KUHLMAN INSTRUMENT COMPANY ULTRA K3 USER`S MANUAL
Contents
1. ENTER to show ENTER PIN and use the cursor keys to enter your PIN Press ENTER to record the test number your PIN and to store the test data DATA LOGGING The data logging function allows the Ultra K3 to log pressure applied to either pressure port and record pressure change for as long as 30 hours Data will be logged for the time selected as test time To enable data logging scroll to the UNIT CONFIGURATION display and press ENTER Scroll to the ENABLE DATA LOGGING display and press ENTER YES or NO will flash Use the or v key to enable the data logging function Press ENTER then press EXIT to return to the main menu To begin a test scroll to the desired pressure range and connect the pressure source to the correct input Press ENTER and CONFIRM LOG DELETE ENTER TO CONTINUE will be displayed If previous data had been downloaded and or deleted press ENTER to begin the test It is most important that data from previous test or data logging sessions be either downloaded or deleted as the Ultra K3 memory has limited capacity and can only store data from a single data logging session INITIALIZING HIGH or low pressure then will be displayed for a few seconds and the test will begin The display will show the initial test pressure I any decrease in pressure D the current pressure C and will count down the time remaining test time At th2. differential pressure by applying first one than the other pressure to the correct pressure port through an optional three way valve displaying the pressures and calculating the difference between the first and second applied pressure Lockup and flow tests of low pressure regulators can also be performed and data recorded The unit can store data from up to 99 tests for later downloading to the optional ULTRA K3 portable printer or to a personal computer Information stored includes a time date stamp an 8 digit test identification number a 3 digit user personal identification number PIN test start and end pressures and test duration The calibration due date and battery life are displayed when the unit is first powered up The unit will automatically shut off 30 minutes after a test is complete unless a longer test time has been programmed Pressing the POWER key restarts the instrument To allow long term pressure testing of pipelines the Ultra K3 includes a data logging function that automatically measures and stores pressure readings over time Tests of up to 30 hours can be done with the pressure sampling interval ranging from once every two minutes to once every 45 minutes depending on test time The ULTRA K3 has a built in timer adjustable to 30 hours for accurately timing leakage tests Separate times may be programmed for low and high pressure tests The ULTRA K3 has a backlit high contrast liquid crystal display LCD with adj
3. ENTER USER PIN TRANSFER DATA STORE TEST DATA DELETE TEST DATA RECORDS UNIT CONFIGURATION Using UNIT CONFIGURATION the following functions enable custom instrument configuration storage and retrieval of test data test number and user PIN number and data logging ENTER TEST ID up to an 12 digit number ENTER USER PIN 0 to 9999 SET TIME SELECT UNITS CHANGE LOW TEST TIME CHANGE HIGH TEST TIME TRANSFER DATA PRINT DATA PRINT CURRENT TEST RECORD PRINT ALL TEST DATA RECORDS DELETE CURRENT RECORD DELETE ALL TEST DATA RECORDS ALARM LEVEL LOW OVER PRESS Sensor OK BATTERY ENABLE DATA LOGGING LOW OVER PRESS Sensor LOW ZERO and USER OFFSET HIGH ZERO and USER OFFSET Use the and v keys to select the desired function then press ENTER to execute the function The display contrast can be changed to viewer preference by pressing and holding ENTER and using the or v key to adjust it Changes to contrast can only be made immediately following instrument power up When the Ultra K3 is used in a cold environment the display contrast may be increased to improve readability 4 PRESSURE MEASUREMENT To measure pressure power up the ULTRA K3 and select either HIGH PRESSURE for measuring pressures from 5 Psig to 299 Psig or LOW PRESSURE for pressures below 5 Psig Use the left port as you face the instrument panel to measure pressures to 5 Psig and the right port for pressur
