Pulsar UltraTWIN User manual

UltraTWIN (UL)
Instruction Manual

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PULSAR MEASUREMENT
3
ULTRATWIN (UL) (THIRD EDITION REV 1)
April 2021
Part Number M-192-6-003-1U
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 UltraTWIN shown on the cover of this manual is used for illustrative purposes only and may
not be representative of the actual UltraTWIN 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… ........................................................................................................ 10
About this Manual ............................................................................................................10
About the UltraTWIN....................................................................................................... 11
Functional Description ....................................................................................................11
Product Specification.......................................................................................................13
EU Certificate of Conformity.........................................................................................15
Chapter 2 UltraTWIN Installation .................................................................................... 16
Unpacking............................................................................................................................ 16
Power Supply Requirements.........................................................................................16
Safety Symbols...................................................................................................................17
Location ................................................................................................................................18
Dimensions .......................................................................................................................... 19
Terminal connection details..........................................................................................23
Power ..................................................................................................................................... 25
Transducer ........................................................................................................................... 26
ATEX ....................................................................................................................................... 26
FM ........................................................................................................................................... 27
Voltage selector and fuse location.............................................................................29
Preparation for Operation ............................................................................................. 30
Maintenance ....................................................................................................................... 31
Chapter 3 How To Use Your UltraTWIN ....................................................................... 32
Operating the Controls...................................................................................................32
Run Mode.............................................................................................................................34
Program Mode...................................................................................................................34
Points of Measurement (P1 and P2).......................................................................... 34
How to Access Program Mode....................................................................................35
Hot Keys................................................................................................................................36
Menu Keys ........................................................................................................................... 37
Numeric Keys...................................................................................................................... 37
Using the Menu System ................................................................................................. 38
Directly Editing Parameters...........................................................................................39

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Test Mode ............................................................................................................................ 40
Using the Serial Interface............................................................................................... 41
Parameter Defaults........................................................................................................... 43
Chapter 4 Quick Setup Guide ...........................................................................................44
Enter Program Mode .......................................................................................................44
Choose Quick Setup......................................................................................................... 44
Level or Volume................................................................................................................. 45
Example 1 Level Monitoring with Alarms................................................................ 51
Example 2 Level Monitoring and Control (up or down) .................................... 53
Example 3 Volume Application.................................................................................... 55
Example 4 Differential Control..................................................................................... 58
Pump......................................................................................................................................62
Quick Setup ......................................................................................................................... 63
Example 1 Sump Control (pump down)...................................................................68
Example 2 Reservoir Control (pump Up) ................................................................. 70
Flow ........................................................................................................................................ 72
Exponential Devices .........................................................................................................79
Calculations ......................................................................................................................... 82
BS3680 Flumes (P700 = 2)............................................................................................. 86
Rectangular Flume Calculations .................................................................................. 87
U-Throated Flume Calculations................................................................................... 88
Example 2 BS3680 U-Throated Flume ......................................................................89
BS3680 Weirs (P700 = 3)................................................................................................91
Rectangular Weir Calculations..................................................................................... 91
V-Notch Weir Calculations............................................................................................92
BS3680 Rectangular Broad Crested Weir ................................................................ 95
Rectangular Broad Crested Weir Calculations....................................................... 95
Special Devices...................................................................................................................97
Palmer Bowlus and H-Flume Calculations .............................................................. 98
V-Notch Angle Weir (Non-BS 3680) Calculations................................................98

ULTRATWIN (UL) INSTRUCTION MANUAL
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Universal Calculations (P700=6)..................................................................................99
Chapter 5 Parameter Guide .............................................................................................100
Menu System ....................................................................................................................100
Top Level Menu ...............................................................................................................100
Application Menu............................................................................................................101
Relays Menu......................................................................................................................102
Pump “Advanced” Menu..............................................................................................103
Digital Inputs Menu........................................................................................................104
Data Logs Menu ..............................................................................................................105
Volume (When P100 = 6).............................................................................................106
OCM Menu (When P100 = 4 or 5) ...........................................................................107
Display Menu....................................................................................................................108
mA Output 1 Menu ........................................................................................................109
mA Output 2 Menu ........................................................................................................109
Compensation Menu .....................................................................................................110
Stability Menu ..................................................................................................................110
Echo Processing Menu..................................................................................................111
System Menu ....................................................................................................................112
Device Comm Menu ......................................................................................................113
Test Menu ..........................................................................................................................114
Application Parameters.................................................................................................115
Operation ...........................................................................................................................115
Operation ...........................................................................................................................115
Dimensions ........................................................................................................................117
Relay Parameters.............................................................................................................119
Alarms..................................................................................................................................121
Pumps..................................................................................................................................128
Control.................................................................................................................................132
Miscellaneous ...................................................................................................................136
Common Relay parameters.........................................................................................138
Pump “Advanced” Parameters...................................................................................139

