Pulsar Ultra 4 User manual

Ultra 4
Instruction Manual

2

PULSAR MEASUREMENT
3
ULTRA 4 (SECOND EDITION REV 3)
August 2021
Part Number M-174-1-002-3P
COPYRIGHT
© Pulsar Measurement, 2020 -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 Measurement.
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 Measurement 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 Ultra 4 shown on the cover of this manual is used for illustrative purposes only and may not
be representative of the actual Ultra 4 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

4
CONTENTS
Chapter 1: Start Here… ...........................................................................................................9
About this Manual ...............................................................................................................9
About the Ultra 4............................................................................................................... 10
Functional Description ....................................................................................................11
How to use this Manual.................................................................................................. 12
Product Specification....................................................................................................... 13
EU Certificate of Conformity......................................................................................... 15
Chapter 2 Ultra 4 Installation............................................................................................16
Unpacking............................................................................................................................ 16
Power Supply Requirements.........................................................................................16
Location ................................................................................................................................16
Typical system wiring....................................................................................................... 18
Dimensions .......................................................................................................................... 19
Wall Mount..........................................................................................................................19
Fascia Mount....................................................................................................................... 21
Terminal connection details..........................................................................................23
Interface Connections ..................................................................................................... 24
Terminal Connections......................................................................................................24
Fuse Location...................................................................................................................... 26
Preparation for Operation ............................................................................................. 27
Maintenance ....................................................................................................................... 27
Chapter 3 How To Use Your Ultra 4 ............................................................................... 28
Operating the Controls................................................................................................... 28
Run Mode............................................................................................................................. 29
How to Access Program Mode....................................................................................38
Menu Keys ........................................................................................................................... 39
Hot Keys................................................................................................................................40
Numeric Keys...................................................................................................................... 40
Using the Menu System .................................................................................................41
Directly Editing Parameters........................................................................................... 42
Test Mode ............................................................................................................................ 43

PULSAR MEASUREMENT
5
Using the Serial Interface............................................................................................... 44
Parameter Defaults........................................................................................................... 46
Chapter 4 Ultra Wizard........................................................................................................47
Enter Program Mode .......................................................................................................47
Choose Ultra Wizard........................................................................................................ 47
Ultra 4 - Level / Volume ................................................................................................. 48
Ultra 4 - Pump control ....................................................................................................48
Ultra 4 - Flow ...................................................................................................................... 49
Chapter 5 Level / Volume................................................................................................... 51
Quick Setup ......................................................................................................................... 53
Example 1 Level Monitoring with Alarms................................................................ 57
Example 2 Level Monitoring and Control (up or down) .................................... 59
Example 3 Volume Application....................................................................................61
Chapter 6 Pump ..................................................................................................................... 64
Quick Setup Menu ............................................................................................................ 66
Example 4 Level Monitoring with Alarms................................................................ 69
Example 5 Sump Control (pump down)...................................................................71
Example 6 Reservoir Control (pump up)..................................................................73
Chapter 7 Flow........................................................................................................................75
Exponential Devices ......................................................................................................... 82
Calculations ......................................................................................................................... 85
BS3680 Flumes (P700 = 2).............................................................................................89
Rectangular Flume Calculations .................................................................................. 90
U-Throated Flume Calculations................................................................................... 91
Example 2 BS3680 U-Throated Flume ......................................................................92
BS3680 Weirs (P700 = 3)................................................................................................ 94
Rectangular Weir Calculations.....................................................................................94
V-Notch Weir Calculations............................................................................................95
BS3680 Rectangular Broad Crested Weir ................................................................ 98
Rectangular Broad Crested Weir Calculations.......................................................99

