Pulsar ULTRA TWIN User manual

ULTRA TWIN
INSTRUCTION MANUAL
P
PP
PULSAR
ULSARULSAR
ULSAR
Process Measurement
Process MeasurementProcess Measurement
Process Measurement

ULTRA TWIN (SECOND EDITION)
March 2008
Part Number M-192-0-002P
COPYRIGHT
© Pulsar Process Measurement Limited, 2005 -08. 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 Process Measurement Limited 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 Process Measurement Limited gives nor implies any process guarantee for the 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 Process
Measurement Limited cannot be held liable for any errors.
Pulsar Process Measurement Limited operates a policy of constant development and improvement
and reserves the right to amend technical details as necessary.
TECHNICAL ENQUIRIES
Please contact Pulsar Process Measurement Limited for technical support.
COMMENTS AND SUGGESTIONS
If you have any comments or suggestions about this product, then please contact:
Pulsar Process Measurement Limited
Cardinal Building
Enigma Business Centre
Sandy’s Road
Malvern
Worcestershire
WR14 1JJ
United Kingdom
Tel: [phone] (International [phone])
Fax: [phone] (International [phone])
Web Site: http://www.pulsar-pm.com
e-mail: [email protected] (general information)
e-mail: support@ pulsar-pm.com (product support)

Contents
ContentsContents
Contents
Chapter 1 Start Here…......................................................................................................................................... 1
About this Manual........................................................................................................................................... 1
About the Ultra Twin...................................................................................................................................... 2
Functional Description.................................................................................................................................... 2
Product Specification ...................................................................................................................................... 4
Chapter 2 Installation............................................................................................................................................ 7
Power Supply Requirements .......................................................................................................................... 7
Location ........................................................................................................................................................... 7
Dimensions...................................................................................................................................................... 8
Wall mount .............................................................................................................................................. 8
Fascia Mount ......................................................................................................................................... 10
Terminal Connection Details........................................................................................................................12
Wall Mount............................................................................................................................................12
Fascia Mount ......................................................................................................................................... 12
Voltage Selector and Fuse Location.............................................................................................................16
Wall mount ............................................................................................................................................16
Fascia mount..........................................................................................................................................16
Preparation for Operation .............................................................................................................................18
Maintenance .................................................................................................................................................. 18
Chapter 3 How To Use Your Ultra Twin ......................................................................................................... 19
Operating the Controls..................................................................................................................................19
Display...................................................................................................................................................19
Run Mode..............................................................................................................................................21
Program Mode.......................................................................................................................................21
How to Access Program Mode.....................................................................................................................22
Test Mode......................................................................................................................................................27
Parameter Defaults ........................................................................................................................................ 28
Factory Defaults.....................................................................................................................................28
Chapter 4 Quick Set-up Guide.............................................................................................................................31
Level or Volume............................................................................................................................................32
Example 1 Level Monitoring with Alarms ..........................................................................................38
Example 2 Level Monitoring and Control (up or down) ....................................................................40
Example 3 Volume Application...........................................................................................................42
Pump ..............................................................................................................................................................45
Example 1 Sump Control (pump down).............................................................................................50
Example 2 Reservoir Control (pump up).............................................................................................52
Flow................................................................................................................................................................54
Exponential Devices......................................................................................................................................61
Point of Measurement........................................................................................................................... 62
Calculations ...........................................................................................................................................64
Example 1 ‘V’ Notch Weir.................................................................................................................65
BS3680 Flumes.............................................................................................................................................67
Point of Measurement........................................................................................................................... 67
Calculations ...........................................................................................................................................67
Example 2 BS3680 U-Throated Flume ..............................................................................................70
BS3680 Thin Plate Weirs .............................................................................................................................72
Point of Measurement........................................................................................................................... 72