4. boot in place USE OF OTHER BRAND ALKALINE CELLS LITHIUM OR RECHARGEABLE BATTERIES VOIDS THE CSA CERTIFICATION AND MANUFACTURER S WARRANTY Other features Pressure readings averaged over time for display stability Differential pressure measurement with optional manifold Logging of pressure data for tests up to 30 hours long Real time clock and date with internal battery backup High impact ABS splash proof enclosure Automatic power shutoff in 30 minutes or after test completion if longer Pressure manifold tapped 1 4 20 for attachment of hook or strap Entire contents copyright Kuhlman Instrument Company 02 16 07 11
5. 2 56 retaining screw and washer DO NOT USE OTHER BATTERY TYPES OR LITHIUM OR RECHARGEABLE CELLS DO NOT USE THE OPTIONAL PRINTER OR PERSONAL COMPUTER CONNECTION IN HAZARDOUS LOCATIONS Although the instrument case is well sealed and quite rugged the ULTRA K3 is not waterproof and can be damaged if dropped or immersed in water Treat the instrument as you would any other precision instrument such as a quality camera If the ULTRA K3 will not be used for more than a month remove the batteries and store the unit in a cool dry place THE UNIT HAS NO USER SERVICEABLE PARTS INSIDE OPENING THE CASE VOIDS THE WARRANTY AND INTRINSIC SAFETY CERTIFICATION For customer service and support please contact Kuhlman Instrument Company 54 East Summit Street Norwalk Ohio 44857 419 668 9533 419 668 2179 fax TechSupport Kuhlmaninstrument com PRODUCT DESCRIPTION The Kuhlman ULTRA K3 is a dual range state of the art digital instrument for pressure testing natural gas and propane distribution mains services and house piping and setting service and appliance regulators The ULTRA K3 has pressure ranges of 0 to 5 Psig and 0 to 299 Psig with a combined nonlinearity and hysteresis of less than or 0 25 of span at room temperature The user may set the units of measurement to either American or metric units To improve the instrument stability and ease of use pressure measurements are averaged over one second The unit also allows measurement of
6. ECTED FUNCTION WILL ONLY DETECT LARGE LEAKS In the UNIT CONFIGURATION menu it is possible to select ALARM LEVEL XX DROP to change the percentage of pressure loss to alarm up to 25 percent Changes are made using the and v keys Press ENTER to confirm the change selected The alarm level setting applies to both low and high pressure ranges The ULTRA K3 is set at the factory for a test time of 10 minutes To change the test time scroll the display to show CHANGE LOW TEST TIME or CHANGE HIGH TEST TIME press ENTER and using the scroll keys set the desired test time from one minute to 30 hours Push ENTER again to confirm the time selected The time set also determines the length of test when logging pressure tests for up to 30 hours DIFFERENTIAL PRESSURE MEASUREMENT Using an optional three way manifold available from Kuhlman Instrument Company the ULTRA K3 can measure pressure drop across meters separators and filters To measure differential pressure connect the three way valve to either the high or low pressure port of the ULTRA K3 depending on the pressure in the system under test Connect the other two ports on the valve across the device under test being sure not to apply more than 5 Psig to the low pressure port or 299 Psig to the high pressure port Use the and v keys to select either HIGH PRESSURE DIFFERENTIAL TEST or LOW PRESSURE DIFFERENTIAL TEST
7. EST TIME or CHG LOW TEST TIME for the desired test pressure range and press ENTER Use the scroll keys to select the desired test time in hours and minutes Press ENTER then EXIT to return to the main menu to select the desired pressure range for the test Be sure the batteries are new or near full capacity before beginning long tests Depending on the test time the pressure sampling interval varies as follows Test Time Sampling Interval 24 to 30 hours every 45 minutes gt 12 hours to 24 hours every 30 minutes gt 6 hours to 12 hours every 15 minutes gt 2 hours to 6 hours every 10 minutes gt 1 hour to 2 hours every 5 minutes lt 1 hour every 2 minutes SETTING THE DISPLAY CONTRAST Display contrast can only be changed when the ULTRA K3 is first powered up To adjust the display contrast press and hold the ENTER key and use the and v scroll keys to change the contrast for optimum viewing The unit remembers the contrast setting even when not powered up When the Ultra K3 is used in a cold environment the display contrast may be increased to improve readability TRANSFERRING DATA TO THE PRINTER An optional compact thermal printer is available from Kuhlman Instrument Company for printing stored test data THE PRINTER IS NOT APPROVED FOR USE IN HAZARDOUS LOCATIONS IT MUST ONLY BE CONNECTED TO OR USED WITH THE ULTRA K3 IN NON HAZARDOUS LOCATIONS To use the printer connect the cable from
