Neptune MACH 10 Product manual

Commercial and Industrial MACH 10®Ultrasonic Meter
Installation and Maintenance Guide

Commercial and Industrial MACH 10®Ultrasonic Meter
Installation and Maintenance Guide

Copyright
This manual is an unpublished work and contains the trade secrets and
confidential information of NeptuneTechnologyGroupInc., which are not to be
divulged to third parties and may not be reproduced or transmitted in whole or
part, in any form or by any means, electronic or mechanical for any purpose,
without the express written permission of NeptuneTechnologyGroupInc. All
rights to design or inventions disclosed herein, including the right to
manufacture, are reserved to NeptuneTechnologyGroupInc.
Neptune engages in ongoing research and development to improve and
enhance its products. Therefore, Neptune reserves the right to change product
or system specifications without notice.
Trademarks Used in This Manual
MACH 10®and E-CODER®are registered trademarks of Neptune Technology
Group Inc. MACH 10®)R900i™, and ProRead™ are trademarks of Neptune
Technology Group Inc. Other brands or product names are the trademarks or
registered trademarks of their respective holders.
FCCNotice
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
lThis device may not cause harmful interference.
lThis device must accept any interference received, including interference that
may cause undesired operation.
Note:This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to Part 15 of the FCCRules. These limits are
designed to provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses, and can radiate radio
frequency energy, and if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or more of
the following measures:
lReorient or relocate the receiving antenna.
lIncrease the separation between the equipment and receiver.
lConnect the equipment to an outlet on a circuit different from that to which
the receiver is connected.
lConsult the dealer or an experienced radio / TV technician for help.

Changes or modifications not expressly approved by the party responsible for
compliance could void the users' authority to operate the equipment.
Professional Installation
In accordance with section 15.203 of the FCCrules and regulations, the Neptune
Meter Interface Unit (MIU) must be professionally installed by trained meter
installers. Changes or modifications not expressly approved by the party
responsible for compliance void the user's authority to operate the equipment.
Industry Canada
This Class B digital apparatus meets all requirements of theCanadian
Interference Causing Equipment Regulations. Operation is subject to the
following two conditions:
lThis device may not cause harmful interference.
lThis device must accept any interference received, including interference that
may cause undesired operation.
Cet appareillage numérique de la classe B répond à toutes les exigences de
l'interférence canadienne causant des règlements d'équipement. L'opération est
sujette aux deux conditions suivantes: (1) ce dispositif peut ne pas causer
l'interférence nocive, et (2) ce dispositif doit accepter n'importe quelle
interférence reçue, y compris l'interférence qui peut causer l'opération peu
désirée.

Commercial and Industrial MACH 10®
Ultrasonic Meter Installation and Maintenance Guide
Literature No. IMMACH 10 C&I 06.2020
Part No. 13920-001
Neptune Technology Group Inc.
1600 Alabama Highway 229
Tallassee, AL 36078
Tel: [phone]
Fax: [phone]
Copyright © 2020
NeptuneTechnologyGroupInc.
All Rights Reserved.

Contents
Chapter 1: Product Description 1
Introduction 1
Understanding Ultrasonic Technology 2
2
3
Transit-Time Technology
Summary
Chapter 2: Commercial and Industrial MACH 10® Specifications 5
Environmental and Performance Specifications 5
Weight and Dimension Specifications 6
Dimensions 6
Additional Specifications 7
Fluid Compatibility 7
Maincase 7
Transducers 8
Battery Requirement 8
Chapter 3: General Installation Guidelines 9
Tools and Materials 9
Safety and Preliminary Checks 10
Installation and Application Considerations 10
Water Temperature 10
Meter Installation 10
Water Flow 11
Meter Sizing and Selection 11
Chapter 4: Installing MACH 10® Ultrasonic Meters 13
13
Installation Instructions for MACH 10® Meters
Prior to Installation 13
Storage 13
Unpacking 13
Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide v

13
14
14
15
Handling the Meter
Upstream and Downstream Requirements
Installation – Commercial and Industrial
Wiring the MACH 10®
Completing the Wiring 17
Chapter 5: Activating and Reading MACH 10® Ultrasonic Meters 19
Activating the LCD Meter Display 19
Timeout Period 19
Meter Display 19
LCD Panel 20
How to Read the Meter 20
Alarms 20
LCD Icons 21
Consumption and Unit of Measure – Commercial and Industrial 22
Rate of Flow 22
Flow Direction 22
AMR / AMI Output 23
Endpoint Reading Resolution 23
Chapter 6: Testing the Commercial and Industrial MACH 10®25
Bench Testing the Commercial and Industrial MACH 10® Meter 25
Meter Accuracy Testing Guidelines 25
Test Bench Setup Procedure 26
Test Procedure 27
Test Data 28
Test Troubleshooting 29
Chapter 7: Maintenance and Troubleshooting 33
Maintenance 33
Unitized Measuring Element (UME) Maintenance 33
Replacement Parts 34
vi Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Contents

Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide vii
General Troubleshooting 34
Checklist 35
Contact Information 35
35
36
By Phone
By Email
Appendix A: MACH 10®)R900i™37
37
37
37
Product Description
MACH 10®)R900i™ Programming
RF Protocol Error Detection
MACH 10®)R900i™ Specifications 38
Dimensions – Commercial and Industrial 38
Electrical Specification 40
Transmitter Specifications 40
Functional Specifications 40
Appendix B: MACH 10®)R900i™ Flags 41
Glossary 43
Index 47
Contents

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viii Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Contents

Figures
2
3
4
6
11
15
15
16
17
17
18
18
19
20
33
38
38
Figure 1 – 3-Inch Commercial and Industrial MACH 10® Ultrasonic Meter
Figure 2 – Cross-Section of a 3-Inch Commercial and Industrial MACH 10®
Figure 3 – Unitized Measuring Element
Figure 4 – Commercial and Industrial Meter Dimensions – Side View
Figure 5 – Bleed Screw Location
Figure 6 – Scotchlok™ Connector
Figure 7 – Seat the Connector Wires
Figure 8 – Crimping Tool
Figure 9 – Three Colored Wires Connected
Figure 10 – Splice Tube
Figure 11 – Gray Wires in Slot
Figure 12 – Cover in Place
Figure 13 – Commercial and Industrial MACH 10® Meter
Figure 14 – MACH 10® LCD Panel
Figure 15 – Unitized Measuring Element Commercial and Industrial MACH 10® Meter
Figure 16 – Commercial and Industrial MACH10®)R900i™ – Top View
Figure 17 – Commercial and Industrial MACH 10®)R900i™ – Front View
Figure 18 – Commercial and Industrial Meter Dimensions – End View 39
Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide ix

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x Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Figures

Tables
5
5
6
7
7
9
9
12
16
21
22
28
28
29
29
30
30
31
31
34
34
40
40
40
41
41
Table 1 – Environmental Specifications
Table 2 – Performance Specifications
Table 3 – Commercial and Industrial MACH 10® Meter Weight Specifications
Table 4 – Commercial and Industrial MACH 10® Meter Dimensions
Table 5 – Additional Specifications
Table 6 – Recommended Tools and Materials for Meter Installation
Table 7 – Recommended Tools for Unitized Measuring Element Replacement
Table 8 – Maximum Flow Rates
Table 9 – Color Codes for Wires
Table 10 – MACH 10® Icons and Displays
Table 11 – Consumption and Units of Measure – Commercial and Industrial
Table 12 – Full Flow Testing
Table 13 – Intermediate Flow Testing
Table 14 – Low Flow Testing
Table 15 – Meter is Under Registering
Table 16 – Meter is Over Registering
Table 17 – Meter Stops Registering During a Test
Table 18 – Meter Does Not Register Water When Running a Test
Table 19 – Meter Does Not Register on Automated Test Bench
Table 20 – LCD Display Does Not Illuminate
Table 21 – MIU or LCD Display Reports Errors
Table 22 – MACH 10® R900i™ Meter Dimensions – Commercial and Industrial
Table 23 – Transmitter Specifications
Table 24 – Functional Specifications
Table 25 – Eighth Digit Resolution by Meter Size – Commercial and Industrial
Table 26 – MACH 10®)R900i™ Flags (digits)
Table 27 – MACH 10®)R900i™ Flags (minutes) 42
Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide xi

xii Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
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Commercial and lndustrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide 1
Chapter 1: Product Description
This chapter provides a general description of the 3-inch to 6-inch Neptune®Commercial
and Industrial MACH 10®Ultrasonic Meter (C&I MACH 10).
Introduction
Ultrasonic technology:
lContains no moving parts.
lProvides long-term accuracy.
lReduces measurement errors due to sand, suspended particles, and pressure
fluctuations.
The MACH 10 solid state meter uses ultrasonic transit-time technology and solid
state electronics. The C&I meter register is contained in a compact, totally encap-
sulated, weatherproof, and ultraviolet (UV) resistant housing for commercial and
industrial applications.
The C&I MACH 10®ultrasonic water meter features solid state ultrasonic technology
including a factory-calibrated, replaceable unitized measuring element (UME) with no
degradation of accuracy over time.
Combined with a corrosion-resistant, lead free, high-copper alloy maincase, the
C&I MACH 10 is built to withstand any demanding service condition and deliver sustained
accuracy over the life of the meter.
The C&I MACH 10 provides a Neptune E-CoderPLUS output signal to Neptune R900®and
other Automatic (or automated) Meter Reading (AMR) / Advanced Metering Infrastructure
(AMI)endpoints.
The meter's electronics and battery are fully potted to eliminate the intrusion of moisture,
dirt, or other contaminants. It is suitable for installation in all environments including meter
pits subject to continuous flooding.