ULTRA 4 INSTRUCTION MANUAL
6
Special Devices.................................................................................................................100
Palmer Bowlus and H-Flume Calculations ............................................................101
V-Notch Angle Weir (Non-BS 3680) Calculations..............................................102
Universal Calculations (P700=6)................................................................................102
Chapter 8 Parameter Guide .............................................................................................103
Menu System ....................................................................................................................103
Top Level Menu ...............................................................................................................103
Application Menu............................................................................................................104
Relays Menu......................................................................................................................105
Data Logs Menu ..............................................................................................................106
Volume: Available when Ultra Wizard = Volume..............................................107
OCM: Available when Ultra Wizard = Flow .........................................................108
Display Menu....................................................................................................................109
mA Output Menu............................................................................................................110
Compensation Menu .....................................................................................................110
Stability Menu ..................................................................................................................111
Echo Processing Menu..................................................................................................112
System Menu ....................................................................................................................113
Device Comm Menu ......................................................................................................114
Test Menu ..........................................................................................................................115
Application Parameters.................................................................................................116
Operation ...........................................................................................................................116
Dimensions ........................................................................................................................117
Relay Parameters.............................................................................................................120
Alarms..................................................................................................................................121
General Control................................................................................................................125
Pumps..................................................................................................................................126
Control.................................................................................................................................129
Miscellaneous ...................................................................................................................131
Common Parameters.....................................................................................................133
Data Log parameters .....................................................................................................133

PULSAR MEASUREMENT
7
Volume ................................................................................................................................138
When Ultra Wizard = 1 Level/Volume....................................................................138
Conversion.........................................................................................................................138
Breakpoints........................................................................................................................143
Tables...................................................................................................................................144
OCM Parameters .............................................................................................................145
Dimensions ........................................................................................................................149
Calculations .......................................................................................................................153
Breakpoints........................................................................................................................154
Tables...................................................................................................................................154
Average Flow ....................................................................................................................154
Display Parameters.........................................................................................................155
Options................................................................................................................................155
Failsafe.................................................................................................................................156
Auxiliary...............................................................................................................................157
Totaliser...............................................................................................................................158
mA Output Parameters.................................................................................................160
Range...................................................................................................................................160
Operation ...........................................................................................................................161
Setpoint...............................................................................................................................161
mA Limits............................................................................................................................162
mA Trim ..............................................................................................................................163
mA Failsafe.........................................................................................................................165
Compensation Parameters..........................................................................................165
Offset....................................................................................................................................165
Temperature......................................................................................................................165
Velocity................................................................................................................................166
Stability Parameters .......................................................................................................167
Damping.............................................................................................................................167
Rate.......................................................................................................................................167

ULTRA 4 INSTRUCTION MANUAL
8
Filters....................................................................................................................................168
Echo Processing Parameters.......................................................................................169
Transducer Status............................................................................................................169
System Parameters .........................................................................................................170
Passcode.............................................................................................................................170
Backup.................................................................................................................................170
Params ↔SD ....................................................................................................................171
System Information........................................................................................................171
Date & Time ......................................................................................................................172
Watchdog...........................................................................................................................172
Daylight Saving Time.....................................................................................................173
Service Alarm ....................................................................................................................176
Language............................................................................................................................177
Device Comm. ..................................................................................................................178
RS232 Set Up ....................................................................................................................178
Modbus...............................................................................................................................178
Profibus...............................................................................................................................180
HART ....................................................................................................................................181
Test Parameters ...............................................................................................................183
Simulation ..........................................................................................................................183
Hardware ............................................................................................................................184
Chapter 9 SD Card Logger ...............................................................................................186
About the Micro SD card logger...............................................................................186
Types of Files ....................................................................................................................186
Setting up the unit to log ............................................................................................187
Chapter 10 Troubleshooting ...........................................................................................188
Chapter 11 Disposal............................................................................................................189

PULSAR MEASUREMENT
9
CHAPTER 1: START HERE…
Congratulations on your purchase of a Pulsar Ultra 4. This quality system has
been developed over many years and represents the latest in high
technology 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 Measurem ent manual to
find helpful information and answers to frequently asked questions .
Additional Information
Additional Information
At various parts of the manual, you will find sections
like this that explain specific things in more detail.

