Pulsar Measurement FlowCERT Lite UL User manual

FlowCERT Lite UL
Instruction Manual

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PULSAR MEASUREMENT
3
FLOWCERT LITE (UL) (FOURTH EDITION REV 1)
February 2021
Part Number M-150-L-003-1U
COPYRIGHT
© Pulsar Measurement, 2005 -21. All rights reserved. No part of this publication may be
reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form without the written permission of Pulsar Process Measurement Limited.
WARRANTY AND LIABILITY
Pulsar Measurement guarantee for a period of 2 years from the date of delivery that it will
either exchange or repair any part of this product returned to Pulsar Process Measurement
Limited if it is found to be defective in material or workmanship, subject to the defect not being
due to unfair wear and tear, misuse, modification or alteration, accident, misapplication, or
negligence.
DISCLAIMER
Pulsar Measurement neither gives nor implies any process guarantee for this product and shall
have no liability in respect of any loss, injury or damage whatsoever arising out of the
application or use of any product or circuit described herein.
Every effort has been made to ensure accuracy of this documentation, but Pulsar Measurement
cannot be held liable for any errors.
Pulsar Measurement operates a policy of constant development and improvement and reserves
the right to amend technical details, as necessary.
The FlowCERT Lite shown on the cover of this manual is used for illustrative purposes only and
may not be representative of the actual FlowCERT Lite supplied.
CONTACT
For technical support, please contact:
Europe: [e-mail]
Outside Europe: [e-mail]
If you have any comments or suggestions about this product, please contact:
Europe: [e-mail]
Outside Europe: [e-mail]
Pulsar Measurement website: www.pulsarmeasurement.com
United States
11451 Belcher Road South
Largo,
FL 33773
888-473-9546
Canada
16456 Sixsmith Drive
Long Sault, Ont.
K0C 1P0
855-300-9151
United Kingdom
Cardinal Building, Enigma
Commercial Centre
Sandy’s Road, Malvern
WR14 1JJ
00 44 (0)1684 891371

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CONTENTS
Chapter 1: Start Here… ...........................................................................................................9
About this Manual ...............................................................................................................9
About the FlowCERT ........................................................................................................ 10
Functional Description .................................................................................................... 11
Product Specification....................................................................................................... 12
EU Certificate of Conformity.........................................................................................14
Chapter 2 FlowCERT Lite Installation ............................................................................. 15
Unpacking............................................................................................................................15
Power Supply Requirements.........................................................................................15
Safety Symbols................................................................................................................... 16
Location ................................................................................................................................17
Dimensions ..........................................................................................................................18
Wall Mount.......................................................................................................................... 18
Cable Entry...........................................................................................................................20
Terminal connection details..........................................................................................20
Terminal connections ...................................................................................................... 20
Transducer ........................................................................................................................... 21
ATEX ....................................................................................................................................... 21
FM ........................................................................................................................................... 21
Internal Temperature Compensation........................................................................24
Mounting Bracket ............................................................................................................. 25
Voltage Selector and Fuse Location .......................................................................... 27
Preparation for Operation ............................................................................................. 28
Maintenance ....................................................................................................................... 28
Chapter 3 How To Use Your FlowCERT Lite ................................................................29
Operating the Controls...................................................................................................29
Run Mode.............................................................................................................................30
Program Mode................................................................................................................... 31
How to Access Program Mode....................................................................................31
Hot Keys................................................................................................................................32
Menu Keys ........................................................................................................................... 33

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Numeric Keys...................................................................................................................... 33
Using the Menu System .................................................................................................34
Directly Editing Parameters ......................................................................................... 35
Test Mode ............................................................................................................................ 36
Using the Serial Interface............................................................................................... 37
Parameter Defaults........................................................................................................... 39
Chapter 4 Quick Setup Guide ........................................................................................... 40
Enter Program Mode .......................................................................................................40
Choose Quick Setup......................................................................................................... 40
Choose Your Application ............................................................................................... 41
Quick Setup ......................................................................................................................... 43
Exponential Devices (P700 = 1)...................................................................................47
Point of Measurement .................................................................................................... 48
Calculations ......................................................................................................................... 50
Example 1 V-Notch Weir................................................................................................ 52
BS3680 Flumes (P700 = 2).............................................................................................54
Calculations ......................................................................................................................... 55
Rectangular Flume............................................................................................................ 55
U-Throated Flume.............................................................................................................56
Example 2 BS3680 U-Throated Flume ......................................................................57
BS3680 Weirs (P700 = 3)................................................................................................59
Calculations ......................................................................................................................... 59
BS3680 Rectangular Weir .............................................................................................. 59
BS3680 V-Notch Weir...................................................................................................... 60
Example 3 BS3680 Rectangular Weir ........................................................................ 61
BS3680 Rectangular Broad Crested Weir ................................................................63
Calculations ......................................................................................................................... 63
Special Devices (P700 =5)..............................................................................................65
Calculations ......................................................................................................................... 66

