Pulsar MicroFlow-i User manual

MICROFLOW-

INSTRUCTION MANUAL

MICRO FLOW- (FIRST EDITION REV 5)

May 2019

Part Number M-MFi-S-001-5P

COPYRIGHT

may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language

in any form without the written permission of Pulsar Process Measurement Limited.

WARRANTY AND LIABILITY

Pulsar Process Measurement Limited guarantee for a period of 2 years from the date of delivery that it

will either exchange or repair any part of this product returned to Pulsar Process Measurement Limited

if it is found to be defective in material or workmanship, subject to the defect not being due to unfair

wear and tear, misuse, modification or alteration, accident, misapplication or negligence.

DISCLAIMER

Pulsar Process Measurement Limited neither gives nor implies any process guarantee for this product

and shall have no liability in respect of any loss, injury or damage whatsoever arising out of the

application or use of any product or circuit described herein.

Every effort has been made to ensure accuracy of this documentation, but Pulsar Process Measurement

Limited cannot be held liable for any errors.

Pulsar Process Measurement Limited operates a policy of constant development and improvement and

reserves the right to amend technical details as necessary.

The MicroFlow-i shown on the cover of this manual is used for illustrative purposes only and may not

be representative of the actual MicroFlow-i supplied.

TECHNICAL ENQUIRIES

Please contact Pulsar Process Measurement Limited for technical support.

COMMENTS AND SUGGESTIONS

If you have any comments or suggestions about this product, then please contact:

Pulsar Process Measurement Limited

Pulsar Process Measurement Inc.

Cardinal Building

Enigma Commercial Centre

Sandy’s Road

Malvern

Worcestershire

WR14 1JJ

United Kingdom

PO Box 5177

Niceville

FL 32578-5177

USA

Tel: + 44 (0) 1684 891371

Fax: + 44 (0) 1684 575985

Tel: + 1 850 279 4882

Fax: + 1 850 279 4886

Web Site: https://www.pulsar-pm.com

e-mail: info@pulsar-pm.com (general

information)

e-mail: support@ pulsar-pm.com (product

support)

Web Site: https://www.pulsar-pm.com

e-mail: info.usa@pulsar-pm.com (general

information)

e-mail: support.usa@ pulsar-pm.com (product

support)

Pulsar® is a registered trademark of Pulsar Process Measurement Ltd in the UK, USA and China.

Contents 
Chapter 1  Start Here… ....................................................................................................................... 1 
About this Manual ........................................................................................................................................... 1 
About the MicroFlow-i ................................................................................................................................... 2 
Benefits ............................................................................................................................................................ 3 
Functional Description .................................................................................................................................... 4 
Product Specification....................................................................................................................................... 5 
EU Declaration of Conformity ....................................................................................................................... 6 
Chapter 2  Installation .......................................................................................................................... 7 
Unpacking ........................................................................................................................................................ 7 
Power Supply Requirements ........................................................................................................................... 7 
Cable Requirements ........................................................................................................................................ 7 
Information specific to Hazardous Area Installation ..................................................................................... 8 
Limitations on use.................................................................................................................................... 8 
Hazardous Area Specific Power Supply and barrier Requirements ...................................................... 9 
Location ......................................................................................................................................................... 11 
Mounting ........................................................................................................................................................ 11 
Angled Mounting Bracket ..................................................................................................................... 12 
MicroFlow-i sensor ............................................................................................................................... 14 
Mounting sensor to a bracket ................................................................................................................ 15 
Terminal Connection Details ........................................................................................................................ 18 
Chapter 3  Locating the MicroFlow-i sensor...................................................................................... 19 
Locating the MicroFlow-i ..................................................................................................................... 19 
Installing the Sensor............................................................................................................................... 22 
Preparation for Operation .............................................................................................................................. 23 
General Maintenance..................................................................................................................................... 23 
Sensor Maintenance. ..................................................................................................................................... 24 
Chapter 4  Understanding how the MicroFlow-i operates .................................................................. 27 
MicroFlow-i HART compatible ................................................................................................................... 27 
4 – 20 mA Device .......................................................................................................................................... 27 
Chapter 5  MicroFlow-i HART PC .................................................................................................... 29 
Software installation ...................................................................................................................................... 29 
Connecting to MicroFlow-i HART PC ........................................................................................................ 30 
Flow Tab ........................................................................................................................................................ 32 
Configuration Tab ......................................................................................................................................... 33 
Parameter Get/Set .................................................................................................................................. 33 
MicroFlow-i Manual Setting ................................................................................................................. 34 
4 – 20mA Trim ...................................................................................................................................... 35 
Trace Tab ....................................................................................................................................................... 36 
Comport ......................................................................................................................................................... 38 
Language ........................................................................................................................................................ 38 
Tools menu .................................................................................................................................................... 38 
Info ................................................................................................................................................................. 39 
Exit ................................................................................................................................................................. 39 
Chapter 6  Parameter Listing and Descriptions .................................................................................. 40 
Parameter Access........................................................................................................................................... 40 
Device Information Parameters .................................................................................................................... 40 
Processing Parameters ................................................................................................................................... 41 
MicroFlow-i Firmware Upgrade .................................................................................................................. 44 
MicroFlow-i HART Firmware Upgrade ...................................................................................................... 46 
Chapter 7  Troubleshooting ............................................................................................................... 48 
Chapter 8  Parameter record .............................................................................................................. 49 
Chapter 9  Disposal ............................................................................................................................ 50 

