ULTRAFLO 2000 FLOW & HEATMETER Operating
Contents
1. 1 455 665 3 3 73 Diethyl ether C4H100 0 713 985 4 87 Diethylene glycol monoethyl ether 4 0 988 1458 Diethylenimide oxide C4HNO 1 00 1442 3 8 1 2 bis DiFluoramino butane 43 C4He NF3 2 1 216 1000 1 2bis DiFluoramino 2 methylpropane 43 C4Ho NF2 2 1 213 900 20 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS Substance Formindex Specific Gravity SoundSpeed Av C m sPC 1 2bis DiFluoramino propane 43 C3H amp NF2 2 1 265 960 2 2bis DiFluoramino propane 43 CsHe NF2 2 1 254 890 2 2 Dihydroxydiethyl ether 1 116 1586 Dihydroxyethane C2H602 1 113 1658 1 3 Dimethyl benzene 46 CsH10 0 868 15 C 1343 1 2 Dimethyl benzene 29 46 CsH10 0 897 20 C 1331 5 1 4 Dimethyl benzene 46 CgHio 1334 2 2 Dimethyl butane 29 33 0 649 20 1079 Dimethyl ketone C3HsO 0 791 1174 Dimethyl pentane 47 0 674 1063 Dimethyl phthalate CsH1004 1 2 1463 Diiodo methane 3 235 980 Dioxane C4HgO2 1 033 1376 Dodecane 23 0 749 1279 1 2 Ethanediol 1 113 1658 Ethanenitrile 2 0 783 1290 Ethanoic anhydride 22 CH3CO 20 1 082 1180 Ethanol 0 789 1207 Ethanol amide C2H7NO 1 018 1724 Ethoxyethane 0 713 985 Ethyl acetate 33 0 901 1085 Ethyl alcohol 0 789 1207 Ethyl benzene 46 CsHio 0 867 20 C 1338 Ethyl bromide 46 C HsBr 1 461 20 900 Ethyliodide 46 1 950 20 876 Ether 0 713 985 Ethyl ether 0 713 985 Ethy2. All transducers are mounted in Reflex or Diagonal mode as described on page 5 and 6 The guide rail assemblies are held in position using chains Diagonal Beam Mode Diagonal beam mounting means the two transducer blocks are mounted on opposite sides of the pipe as shown in figure 7 This is the default setting for all applications above 215mm If you encounter a difficult application or the maximum flow velocity is outside of the default operating range when working in the Reflex mode it is possible to reprogram the instrument to operate in Diagonal mode see page 11 Set up Sensors Diagonal Set up Procedure a Using whatever means available mark a reference line around the circumference of the pipe reference line D As shown in figure 7 b Locate and mark two positions exactly 180 apart around this reference line c On both of these positions draw a reference line E perpendicular to line D parallel to the pipe axis and approximately 1 metre long See figure 7 d Take each of the guide rails and load the transducers as described previously on page 5 Only one transducer goes in each guide rail d Attach the one guide rail to the pipe using the chain provided such that it is parallel to the reference line E and position so that the transducer face can be aligned with reference line D e Program the flow meter and obtain the separation distance f From the intersection of the circumference ref
3. 1207 4 04 1 27 CsHis 0 736 20 C 1207 4 0 Octane 23 CsHis 0 703 1172 4 14 n Octane 29 CsHis 0 704 20 C 1212 5 3 50 1 Octene 27 0 723 20 1175 5 410 Oil of Camphor Sassafrassy 1390 3 8 Oil Car SAE 20a 30 1 74 870 Oil Castor 0 969 1477 3 6 Oil Diesel 0 80 1250 Oil Fuel AA gravity 0 99 1485 3 7 Oil Lubricating X200 1530 5019 9 Oil Olive 0 912 1431 2 75 Oil Peanut 0 936 1458 Oil Sperm 0 88 1440 Oil 6 1509 2 2 Oxydiethanol C4H1003 1 116 1586 2 4 Oxygen 45 1 155 186 952 Pentachloro ethane 47 C2HCls 1 687 1082 Pentalin 47 C HCls 1 687 1082 Pentane 36 CsHi2 0 626 20 C 1020 n Pentane 47 CsHi2 0 557 1006 Perchlorocyclopentadiene 47 CsCle 1 718 1150 Perchloro ethylene 47 C2Cl4 1 632 1036 Perfluoro 1 Hepten 47 CF44 1 67 583 Perfluoro n Hexane 47 CoF 14 1 672 508 Phene 29 40 41 0 879 1306 4 65 p Phenyl acrolein CHO 1 112 1554 3 2 Phenylamine 41 CsH5NO2 1 022 1639 4 0 Phenyl bromide 46 5 1 522 1170 Phenyl chloride C amp HsCI 1 106 1273 3 6 Phenyl iodide 46 1 823 1114 Phenyl methane 16 52 C7Hs 0 867 20 C 1328 4 27 3 Phenyl propenal CHO 1 112 1554 3 2 Phthalardione CsH403 1125 Phthalic acid anhydride C8H403 1125 Phthalic anhydride 1125 Pimelic ketone 0 948 1423 4 0 Plexiglas Lucite Acrylic 2651 Polyterpene Resin 0 77 1099 8 Potassium bromide 42 Kbr 1169 0
4. 1273 3 6 1 Chloro butane 22 46 C4H Cl 0 887 1140 4 57 Chloro diFluoromethane 3 Freon 22 1 491 69 893 9 4 79 Chloroform 47 CHCl 1 489 979 3 4 1 Chloro propane 47 C3H7Cl 0 892 1058 Chlorotrifluoromethane 5 CCIF 724 5 26 Cinnamaldehyde CHO 1 112 1554 3 2 Cinnamic aldehyde CHO 1 112 1554 3 2 Colamine C H NO 1 018 1724 3 4 o Cresol 46 C7H0 1 047 20 C 1541 m Cresol 46 C7H0 1 034 20 C 1500 Cyanomethane C2H3N 0 783 1290 4 1 Cyclohexane 15 0 779 20 1248 5 41 Cyclohexanol 0 962 1454 3 6 0 948 1423 4 0 Decane 46 CioH22 0 730 1252 1 Decene 27 CroH20 0 746 1235 4 0 n Decylene 27 Cio Hoo 0 746 1235 4 0 Diacetyl 0 99 1236 4 6 Diamylamine 1256 3 9 1 2 Dibromo ethane 47 C2H4Br2 2 18 995 trans 1 2 Dibromoethene 47 C2H2Br2 2 231 935 Dibutyl phthalate CgH2204 1408 Dichloro t butyl alcohol C4HgCl20 1304 3 8 2 3 Dichlorodioxane C2H6Cl202 1391 3 7 Dichlorodifluoromethane 3 Freon 12 CCIF 1 516 40 C 774 1 4 24 1 2 Dichloro ethane 47 1 253 1193 1 2 Dichloro Ethene 3 47 C2H2Cl2 1 284 1061 trans 1 2 Dichloro ethene 3 47 C2H2Cl2 1 257 1010 Dichloro fluoromethane 3 Freon 21 1 426 0 891 3 97 1 2 Dichlorohexafluoro cyclobutane 47 C4Cl2F6 1 654 669 1 3 Dichloro isobutane C4HgCle 1 14 1220 3 4 Dichloro methane 3 CH2Cle 1 327 1070 3 94 1 1 Dichloro 1 2 2 2 tetra fluoroethane
5. 8 10 5 1177 1 13 22 ULTRAFLO 2000 Sulphuric acid 1 Tellurium 7 1 1 2 2 Tetrabromo ethane 47 1 1 2 2 Tetrachloro ethane 67 Tetrachloroethane 46 Tetrachloro ethene 47 Tetrachloro methane 33 47 Tetradecane 46 Tetraethylene glycol Tetrafluoro methane 14 Freon 14 Tetrahydro 1 4 isoxazine Toluene 16 52 o Toluidine 46 p Toluidine 46 Toluol Tribromo methane 46 47 1 1 1 Trichloro ethane 47 Trichloro ethene 47 Trichloro fluoromethane 3 Freon 11 Trichloro methane 47 1 1 2 Trichloro 1 2 2 Trifluoro Ethane Triethyl amine 33 Triethylene glycol 1 1 1 Trifluoro 2 Chloro 2 Bromo Ethane 1 2 2 Trifluorotrichloro ethane Freon 113 4 1 3 3 camphor Trinitrotoluene 43 Turpentine Unisis 800 Water distilled 49 50 Water heavy Water sea Wood Alcohol 40 41 Xenon 45 m Xylene 46 o Xylene 29 46 p Xylene 46 Xylene hexafluoride Zinc 7 INSTALLATION amp OPERATING INSTRUCTIONS H2SO Te C H Br4 C2H2Cl4 C2H2Cl4 C2Cl4 CCl C14H30 5 CF C4HsgNO C Hs C7HgN C Hs 2 C2HCls CCI3F CHCl CegHisN CeHi404 CoHCIBrF3 CioHigO C7Hs NOz s 0 10 10 CsH4Fe Zn 23 1 841 2 966120 1 595 1 553 20 C 1 632 1 595 20 C 0 763 20 C 2 89 20 C 1 33 1 464 1 49 1 489 1 563 0 726 1 123 1 869 1 563 0 947 1
6. OPERATING INSTRUCTIONS Finally to ensure accurate flow measurement it is imperative that the liquid is flowing uniformly within the pipe and that the flow profile has not been distorted by any upstream or downstream obstructions To obtain the best results from the Ultraflo 2000 it is absolutely necessary that the following rules for positioning the transducers are adhered to and that the condition of the liquid and the pipe wall are suitable to allow transmission of the sound along its predetermined path Selecting A Meter Position As the transducers with the Ultraflo 2000 are clamped to the outside surface of the pipe the meter has no way of determining exactly what is happening to the liquid The assumption therefore has to be made that the liquid is flowing uniformly along the pipe either under fully turbulent conditions or under laminar flow conditions It is further assumed that the flow velocity profile is uniform for 360 around the pipe axis The Ultraflo 2000 is normally supplied calibrated for use on turbulent flows but by adjustment of the CAL FACTOR the instrument can be used for laminar flow applications Figure 11 Figure 11 shows a uniform profile as compared to a distorted profile The difference between a and b is that the Mean Velocity of the flow across the pipe is different and the Ultraflo 2000 expects a uniform flow as in a The distorted flow in b will give measurement errors whic
7. is also an indication that the sensors need re greasing Ensure the person who services your instrument is qualified to do so If in doubt return the instrument to Micronics with a detailed report on the nature of the problem Ensure that suitable protective precautions are taken when using any materials to clean the instrument sensors Calibration of the instrument and sensors is recommended to be done at least once every 12 months If the instrument was supplied with dust or dirt caps make sure they are re fitted when the instrument is not in use It is the users responsibility to tidy cables so they will not cause harm to other people When returning product to Micronics make sure it is clean Notify Micronics if the instrument has been in contact with any hazardous substances Document Number 001 150 Software Version v1 18 17 April 2003 28 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS o rrucrornics ULTRAFLO 2000 CalecST heat meter Transit time flow meter heatmeter Wiring diagram CalecST Heatmeter 61 24 25100101 1017 3 ajs 1 2 6 M3 pulse out 4 Kw pulse out PT Cold side PT Hot side Micronics U2000 clamp on flow meter 14 15 T NC COM NO u RELAY 24 0 5 Telephone 44 156 Facsimilie 44 2 10 E mail sales micronicsitd co uk Web site 29