8. KUHLMAN INSTRUMENT COMPANY ULTRA K3 USER S MANUAL WARRANTY The ULTRA K3 is warranted for one year against defects in material or workmanship This warranty does not cover water or physical damage damage from over pressure or battery leakage THIS IS YOUR ONLY WARRANTY NO OTHER WARRANTIES SUCH AS FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSED OR IMPLIED KUHLMAN INSTRUMENT COMPANY SHALL NOT BE LIABLE FOR ANY DAMAGES FROM USE OR MISUSE OF THIS INSTRUMENT WARNINGS AND PRECAUTIONS The ULTRA K3 is a precision instrument Although rugged it can be damaged by excessive pressure to either pressure port MAXIMUM PRESSURE TO THE LOW PRESSURE PORT MUST NOT EXCEED 5 PSIG OR THE INSTRUMENT MAY BE PERMANENTLY DAMAGED MAXIMUM PRESSURE TO THE HIGH PRESSURE PORT MUST NOT EXCEED 299 PSIG The instrument can be damaged by over tightening the pressure fittings Although splash resistant the instrument is not waterproof If immersed in water it should be returned immediately to Kuhlman Instrument Company for repair To assure continued accuracy of the ULTRA K3 over time it should be returned to Kuhlman Instrument Company or a Kuhlman Instrument Company authorized calibration facility annually for recalibration The ULTRA K3 is certified as intrinsically safe for use in Class Division 1 Group D locations methane or propane in air to 104 F 40 C only when used with Duracell Ultra MX 1500 alkaline batteries with the battery cover fastened by the
9. NPTF port Maximum pressure without possible sensor damage 10 Psig Media compatible with 316L stainless steel and 6061T6 aluminum Combined hysteresis and nonlinearity lt 0 25 of span One year long term stability lt 0 1 of span Temperature stability lt 0 008 of span per degree F Resolution 0 1 H20 0 0036 Psig High pressure port Input pressure range 0 299 Psig to 1 8 27 NPTF port Maximum pressure without possible sensor damage 900 Psig Media compatible with 316L stainless steel and 6061T6 aluminum Combined hysteresis and nonlinearity lt 0 25 of span One year long term stability lt 0 1 of span Temperature stability lt 0 004 of span per degree F Resolution 0 1 Psig Printer serial port Serial RS232 format via 9 pin DSUB connector Comma delimited serial data format Operator interface Seven switch keypad and two line 20 character backlit liquid crystal display Power supply Four 1 5 volt AA Duracell Ultra MX 1500 alkaline cells Estimated battery life in excess of 50 hours when used 4 hours per day Battery condition monitor with low battery warning Certification The ULTRA K3 has been certified by the Canadian Standards Association CSA as intrinsically safe for use in Class Division 1 Group D locations methane or propane in air to 104 F 40 C in the United States and Canada ONLY when used with Duracell Ultra MX 1500 alkaline AA cells and with the battery cover washer 2 56 retaining screw and vinyl
10. NTRINSIC SAFETY CERTIFICATION AND WARRANTY To install batteries remove the black vinyl boot covering the bottom of the case remove the 2 56 x 1 Phillips head screw and washer then remove the battery compartment cover and insert four cells observing correct polarity Replace the cover washer and screw and replace the boot The cover washer 2 56 screw and boot must be in place for the intrinsic safety certification to be valid The instrument has a battery status indicator Replace batteries when the indicator shows less than 25 Capacity remaining Under normal operation battery life should exceed 50 hours when used 4 hours per day If doing a long test be sure to have sufficient battery capacity remaining to complete the test OPERATION The ULTRA K3 is a menu driven instrument that uses seven front panel keys to select all operating functions The keys are POWER hold down 3 seconds to turn the instrument on or off ENTER executes the selected operational function up scrolls up between displayed functions and increases the value of flashing display digits v down scrolls down between displayed functions and decreases the value of flashing display digits lt left scrolls left between flashing display digits gt right scrolls right between flashing display digits EXIT returns to the previous screen without executing the operation displayed The ENTER key is used to enter functions and v