FLOWCERT LITE (UL) INSTRUCTION MANUAL
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Universal Calculations (P700=6)..................................................................................67
Calculations ......................................................................................................................... 67
Chapter 5 Parameter Guide ...............................................................................................68
Menu System ...................................................................................................................... 68
Top Level Menu ................................................................................................................. 68
Application Menu.............................................................................................................. 69
Relays Menu........................................................................................................................70
Data Logs Menu ................................................................................................................ 71
OCM Menu .......................................................................................................................... 72
Display Menu......................................................................................................................73
mA Output Menu.............................................................................................................. 73
Compensation .................................................................................................................... 74
Stability Menu .................................................................................................................... 74
Echo Processing Menu....................................................................................................75
System Menu ...................................................................................................................... 76
Device Comm Menu ........................................................................................................77
Test Menu ............................................................................................................................ 78
Chapter 6 Parameter Listing and Description ............................................................ 79
Application Parameters................................................................................................... 79
Operation ............................................................................................................................. 79
Dimensions ..........................................................................................................................80
Relay Parameters............................................................................................................... 82
Alarms.................................................................................................................................... 83
Pumps.................................................................................................................................... 87
Control................................................................................................................................... 91
Miscellaneous ..................................................................................................................... 93
Common Relay parameters...........................................................................................95
Data Log parameters ....................................................................................................... 96
Totaliser Audits .................................................................................................................. 96
Temperature........................................................................................................................96

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OCM Parameters ............................................................................................................... 98
PMD Setup........................................................................................................................... 98
Dimensions ........................................................................................................................101
Calculations .......................................................................................................................107
Breakpoints........................................................................................................................107
Tables...................................................................................................................................108
Average Flow ....................................................................................................................108
Display Parameters.........................................................................................................109
Options................................................................................................................................109
Failsafe.................................................................................................................................110
Auxiliary...............................................................................................................................111
Totaliser...............................................................................................................................113
Bargraph .............................................................................................................................115
mA Output Parameters.................................................................................................115
Range...................................................................................................................................115
Operation ...........................................................................................................................116
Setpoint...............................................................................................................................116
Limits....................................................................................................................................117
Trim.......................................................................................................................................117
Failsafe.................................................................................................................................118
Allocation ...........................................................................................................................118
Compensation Parameters..........................................................................................118
Offset....................................................................................................................................118
Temperature......................................................................................................................119
Velocity................................................................................................................................119
Stability Parameters .......................................................................................................120
Damping.............................................................................................................................120
Indicator..............................................................................................................................121
Rate.......................................................................................................................................121

FLOWCERT LITE (UL) INSTRUCTION MANUAL
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Filters....................................................................................................................................122
Echo Processing Parameters.......................................................................................123
Transducer Status............................................................................................................123
System Parameters .........................................................................................................124
Passcode.............................................................................................................................126
Backup.................................................................................................................................126
System Information........................................................................................................126
Date & Time ......................................................................................................................128
LED Colour .........................................................................................................................128
Watchdog...........................................................................................................................129
Daylight Saving Time.....................................................................................................130
Device Comm. ..................................................................................................................133
RS232 Set Up ....................................................................................................................133
RS 485 Set Up...................................................................................................................133
Remote Alarm...................................................................................................................134
Test Parameters ...............................................................................................................136
Simulation ..........................................................................................................................136
Hardware ............................................................................................................................137
Chapter 7 Troubleshooting..............................................................................................140
Chapter 8 Disposal ..............................................................................................................141
Notes ........................................................................................................................................142

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CHAPTER 1: START HERE…
Congratulations on your purchase of a Pulsar FlowCERT Lite. This quality
system has been developed over many years and represents the latest in
high technology ultrasonic level measurement and control.
It has been designed to give you years of trouble-free performance, and a
few minutes spent reading this operating manual will ensure that your
installation is as simple as possible.
About this Manual
It is important that this manual is referred to for correct installation and
operation. There are various parts of the manual that offer additional help
or information as shown.
Tips
TIP: Look for this icon throughout your Pulsar Measurement manual to
find helpful information and answers to frequently asked questions .
Additional Information
References
See Also
References to other parts of the manual.
Additional Information
At various parts of the manual, you will find sections
like this that explain specific things in more detail.