8. number between 0 and 40 000 which is a number internal to the Ultraflo The first stage is to adjust the output current to 4mA Use the scroll key decimal point key or keys 5 and 6 The scroll and decimal point key move the DAC value in large steps of 25 Keys 5 and 6 move the value one digit at a time The DAC value should be approximately 8000 for 4mA and 40 000 for 20mA By watching the actual current value displayed on the meter it is possible to set this exactly The display will show the following CAL 4mA DAC value Use the scroll and decimal point key to set and keys 5 and 6 to trim Press ENTER when complete The display will then show the following INSTALLATION amp OPERATING INSTRUCTIONS Use the scroll and decimal point key to set 20mA and keys 5 and 6 to trim Press ENTER when complete The following will be displayed Press SCROLL CAL 20mA DAC value 40000 MAIN MENU Calibrate 4 20mA The following will be displayed MAIN MENU Read flow MAIN MENU Read flow Pressing SCROLL will take the instrument back to MAIN MENU Quick start Pressing ENTER displays the following Approx max flow k k kk It is possible to change the flow units by pressing SCROLL When a new unit is selected press ENTER Pressing ENTER displays the following Press ENTER to read flow Attach sensors REFLEX Sep This informs the user of the mode of operation and the
9. output required by pressing SCROLL and ENTER SETUP 4 20MA Units It is possible to set the output different from that on the display For example the display may show gallons minute but the output needs to be set up in m hour When a Heatmeter is supplied the options will include kW kCal hr MJ hr min sec and temperature differential Scroll through the options and press ENTER to select ULTRAFLO 2000 The display will show the following SETUP 4 20MA Max This function allows the user to scale the 4 20mA Press ENTER to select and enter your required maximum flow rate in the units selected For example when the flow rate reaches the maximum set the output will be 20mA Press ENTER when complete The display will show the following SETUP 4 20MA Min The user is now required to enter the minimum flow rate required in the units selected Press ENTER when complete The display will show the following SETUP 4 20MA mA on error This gives an error output which would inform the user of loss of signal This can be set to any figure between zero and 24mA but defaults to 22mA Press ENTER to select enter the figure required and press ENTER The display will show the following SETUP 4 20MA Exit Press SCROLL to stay in the SETUP 4 20mA menu or ENTER to go back to the FUNCTIONS menu FUNCTIONS Pulses set point The following will be displayed Press ENTER to select FUNCTIONS Puls
10. separation distance Pressing SCROLL takes the instrument into SETUP SENSOR mode SETUP SENSORS Mode REFLEX Pressing ENTER will read flow 0 00 0 00 When measuring flow there are only three keys that are active FUNCTION RESTART and SCROLL see also page 7 The Function key when pressed in flow mode displays a range of information that will improve the performance of the instrument and will assist with the setting up of the unit The Restart key will at any point in the program display the start up message This allows the user to restart the program from the beginning The Scroll key when pressed in flow mode will display the signal level and the output ULTRAFLO 2000 Pressed for a second time it will display the ERRORS PENDING see page 16 Error amp Warning Messages When pressed for a third time it will read flow FUNCTIONS When the instrument is measuring flow there are certain functions that the user can access These functions are accessible by pressing the function key on the keypad then entering the password 2000 The display will read the following Select one of the options by using the scroll key and press ENTER to select FUNCTIONS Display Setup 4 20mA Pulses set point L M Cutoff m s 0 05 Set zero flow Reset total flow Damping 5 Cal factor 1 000 Diagnostics Save and exit FUNCTIONS Display The display will show the following Press ENT
11. to 1000 This will be in the units selected previously It can now be changed to the required amount by pressing ENTER Enter the new amount then press ENTER The display now reads the following Press ENTER to return to Functions PULSES SET POINT Exit FUNCTIONS Cutoff m s The display will now show the following FUNCTIONS Cutoff m s The instrument has a preset CUTOFF of 0 05m sec which has been programmed into the instrument Micronics cannot guarantee measuring flows below this range because of instabilities in the measuring process It is possible for the user to change or cancel this figure but Micronics cannot guarantee the performance below this It is also possible to enter any figure up to a velocity of 1m sec FUNCTIONS Set Zero Flow Press ENTER to select FUNCTIONS Cutoff m s On some applications the instrument is capable of picking up noise which may show a small offset when in flow mode This offset should be cancelled out which will increase the accuracy of the instrument Before this function is used you have to be sure that the flow has stopped completely To set zero flow before the flow has stopped will result in an error message This will occur when the flow is still above 0 25m sec This could mean that the flow has not totally stopped Press SCROLL to answer NO and ENTER to answer YES The following is displayed FLOW gt 0 25 m s Continue If the flow is b
12. 1 Follow the Quick Start menu on page 8 to read flow Note that if the fluid selected is not water the user will be prompted for the SHC specific heat capacity and the density relative to water specific gravity For water 9 20 C the SHC is 4 2 kj m and the density is 996kg m To calculate the SHC figure to enter into the unit find the SHC of the liquid being measured in kJ kg K and divide by 4 2 kJ kg K Now enter this figure into the unit 2 To calculate the relative density find the density in kg m and divide by the density of water 20 C 996 kg m Now enter this number into the unit The SHC and Density figures are usually available from your supplier 3 Select the Energy units required when setting up the display or outputs from the FUNCTION menu on page 13 Scroll through the options and press ENTER to select 4 Itis now possible to set either of the two 4 20mA outputs for Flow Energy or Temperature differential as described in FUNCTIONS on page 13 26 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS CE MARKING The Ultraflo 2000 has been tested and found to conform to EN50081 1 Emission Standards and EN50082 1 Immunity Standards The tests were conducted by AQL EMC Ltd of 16 Cobham Road Ferndown Industrial Estate Wimborne UK BH21 7PG The unit was tested with all cables as supplied of a maximum length of 3m While the operation of the unit may not be affected by the use of longer cables Micronics c
13. 64 0 88 0 87 0 996 1 025 0 791 20 C 0 868 15 C 0 897 20 C 1 37 1257 6 991 1027 1147 1170 1036 926 1331 1586 5203 4 875 24 1442 1328 1618 1480 1308 918 985 1028 828 3 979 783 7 1123 1608 693 783 7 1320 1610 1255 1346 1498 1400 1531 1076 630 1343 1331 5 1334 879 3298 1 43 0 73 3 0 6 61 3 8 4 27 4 2 3 56 3 4 4 47 3 8 3 44 2 4 2 92 4 1 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS Solid Sound Speeds 1 Use Shear Wave for A amp B Transducers 2 Use Long Wave for C amp D Transducers Steel 1 Carbon hardened 3150 5880 Carbon Steel 3230 5890 Mild Steel 3235 5890 Steel 1 Carbon 3220 302 Stainless Steel 3120 5660 303 Stainless Steel 3120 5660 304 Stainless Steel 3075 316 Stainless Steel 3175 5310 347 Stainless Steel 3100 5740 410 Stainless Steel 2990 5390 430 Stainless Steel 3360 Aluminium 3100 6320 Aluminium rolled 3040 Copper 2260 4660 Copper annealed 2325 Copper rolled 2270 CuNi 70 Cu 30 Ni 2540 5030 CuNi 90 Cu 10 Ni 2060 4010 Brass Naval 2120 4430 Gold hard drawn 1200 3240 Inconel 3020 5820 Iron electrolytic 3240 5900 Iron Armco 3240 5900 Ductile Iron 3000 4550 Cast Iron 2500 Monel 2720 5350 Nickel 2960 5630 Tin rolled 1670 3320 Titanium 3125 6100 Tungsten annealed 2890 5180 Tungsten drawn 2640 Tungsten carbide 3980 Zinc rolled 2440 4170 Glass