Calculations ........................................................................................................................................... 72
Example 3 BS3680 Rectangular Weir................................................................................................ 74
Special Devices ............................................................................................................................................. 76
Point of Measurement........................................................................................................................... 76
Calculations ........................................................................................................................................... 77
Universal Calculations.................................................................................................................................. 78
Point of Measurement........................................................................................................................... 78
Calculations ........................................................................................................................................... 78
Chapter 5 Parameter Guide..............................................................................................................................79
Menu System Diagrams ............................................................................................................................... 79
Top Level Menu.................................................................................................................................... 79
Application Menu ................................................................................................................................. 80
Relays Menu.......................................................................................................................................... 81
Pump “Advanced” ................................................................................................................................ 82
Digital Inputs (Fascia Mount)............................................................................................................... 83
Digital Inputs (Wall Mount).................................................................................................................84
Data Logs............................................................................................................................................... 85
Volume Menu........................................................................................................................................ 86
OCM Menu ........................................................................................................................................... 87
Display................................................................................................................................................... 88
mA Output 1 Menu............................................................................................................................... 89
mA Output 2 Menu............................................................................................................................... 89
Compensation........................................................................................................................................ 90
Stability Menu....................................................................................................................................... 90
Echo Processing Menu ......................................................................................................................... 91
System Menu......................................................................................................................................... 92
Device Comm Menu............................................................................................................................. 93
Test Menu.............................................................................................................................................. 94
Parameter Listing .......................................................................................................................................... 95
Application Parameters................................................................................................................................. 95
System Units.......................................................................................................................................... 95
Operation ............................................................................................................................................... 95
Dimensions............................................................................................................................................ 97
Relay Parameters........................................................................................................................................... 99
Alarms..................................................................................................................................................100
Pumps ..................................................................................................................................................106
Control .................................................................................................................................................110
Miscellaneous......................................................................................................................................114
Common Parameters...........................................................................................................................116
Pump “Advanced” Parameters...................................................................................................................117
Pump Run On......................................................................................................................................117
Starting.................................................................................................................................................117
Stopping...............................................................................................................................................118
Pump Exercising .................................................................................................................................118
Wall Cling............................................................................................................................................119
Digital Inputs...............................................................................................................................................119
Common Par........................................................................................................................................119
Digital Inputs ....................................................................................................................................... 121
Data Log Parameters...................................................................................................................................124
Totaliser Audits ...................................................................................................................................124
Temperature......................................................................................................................................... 124
Pump Logs...........................................................................................................................................125

Volume.........................................................................................................................................................126
Conversion...........................................................................................................................................127
Breakpoints..........................................................................................................................................131
Tables...................................................................................................................................................132
OCM Parameters.........................................................................................................................................133
PMD Setup ..........................................................................................................................................133
Dimensions..........................................................................................................................................136
Calculations .........................................................................................................................................139
Breakpoints..........................................................................................................................................140
Tables...................................................................................................................................................140
Average Flow.......................................................................................................................................141
Display Parameters......................................................................................................................................141
Options.................................................................................................................................................141
Failsafe.................................................................................................................................................143
Auxiliary ..............................................................................................................................................144
Totaliser................................................................................................................................................146
Bargraph...............................................................................................................................................148
mA Output 1 Parameters ............................................................................................................................149
Range ...................................................................................................................................................149
Operation .............................................................................................................................................150
Setpoint ................................................................................................................................................150
Limits ...................................................................................................................................................151
Trim......................................................................................................................................................151
Failsafe.................................................................................................................................................152
Allocation.............................................................................................................................................152
mA Output 2 Parameters ............................................................................................................................153
Range ...................................................................................................................................................153
Operation .............................................................................................................................................154
Setpoint ................................................................................................................................................154
Limits ...................................................................................................................................................155
Trim......................................................................................................................................................155
Failsafe.................................................................................................................................................156
Allocation.............................................................................................................................................156
Compensation Parameters ..........................................................................................................................157
Offset....................................................................................................................................................157
Temperature.........................................................................................................................................158
Velocity................................................................................................................................................159
Stability Parameters.....................................................................................................................................159
Damping ..............................................................................................................................................159
Indicator ...............................................................................................................................................160
Rate ......................................................................................................................................................160
Echo Processing Parameters.......................................................................................................................161
Transducer 1 Status.............................................................................................................................161
Transducer 2 Status.............................................................................................................................162
System Parameters ......................................................................................................................................162
Passcode...............................................................................................................................................162
Backup .................................................................................................................................................162
System Information .............................................................................................................................163
Date & Time........................................................................................................................................164
LED Colour .........................................................................................................................................164
Watchdog.............................................................................................................................................165
Daylight Saving Time .........................................................................................................................166
Device Comm..............................................................................................................................................170

RS232 Set Up......................................................................................................................................170
RS 485 Set Up (Optional)...................................................................................................................170
Remote Alarm .....................................................................................................................................170
Test Parameters ...........................................................................................................................................172
Simulation............................................................................................................................................172
Test Setup ............................................................................................................................................173
Hardware..............................................................................................................................................173
Chapter 6 Troubleshooting...............................................................................................................................175
Parameter Record...............................................................................................................................................177

Page 1
Chapter 1 Start Here…
Congratulations on your purchase of a Pulsar Ultra Twin. 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
About this ManualAbout this Manual
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
At various parts of this
manual you will find tips to
help you.
Additional Information
Additional Information
At various parts of the manual, you will find sections
like this that explain specific things in more detail.
References
See Also
References to other parts of the manual

Page 2
About the
About the About the
About the Ultra
Ultra Ultra
Ultra Twin
TwinTwin
Twin
Ultra Twin has two independent points of measurement, the wallmount
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
auxillary display line. In both models the display will provide information
relevant to the point of measurement selected whilst in RUN and
PROGRAM mode.
Ultra Twin 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
Functional DescriptionFunctional Description
Functional Description
Ultra Twin 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 Ultra Twin. The time taken to receive the echo is
measured and the distance from the transducer face to the surface being
monitored is calculated.