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About the FlowCERT
The FlowCERT lite open channel flow meter is a state-of-the-art ultrasonic
flow metering and control system which provides comprehensive flow
monitoring with data logging (optional) and control functions for a
complete range of flumes, weirs and channels.
Easy calibration via the “Quick Set Up” menu and maintenance free “fit and
forget” performance means that you can install the FlowCERT LITE rapidly
and with confidence.
FlowCERT LITE is equipped with five user definable relays enabling initiation
of control or indication devices such as pumps, samplers and remote
totalisers, along with an isolated mA output to provide remote indication
while local indication of flow and total flow is provided by a back lit LCD
display and bar graph.

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Functional Description
FlowCERT Lite sends a transmit pulse to the transducer, which emits an
ultrasonic pulse perpendicular to the transducer face, and the returned echo
is sent back to the FlowCERT Lite. The time taken to receive the echo is
measured and the distance from the transducer face to the surface being
monitored is calculated.
FlowCERT Lite can measure from zero to 52.49 feet (16m) from the face of
the transducer to the surface being monitored, dependent on the
application chosen and transducer used.
The relays can be programmed to activate alarms, pump starters, or other
control equipment. There is an isolated 4-20 mA output that can be
connected to a recorder or PLC, to monitor, level space, distance, OCM
head, or OCM flow, independently from that shown on the display.
Additionally, there is an RS232 port, so that the FlowCERT Lite can be
operated remotely by a PC or other equipment.
FlowCERT Lite can be programmed either by the built-in keypad (standard),
or by PC via the RS 232 Serial Interface (optional). All parameters are stored
in non-volatile memory, so are retained in the event of power interruption. A
second backup copy of all parameters can also be retained in the FlowCERT
Lite memory, in case an alternative set of parameters needs to be stored.
Five user definable control relays with individual setpoints and intelligent
performance logging software features ensure maximum control versatility.
The system utilises the unique DATEM software (Digital Adaptive Tracking of
Echo Movement). This is a proven digital mapping technique developed
especially for the Pulsar Ultra range, which gives the system unequalled
ability when identifying the “true target level” in the face of competing
echoes from pipes, pumps, or other obstructions. Coupled with the powerful
‘all new’ dB transducer range, the FlowCERT Lite lives up to its reputation as
the most reliable ultrasonic level measurement system available.
The Pulsar FlowCERT Lite ultrasonic level controller has been designed to
provide maintenance-free fit and forget performance.

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Product Specification
PHYSICAL
Wall Mount Outside Dimensions
9.25 x 7.24 x 4.72 inch (235 x 184 x 120 mm)
Weight
Nominal 2.2lbs (1kg)
Enclosure Material/Description
Polycarbonate, flame resistant to UL94-5V
Cable Entry Detail
10 cable entry knock outs, 1 x M16, 5 x M20
underside, 4 x 18mm dia (PG11) at rear
Transducer Cable Extensions
3-conductor 20AWG screened
Maximum Separation
3,250 ft (1,000m), 1,640 ft (500m) for mmWave
ENVIRONMENTAL
IP Rating (Wall)
IP65 (NEMA 4X), IP20 when open
Max. & min. temperature
(electronics)
-20 ºC to +50 ºC (-4˚F to +120˚F)
Flammable atmosphere approval
Safe area: compatible with approved dB transducers
(see transducer spec' sheet)
APPROVALS
CE Approval
See EU Declaration of Conformity
UL
Certificate Number E257330
PERFORMANCE
Accuracy
0.1% of the measured range (dB3 and external
temperature compensation or internal
compensation using twin sunshields)
Resolution
0.5mm (dB3 and external temperature compensation)
Max. Range
Dependent on application and transducer (maximum
52.49ft (16m) dBR16
Min. Range
Dependent upon application and transducer
(minimum zero dB Mach3)
Rate Response
Fully adjustable
ECHO PROCESSING
Description
DATEM (Digital Adaptive Tracking of Echo
Movement)

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OUTPUTS
Analogue output
Isolated (floating) output (to 150V) of 4-20 mA or 0-20
mA into 500Ω(user programmable and adjustable)
1µA resolution
Digital output
Full Duplex RS232
Volt free contacts, number, and
rating
5 form "C" (SPDT) rated at 5A at 115V AC
Display
6 digits plus 12-character text, plus bar graph with
direction indicators, remote communicator identifier,
and program/run/test mode indicators
PROGRAMMING
On-board programming
By integral keypad
PC programming
Via RS232
Programming security
Via passcode (user selectable and adjustable)
Programmed data integrity
Via non-volatile RAM, plus backup
SUPPLY
Power Supply
115V AC + 5% / -10% 50/60 Hz,
dc 22 - 28V (If using a battery then 24V minimum
1AH, dependant on life required, externally fused with
1A fast blow fuse. 10W maximum power (typically
6W)
Overvoltage Category
II
Fuses
Mains (F1)
125mA T at 155V AC
DC (Battery) (F2)
1A Thermal (self resetting after power removed). Not
user replaceable
Transducer (F3, F5, Ch.1 & F4,
F6 Ch.2)
Little fuse 242 series 100mA Part No. 0242.100. This
fuse is not user replaceable and has a 4000A
breaking capability to comply with certification of the
Exm version of dB series transducers.
REMOTE COMMUNICATOR
Enclosure protection
IP68
Max and Min Temperature
-20 ºC to +70 ºC (-4˚F to +158˚F)
Pulsar Measurement operates a policy of constant development and
improvement and reserve the right to amend technical details, as necessary.