14. 71 Potassium fluoride 42 KF 1792 1 03 Potassium iodide 42 KI 985 0 64 Potassium nitrate 48 KNO 1 859 352 C 1740 1 1 1 Propane 2 13 45 to 130 C 0 585 45 1003 5 7 1 2 3 Propanetriol 1 26 1904 2 2 1 46 0 78 20 1222 2 46 0 785 20 1170 2 0 791 1174 4 5 17 18 35 6 0 563 13 963 6 32 n Propyl acetate 22 CsH1002 1280 2 C 4 63 n Propyl alcohol CHO 0 78 20 C 1222 Propylchloride 47 C3H7Cl 0 892 1058 Propylene 17 18 35 6 0 563 13 963 6 32 Pyridine 0 982 1415 4 1 Refrigerant 11 3 4 CCI3F 1 49 828 3 3 56 Refrigerant 12 3 CCIF 1 516 40 C 774 1 4 24 Refrigerant 14 14 CF 1 75 150 C 875 24 6 61 Refrigerant 21 3 1 426 0 891 3 97 Refrigerant 22 3 CHCIF 1 491 69 C 893 9 4 79 Refrigerant 113 3 CCLhF CCIF 1 563 783 7 3 44 Refrigerant 114 3 CCIF2 CCIF2 1 455 665 3 3 73 Refrigerant 115 3 C CIFs 656 4 4 42 Refrigerant C318 3 1 62 20 C 574 3 88 Selenium 8 1072 0 68 Silicone 30 0 993 990 Sodium fluoride 42 NaF 0 877 2082 1 32 Sodium nitrate 48 NaNO 1 884 336 C 1763 3 0 74 Sodium nitrite 48 NaNO 1 805 292 1876 8 Solvesso 3 0 877 1370 3 7 Spirit of wine 0 789 1207 4 0 Formindex Gravity SoundSpeed _ Av C m s C Sulphur 7
15. Alcohol C2H6O 0 789 1207 4 0 Alkazene 13 CisHo4 0 86 1317 3 9 Alkazene 25 CroHi2Cle 1 20 1307 3 4 2 Amino ethanol C H NO 1 018 1724 3 4 2 Aminotolidine 46 C HsN 0 999 20 C 1618 4 Aminotolidine 46 C HsN 0 966 45 C 1480 Ammonia 35 NH3 0 771 1729 6 68 Amorphous Polyolefin 0 98 962 6 t Amyl alcohol CsH120 0 81 1204 Aminobenzene 41 CsH5NO2 1 022 1639 4 0 Aniline 41 CsHsNO2 1 022 1639 4 0 Argon 45 Ar 1 400 188 C 853 Azine 0 982 1415 4 1 Benzene 29 40 41 0 879 1306 4 65 Benzol 29 40 41 0 879 1306 4 65 21 2 928 889 3 0 Bromo benzene 46 C HsBr 1 522 1170 1 Bromo butane 46 C H Br 1 276 20 C 1019 Bromo ethane 46 C2HsBr 1 460 20 C 900 Bromoform 46 47 CHBrs 2 89 20 C 918 34 n Butane 2 0 0 601 0 1085 5 8 2 Butanol 0 81 1240 3 3 sec Butylalcohol 0 81 1240 3 3 n Butyl bromide 46 C4H Br 1 276 20 C 1019 n Butyl chloride 22 46 C4HsCI 0 887 1140 4 57 tert Butyl chloride C4HsCI 0 84 984 4 2 Butyl oleate 1404 3 0 2 3 Butylene glycol C4H1902 1 019 1484 1 51 Cadmium 7 Cd 2237 7 Carbinol 40 41 0 791 20 1076 2 92 Carbitol 0 988 1458 Carbon dioxide 26 CO 1 101 37 C 839 7 71 Carbon disulphide CS 1 261 22 C 1149 Carbon tetrachloride 33 35 47 CCl 1 595 20 C 926 2 48 Carbon tetrafluoride 14 CF 1 75 150 C 875 2 6 61 Cetane 23 0 773 20 1338 3 71 Chloro benezene 1 106
16. ER to select Functions Display By pressing ENTER then SCROLL the user is able to change the measuring units When selected press ENTER The units displayed will depend on whether a Flow meter or Heatmeter has been purchased Energy options appear the list of flow units have been displayed Press Enter when you have selected what you would like displayed This is the same operation for both the Heatmeter and Flowmeter FUNCTIONS Setup 4 20mA If a Heatmeter is supplied there will be two 4 20mA outputs available for use They can be set up separately to whatever output is required When using the 4 20mA to monitor temperature it will only monitor the temperature difference and not the individual temperatures of the flow and return The display will show the following Press ENTER to select Functions Setup 4 20mA The display will show the following Scroll through each item and press ENTER to select SETUP 4 20MA INSTALLATION amp OPERATING INSTRUCTIONS mA out Output Units Max Min mA on error Exit The display will show the following Press Enter to select SETUP 4 20MA Output This shows the user what the output is giving at any particular time Press SCROLL to continue The display shows the following Select the output required and press ENTER OUTPUT OFF 4 20mA 0 20mA 0 16mA It is possible to choose between switching the output ON OFF or selecting the
17. Exit 16 WARRANTY 27 PRODUCT CARE AND 28 MAINTENANCE WARNING users should ensure or note that a The Ultraflo 2000 is not certified for use in hazardous areas b Thelocal site safety regulations are complied with c Work is carried out in accordance with The Health amp Safety at Work Act 1974 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS FIGURE 1 SYSTEM IDENTIFICATION FLOW SENSORS ASSEMBLY U DOWN P HE f 110 240V 4 20mA 1 CAES T T eee er 24VDC IN Figure 1 4 20mA 2 OUTPUT PT100 TEMPERATURE SENSORS please see page 29 if supplied The following information is required by Micronics when placing an order EXAMPLE APPLICATION TEMP TRANSDUCER CABLE LENGTH 50 METRES MAX FLOW IN UNITS 150L MIN MAX ENERGY RATE HEATMETER ONLY 1000KW TEMPERATURE DIFFERENTIAL HEATMETER ONLY TEMPERATURE PROBE CABLE LENGTH HEATMETER ONLY Example Order Code 24 60 S 60 W 50 150L min ULTRAFLO 2000 INTRODUCTION The Ultraflo 2000 is a Clamp on liquid flow meter that uses the Transit Time method of measurement to read flow Using two PT100 temperature probes to measure temperature it can also be used as a Heat Energy meter The Ultraflo is able to measure the flow of liquid in any pipe from 13mm to 5000mm providing the pipe is flooded and the correct transducers are used Units are supplied according to application data provided by the customer The ins
18. Imperial and US metres sec feet sec 0 2 12 m sec to 4 Significant Figures 12 Digits Opto isolated with user definable scaling 0 196 of full scale User definable scaling kW kCal hr MJ hr min sec kJ hr min sec Opto isolated with user definable scaling User definable scaling 20 C to 220 C 220 C Flow Velocity Range 0 2 m sec 4 m sec 8 m sec 0 2 m sec 8 m sec 12 m sec 0 2 m sec 4 m sec 7 m sec 0 2 m sec 4 m sec 7 5 m sec 1MHz 2MHz 0 5MHz Standard IP65 50 Ohm Coax Cable 3 metres Standard Optional up to 200 metres 20 C to 200 C D only up 80 C Specification assumes turbulent flow profile with Reynolds numbers above 4000 REPEATABILITY 0 5 with unchanged transducer position PIPE MATRIALS Any sonic conducting medium such as Carbon Steel Stainless Steel Copper UPVC PVDF Concrete Galvanised Steel Mild Steel Glass Brass Includes lined pipes Epoxy Rubber Steel Plastic Micronics reserve the right to alter any specification without notification 25 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS HEATMETER INSTRUCTIONS 1 Installation Connect the flow transducers to the instrument as described in the HARDWARE section of this manual Note that the Ultraflo must read positive flow otherwise the energy displayed will read zero Attach the temperature probes to the outside of the flow and return pipes Use the stainless steel banding to attach the te
19. Pyrex 3280 5610 Glass heavy silicate flint 2380 Glass light borate crown 2840 5260 Nylon 1150 2400 Nylon 6 6 1070 Polyethylene HD 2310 Polyethylene LD 540 1940 PVC cPVC 2400 Acrylic 1430 2730 Asbestos Cement 2200 Tar Epoxy 2000 Rubber 1900 24 ULTRAFLO 2000 SPECIFICATION INSTALLATION amp OPERATING INSTRUCTIONS ELECTRONIC ENCLOSURE SUPPLY VOLTAGE FLOW OUTPUTS Flow Display Analogue Set Point or Pulse HEATMETER OPTIONS Display Analogue Pulse Output Temperature Sensors Protection Class Material Dimensions Display Keypad Sensor Connections All Other Connections Temperature Range Switchable Volumetric Flow Flow Velocity Flow Rate Total Flow Signal Level Indication ERROR messages 4 20mA into 750 Resolution Max 1 pulse per second Energy 2 4 20mA 1 pulse second 100 Max temp differential Pipe Sizes B C D Frequency Flow Transducer Protection Flow Transducer Cables Flow Transducer Cable Length Flow Transducer Temp Range ACCURACY t 1 2 of reading or 0 02 m sec whichever is the greater 50 mm 89 mm 90 mm 1000 mm 300 mm 2000 mm 1000 mm 5000 mm IP67 ABS 264 x 230 x 101 mm 2 x 16 Character Super Twist LCD backlit IP67 TNC Coax Connectors 65 Glands 0 C to 50 C Operating 10 to 60 C Storage 110 240 VAC 50 60 Hz Max 5 watts 24 Volt DC m litres gallons
20. TYPES MAY INVALIDATE ANY APPROVAL OR WARRANTY APPLYING TO THE INSTRUMENT AND MAY BE DANGEROUS IF INDOUBT CONTACT MICRONICS SALES OR SERVICE Do not disassemble this unit unless advised by Micronics Return the unit to the place of purchase for further advice Do not drop Wipe the exterior of the instrument with a clean damp cloth or paper towel the use of a solvent may damage the paint surface Ensure the unit is switched off and disconnected from the mains Do not place the instrument electronics near to naked flames or sources of intense heat such as an electric fire or hot pipes in excess 50 C Dispose of any batteries safely and in accordance with any regulations in force in the country of operation Ensure all connectors are kept clean and free from grease They may be cleaned with a general purpose switch cleaner Avoid the use of excessive grease ultrasonic couplant on the sensors This may impair the performance of the equipment Read the instructions in the manual on how to apply the couplant Any excessive grease couplant can be removed from the sensors and guide rails using an absorbent paper towel and a general purpose solvent cleaner Regularly check all cables parts for damage Replacement parts are available from Micronics On fixed instruments it is recommended the ultrasonic couplant is replaced on the sensors every 6 months especially on pipes where the application is too hot to touch If signal level drops below 30 this
21. ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS ULTRAFLO 2000 FLOW amp HEATMETER Operating Manual yn Through measurement comes control ug Micronics Ltd Knaves Beech Business Centre Davies Way Loudwater High Wycombe Bucks ENGLAND HP10 9QR TEL 44 0 1628 810456 FAX 44 0 1628 531540 e mail sales micronicsltd co uk www micronicsltd co uk ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS CONTENTS SYSTEM IDENTIFICATION 3 ERROR MESSAGES E1 High Flow 16 INTRODUCTION 4 E2 No Flow Sig 16 E3 Hot Fault 16 HARDWARE E4 Cold Fault 16 Electronics Housing 4 Transducers 4 WARNING MESSAGES Transducer Connections 4 W1 Check Data 16 Transducer Hardware 5 W2 Timing Poor 16 Transducer Mounting 5 W3 Signals Poor 16 Transducer Cables 6 W4 Ma 1 OVER 16 Keypad 6 W5 Ma 2 OVER 16 W6 Pulse At 17 MAIN MENU Power up 7 APPLICATION INFORMATION Quick Start 8 Application Notes 17 View Edit Site Data 10 Select a Metering Position 17 Set up Sensors 11 Mounting The Transducers 18 Calibrate 4 20mA 12 Liquid Conditions 19 Read Flow 12 Propagation Velocity 19 Maximum Flow 19 FUNCTIONS Application Temperature 19 Display 13 Flow Range 19 Set up 4 20mA 13 Liquid Sound Sppeds 20 Pulses Set Point 14 Solid Sound Speeds 24 CutOff M S 15 Set Zero Flow 15 SPECIFICATION 25 Reset Total Flow 15 Reset Total Energy 15 HEATMETER INSTRUCTIONS 26 Damping 15 Cal Factor 16 CE MARKING Guidance Notes 27 Diagnostics 16 Save And
22. age 7 Before programming the instrument it is necessary to attach the transducers to the pipe wall such that they can be finally locked in the correct position based on exact data provided by the instrument TRANSDUCERS Each instrument uses two identical transducers which transmit and receive the ultrasonic waves They are clamped to the pipe surface using the mounting hardware supplied as described on pages 5 6 The standard transducers are made from a Peek material with an aluminium plate supporting the stud used to lock the sensor in position A flying armoured lead is attached between the sensor block and the tuning circuit Figure 3 1MHz Sensors with TNC Coaxial Connector Transducers are supplied according to the pipe size and flow velocity and are available to meet an operating temperature range from 20 C up to 200 C Transducer Connections Transducers are connected to the electronics from the tuning circuit by TNC connectors All other output and input connections are made through metal glands to the clearly marked terminals 220VAC 24V 0000000000 lo00 00 110VAC 12345678910 111213 oco NCCOMNO F MA1 MA2 HOT COLD RELAY Y 24VDC Coax sensor connectors a Coax cable ULTRAFLO 2000 Only one current output can be used with the flow meter The heatmeter option is supplied with a separate heat integrator please see page 29 PT100 temperature pro
23. always default to litres per minute The instrument now displays the maximum flow rate that it is capable of with the sensors provided and the application data that has been entered by the user Pressing SCROLL at this point will allow the user to change the units to be displayed in the flow mode Press ENTER when the units have been selected The Heatmeter option will also display kW Kcal h MJ h MJ m kJ m kJ s and Temp C Approx max flow Mi d g m kg h Usg m Uskg h m3 h m3 m m3 s m s TOC ft s k kkk k kkk The following will now be displayed Attach sensors REFLEX Sep mm inches Pressing ENTER at this point will take the instrument into reading flow 0 00 000 0 ULTRAFLO 2000 MAIN MENU View Edit Site From the MAIN MENU select View Edit site data by pressing ENTER This enables the user to view and edit the application data that has been entered into the unit previously The display will show the following Press ENTER to select 0 00 000 0 The display will show the following Press ENTER to select MAIN MENU View Edit Site The display will show the following VIEW EDIT SITE Dimension MM INCHES To change the dimensions press ENTER Select the units by pressing SCROLL Press ENTER to select This will convert all previous data entered into the units selected The display
24. an make no statement about conformance to the above standards when these cables are in use MANUFACTURERS WARRANTY The Ultraflo 2000 Ultrasonic liquid flow meter is guaranteed by MICRONICS to be free from defects in materials and workmanship for a period of one year from the date of shipment to the original customer provided that the equipment has been installed and used in the manner described in this User s Manual Fuses and sensor cables are not included in this warranty Repair or replacement at MICRONICS option will be made without charge at its factory during the warranty period If any problems develop take the followings steps 1 Notify MICRONICS or the Distributor from whom you purchased the meter giving full details of the problem Be sure to include the model and serial numbers of your flow meter You will then receive service data and or shipping instructions depending on your problem 2 If you are instructed to send your meter back to the factory please send it prepaid to the authorised repair station as indicated in the shipping instructions The warranty of the ULTRAFLO 2000 Ultrasonic Liquid Flow meter by MICRONICS is limited to those stated above and MICRONICS will not be liable for anything beyond this 27 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS PRODUCT CARE AND MAINTENANCE WARNING USE ONLY BATTERIES CHARGER ACCESSORIES CABLES APPROVED FOR THIS PARTICULAR MODEL THE USE OF ANY OTHER
25. as been programmed the data can be reviewed and changed if necessary The instrument displays information in the following 3 ways Flow in selected units l min 0 00 0 00 Energy in selected units kW 0 00 kWh 0 00 Temperature differential 50 10 Diff 40 C The flow information can be factored to suit the users requirements by selecting CAL FACTOR INSTALLATION amp OPERATING INSTRUCTIONS from the FUNCTIONS menu The Totalised Flow data can also be reset to zero PROGRAMMING MAIN MENU Power Up DO NOT PROVIDE POWER THE INSTRUMENT UNTIL THE SERVICE COMPARTMENT COVER HAS BEEN REPLACED The power supply is factory set To change from 110 220VAC to 24VDC the left hand switch needs to be in the down position The right hand switch is only used when changing from 110VAC to 220 When power is applied to the Ultraflo 2000 it will react in 2 distinctly different ways depending upon whether any application data has been programmed into the EEROM All new meters received from the factory will have had the EEROM memory wiped clean Apply power Initial display will show Micronics Ltd ULTRAFLO 2000 Within 5 seconds the display will change to DIMENSION Millimetres Application data can now be keyed in If the instrument has been used then application data will be stored in the EEROM and the following will be displayed If SCROLL is not pressed within 5 seconds a
26. bes should be connected to the supplied integrator please see page 29 Transducer Hardware Transducer alignment guide rails chains and couplant are supplied with all units in order to ensure that the transducers are accurately aligned with respect to the pipe axis A single guide rail assembly is supplied for mounting the transducers in Reflex mode and two guide rails are provided for mounting in Diagonal mode Figure 4 1MHz Reflex Mounting Assembly Transducer Mounting The two different methods of mounting the transducers are shown on pages 5 amp 6 When ordering the Ultraflo 2000 specific application information should have been given This information determines the correct hardware to be supplied with each instrument Reflex Mode Reflex mode is a default setting on all applications up to 215mm Above this the instrument will default to Diagonal mode It is possible to change these default settings if required see page 11 Set up sensors INSTALLATION amp OPERATING INSTRUCTIONS Before attempting to attach the transducers it is imperative to ensure that the correct position has been chosen to site the transducers and that the pipe surface conditions are suitable Go to page 17 and carefully follow all instructions for the selecting and preparing the transducer mounting site At this point program the instrument to determine the separation distance When you have this information from the instrument follow the
