2 U1000MkII-HM ..........................................................................................................10
2.4 Adjust Flow Sensor Separation.........................................................................................12
2.5 Apply Gel Pads.................................................................................................................12
2.6 Clamp Sensor Assembly to Pipe.......................................................................................12
2.6.1 Pipe Adaptors............................................................................................................13
2.6.2 Attaching to Pipe .......................................................................................................13
2.7 Remove Sensor-Holding Screws......................................................................................14
2.8 Connect Electronics Module.............................................................................................15
2.9 Attach the Temperature Sensors (U1000MkII-HM Only)...................................................15
2.9.1 To ensure an accurate temperature differential:.........................................................15
2.10 Clip Electronics Module to Sensor Assembly....................................................................16
2.11 Setting Zero Flow..............................................................................................................16
3MENU STRUCTURES.........................................................................................................................................18
3.1 Accessing the Menus........................................................................................................18
3.2 Setup Menu Metric............................................................................................................19
3.3 Setup Menu Imperial.........................................................................................................20
3.4 Volume Total Menu...........................................................................................................21
3.5 Current Output Menu........................................................................................................21
3.6 Pulse Output Menu...........................................................................................................22
3.7 Calibration Menu ..............................................................................................................23
3.8 Diagnostics Menu.............................................................................................................24
4OUTPUTS ..........................................................................................................................................................25

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4.1 Pulse Output.....................................................................................................................25
4.1.1 Volumetric Pulse........................................................................................................25
4.1.2 Frequency Mode........................................................................................................25
4.1.3 Energy Pulse (U1000MkII-HM only)...........................................................................26
4.1.4 Flow Alarm - Low Flow ..............................................................................................26
4.1.5 Flow Alarm –Signal Loss ..........................................................................................26
4.2 4–20 mA Current Output...................................................................................................26
5CALIBRATION ...................................................................................................................................................27
6RELOCATING THE UNIT....................................................................................................................................28
7TROUBLESHOOTING THE INSTALLATION.......................................................................................................29
7.1 Incorrect pipe data............................................................................................................29
7.2 Sensor not in contact with the pipe...................................................................................29
7.3 Air in the liquid/pipe ..........................................................................................................29
7.4 No Gel pad or grease on the sensor.................................................................................29
7.5 Very poor pipe condition-surface/inside............................................................................29
7.6 Positioning........................................................................................................................29
7.7 Flow reading when the system is closed...........................................................................31
7.8 No flow reading visible when the system is active.............................................................31
7.9 Limitations with galvanised pipe........................................................................................31
7.10 Limitations with Mixtures...................................................................................................31
7.10.1 Glycol / Water mixes..................................................................................................31
7.10.2 Ethanol Water mixes..................................................................................................31
7.10.3 Additives....................................................................................................................31
7.11 Limitations with composite pipes.......................................................................................31
8APPENDIX.........................................................................................................................................................32
8.1 Specification.....................................................................................................................32
8.2 Default values...................................................................................................................34
8.2.1 Data Entry Errors.......................................................................................................35
Figure 1 : Priciple of Operation .........................................................................................................2
Figure 2 : Typical Package Contents ................................................................................................3
Figure 3 : Display..............................................................................................................................4
Figure 4 : Location of U1000.............................................................................................................5
Figure 5 : Location with Temperature Probes ...................................................................................5
Figure 6 : Cable Wiring Assignment..................................................................................................6
Figure 7 : Attach Electronics Module...............................................................................................16
Figure 8 : Sensor Positioning..........................................................................................................30

Micronics U1000MKII User Manual
Page 1
1INTRODUCTION
1.1 General Description
This manual describes the installation and use of the two models in the U1000MkII range:
•U1000MkII-FM is an ultrasonic clamp-on flow meter for measuring flow rate and total flow with
a volume pulse output and optional Modbus, M-Bus or 4-20mA flow proportional output. It can
be used as a standalone meter or as part of an integral management system.
•U1000MkII-HM is an ultrasonic clamp-on thermal, heat/energy meter. It uses ultrasound to
measure flow rate and is also equipped with PT100 temperature sensors to measure flow and
return temperatures. The U1000MKII-HM displays energy rate and totalised energy with pulse
output and communication options, so it can be used as a standalone meter or as an integral
part of Automatic Monitoring & Targeting (aM&T) or a Building Energy Management System
(BEMS).