11. alues into the instruments memory as well as to store test results The and v scroll keys are used to scroll between the various operational functions of the instrument and increase or decrease each digit value as test and PIN numbers are entered The lt and gt keys are used to scroll between digits on the display when changing test times test or PIN numbers The EXIT key returns the the previous function displayed without executing the function There are no other user adjustable controls on the ULTRA K3 Calibration is performed by the manufacturer with special software To turn the instrument on press and hold the POWER key until the display illuminates The instrument will do a self test and the display will show KUHLMAN ULTRA K3 Version X X X X After a few seconds it will display BATTERY X X Volts XX CAL DUE XX XX XX In a few more seconds the instrument will then display HIGH PRESSURE indicating that the instrument is ready to measure high pressures up to 299 Psig To turn the power off press and hold the POWER key until the instrument counts down to zero then release the key The major menu functions of the instrument are HIGH PRESSURE measurement LOW PRESSURE measurement LOW PRESSURE DIFFERENTIAL TEST HIGH PRESSURE DIFFERENTIAL TEST START HIGH PRESSURE LEAKAGE TEST START LOW PRESSURE LEAKAGE TEST START LOCKUP AND FLOW TEST ENABLE DATA LOGGING ENTER TEST ID
12. depending on the pressure port used Set the three way valve to port the first pressure to the ULTRA K3 and press ENTER Then set the three way valve to apply the second pressure to the instrument and again press ENTER The ULTRA K3 will display the first pressure P1 the second pressure P2 and the difference in pressure between P1 and P2 Press EXIT to end the test or press ENTER to save the data LOCKUP AND FLOW TESTING The lockup and flow test is used to detect leakage through a low pressure regulator with no gas flow and the set pressure at a predetermined gas flow rate To measure lockup and flow use the or v key to select START LOCKUP AND FLOW TEST Press ENTER and APPLY NO FLOW PRESS will be displayed When pressure has been applied to the low pressure port with no gas flowing through the regulator press ENTER APPLY FLOW PRESS will be displayed along with 1 XX X and the no flow pressure Open a valve downstream of the regulator to allow a calibrated gas flow as stated in your company s manual of approved procedures When flow has stabilized press ENTER to record the flowing pressure MAKE SURE FLOWING GAS IS SAFELY VENTED The display will show 1 X X and 2 X X for the respective no flow and flow pressures and COMPLETE Press ENTER again to enter the test ID number Use the cursor keys to enter the correct ID number then press
13. e PC is set to receive data push the ENTER key to download the data to the PC Data is sent in serial comma delimited format Kuhlman Instrument Company offers software to help manage data from the instrument When the printer or PC data cable is not used the RS 232 port should be covered using the plastic cover supplied DELETING TEST RECORDS To delete either the current test record individual records or all test records scroll until UNIT CONFIGURATION is displayed and push ENTER Scroll until DELETE STORED DATA is displayed and push the ENTER key again Scroll until either DELETE RECORD or DELETE ALL TEST DATA RECORDS is displayed Use 8 DELETE RECORD to delete individual records or DELETE ALL TEST DATA RECORDS to delete all stored test records Individual records can be deleted by using the lt and gt keys to select the record to be deleted then pressing ENTER To delete it press ENTER again CONFIRM DELETE will be displayed Press ENTER again to delete the record To delete all test records select DELETE ALL TEST DATA RECORDS and press ENTER The unit will display CONFIRM DELETE Press ENTER again to perform the deletion CHANGING DATE AND TIME OF DAY The instrument has an internal backup battery to keep its calendar and clock running even when the AA batteries are not installed Should it be necessary to change