27. correct application data has been entered into the unit when being installed The calibration factor enables the instrument to be calibrated to any existing meter or flow rate The transducers are always calibrated to work with the electronics supplied If for any reason the transducers are damaged the new ones supplied will not have been calibrated with the electronics The calibration factor could then be used to give the same reading as other transducers If the new reading is 4 higher than normal then entering 0 96 will reduce the flow reading by 4 If the reading is 4 lower than normal entering 1 04 would increase the reading by 4 When the instrument is supplied it will always default to 1 00 If it has to be changed the new cal number will stay in the memory until changed again Press ENTER to select Enter new data and press ENTER FUNCTIONS Diagnostics The display will now read FUNCTIONS Diagnostics Diagnostics is not an option for the user The numbers displayed cannot be changed in any way and are only of benefit to Micronics engineers when testing the instrument or fault finding Press SCROLL to continue FUNCTIONS Save and Exit The display now reads FUNCTIONS Save and exit Press SCROLL to start at the beginning of the FUNCTIONS menu again or ENTER to save all the changes made and read flow ERROR and WARNING MESSAGES E1 High Flow When the instrument is programmed the user is informed
28. e fluid temperature press ENTER Press ENTER again when a new temperature has been entered The display will now show the following VIEW EDIT SITE Read flow Pressing SCROLL at this point will ask the user if they wish to exit the VIEW EDIT SITE loop Pressing ENTER will take the instrument back to the MAIN MENU option Setup sensors Pressing ENTER will display the following Approx max flow change the flow units press SCROLL and use the scroll key to select from the options available and press ENTER Pressing ENTER will display the following Attach sensors REFLEX Sep ULTRAFLO 2000 Pressing ENTER at this point will take the instrument into reading flow 0 00 000 0 MAIN MENU Setup sensors Press ENTER to select this option MAIN MENU Setup sensors This gives the user the opportunity to change the mode of operation from Reflex to Diagonal see figure 5 page 5 When application information is programmed into the instrument it automatically selects the mode of operation from that data It is possible however to use the same sensors in different modes The Setup sensors option is available for two main reasons Firstly if from the data that has been entered the instruction comes back that the sensors should be mounted in Diagonal mode it may be that this is not possible in the case of a partially buried pipe Under these circumstances provided that the
29. e runs Figure 14 Horizontal pipes BOTTOM INCORRECT CORRECT 4 Apply interface couplant to the face of the transducers The amount of couplant used is extremely important particularly on pipes of less than 100mm bore Use the syringe supplied with the instrument and apply couplant as shown On small pipes below 90mm the bead of grease used must be approximately 20mm long and 2mm maximum diameter Using more grease will cause ULTRAFLO 2000 wall signals to be generated which cause errors measurement Figure 15 On Stainless Steel pipes the amount of couplant applied should never exceed the amount indicated in the examples above For large plastic and steel pipes the amount of couplant applied is less critical however do not use more than is absolutely necessary 5 Attach the guide rail assembly to the pipe so that it is perfectly parallel to the pipe axis 6 When screwing the transducers on to the pipe surface use only enough force to ensure that the transducer is flat against the pipe surface and then lock in position 7 Clamping the transducers in exactly the correct position is extremely important The Ultraflo 2000 calculates the separation distance and the transducers must be positioned and clamped exactly at the distance specified 8 Always use the couplant provided Liquid Conditions Transit Time ultrasonic meters perform best on liquids that are totally free from entrained air and
30. e up to a maximum of 200 mteres Keypad All data is entered for set up and calibration via the front panel keypad Figure 9 shows the keypad layout Keys To give a NO answer and scroll through listed options press SCROLL e select options store data and move on to the next option press ENTER ULTRAFLO 2000 e f data has been incorrectly entered press Y until the display is clear then re enter the data correctly Restart Key The RESTART key can be pressed at any point in the program and will take the instrument back to the opening display Press SCROLL to enter the password 2000 and reprogram the instrument If the instrument has already been measuring flow and the SCROLL key is not pressed it automatically returns to flow mode Scroll Key When the SCROLL key is pressed in flow mode the display will read the following Signal 8096 0 00 mA This displays the signal level of the instrument and the current output status of the 4 20mA Both will be displayed if a Heatmeter is supplied Press ENTER again and the following will be displayed ERRORS PENDING No errors This will display all Error and Warning messages see page 16 To program the Ultraflo 2000 accurate application data must be keyed in via the keypad Data and instructions are requested via the display and all questions must be answered before the program will step through to the point of measuring flow Once the unit h
31. elow 0 25 m sec then the following will be displayed Stop the flow and press ENTER INSTALLATION amp OPERATING INSTRUCTIONS Follow the instructions on the display by pressing ENTER Zero flow set Press ENTER FUNCTIONS Reset Total Flow The display will now show the following FUNCTIONS Reset total flow This function resets the total Flow or Energy If a Heatmeter was supplied it is possible to re set the total Energy Press ENTER The display will now ask the following RESET TOTAL FLOW Are you sure Or RESET TOTAL ENERGY Are you sure Answer YES by pressing ENTER and NO by pressing SCROLL If you have answered YES the following will be displayed Press SCROLL to continue RESET TOTAL FLOW Total reset If you have answered NO the following will be displayed Press SCROLL to continue FUNCTIONS Reset total flow FUNCTIONS Damping The display will show the following FUNCTIONS Damping This option is used when flow readings are unstable due to turbulence caused by internal obstructions or bends etc Damping or averaging can be used to make the readings more stable It can be set to up date the display between every 3 to 100 seconds Press ENTER to select Enter the time in seconds then press ENTER ULTRAFLO 2000 FUNCTIONS Cal Factor The display will show the following FUNCTIONS Cal factor This facility should never have to be used if the
32. erence line D and the second reference line E measure and mark the separation distance XXX Now mount the second guide rail such that the transducer face can be positioned on this intersection ensuring that the guide rail is parallel to the reference line E See figure 7 0 Screw down both of the transducers and lock in position as previously described h RG223 Coaxial Cable 50 Different lengths up to 200 metres available on request INSTALLATION amp OPERATING INSTRUCTIONS Figure 7 SEPARATION DISTANCE mm Ref Line E HINT DRAWING A TRUE CIRCUMFERENCE AROUND A PIPE An easy way to draw perpendicular circumference around a large pipe is to wrap a length of material such as chart paper around the pipe aligning the edges of the paper precisely at the overlap With the edge of the chart paper being parallel then either edge describes circumference around the pipe that is perpendicular to the pipe axis BISECTING THE CIRCUMFERENCE Mark the chart paper exactly where it overlaps Then after removing the paper from the pipe fold the measured length in half keeping the edges parallel The fold line now marks a distance exactly half way around the pipe Put the paper back on the pipe and use the fold line to mark the opposite side of the pipe Transducer Cables The transducers are connected to the electronics via 50ohm coaxial cables and TNC connectors The total length of the cable b