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1.2 How Does It Work?
The U1000MKII uses a cross correlation 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 as shown in the upper half of Figure 1. The transmission is then made in the reverse
direction, being sent from the upstream transducer to the downstream transducer 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.
With HM models, two temperature sensors measure the difference in temperature between the flow
and return of the flow system being monitored. The temperature difference, in combination with the
volume of water that has flowed through the system, is then used to calculate the energy transferred
to or from the water.
Figure 1 : Priciple of Operation

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1.3 Package Contents
The unit consists of two parts:
1. Electronics Module
Consisting of the keypad and display, power, signal and comms connections. The Electronics
Module clips onto the Sensor Assembly.
2. Sensor Assembly
Incorporating guide rails and two transducers for flow measurement.
In addition, the kit contains:
3. Adhesive gel pads (4).
4. 2-part adaptors for fixing sensor assembly to pipes with an OD less than 60mm (2)
5. Quick release clamps for use with pipes with an OD of 51-127mm (2)
6. Quick release clamps for use with pipes with an OD of 25-70mm (2)
7. U1000MkII-HM only: non-releasable stainless cable ties for temperature sensors (2).
8. U1000MkII-HM only: PT100 temperature sensors with 3m cable (2).
9. Modbus/M-Bus cable (as needed).
Figure 2 : Typical Package Contents
1
2
9
3
4
5
6
7
8

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1.4 Display
1. For a HM the front panel will indicate “Energy” for the Top Led. Illuminates if Pulse O/P is on
and set to energy (not flow).
4-20mA (1.)
4-20mA function is
Enabled.
Energy if HM and
Pulse O/P is set to
Energy
Pulse
Illuminated when the
Pulse, Frequency or
Alarm functions are
enabled.
Select
Selection key.
Choose between
options on the
display.
Decrease/Down
Decrement the
value of each
digit in numeric
entry fields/move
menu down.
Increase/Up
Increment the
value of each
digit in numeric
entry
fields/move
menu up.
Enter
Enter displayed
selection/
terminate the
data entry.
Select menu or
exit to Flow
Reading screen.
Flow
Measured flow.
Signal strength
For accurate
results, must be
over 40%.
Flow Units
Units applicable to
measured flow.
Flow Direction
* Indicates positive
flow
! Indicates
reversed flow.
Figure 3 : Display

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2INSTALLATION
2.1 Identify Suitable Location
We recommend a location where there is a straight length of pipe with no bends, constrictions, or
obstructions within at least 10 times the pipe diameter upstream, and 5 times the pipe diameter
downstream.
Figure 4 : Location of U1000
Important: Do not expect to obtain accurate results if the unit is positioned close to
any obstruction that distorts the uniformity of the fluid flow profile. Micronics ltd
accepts no responsibility or liability if product has not been installed in accordance
with these instructions.
2.1.1 Additional Considerations for Locating U1000MkII-HM
For optimum reliability on boiler applications, the flow measurement needs to be made on the cold
side of the system. For optimum reliability in chiller applications, the flow measurement needs to be
made on the warmer side of the system.
Figure 5 : Location with Temperature Probes
UPSTREAM
10 x pipe
diameter
DOWNSTREAM
5 x pipe
diameter
U1000MkII
fluid flow

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2.1.2 Clean the Pipe's Flow Sensor Contact Area
Prepare the pipe by removing any paint and degreasing the area to be installed to obtain the best
possible surface. A smooth contact between pipe surface and the face of the sensors is an
important factor in achieving a good ultrasound signal strength and therefore maximum accuracy.
U1000MkII-HM: The area of pipe where the temperature sensors are to be attached must be free of
grease and any insulating material. It is recommended that any coating on the pipe is removed so
that the sensor has the best possible thermal contact with the pipe.
2.2 Connect Power and Signal Cables
This section explains how to connect power and signal cables to the Electronics Module.
2.2.1 Power Supply
The U1000MKII will operate within the voltage range 12–24 VDC/24 VAC. The supply must have a
minimum rating of 7 W/7 VA per instrument.
External power supply must be class 2 rated.
Important: It is the responsibility of the installer to conform to the regional
voltage safety directives when connecting the U1000MKii to a power supply
using a mains-rated transformer.
Figure 6 : Cable Wiring Assignment
The un-insulated wire is the connection to the screen of the cable and should be earthed for full
immunity to electrical noise.