ULTRA 4 INSTRUCTION MANUAL
10
About the Ultra 4
Ultra 4 is a brand-new concept in ultrasonic level measurement. Within its
memory are all the functions and settings of three different and separate
ultrasonic devices.
The Ultra 4 does not offer a multiple range of functions blended together
which leads to complicated calibration and a compromise to the
specification. The Ultra 4 is the first ever system to offer the ability to
dedicate the functionality of the unit to any of three specific duties i.e., level
or volume measurement, pump control, or flow measurement. Diagnostic
trace information and measurement trending can be viewed directly on the
display of the unit itself and automatically logged to SD card.
The benefits are many but most importantly the unit provides:
1. A most versatile system which can be configured quickly, to offer
one of three separate functions within a matter of seconds. Ideal
for simplicity of purchase and off the shelf spares.
2. Ability to log vast amounts of data using the integral Micro SD
card slot, and at a minimum of 1-minute intervals.
3. A totally dedicated device with the ability to perform all aspects of
the task required i.e., no compromise in specification.
4. Easy to set up using Pulsars unique “Quick Set Up” Menu. To
calibrate the unit, first set the Ultra Wizard for the desired task,
then refer to the relevant chapter in this manual that relates to
your application:
Chapter 5 for Level or Volume,
Chapter 6 for Pump Control
Chapter 7 for Flow

PULSAR MEASUREMENT
11
Functional Description
Ultra 4 sends a transmit pulse to the transducer, which emits an ultrasonic
pulse or radar signal (dependent on transducer) perpendicular to the
transducer face, and the returned echo is sent back to the Ultra 4. The time
taken to receive the echo is measured and the distance from the transducer
face to the surface being monitored is calculated.
Ultra 4 can measure from zero to 40m 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, depending on application
chosen, level, space, distance, OCM head, OCM flow or volume,
independently from that shown on the display. There is an RS232 port, so
that the Ultra 4 can be operated remotely by a PC or other equipment.
Ultra 4 can be programmed either by the built-in keypad (standard on all
wall and fascia units), via the SD card slot or by PC via the RJ11 Serial
Interface. All parameters are stored in a 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 Ultra 4 memory, in case an alternative
set of parameters needs to be stored.
Four user definable 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,
long-range abilities of the ‘all new’ dB transducer range, the Ultra 4 lives up
to its reputation as the most reliable ultrasonic level measurement system
available.
The Pulsar Ultra 4 ultrasonic level controllers have been designed to provide
maintenance-free fit and forget performance.

ULTRA 4 INSTRUCTION MANUAL
12
How to use this Manual
1. Read the installation and operating instructions contained in,
Chapters 2 and 3, carefully, they are applicable in every use of this
product.
2. Decide which “task” you wish your Ultra 4 to perform for you and
then configure the unit using “Ultra Wizard” as described in
Chapter 4.
3. Move directly to the appropriate chapter of this manual, as listed
below, for details on how to program Ultra 4 using the “Quick Set
Up” Menu.
4. Alternatively, if you are familiar with Pulsar products or you wish to
directly program your unit, please refer to Chapter 8 Parameter
descriptions.
CHAPTER
DUTY / TASK
Chapter 5 Level/Volume
Measurement of Level or Volume
Chapter 6 Pump
Control of Pumps
Chapter 7 Flow
Measurement of Open Channel Flow

PULSAR MEASUREMENT
13
Product Specification
PHYSICAL
Wall Mount outside Dimensions
150 x 130 x 64mm (5.9 x 5.1 x 2.5”)
Weight
Nominal 700g
Enclosure Material/Description
Polycarbonate flame resistant to UL94-5V
Cable entry detail
3 x M20 cable glands, for cable dia. 5 to 13mm (0.2” to
0.5”)
Fascia Mount outside
dimensions
160 x 180 x 64mm (6.3 x 7.1 x 2.5”)
Weight
1.3kg
Enclosure material/description
Polycarbonate flame resistant to UL94-5V
Transducer Cable Extensions
2-core screened (minimum)
Maximum Separation
1000m (3,280 ft), 500m (1,640 ft) for mmWave
ENVIRONMENTAL
IP Rating (Wall)
IP67 / NEMA 4X
IP Rating (Fascia)
IP64
Max. & min. temperature
(electronics)
-20°C to +45°C (-4°F to +113°F)
Flammable atmosphere approval
Safe area: compatible with approved transducers and
sensors. (see spec. sheets)
CE Approval
See EU Declaration of Conformity
UL Approval
UL61010-1
PERFORMANCE
Accuracy
0.25% of the measured range or 6 mm (whichever is
greater). ± 2mm for mmWAVE RADAR
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)
Technology
Ultrasonic and MCW Radar