33. es set point This gives the user a choice of using a pulse output or the set point facility Pulse output and set point cannot be used at the same time the Press Scroll through following options ENTER to select INSTALLATION amp OPERATING INSTRUCTIONS PULSES SET POINT Units Output Set point Exit The display shows the following Use the scroll key to select units press ENTER PULSES SET POINT Units At this point the user is able to select the units required by pressing ENTER Scroll through the options required and press ENTER when selected The display will show the following Press ENTER to select PULSES SET POINT Output OFF PULSES SET POINT Note The display will show the previous OUTPUT Pulses Set point selection Press SCROLL to select and then ENTER This facility allows the user to set the Pulses Set point or switch it off altogether Selecting Off and pressing ENTER will move the program to Cutoff m s Press SCROLL to select Pulses or Set point and press ENTER If Pulses were selected the display will show the following PULSES l pulse This can be scaled to the users requirements up to a maximum of one pulse per second Or SET POINT Set point The Set point can be set to the users requirements to trigger an alarm or indicator ULTRAFLO 2000 when the flow has reached a minimum or maximum level The instrument defaults
34. ethane 2 28 20 C 978 Isobutyl acetate 22 1180 Isobutanol 0 81 20 C 1212 Iso Butane 1219 8 Isopentane 36 0 62 20 C 980 Isopropanol 46 0 785 20 1170 Isopropyl alcohol 46 0 785 20 C 1170 Kerosene 0 81 1324 Ketohexamethylene 0 948 1423 Lithium fluoride 42 i 2485 Mercury 45 13 594 1449 Mesityloxide 0 85 1310 Methane 25 28 38 39 CH 0 162 405 89 15 C Methanol 40 41 0 791 20 C 1076 Methyl acetate 0 934 1211 o Methylaniline 46 0 999 20 1618 4 Methylaniline 46 0 966 45 C 1480 Methyl alcohol 40 44 0 791 20 C 1076 2 92 Methyl benzene 16 52 0 867 1328 4 27 2 Methyl butane 36 0 62 20 C 980 Methyl carbinol 0 789 1207 4 0 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS Methyl chloroform 47 C2HsCls 1 33 985 Methyl cyanide C2H3N 0 783 1290 3 Methyl cyclohexanol 0 92 1400 Methylene chloride 3 1 327 1070 3 94 Methylene iodide 3 235 980 Methyl formate 22 C2H402 0 974 20 C 1127 4 02 Methyl iodide CHsl 2 28 20 978 a Methyl naphthalene C11H10 1 090 1510 3 7 2 Methylphenol 46 C7H0 1 047 20 C 1541 3 Methylphenol 46 C7H0 1 034 20 C 1500 Milk homogenized 1548 Morpholine C4HNO 1 00 1442 3 8 Naphtha 0 76 1225 Natural Gas 37 0 316 103 C 753 Neon 45 Ne 1 207 246 C 595 Nitrobenzene 46 CsHsNO2 1 204 20 C 1415 Nitrogen 45 0 808 199 962 Nitromethane 43 CH3NO 1 135 1300 4 0 Nonane 23 0 718 20
35. fter the initial display the instrument will go directly to flow mode Apply power Initial display will show Micronics Ltd ULTRAFLO 2000 PRESS SCROLL within 5 seconds of initial start up Display will then show ENTER PASSWORD Key in password 2000 only required if the unit has been previously used ULTRAFLO 2000 ENTER PASSWORD kk kk Display will show MAIN MENU Quick Start MAIN MENU To get into the MAIN MENU press RESTART SCROLL then enter the password 2000 The MAIN MENU has 5 options that are selectable by using the scroll key Press ENTER to select MAIN MENU Quick Start View Edit Site Setup sensors Calibrate 4 20 Read flow MAIN MENU Quick Start The Quick Start option enables the user to quickly read flow The display will show the following MAIN MENU Quick Start Press ENTER to select this option and enter application data The user now has the option of selecting millimetres or inches Press SCROLL to display units and ENTER to select DIMENSION Millimetres Inches The display will show the following Enter the outside diameter and press ENTER PIPE OD mm inches Enter the wall thickness in the selected units and press ENTER WALL THICKNESS mm inches The display will show the following INSTALLATION amp OPERATING INSTRUCTIONS LINING THICKNESS mm inches If the pipe has a LINING enter the thickness now and
36. h cannot be predicted or compensated for Flow profile distortions result from upstream disturbances such as bends tees valves pumps and other similar obstructions To ensure a uniform profile the transducers must be mounted far enough away from any cause of distortion such that it no longer has an effect ULTRAFLO 2000 Figure 12 CORRECT INCORRECT 2n D 20D 10 20 5 20 FLOW 1 FLOW TN The minimum length of upstream straight pipe is 20 diameters and 10 diameters downstream which ensures that accurate results will be achieved Flow measurements can be made on shorter lengths of straight pipe down to 10 diameters upstream 5 diameters downstream but when the transducers are sited this close to any obstruction errors can be considerable It is not possible to predict the amount of error as this depends entirely upon the type of obstruction and the configuration of the pipework The message therefore is clear Do not expect to obtain accurate results if the transducers are positioned closer than allowed to any obstruction that distorts the uniformity of the flow profile Examples of the effects of two different pipe configurations are shown in Figure 13 Figure TYPICAL ERROR PROFILE VS 90 BEND MEASUREMENT ERROR DIAMETERS FROM BEND TYPICAL ERROR PROFILE VS DIAMETER TRASITION 2 4 zT 1 0 SQMM to 100MM WATER 1 8 MEASUREMENT ERROR DIAMETERS FROM TRANSITION Mounting The Tran
37. ipe diameter from 13mm bore up to 5000mm made of any material and over a wide range of operating temperatures The system operates as follows FLOW When ultrasound is transmitted from transducer X to transducer Y the speed at which the sound travels through the liquid is accelerated slightly by the velocity of the liquid If sound is transmitted in the opposite direction from Y to X itis decelerated because it is travelling against the flow of the liquid The difference in time taken to travel the same distance but in opposite directions is directly proportional to the flow velocity of the liquid Having measured the flow velocity and knowing the pipe cross sectional area the volumetric flow can be easily calculated All of the calculations required to first determine the correct siting of the transducers and subsequently compute the actual flow are carried out by the microprocessor To measure flow it is first necessary to obtain detailed information about each application which is then programmed into the processor via the keypad This information must be accurate otherwise flow measurement errors will occur Further having calculated the precise position at which the transducers must be clamped onto the pipe wall it is equally important to align and separate the transducers accurately with respect to one another as failing to do so will again cause errors in measurement INSTALLATION amp
38. lene bromide 47 C2H4Br2 2 18 995 Ethylene chloride 47 C2H4Cl2 1 253 1193 Ethylene glycol C2H602 1 113 1658 50 Glycol 50 1578 d Fenochone CioH16O 0 947 1320 d 2 Fenechanone CioH16O 0 947 1320 Fluorine F 0 545 143 C 403 Fluoro benzene 46 1 024 20 1189 Formaldehyde methyl ester 0 974 1127 Formamide 1 134 20 1622 Formic acid amide CHNO 1 134 20 C 1622 Freon R12 774 Furfural CsHsO2 1 157 1444 Furfuryl alcohol C5HsO2 1 135 1450 Fural CsHsO2 1 157 1444 2 Furaldehyde CsHsO2 1 157 1444 2 Furancarboxaldehyde Cs5HsO2 1 157 1444 2 Furyl Methanol 1 135 1450 6 095 2870 30 1 26 1904 Glycerol 1 26 1904 Glycol C HsO 1 113 1658 Helium 45 He 0 125 268 8 183 Heptane 22 23 0 684 20 1131 29 33 0 684 20 1180 Hexachloro Cyclopentadiene 47 CsCle 1 7180 1150 Hexadecane 23 0 773 20 1338 Hexalin 0 962 1454 16 22 23 0 659 1112 29 33 0 649 20 1079 2 5 CsH1002 0 729 1399 n Hexanol 0 819 1300 Hexahydrobenzene 15 2 0 779 1248 Hexahydrophenol 0 962 1454 Hexamethylene 15 0 779 1248 Hydrogen 45 0 071 256 C 1187 2 Hydroxy toluene 46 1 047 20 C 1541 3 Hydroxy tolune 46 1 034 20 C 1500 lodo benzene 46 1 823 1114 lodo ethane 46 1 950 20 C 876 lodo m
39. mperature probe Heat sink compound should be applied between the probe and pipe for better heat transfer Lagging should then be wrapped over the temperature probe itself to stabilise the temperature One temperature probe should be attached to the feed pipe as the HOT SENSOR and the other is attached to the return pipe as the COLD SENSOR TEMPERATURE Figure 17 PROBE HEAT SINK LJ COMPOUND STAINLESS STEEL BANDING Remove the terminal lid and connect the temperature probes making sure the power is turned off Connect the HOT sensor to the terminal marked HOT Pins 5 6 7 and the COLD sensor to the terminal marked COLD Pins 8 9 10 A reversed temperature connection will make the measured energy zero 110 220VAC 220VAC 00000000001 l0 00 B 00 2 4VDC 110VAC MA1 MA2 HOT COLD RELAY AC IN 12345678910 111213 16 17 18 44 NCCOMNO HE U L N E E The WHITE core from each temperature probe must always be connected to the negative Pins 6 and 9 The other two cores on each temperature probe connect to either of the positive terminals Pins 5 7and Pins 8 10 Always remember to earth the 100 probes using the screen core The PT100 are subject to interference from power sources such as pumps and invertors and any electrical equipment The interference will cause an error in the measurement of temperature 2 Operation Connect power to the instrument and wait for a few seconds