Page 1

Chapter 1 Start Here…

Congratulations on your purchase of a Pulsar MicroFlow-i. This quality system

has been developed over many years and represents the latest in high technology

flow monitoring.

It has been designed to give you years of trouble free performance, and a few

minutes spent reading this operating manual will ensure that your installation is as

simple as possible.

About this Manual

It is important that this manual is referred to for correct installation and

operation.

There are various parts of the manual that offer additional help or information as

shown.

Tips

TIP

At various parts of this manual

you may find tips to help you.

Additional Information

At various parts of the manual, you will find sections

like this that explain specific things in more detail.

References

See also text in Bold as these may be references to other parts of this or another

manual.

Drawings

It should be noted that drawings or pictures shown in this manual may not be to

scale.

Page 2

About the

MicroFlow-i

The MicroFlow-i is a 2-wire loop-powered non-contacting velocity sensor,

with hazardous area approval. The sensor provides reliable flow velocity

measurements using short pulses of micro-waves, which are transmitted by an

enclosed antenna. When reflected off a moving surface, the signal experiences

a shift in frequency characteristics. The reflected signal is captured by the on-

board microprocessor via the antenna, and analysed to determine the velocity.

The MicroFlow-i’s compact and versatile design makes it easy to install and

ideal for confined spaces. Housed in a robust enclosure coupled with a fully

encapsulated microwave antenna, it provides an effective fit-and-forget flow

velocity solution.

Perfect for remote monitoring or when there is no mains power available, due

to its low power consumption. To access flow velocity data, use Pulsar’s

MicroFlow-i HART PC or HART protocol.

Overall the device has outstanding stability, accuracy and repeatability.

Page 3

Benefits

Combined with the ease of programming there are many other benefits to using

the MicroFlow-i, these are listed below:

• Non-contact velocity measurement.

• Loop powered and ideal for remote monitoring.

• Low-power consumption.

• Hazardous area approval (Ex ia) for Zone 0.

• ‘See through’ capability for enclosed plastic pipes and concrete (not

reinforced) channels.

• Suitable for abrasive and aggressive materials.

• Resilient to liquid vapour, wind or temperature.

• No minimum liquid level required for measurement

• Maintenance free.

• No interruption to operational flow.

• Can be installed in addition to existing in process contact measuring

devices.

• Easily setup using MicroFlow-i HART PC.

• The sensor is capable of monitoring flow of very shallow liquid,

mitigating the constraint associated with in-liquid techniques.

Page 4

Functional Description

Based upon state-of-the-art micro-wave sensing technology, the MicroFlow-i

integrates Pulsar’s innovative and award winning DSP (Digital Signal Processing)

platform, offering you a cost effective solution with excellent reliability and

performance.

The Pulsar MicroFlow-i has been designed to provide maintenance free

performance. The MicroFlow-i i is also intrinsically safe (Ex ia) for Zone 0.

The MicroFlow-i can be mounted via a rear 1” BSP to M20 thread adapter

(supplied with unit). The MicroFlow-i is loop powered and gives a 4 to 20mA

output which is proportional to the flow velocity. A ‘fault condition’ alarm will

give out a reading of either 3.8mA or 22mA.

The 2 wire sensor can either be used in digital HART mode or as 4-20mA loop

powered device. The MicroFlow-i loop powered version can be set up using a

HART modem with either proprietary HART software such as Pact ware or Pulsar

MicroFlow-i HART PC software.

Boot up time from power up to stable reading: cold boot 8.5 seconds, warm boot

4 seconds (if within 12 hours from last start up).

Page 5

Product Specification

Physical

Sensor body material Valox 357

Mounting Connection Via 1” BSP back mounted thread, 45

o

Angled

Mounting bracket and M20 thread adaptor

(optional).