FLOWCERT LITE (UL) INSTRUCTION MANUAL
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EU Certificate of Conformity

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CHAPTER 2 FLOWCERT LITE INSTALLATION
Unpacking
Power Supply Requirements
FlowCERT lite can operate from AC supply or from a DC battery. The AC is
either 115 +5%/-10% 50/60Hz or 230V +5%/-10% 50/60Hz, depending on
the position of the selector switch. The DC is 22-28V. In all cases the
FlowCERT lite will typically consume 6W of power, with a maximum of 10W.
If FlowCERT lite has both an AC and DC supply available then the AC supply
source will be automatically sensed and used, should the AC supply be
removed for any reason then the DC supply will take over.
The AC and DC wiring should be completed using either 1.5–2.5mm2(16 –
14AWG) stranded or 1.5–4mm2(16 –14AWG) solid wire, with all terminals
being tightened to (0.5Nm) (4.5in. lbs.). An external supply isolator/circuit
breaker (AC or DC) must be fitted and labelled to identify the instrument to
which it refers.
Important Information
All shipping cartons should be opened carefully. When using a box cutter, do not
plunge the blade deeply into the box, as it could potentially cut or scratch
equipment components. Carefully remove equipment from each carton,
checking it against the packing list before discarding any packing material. If
there is any shortage or obvious shipping damage to the equipment, report it
immediately to Pulsar Process Measurement Limited.

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Safety Symbols
Detailed below are descriptions and meanings of safety/warning symbols
that are used on the FlowCERT Lite and in this manual.
SYMBOL
DESCRIPTION
DIRECT CURRENT (DC)
ALETRNATING CURRENT (AC)
PROTECTIVE CONDUCTOR TERMINAL
CAUTION (Refer to accompanying Documents)
!

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Location
The FlowCERT Lite must be mounted in a non-hazardous (safe) area, and the
transducer fitted in the hazardous area
When choosing a location to mount the enclosure, bear in mind the
following:
•Ensure that the FlowCERT Lite is installed in a “Safe”, non-hazardous
area.
•For a clear view of the LCD display, it is recommended that it is
mounted at eye level.
•The mounting surface is to be vibration free.
•The ambient temperature is between -20°C and 50°C.

FLOWCERT LITE (UL) INSTRUCTION MANUAL
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•There should be no high voltage cables or inverters nearby,
Dimensions
Wall Mount
The dimensions of the wall fixing holes are as shown below:
The FlowCERT Lite should be mounted by drilling three holes suitable for
size 8 screws (length to suit the application) and fixing the screw in place.
Hang the unit on this and fix the two remaining screws by removing the
terminal access cover to access the pre-drilled holes.
198mm (7.80”)
30mm
(1.18”)
142mm
(5.59”)
FIXING HOLES
Important Information
All electronic products are susceptible to electrostatic shock, so follow proper
grounding procedures during installation.

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The full dimensions of the enclosure are as shown below:
235mm (9.25”)
184mm (7.24”)
212mm (8.35”)
0.96”
(24.5mm)
1.89”
(48mm)
0.96”
(24.5mm)
1.06”
(27mm)
1.10”
(28mm)
1.10”
(28mm)
1.10”
(28mm)
1.18”
(30mm)
142mm (5.59”)
4.72” (120mm)

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Cable Entry
There are 6 cable gland knockouts on the base of the FlowCERT Lite (5 x
20mm (0.79"), 1 x 16mm (0.63")) and 4 on the rear (4 x 18mm dia (0.73")).
Select which ones you wish to take out, and remove them by using a circular
cutter, such as a tank cutter. Take care not to damage the circuit board
inside whilst undertaking this. Do not use a hammer, as this may cause
damage to the enclosure. It is recommended that you use suitable cable
glands to ensure that the ingress rating is maintained.
Terminal connection details
There is a wiring diagram inside the terminal access cover, and is shown
below:
Terminal connections
Power
The FlowCERT can operate from mains AC and automatically from DC or
battery backup in the event of power failure or can be operated permanently
from DC or batteries.