40. of the maximum flow rate that the instrument can measure If this is exceeded the High flow message occurs It may be possible to get round these problems by using another set of transducers in another mode This should not be necessary as the unit would have been supplied for a particular application with the correct transducers INSTALLATION amp OPERATING INSTRUCTIONS E2 No Flow Sig This message appears when the two transducers cannot send or receive signals This could happen for a variety of reasons Firstly check that all cables are connected transducers are on the pipe correctly and at the correct separation distance Check that there is couplant on the transducers This message may also appear when trying to measure a partially full pipe aerated liquid or when the particulate content of that liquid is too high The condition of the pipe being measured could also be a problem Fault only applicable for the Heatmeter This message appears when the temperature probe on the feed pipe is not connected Check the connections under the terminal lid E4 COLD Fault Heatmeter This message appears when the temperature probe on the return pipe is not connected Check the connections under the terminal lid only applicable for the WARNING MESSAGES W1 Check Data This message occurs when the application information has been entered incorrectly or the transducers have been attached to the wrong pipe size Thi
41. press ENTER If there is no LINING press ENTER to continue WALL M Steel The display will show the following There are 11 wall material options that are selectable by using the scroll key Select the material required and press ENTER when displayed WALL M Steel ee S Steel 303 Plastic Cast Iron Ductile Iron Copper Brass Concrete Glass Other m s If Other m s is selected the user needs to enter the speed of sound in metres per second of the particular pipe material being used Enter a figure and press ENTER Contact Micronics if the sound speed is not known If a Lining material thickness has been selected the following is displayed LINING Steel There are 6 Lining material options that are selectable by using the scroll key These are only displayed if a Lining was selected previously Select the material required then press ENTER to select LINING Steel Rubber Glass Epoxy Concrete Other m s If Other m s is selected the user needs to know the speed of sound in metres per second of the particular lining material being used Enter a ULTRAFLO 2000 figure and press ENTER Contact Micronics if the sound speed is not known The display will show the following FLUID Water Press Scroll There are 6 fluid options that are selectable by using the scroll key Select the fluid required then press enter to select Glycol 50 Lub oil Diesel oil Freon Other m
42. s If Other m s is selected the user needs to know the speed of sound in metres per second of the particular fluid being measured Enter a figure and press ENTER Contact Micronics if the sound speed is not known The display will show the following FLUID TEMP enter minus temperature press Y the keypad When the temperature has been entered press ENTER The Ultraflo has a temperature range between 20 C and 200 C If the temperature entered is out of range the following will be displayed Temp out of rang Press any key When the correct temperature is entered the following will be displayed Approx max flow ko l m NOTE If you have purchased a Heatmeter the following will be displayed unless water has been selected RELATIVE SHC Enter the specific heat capacity of the liquid being measured Heatmeter only See Heatmeter Instructions on page 21 and press Enter INSTALLATION amp OPERATING INSTRUCTIONS If you have eneterd a SHC the following will now be displayed RELATIVE DENSITY Enter the relative density of the liquid being measured Heatmeter only See the Heatmeter instructions on page 21 and press Enter The following will now be displayed Approx max flow k kkk I m The data that is entered and the application information that has been given to Micronics when purchasing the equipment determine the approximate maximum flow The instrument will
43. s will cause the timing to be in error The site data needs to be checked and the instrument reprogrammed W2 Timing Poor Unstable signal timing or differing up down stream times indicate that the liquid is aerated or pipe surface is of poor quality W3 Signals Poor This warning appears when there is a signal lower than 25 This could be due to the application or a poor quality pipe etc W4 mA 1 Over The mA 1 output is over range when the Flow Energy or Temperature differential is higher than the maximum mA range It is possible to re scale the 4 20mA to be able to cope with the higher range W5 mA 2 Over Only one 4 20mA output is available with the Flowmeter but both are available with the Heatmeter Both 4 20mA outputs are set up in the same way when supplied ULTRAFLO 2000 W6 Pulse at This message occurs when the pulses have exceeded the maximum setting It is possible to re scale the pulse output to cope with the higher flow rate APPLICATION NOTES The ULTRAFLO 2000 is a Transit Time Ultrasonic flowmeter which has been designed to work with Clamp On transducers thus enabling liquid flowing within a closed pipe to be measured accurately without the need for any mechanical parts to be inserted either through the pipe wall or protrude into the flow system The meter is controlled by a micro processor containing a wide range of data which enables the instrument to measure flow in any p
44. sducers INSTALLATION amp OPERATING INSTRUCTIONS It will be impossible to achieve the accuracy of measurement specified for the Ultraflo 2000 if the transducers are not clamped to the pipe correctly and if the data 1 0 O D Temperature Pipe Material are not accurate The transducers are supplied with a guide rail the purpose of which is to ensure that the transducers are aligned accurately with the pipe axis and that the face of the sensor is tangential to the axis Apart from the correct positioning and alignment of the transducers of equal importance is the condition of the pipe surface in the area under each of the transducers An uneven surface that prevents the transducers from sitting flat on the surface of the pipe can cause Signal Level and Zero Offset problems The following procedure is offered as a guide to good practice with respect to positioning and mounting the transducers 1 Select the site following the rules laid down on page 17 2 Inspect the surface of the pipe to ensure it is free from rust and unevenness Transducers can be mounted directly on painted surfaces as long as the surface is smooth and that the underlying metal surface is free from rust particles On bitumen or rubber coated pipes the coating must be removed in the area under the transducers as it is preferable that the transducers are mounted directly on to base metal 3 Transducers can be mounted on both Vertical or Horizontal pip
45. set up procedure below Procedure a Insert the transducers into the guide rail so the tails come out of either end b By turning the locking nut centre clockwise withdraw the transducers up into the guide rail Apply bead of coupling grease to each transducer See page 19 figure 15 d Attach both lengths of chain to the quick links provided and offer the guide rail up to the pipe wall at 45 e Wrap the chain around the pipe and connect to the J bolt Complete the same for both ends of the guide rail then tighten the locking nuts on the J bolt This will secure the complete assembly to the pipe f By turning the centre of the locking assembly anti clockwise lower one block onto the pipe Now adjust the second block to required separation distance and repeat the procedure The separation distance is measured from the front edge of each block and not the centre of the locking nut 9 If the instrument now reads a negative flow swapping the TNC connectors on the instrument can change this h Now lock the transducers in position by tightening the nut on locking assembly DO NOT USE EXCESS PRESSURE Note When moving the transducers into position ensure that they are withdrawn into the guide rail as far as possible This ensures that the couplant will not be removed from the transducer face before it is screwed down into position Figure 6 74 DISTANCE ULTRAFLO 2000