Page 3
Ultra Twin 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 which can
be allocated to either point of measurement. 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 Ultra Twin can be operated
remotely by a PC or other equipment.
Ultra Twin 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 Ultra Twin 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
Ultra Twin lives up to its reputation as the most reliable ultrasonic level
measurement system available.
The Pulsar Ultra Twin ultrasonic level controller has been designed to
provide maintenance-free fit and forget performance.

Page 4
Product Specification
Product SpecificationProduct Specification
Product Specification
Physical
Wall Mount
Overall Outside dimensions 235 x 184 x 120 mm
Weight Nominal 1 kg
Enclosure material/description Polycarbonate, flame resistant to
UL91
Cable entry detail 11 cable entry knock outs, 5 x PG11,
1 x PG9, 4 x PG11 at rear
Fascia Mount
Outside dimensions 200 x 112 x 108
Weight Nominal 1.3kg
Enclosure material/description Stainless Steel back, ABS front and
bezel
Transducer cable extensions 2-core screened
Maximum separation 1000 m
Environmental
IP Rating (Wall) IP65
IP Rating (Fascia) IP64
Optional IP rated panel mount IP54
Max. & min. temperature (electronics) -20 ºC to +50 ºC
Flammable atmosphere approval Safe area: compatible with approved
dB transducers (see transducer spec'
sheet)
CE approval EMC approval to BS EN 50081-1:1992
for emissions and BS EN50082-
2:1995 for immunity,
and to BS EN61010-1:1993 for low
voltage directive
Performance
Accuracy 0.25% of the measured range or
6 mm (whichever is greater)
Resolution 0.1% of the measured range or 2 mm
(whichever is greater)
Max. range Dependant on application and
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)
Outputs (x2)
Analogue output Isolated (floating) output (to 150V) of
4-20 mA or 0-20 mA into 500Ω(user
programmable and adjustable) 0.1%
resolution
Digital output Full Duplex RS232

Page 5
Volt free contacts, number and rating 6 form "C" (SPDT) rated at 5A at 240V
AC
Digital Inputs
Wall Mount x4 Min. Input Voltage 4.5VDC
Fascia Mount x7 Max. Input Voltage 30VDC (Max Current
3mA)
24VDC Input Supply maximum total
current 24mA.
Displays
Wallmount x2 6 digits plus 12 character text, plus
Fascia Mount x1 bargraph 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,
230V ac + 5% / -10% 50/60 Hz,
dc 18 - 36V
10W maximum power (typically 6W)
Fuses 100 mA at 170-240 VAC
200 mA at 85-120 VAC
Pulsar Process Measurement Limited operates a policy of constant development and
improvement and reserve the right to amend technical details as necessary.

Page 6
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Page 7
Chapter 2 nstallation
Power Supply Requirements
Power Supply RequirementsPower Supply Requirements
Power Supply Requirements
The Ultra Twin can operate from AC supply or from a DC battery. The AC
is either 85-120V 50/60Hz or 170-240V 50/60Hz, depending on the position
of the selector switch. The DC is 18-36V. In all cases the Ultra Twin will
typically consume 6W of power, with a maximum of 10W.
Location
LocationLocation
Location
All electronic products are susceptible to electrostatic
shock, so follow proper grounding procedures during
installation.
The Ultra Twin must be mounted in a non-hazardous (safe) area, and the
transducer fitted in the hazardous area.

Page 8
When choosing a location to mount the enclosure, bear in mind the
following:
•Ensure that the Ultra Twin 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 vibration-free.
•The ambient temperature is between -20ºC and 50ºC.
•There should be no high voltage cables or inverters close by.
Dimensions
DimensionsDimensions
Dimensions
Wall mount
The dimensions of the wall fixing holes are as shown below.

Page 9
The Ultra Twin 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.
The full dimensions of the enclosure are as shown below.

Page 10
Cable Entry
There are 6 cable gland knockouts on the base of the Ultra Twin (4 x PG11,
1 x PG9, 1 x PG13.5) and 5 on the rear (5 x PG11). 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.
Fascia Mount
The Fascia mount Ultra Twin should be installed by cutting a hole in the
panel as detailed below.

Page 11
The full dimensions of the Fascia mount enclosure are as shown below.

Page 12
Terminal C
Terminal CTerminal C
Terminal Connection Details
onnection Detailsonnection Details
onnection Details
Wall Mount
The terminal strip is as detailed below. There is also a wiring diagram inside
the terminals access cover.
Fascia Mount