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Pump Run On ...................................................................................................................139
Starting................................................................................................................................139
Stopping .............................................................................................................................140
Pump Exercising ..............................................................................................................140
Wall Cling ...........................................................................................................................141
Digital Inputs.....................................................................................................................142
Digital Input Parameters ..............................................................................................148
Digital Inputs.....................................................................................................................150
Digital Input.......................................................................................................................152
Data Log parameters .....................................................................................................153
Totaliser Audits ................................................................................................................153
Temperature......................................................................................................................153
Pump Logs.........................................................................................................................154
Volume ................................................................................................................................155
Conversion.........................................................................................................................156
Breakpoints........................................................................................................................161
Tables...................................................................................................................................162
OCM .....................................................................................................................................163
PMD Setup.........................................................................................................................163
Dimensions ........................................................................................................................166
Calculations .......................................................................................................................170
Breakpoints........................................................................................................................170
Tables...................................................................................................................................171
Average Flow ....................................................................................................................171
Display Parameters.........................................................................................................172
Options................................................................................................................................172
Failsafe.................................................................................................................................174
Auxiliary...............................................................................................................................175
Totaliser...............................................................................................................................178
Bargraph .............................................................................................................................180

ULTRATWIN (UL) INSTRUCTION MANUAL
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mA Output 1 Parameters .............................................................................................181
Range...................................................................................................................................181
Operation ...........................................................................................................................182
Setpoint...............................................................................................................................182
mA1 Limits .........................................................................................................................183
mA1 Trim............................................................................................................................183
mA1 Failsafe......................................................................................................................184
mA1 Allocation.................................................................................................................184
mA Output2 Parameters ..............................................................................................185
Range...................................................................................................................................185
Operation ...........................................................................................................................186
Setpoint...............................................................................................................................186
mA2 Limits .........................................................................................................................187
mA2 Trim............................................................................................................................187
mA2 Failsafe......................................................................................................................188
mA2 Allocation.................................................................................................................188
Compensation Parameters..........................................................................................190
Offset....................................................................................................................................190
Temperature......................................................................................................................190
Velocity................................................................................................................................191
Stability Parameters .......................................................................................................192
Damping.............................................................................................................................192
Indicator..............................................................................................................................192
Rate.......................................................................................................................................192
Filters....................................................................................................................................193
Echo Processing Parameters.......................................................................................194
Transducer 1 Status........................................................................................................194
Transducer 2 Status........................................................................................................195
DATEM Parameters.........................................................................................................196
System Parameters .........................................................................................................197
Backup.................................................................................................................................197

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System Information........................................................................................................198
Date & Time ......................................................................................................................199
LED Colour .........................................................................................................................199
Watchdog...........................................................................................................................200
Daylight Saving Time.....................................................................................................201
Device Comm. ..................................................................................................................205
RS232 Set Up ....................................................................................................................205
RS 485 Set Up...................................................................................................................205
Remote Alarm...................................................................................................................206
Test Parameters ...............................................................................................................208
Simulation ..........................................................................................................................208
Hardware ............................................................................................................................209
Chapter 6 Troubleshooting..............................................................................................211
Chapter 7 Disposal ..............................................................................................................212
Notes ........................................................................................................................................213

ULTRATWIN (UL) INSTRUCTION MANUAL
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CHAPTER 1: START HERE…
Congratulations on your purchase of a Pulsar UltraTWIN. 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 UltraTWIN
UltraTWIN has two independent points of measurement, the wall mount
model provides a dedicated display to each point of measurement, whilst
the fascia model, whilst in RUN, will show detail of one point of
measurement in the main display line, with the second point being displayed
on the auxiliary display line. In both models, the display will provide
information relevant to the point of measurement selected whilst in RUN
and PROGRAM mode
UltraTWIN combines premium specification with high performance in a most
versatile system which is quickly configurable offering a choice of
applications in any combination, between the two points of measurement of
three specific applications i.e., level or volume measurement, pump control
or flow measurement.
Functional Description
UltraTWIN sends a transmit pulse to the transducer(s), which emits an
ultrasonic pulse perpendicular to the transducer face, and the returned echo
is sent back to the UltraTWIN. The time taken to receive the echo is
measured and the distance from the transducer face to the surface being
monitored is calculated.
UltraTWIN can measure from zero to 40m from the transducer to the surface
being monitored, dependent on the application chosen and transducer
used.
Six user-definable relays can be programmed to activate alarms, pump
starters, or other control equipment, and can be allocated to either point of
measurement. Also provided are four user definable digital inputs on the
wall mount model and seven on the fascia mount model, which can be
allocated to either point of measurement.

ULTRATWIN (UL) INSTRUCTION MANUAL
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There is an isolated 4-20 mA output for each point of measurement that can
be connected to a recorder or PLC, to monitor level space, distance,
volume, OCM head or flow (dependant on the application chosen),
independently from that shown on the display. There is an RS232 port, so
that the UltraTWIN can be operated remotely by a PC or other equipment.
UltraTWIN 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 UltraTWIN memory, in case an alternative set of
parameters needs to be stored.
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,
long-range abilities of the ‘all new’ dB transducer range, the UltraTWIN lives
up to its reputation as the most reliable ultrasonic level measurement
system available.
The Pulsar UltraTWIN ultrasonic level controller has been designed to
provide maintenance-free fit and forget performance.
The UltraTWIN can show level, space, distance, on the display. The relays
can be programmed to activate alarms, pump starters, or other control
equipment. In addition, the digital inputs can be used to modify pump and
control regimes to optimise performance. There is an isolated 4-20 mA
output that can be connected to a chart recorder or PLC, to monitor level,
space or distance, independently from that shown on the display. There is an
RS232 port, so that the UltraTWIN can be operated remotely by a PC or
other equipment.
The UltraTWIN is programmed by the built-in keypad or by PC via the RS
232 Serial Interface (optional). All the 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 UltraTWIN, in case
a previous set of parameters needs to be restored.