14. e end of the test the alarm will sound the light will flash and T COMPLETE will be displayed Press ENTER to display ENTER TEST ID and use the scroll keys to enter the test ID number Press ENTER and ENTER USER PIN will be displayed Again use the scroll keys to enter your PIN Press ENTER to complete the test This completes the test and stores the data for printing or transfer to a computer To stop the test before it is complete press ENTER Follow the instructions above to store data from the test Remember to disable the data logging function to return the Ultra K3 to normal operation When using data logging test time should be selected so that the operator can store the data within 30 minutes of the end of the test as at the conclusion of a test the Ultra K3 will shut down 30 minutes later If the test ID and user PIN are not entered within 30 minutes of the end of a test data will not be saved If the pressure falls below the the preselected percentage alarm level setting the alarm will sound and the test will be ended Data will be recorded but must be saved within 30 minutes It can be stored as above To set the test times for low or high pressure data logging first scroll to UNIT CONFIGURATION press ENTER and scroll to ENABLE DATA LOGGING Press ENTER and use the or v key to display YES and press ENTER Then scroll up to show CHG HIGH T
15. es greater than 5 Psig The display will show the pressure applied to the port selected If more than 5 Psig is applied to the low pressure port the instrument will sound a warning tone APPLYING MORE THAN 5 PSIG TO THE LOW PRESSURE PORT MAY RESULT IN DAMAGE TO THE LOW PRESSURE SENSOR If unsure of the applied pressure first use the high pressure port to measure it To change the units of pressure displayed from pounds per square inch Psig to inches of water column H2O ounces per square inch Osi kilopascals KPa or megapascals MPa follow the instructions in the section CHANGING THE PRESSURE UNITS DISPLAYED below LEAKAGE TESTING To begin a leakage test select either HIGH PRESSURE or LOW PRESSURE press the ENTER key and apply the test pressure to the appropriate pressure port Select LOW PRESSURE for tests to 5 Psig and HIGH PRESSURE for tests between 5 Psig and 299 Psig Apply the test pressure to the pipeline under test and allow the system pressure to stabilize When the correct test pressure is indicated on the display press the ENTER key again to begin the leakage test The instrument will display START HIGH PRESSURE TEST or START LOW PRESSURE TEST depending on the range selected Press the ENTER key to begin the test The display will show the initial test pressure I the current pressure C the pressure decrease D and the test time remaining T When the t
16. est is complete the alarm will sound for 30 seconds the light will flash and the display will indicate the initial applied pressure I the pressure decline if any D the final pressure C and T COMPLETE Pressing EXIT will exit the test without storing data Pressing the EXIT key during a test will stop the test If EXIT is pressed during a test ARE YOU SURE will display Press ENTER to confirm To store data at the completion of the test press the ENTER key to display ENTER TEST ID and ID XXXXXXXXXXXX Use the scroll keys to enter the test number Push ENTER again to display ENTER USER PIN and PIN XXXX Use the scroll keys to enter your PIN number Then press the ENTER key to store data from the test The instrument is now ready to perform another test When performing a leakage test the instrument monitors pressure change during the test If a pressure drop of more than the preset alarm percentage of the applied pressure is detected during the test the alarm will sound the light will flash and LEAK DETECTED TEST TERMINATED will be displayed Press the ENTER key to stop the alarm THIS FUNCTION IS ONLY TO BE USED AS AN AID TO DETECT VERY LARGE LEAKS IT MUST NOT BE DEPENDED UPON TO DETECT ALL LEAKS IT IS THE USER S RESPONSIBILITY TO DETERMINE IF A LEAK IS DETECTED BASED ON THE PRESSURE DROP INDICATED DURING THE TEST THE LEAK DET
17. range only MPa megapascals high pressure range only Different units may be selected for low and high pressure ranges To change the displayed units scroll until SELECT UNITS is displayed push ENTER then use or v to choose LOW PRESSURE UNITS or HIGH PRESSURE UNITS Use the lt and gt scroll keys to change the units When the desired units are selected for both the high and low pressure ranges press ENTER to save the changes ULTRA K3 SELF TEST FUNCTIONS The UNIT CONFIGURATION menu includes display of battery voltage in volts and approximate percentage of battery life remaining This is useful when planning a long term test to assure that sufficient battery capacity remains to complete the test LOW OVER PRESS records any pressure of more than 5 psig applied to the low pressure port If over pressurization has occurred the Ultra K3 must be returned to the factory for inspection possible repair and recalibration This display can only be reset at the factory Remember that applying more than 5 psig to the low pressure port may damage the instrument and is not covered by warranty The LOW ZERO and HIGH ZERO USER OFFSET functions are to assure the sensor zero setting Pressing ENTER when this screen is shown will offset any small drift of either sensor 10 ULTRA K3 SPECIFICATIONS Low pressure port Input pressure range 0 5 Psig to 1 8 27