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2.2.2 Pulse Output Connection
The isolated pulse output is provided by a SPNO/SPNC MOSFET relay which has a
maximum load current of 500 mA and maximum load voltage of 24 V AC/DC.
This output is suitable for SELV circuits only.
Electrically this is a Volt, or potential free contact and, when selected as a low flow alarm, is
configurable NO/NC.
2.2.3 Current Output
The isolated 4–20mA is a current source and can drive into a maximum load of 620Ω.
The alarm current due to a flow outside the range specified or due to a loss of signal is set at
3.5 mA.
This output is suitable for SELV circuits only.

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2.3 Switch On
The initial screen sequence is different for the FM and HM models.
2.3.1 U1000MkII-FM
Switch on the power to the Electronics Module. A Micronics start-up screen is displayed for 5
seconds followed by hardware and software version information.
You are then prompted to enter the internal diameter
of the pipe:
Use the , and keys to change the
value.
Press to confirm the value.
Select the pipe material by using the and
keys
to scroll through the list.
Press to confirm the material.
Select the fluid using and to select Water,
Glycol or Ethanol
Press to confirm the fluid name.
Next for Water enter the HOT / COLD Option
With Glycol or Ethanol enter the %age Mix then
the actual Temperature
Either Select the %age of Ethanol.
Or Select the %age mix of Glycol.
For Glycol and Ethanol, an actual Temperature is
entered for sub 0 °C.
Allowed range:
-20.0–140.0 °C (-4.0–284.0 °F).
For Water the Temperature range is entered
For a temperature of <= 40.0 °C select “COLD”.
For a temperature of > 40.0 °C select “HOT”.
Enter Pipe ID:
050.0 mm
Pipe Material:
PLASTIC
Instrument Fluid
Water
Temperature:
+020.0 °C
Temperature:
HOT | COLD
Glycol %age:
30/70 %
Ethanol %age:
10 %

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The unit now shows the flow sensor separation
Code
Make a note of the Code. Is needed during the
installation.
All subsequent start-ups will use the same configuration.
Continue with the installation of the Sensor Assembly (see page 12).
Set Separation:
B-2

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2.3.2 U1000MkII-HM
Switch on the power to the Electronics Module. A Micronics start-up screen is displayed for 5
seconds followed by hardware and software version information.
You are then prompted to enter the internal diameter
of the pipe:
Use the , and keys to change the
value. Press to confirm the value.
Select the pipe material by using the and
keys to scroll through the list.
Press to confirm the material.
Select the Instrument Type using .
The unit is preconfigured for Heating applications.
Press to confirm the setting.
Select the Instrument Side (where flow sensors are
installed) using .
The unit is preconfigured for Flow.
Press to confirm the setting.
Select the fluid using and to select Water,
Glycol or Ethanol. Press to confirm.
Next for Water enter the HOT / COLD Option
With Glycol or Ethanol enter the %age Mix then
the actual Temperature
Either Select the %age of Ethanol.
Or Select the %age mix of Glycol.
For Glycol and Ethanol, Set an actual Temperature
sub 0 °C may be needed.
Allowed range:
-20.0–140.0 °C (-4.0–284.0 °F).
to accept and move to Set Separation Menu
Enter Pipe ID:
050.0 mm
Pipe Material:
PLASTIC
Instrument Type:
Heating|Chiller
Instrument Side:
Return|Flow
Instrument Fluid
Water
Ethanol %age:
10 %
Glycol %age:
30/70 %
Temperature:
+020.0 °C

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For Water the Temperature range is entered
For a temperature of <= 40.0 °C select “COLD”.
For a temperature of > 40.0 °C select “HOT”.
The unit now shows the correct flow sensor
separation (in this case, “B-2”) for the chosen values
of pipe ID, pipe material and fluid.
Make a note of the separation code.
All subsequent start-ups will use the same configuration
Continue with the installation of the Sensor Assembly (see page 12).
Temperature:
HOT | COLD
Set Separation:
B-2