46. sing SCROLL will move the instrument onto the next option The display will show the following SETUP SENSORS Read flow If the sensor mode has been changed from the default settings i e Reflex to Diagonal or Diagonal to Reflex then this option will have to be selected to make sure that the new mode of operation is used to read flow If this is not selected the default settings will be used The display will show the following SETUP SENSORS Exit and default Press ENTER at this point to Exit and return to the MAIN MENU This will re set all the default sensor settings in the instrument that may have been changed by the user ULTRAFLO 2000 Pressing ENTER to continue will display the following Approx max flow ko l m Pressing ENTER again displays the following Attach sensors REFLEX Sep mm inches The instrument now displays the mode of operation and separation distance Attach the transducers as described on pages 5 and 6 Pressing ENTER will take the instrument into reading flow 0 00 000 0 MAIN MENU Calibrate 4 20mA Note A meter is required to measure the output current The display will read the following Press ENTER to select MAIN MENU Calibrate 4 20mA The 4 20mA output is calibrated before it leaves the factory and should not need adjusting although this option allows the user to adjust it if necessary to match a specific requirement The DAC value is a
47. solids With sufficient air in the system the Ultrasound beam can be attenuated totally and therefore prevent the instrument from working Often it is possible to tell whether there is air in the system or not If a flow signal cannot be obtained a simple test to determine whether the flow is aerated involves cutting off the flow for a period of 10 15 minutes During this time the air bubbles will rise to the top of the pipe and the flow signal should return When the flow signal has returned Switch on the flow and if sufficient entrained air is locked in the System it will very quickly disperse and kill the signal Propagation Velocity To make a flow measurement using the Ultraflo 2000 on any liquid other than water it is necessary to know propagation velocity 19 INSTALLATION amp OPERATING INSTRUCTIONS metres second of the particular liquid Micronics can supply this information Maximum Flow The Ultraflo 2000 is normally supplied with hardware suitable for the specific application for which the instrument has been purchased It is possible to use the instrument on a wide range of applications as long as the transducers will cope with the maximum velocity and temperature required Application Temperature On any application with an operating temperature above or below ambient temperature ensure that the transducers reach and are maintained at the application temperature before undertaking calibra
48. tion When applying the transducers to low temperature pipes do not allow the pipe surface to ice up between the transducer and the pipe wall Wherever possible insulate the transducers such that variations in ambient air temperature do not effect the relationship between the transducer and the liquid temperature The instrument automatically compensates for changes in application temperature over a range of approximately 20 C FLOW RANGE Figure 16 Transducer set D 5000mm 1 1 1 1 1 Transducer set C 2000mm 1 Transtucer set D 1000mm Transducer set C 300mm Trhnsduder set 90mm Transducer set A 89mm m s 0 02 0 03 0 06 0 07 0 1 0 4 1 3 2 4 6 7 8 1 5 0 06 0 09 0 19 0 22 0 32 1 31 4 26 6 56 13 12 19 68 22 96 26 24 ULTRAFLO 2000 INSTALLATION amp OPERATING INSTRUCTIONS Liquid Sound Speeds at 25 C Substance Formindex Specific Gravity Sound Speed 2 Acetic anhydride 22 CH3CO O 1 082 20 C 1180 2 5 Acetic acid anhydride 22 CH3CO O 1 082 20 C 1180 2 5 Acetic acid nitrile C2H3N 0 783 1290 4 1 Acetic acid ethyl ester 33 C4HasO2 0 901 1085 4 4 Acetic acid methyl ester 0 934 1211 Acetone 0 791 1174 4 5 Acetonitrile C2H3N 0 783 1290 4 1 Acetonylacetone 2 0 729 1399 3 6 Acetylene dichloride 1 26 1015 3 8 Acetylene tetrabromide 47 C H Brra 2 966 1027 Acetylene tetrachloride 47 C2H2Cl4 1 595 1147
49. trument displays volumetric flow rate in m hr m min m sec g min USg hr l min l sec and linear velocity in metres and feet per second The total volume of flow will be displayed up to a maximum 12 digit number When supplied as a Heatmeter kW kCal hr MJ hr MJ min and MJ sec can be displayed as well as the temperature differential The flowmeter is supplied with electronics sensors and all mounting hardware The Heatmeter version will also be supplied with PT100 temperature probes HARDWARE Electronics Housing An ABS housing with an opaque door contains the master PCB The housing is designed for wall mounting using the brackets provided see Figure 2 for mounting pattern Drilling further fixing holes in the Housing remove the IP67 protection rating and CE approval Mounting the housing into position does not require the removal of the electronics or the front display panel Fiqure 2 DO NOT PROVIDE POWER to the instrument until the service compartment cover has been replaced The electronics are factory set for a particular supply voltage Should it be necessary to change the settings for the power supply see page 7 Power up INSTALLATION amp OPERATING INSTRUCTIONS Having completed the procedure for mounting the electronics connecting all cables and checking the power supply the power can now be applied The Ultraflo 2000 is now ready for programming A full programming procedure is described on p
50. velocity is low enough it may be possible to use the transducers provided in Reflex mode see figure 4 page 5 The second reason for this option is that in the case of applications where the signal strength is not strong enough to get through a corroded pipe in Reflex mode the instrument may be used in Diagonal mode This has the effect of increasing the signal strength and maximum flow velocity The display will read the following SETUP SENSORS Mode REFLEX To change the mode of operation press ENTER There are 4 options under the heading of SETUP SENSORS and these are selectable by pressing scroll INSTALLATION amp OPERATING INSTRUCTIONS The display will show the following SETUP SENSORS Mode REFLEX Sensor params Read flow Exit and default Select mode of operation by pressing SCROLL then press ENTER SETUP SENSORS Mode REFLEX The display will show the following MODE Reflex Pressing SCROLL will allow you to choose between Reflex and Diagonal operation Press ENTER when new mode is selected The display will show the following SETUP SENSORS Sensor params The user cannot change this option It is only used by Micronics engineers to set sensor parameters for a particular application and to make sure the correct transducers are supplied with the instrument If this option is selected in error the instrument will ask for a password that is only known by Micronics engineers Pres
51. will now show the following VIEW EDIT SITE Pipe OD 55 0 To change the outside diameter of the pipe press ENTER Enter the new outside diameter in the units selected previously and press ENTER The display will now show the following VIEW EDIT Wall thickness To change the pipe wall thickness press ENTER Enter the new wall thickness in the units selected and press ENTER The display will now show the following VIEW EDIT SITE Lining thick To change or enter a pipe lining thickness press ENTER Enter the new lining thickness in the units selected previously and press ENTER The display will now show the following VIEW EDIT SITE Wall M Steel INSTALLATION amp OPERATING INSTRUCTIONS To change the wall material of the pipe press ENTER Scrolls through the options press ENTER when a new material has been selected The display will now show the following VIEW EDIT SITE Lining It will only be possible to change the pipe lining material if a lining thickness has been entered previously To change the lining material press ENTER Use the SCROLL key to select from the options available and press ENTER The display will now show the following VIEW EDIT SITE Fluid To change the fluid type press ENTER Use the Scroll key to select from the options available and press ENTER The display will now show the following VIEW EDIT SITE Fluid C 20 0 To change th
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