18. the printer to the 9 pin connector on the ULTRA K3 apply power to the printer and turn the ULTRA K3 and the printer on Scroll to the screen TRANSFER DATA push ENTER then scroll to the screen PRINT DATA and push ENTER The last test record its date and the user s PIN number will be displayed If it is desired to print only this test record press ENTER PRINT DATA will be displayed Press ENTER again to print the record To print any previously stored data record when the test ID is displayed use the lt or gt keys to scroll to the desired test to print Then push ENTER PRINT DATA will be displayed Push ENTER to print To print all test records stored in the Ultra K3 proceed as above then scroll to the next screen PRINT ALL TEST DATA RECORDS and push ENTER to print all the records stored in the instrument TRANSFERRING DATA TO A COMPUTER The ULTRA K3 has a standard 9 pin RS 232 connector to allow the transfer of test data to a personal computer Transferring data to a computer is similar to transferring data to the printer except when in the PRINT DATA screen scroll until TRANSFER DATA TO PC is displayed Connect the optional cable from the Ultra K3 to the serial data port on the PC THIS FUNCTION MUST NOT BE USED IN HAZARDOUS LOCATIONS A COMPUTER MUST ONLY BE CONNECTED TO OR USED WITH THE ULTRA K3 IN NON HAZARDOUS LOCATIONS When th
19. the time such as when changing time zones scroll the display until UNIT CONFIGURATION is shown and press ENTER Scroll to the screen SET TIME and press ENTER Use the scroll keys to select and change the time as required Press ENTER to confirm all changes The unit uses a 24 hour clock beginning at midnight 00 00 The date is set at the factory and cannot be changed by the user If the calendar becomes inoperative the ULTRA K3 must be returned to the factory for backup battery replacement CHANGING TEST TIME When shipped the ULTRA K3 is set for a test time of 10 minutes To change the test duration scroll until UNIT CONFIGURATION is displayed Press ENTER to show CHG LOW TEST TIME or CHG HIGH TEST TIME is shown then push ENTER and EDIT LOW or high TEST TIME will be displayed Use the scroll keys to change the test time from 1 minute to 30 hours When the desired test time is set use the ENTER key to confirm the new time Press EXIT to return to the UNIT CONFIGURATION display Different times may be selected for the high and low pressure test functions CHANGING THE PRESSURE UNITS DISPLAYED The ULTRA K3 can display pressure in the following units Osi ounces per square inch gauge low pressure range only Psi pounds per square inch gauge either pressure range H20 inches of water column low pressure range only KPa kilopascals low pressure
20. ustable contrast for easy viewing The display and keyboard panels are covered with a tough polycarbonate film DO NOT USE ABRASIVE OR CHEMICAL CLEANERS TO CLEAN THE PANEL Use only Plexus brand cleaner or clean water with mild soap if needed Pressure connections to the ULTRA K3 are through two aluminum 1 8 NPT female threaded ports on the top of the case DO NOT OVER TORQUE FITTINGS CONNECTED TO THE PRESSURE PORTS USE ONLY TEFLON TAPE ON THE THREADS DO NOT USE PIPE DOPE USE OF PIPE DOPE WILL VOID THE WARRANTY The Ultra K3 is supplied with quick connect fittings and 1 4 tubing for connection to the piping system and Shrader connections for applying test pressures Although the sensors are stainless steel and manifold is aluminum only dry air natural gas propane nitrogen or carbon dioxide should be used to pressurize the Ultra K3 Evidence of damage from corrosive materials will void the warranty Transfer of data to the optional Kuhlman ULTRA K3 thermal printer or to a personal computer is through the 9 pin connector located on the top of the case When not in use this connector should be kept covered with the cap supplied Data may be displayed on a personal computer using optional Kuhlman supplied software BATTERY INSTALLATION The ULTRA K3 uses four 1 5 volt AA alkaline cells USE ONLY DURACELL BRAND ULTRA MX 1500 ALKALINE BATTERIES USE OF OTHER BRAND ALKALINE CELLS LITHIUM OR RECHARGEABLE BATTERIES IN THE ULTRA K3 VOIDS THE I
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