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Product Specification
PHYSICAL
Wall Mount Outside dimensions
9.25 x 7.24 x 4.72” (235 x 184 x 120 mm)
Weight
Nominal 2.2lbs (1 kg)
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 PG11 at rear
Fascia Outside dimensions
7.87 x 4.41 x 4.25” (200 x 112 x 108 mm)
Weight
Nominal 2.8lbs (1.3kg)
Enclosure material/description
Stainless steel back, Polycarbonate UL94-V0 front and
bezel
Transducer cable extensions
3-conductor 20AWG screened
Maximum separation
3,280 ft (1000m) 1,640 ft (500m for mmWAVE)
ENVIRONMENTAL
IP Rating (Wall)
IP65 (NEMA 4x) When closed, IP20 when open
IP Rating (Fascia)
IP64 (from front of panel)
Max. & min. temperature
(electronics)
-20 ºC to +50 ºC
Flammable atmosphere approval
Safe area: compatible with approved dB transducers
(see transducer spec' sheet) <35 ºC at 93% relative
humidity Pollution Degree 2
SUPPLY
UL
Certificate Number E257330
CE Approval
See EU Declaration of Conformity
PERFORMANCE
Accuracy
0.25% of the measured range or 6 mm (whichever is
greater). mmWAVE ± 2mm.
Resolution
0.1% of the measured range or 2 mm (whichever is
greater)
Max. Range
Dependant on transducer (maximum 40m dB40)
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)

ULTRATWIN (UL) INSTRUCTION MANUAL
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OUTPUTS X 2
Analogue Outputs
Isolated (floating) output (to 150V) of 4-20 mA or 0-20
mA into 500(user programmable and adjustable)
0.1% resolution
Digital output
Full Duplex RS232
Volt free contacts, number, and
rating
6 form "C" (SPDT) rated at 5A at 115V AC
DIGITAL INPUTS
Wall Mount x 4
Fascia Mount x 7
Min. Input Voltage 4.5VDC. Max. Input Voltage
30VDC (Max Current 3mA). 24VDC Input Supply
maximum total current 24mA.
DISPLAY
Wall Mount x 2
Fascia Mount x 1
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 18 - 30V (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
Main (F1)
125 mA T at 115 VAC
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.
Pulsar Measurement operates a policy of constant development and
improvement and reserve the right to amend technical details, as necessary.

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EU Certificate of Conformity

ULTRATWIN (UL) INSTRUCTION MANUAL
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CHAPTER 2 ULTRATWIN INSTALLATION
Unpacking
Power Supply Requirements
The UltraTWIN can operate from AC supply or from a DC battery and is
designed for use in temperatures between -4oF to +140oF (-20oC to +50oC).
The AC is 115 +5% / -10% 50/60Hz. The DC is 18-30V. In all cases the
UltraTWIN will typically consume 6W of power, with a maximum of 10W. If
UltraTWIN 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 16 –14AWG (1.5–
2.5mm2) stranded or 16 –14AWG (1.5–4mm2) solid wire, with all terminals
being tightened to 4.5in. lbs. (0.5Nm). An external supply isolator/circuit
breaker (AC or DC) must be fitted near to the unit 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 UltraTWIN and in this manual:
SYMBOL
DESCRIPTION
DIRECT CURRENT (DC)
ALETRNATING CURRENT (AC)
PROTECTIVE CONDUCTOR TERMINAL
CAUTION (Refer to accompanying
Documents)
!

ULTRATWIN (UL) INSTRUCTION MANUAL
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Location
The UltraTWIN 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 UltraTWIN 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.
•There should be no high voltage cables or inverters nearby,
Important Information
All electronic products are susceptible to electrostatic shock, so follow proper
grounding procedures during installation.

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Dimensions
Wall Mount
The dimensions of the wall fixing holes are as shown below:
The UltraTWIN should be mounted by drilling three holes suitable for size 8
screws (length to suit your application), and fixing the top screw in place.
Hang the unit on this and fix the two remaining screws by removing the
terminals access cover to access the pre-drilled holes.
1.18"
(30mm)
5.59"
(142mm)
7.80”(198mm)

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The full dimensions of the Wall enclosure are as shown below:
0.96”
0.96”
1.89”
(24.5mm
)
(48mm)
(24.5mm)
8.35”(212mm)
9.25”(235mm)
6.02 “ (153mm)
7.24” (184mm)
4.72” (120mm)
1.06”
1.10”
1.10”
1.10”
1.18”
(27mm)
(28mm)
(28mm)
(28mm)
(30mm)