Figure 1 – 3-Inch Commercial and Industrial MACH 10®Ultrasonic Meter
Understanding Ultrasonic Technology
An ultrasonic water meter uses high-frequency sound waves to measure the velocity of an
acoustically-conductive fluid moving through it. The velocity of the fluid is then converted to
volume throughput using sophisticated algorithms and electronics.
Transit-Time Technology
The MACH 10 utilizes transit-time ultrasonic technology. This technology takes advantage of
the principle that an acoustic signal travels faster with the flow than against the flow of the
fluid. These meters use transducers that are essentially transceivers, sending and receiving
the acoustic signals.
2 Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Chapter 1: Product Description

In the following image, the dashed lines show the acoustic path.
Figure 2 – Cross-Section of a 3-Inch Commercial and Industrial MACH 10®
The difference between the downstream and upstream transit time—the time it takes for the
signal to travel from one transducer set to the other—is proportional to the flow rate.
The calculated velocity of the water is then converted to volume based on the area of the
measurement section.
Summary
The MACH 10 meter is a transit-time ultrasonic flow meter with wetted transducers. Designed
as an alternative for mechanical meters, the MACH 10 meter utilizes traditional utility pipe
connectors and lay lengths. It is totally self-contained. The C&I MACH 10 battery, processor
circuit, and electronic display are fully potted and housed in a replaceable UME. The UME is
totally self-contained which not only minimizes field maintenance, but also eliminates the
need to remove the main case from service.
Commercial and lndustrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide 3
Chapter 1: Product Description

The MACH 10 meter provides an E-CoderPLUS output signal to Neptune R900®and other
AMR / AMI endpoints. The MACH 10®)R900i™ contains a MACH 10 meter and an integrated
R900 radio for transmitting meter reading data.
Figure 3 – Unitized Measuring Element
4 Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Chapter 1: Product Description

Commercial and lndustrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide 5
Chapter 2: Commercial and Industrial MACH 10®Specifications
This chapter provides the specifications for the C&I MACH 10®Ultrasonic Meter.
Environmental and Performance Specifications
This table defines environmental specifications that apply to the C&I MACH 10 meters.
Specification Description
Operating temperature 14° to 149° F (-10° to 65° C)
Storage temperature –40° to 158° F (–40° to 70° C)
Water temperature* 33° to 122° F (+0.5° to 50° C)
Operating humidity 0 to 100% condensing
Table 1 – Environmental Specifications
*Meets AWWA C-715 accuracy specifications for water temperatures from 33° to 122° F (+0.5 C to
50° C).
This table defines performance specifications that apply to C&I MACH 10 meters.
Meter Size
Extended Low
Flow @ 100%
Accuracy
(U.S. gpm, ± 3%)
Normal Operating
Range @ 100%
Accuracy (U.S. gpm,
± 1.5%)
Safe Maximum Operating
Capacity (U.S. gpm)
Standard Fire
Services
3 inch 0.50 .75 to 500 500 420
4 inch 0.75 1.5 to 1250 1250 1100
6 inch 1.0 2.0 to 2000 2000 1800
Table 2 – Performance Specifications

Weight and Dimension Specifications
The following tables define the weight and dimension specifications for the C&I MACH 10
meter.
Meter Size Length (in Inches) Weight
3 Inch 12 39 lbs.
17 42 lbs.
4 Inch 14 51 lbs.
20 57 lbs.
6 Inch 18 79 lbs.
24 91 lbs.
Table 3 – Commercial and Industrial MACH 10®
Meter Weight Specifications
Dimensions
This section defines the dimensions of the Commercial and Industrial MACH 10 meter.
Figure 4 – Commercial and Industrial Meter Dimensions – Side View
The following table defines the dimensions for the MACH 10 meter. All measurements are in
inches.
6 Commercial and Industrial MACH 10®Ultrasonic Meter Installation and Maintenance Guide
Chapter 2: Commercial and Industrial MACH 10® Specifications