ULTRA 4 INSTRUCTION MANUAL
14
OUTPUTS
Analogue I/O
Isolated (floating) output (to 150V) of 4-20 mA or 0-20
mA into 1K(user programmable and adjustable)
Digital output
Full Duplex RS232
Volt free contacts, number, and
rating
3 x SPCO isolated relays, rated at 5A at 250V AC and 1
solid state SPNO isolated relay, rated 30V at 100mA
(to suit pulse counter applications).
Display
Monochrome graphical dot-matrix, 160 x 240 pixels.
Fully programmable display options with integral
keypad and menu navigation keys.
PROGRAMMING
On-board programming
By integral keypad
PC programming
Via RJ11 port on unit, or via Micro SD
Programming security
Via passcode (user selectable and adjustable)
Programmed data integrity
Via non-volatile RAM, plus backup
Data logging and removable
storage
Via micro-SD card slot and internal 10-day totaliser
logs (flow only).
SD card memory (included)
16GB
SUPPLY
Power Supply
115VAC +5% / -10% 50/60 Hz,
230VAC + 5% / -10% 50/60 Hz,
dc 18 - 30V
10W maximum power (typically 6W)
Fuse, mains
100mA at 230V AC (fitted as standard to wall units)
200mA at 115V AC (fitted as standard to fascia units)
Fuse, transducer
100mA barrier type, 4000A breaking
COMMUNICATIONS (OPTIONAL
Modbus RTU/ASCII
Isolated RS485
Profibus DPV1
Isolated RS485
HART 7
Isolated 4-20mA
DNP3/WITS
Gateway interface (pending)
Pulsar Measurement operates a policy of constant development and
improvement and reserve the right to amend technical details, as necessary.

PULSAR MEASUREMENT
15
EU Certificate of Conformity

ULTRA 4 INSTRUCTION MANUAL
16
CHAPTER 2 ULTRA 4 INSTALLATION
Unpacking
Power Supply Requirements
Ultra 4 can operate from AC supply or from a DC supply or battery. The
rated AC range is between 100V and 240V 50/60Hz. The DC range is 10 –
28V. In both cases the Ultra 4 will typically consume 6W of power, with a
maximum of 10W.
Location
When choosing a location to mount the enclosure, please bear in mind the
following:
•Ensure that the Ultra 4 is installed in a “Safe”, non-hazardous, area.
•For a clear view of the display, it is recommended that it is mounted
at eye level.
•The mounting surface is vibration-free.
•The ambient temperature is between -20ºC and 45ºC (-4oF and
113oF).
•When installing the fascia, remember the temperature within an
equipment cabinet may be higher than the outside ambient,
depending on the heat generated within and ventilation provided.
•There should be no high voltage cables or inverters close by.
•There should not be any heat-generating components nearby.
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 your local Pulsar distributor.

PULSAR MEASUREMENT
17
All electronic products are susceptible to electrostatic shock, so follow
proper grounding procedures during installation.
When forming part of a system used in a hazardous area, the Ultra 4 must
be mounted in a non-hazardous (safe) area, and the transducer / sensor
fitted in the hazardous area.
Appropriate safety precautions must be taken (IECEx / ATEX / FM).
Exia (I.S.) installations require a safety barrier and protective earth.
Exmb installations require protected cable runs and adequate fusing.
Refer to local regulations and standards for specific requirements.
Important Information
All electronic products are susceptible to electrostatic shock, so follow proper
grounding procedures during installation.
LEVEL SENSOR

ULTRA 4 INSTRUCTION MANUAL
18
Typical system wiring

PULSAR MEASUREMENT
19
Dimensions
Wall Mount
The dimensions of the wall fixing holes are as shown below:
Ultra 4 (wall-mount) should be mounted by drilling four holes suitable for
size 8 self-tapping screws (length to suit your application).
Where machine screws are required, M3.5 is the best size to use.

ULTRA 4 INSTRUCTION MANUAL
20
The full dimensions of the wall-mount enclosure are shown below:
Cable Entry
Three M20 cable glands are supplied fitted. They accept cables between 5.0
and 13.0mm (0.2” to 0.5”) overall diameter. The gland cable nuts require a
24mm A/F spanner; tighten to a torque of 2Nm.
63.5mm (2.5”)
Fixing
screws,
thread
d.43mm
(0.16”) max
head
d. 7.6mm
(0.300”) max
130mm (5.12”)
13mm
(0.51”)
150mm (5.91”)
3 off M20 glands