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2.4 Adjust Flow Sensor Separation
Using the separation code displayed by the Electronics Module, take the Sensor Assembly and
adjust the flow sensor separation accordingly:
1. Adjust the screws on the flow sensors as to allow sideways movement. DO NOT fully unfasten
or remove the screws at this stage.
2. Slide the flow sensors to the positions indicated on the display.
3. With the flow sensors in the correct positions, tighten the sensor-holding screws so that the
sensors are fully recessed into the guiderail.
2.5 Apply Gel Pads
1. Apply a gel pad centrally onto the bases of each of the two flow sensors.
2. Remove the covers from the gel pads.
3. Ensure there are no air bubbles between each pad and sensor base.
2.6 Clamp Sensor Assembly to Pipe
The next step involves clamping the Sensor Assembly onto the pipe. Ensure that you have selected
a suitable location and that the pipe is clean. If you are installing the unit on a pipe with an outside
diameter less than 60mm use one or more of the adaptors supplied with the unit.

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2.6.1 Pipe Adaptors
The diagrams below show how the adaptors are fitted. The top ‘V’ shaped adaptor clips onto the
ends of the Sensor Assembly and this should be used with all pipes with an outside diameter less
than 60 mm.
Additionally, for pipes with an outside diameter less than 40 mm, a second adaptor should also be
used. This fits underneath the pipe as shown below.
Important: Do not use these adaptors if the pipe has an outside diameter greater than
60 mm.
2.6.2 Attaching to Pipe
1. For pipes with an outside diameter less than 60 mm, attach the black clips to the bottom of the
Sensor Assembly as shown below.
2. Place the Sensor Assembly on pipe.
3. For pipes with an outside diameter less than 40 mm, position the curved adaptor under the
pipe.

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4. Using the hose clips provided, clamp the Sensor Assembly (and adaptors, if used) to the pipe at
an angle of 45° to the top of the pipe. Experience has shown that the most consistently
accurate results are achieved when the unit is mounted at this angle. This minimises the effect
of any flow turbulence resulting from entrained air along the top of the pipe and sludge at the
bottom.
2.7 Remove Sensor-Holding Screws
Release and remove the sensor-holding screws. The flow sensors are spring-loaded to ensure good
contact with the pipe surface.
Note: The sensor-holding screws and washers should be kept in a safe place in case
it is necessary to relocate the unit.
45°
Air
Sludge

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2.8 Connect Electronics Module
1. Ensure that the power is switched off.
2. Connect the Electronics Module. The two leads can be connected either way round. The SMB
connections are fragile so be careful when installing not to snap them off.
2.9 Attach the Temperature Sensors (U1000MkII-HM Only)
Important: The temperature sensors must be balanced before initial use, using the
procedure described below and used with the cable length supplied. Extending or
shortening the cables will negate the calibration of the sensors.
The area of pipe where the probes are to be attached must be free of grease and any insulating
material. It is recommended that a thermal compound is used with the sensor, so it has the best
possible thermal contact with the pipe. Lagging should also be places over the sensor to remove the
possibility of environmental factors affecting the reading
The sockets on the Electronics Module are marked Cold and Hot. This defines the location of the
temperature sensors on installations where heat is being extracted from the system.
2.9.1 To ensure an accurate temperature differential:
1. Plug the temperature sensors into the Electronics Module and place them touching each other
for 1 minute.
DO NOT HOLD HT EPROBES TOGETHR WITH YOUR HAND.

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2. Enter the password-controlled menu and scroll to the Calibration sub-menu.
3. Press the Enter key until the Zero Temp Offset screen is displayed.
4. Select Yes and press the Enter key to display the Attach Sensors screen.
5. Press the Enter key again and wait for instrument to return to the Zero Temp Offset screen.
6. Switch off the power to the Electronics Module.
7. Complete the installation of the temperature sensors. The temperature sensors have a cut out
profile to locate them; they are then anchored using the supplied cable ties. The cable ties
should not be over tightened, or the sensors may be damaged. If the sensors are located under
pipe-lagging, then ensure this does not put a strain on the sensor cables.
8. Tie down the sensor cables.
2.10 Clip Electronics Module to Sensor Assembly
If the unit is working correctly, clip the Electronics Module onto the Sensor Assembly. Secure in
place with the screw on the right side.
Figure 7 : Attach Electronics Module
2.11 Setting Zero Flow
To obtain accurate readings from the installation the flow sensors must be zeroed in their installed
application. This will mean that the meter is reading accurately from a known set point