Mounting angle: 45° optimum and mounted at the centre line

of the channel with clear uninterrupted view

Sensor body dimensions Diameter 90mm x height 140mm (3.54in x 5.51in)

Sensor body weight Nominal 0.7kg (1.54 lbs)

Transducer cable extensions 2 core screened

Maximum separation Up to 1000m (3280ft)

Environmental

Enclosure protection IP68

Max. & min. temperature (electronics) -20 ºC to +60 ºC (-4°F to +140°F)

Approvals

ATEX CML 16ATEX2331X, IECEx CML 16.0105X

II 1 G Ex ia IIC T4 Ga

II 1 D Ex ia IIIC T135

0

C Da

CE and Radar Approval See EU Declaration of Conformity

Performance

Velocity Range 0.2 – 6.0 m/s (0.66 – 19.7 ft/s)

Accuracy The greater of ± 1.5% or 0.05 m/s (0.1ft/s)

Optimum installation Install at an angle of 45° in line with flow. For

more information, see ‘Locating the MicroFlow-i

sensor’ section of this manual

Maximum channel width per sensor 1.5m (4.92ft)

Radar K-Band (ISM)

Transmitter Power <15 dBm

Beam width 20° inclusive

Outputs

Communication HART compatible, 4-20mA loop powered

Programming

PC programming MicroFlow-i HART PC

Programming security via passcode

Programmed data integrity Via non-volatile memory

PC setup and monitoring software compatible Win 7, Win 8, Win 10

Supply

Operating Voltage 10 – 28VDC

Power Consumption Start up = 20mA. Average current = 60µA per

hour when one velocity measurement is

performed every 15 minutes

Pulsar Process Measurement Limited operates a policy of constant development and improvement

and reserve the right to amend technical details as necessary.

Page 6

EU Declaration of Conformity

Page 7

Chapter 2 Installation

Unpacking

Power Supply Requirements

The MicroFlow-i can operate from a DC supply of 10 to 28V. In all cases the unit

typically consumes 0.52W of power and will typically draw less than 22mA.

Cable Requirements

The MicroFlow-i comes with a fitted integral cable, if this cable is extended then

the total capacitance must not exceed the limits for the voltage applied, and the

hazardous area it is installed in.

The HART modem and PC or HART programmer are used to set up the

operation parameters for the MicroFlow-i sensor. The output can either be as a

4-20mA current giving flow velocity or as a digital signal via a HART master.

The MicroFlow-i cable is a twisted pair with an overall cable screen. The

twisted pair are red and black, connect the red to +ve and the black to the -ve.

The screen should go to signal ground.

Important Information

All shipping cartons should be opened carefully. When using a box cutter,

do not plunge the blade deeply into the box, as it could potentially cut or

scratch equipment components. Carefully remove equipment from each

carton, checking it against the packing list before discarding any packing

material. If there is any shortage or obvious shipping damage to the

equipment, report it immediately to Pulsar Process Measurement Limited.

Important Information

If the equipment is installed or used in a manner not specified in this

manual, then the protection provided by the equipment may be impaired.

Page 8

Information specific to Hazardous Area Installation

(Reference European ATEX Directive 2014/34/EU)

The following instructions apply to equipment covered by certificate number CML

16ATEX2331X

1. The equipment may be used with flammable gases and vapours with apparatus

groups IIC, IIB, and IIA with temperature classes; T4 ambient temperature

range -20

o

C to +60

o

C.

2. The equipment is only certified for use in ambient temperatures in the range -

20

o

C to +60

o

C and should not be used outside this range.

3. Installation shall be carried out in accordance with the applicable code of

practise by suitably trained personnel.

4. Repair of the equipment shall be carried out in accordance with the acceptable

code of practise.

5. Certification as detailed in drawing number D-804-1200 (Ex ia).

6. If the equipment is likely to come into contact with aggressive substances, then

it is the responsibility of the user to take suitable precautions that prevent it

from being adversely affected, thus ensuring that the type of protection is not

compromised.

Aggressive Substances: e.g. such as acidic liquids or gases that may attack

metals or solvents that may affect polymeric materials.

Suitable precautions: e.g. regular checks as part of routine inspections or

establishing from the materials data sheet that it is resistant to specific

chemicals.

7. The certificate number has an ‘X’ suffix that indicates that the following

special condition of certification applies. In the case of the MicroFlow-i

sensor, due to the housing and labels being non-conductive plastic care needs

to be taken with regards to electrostatic charge. The equipment shall not be

installed if the conditions are conductive to the build-up of electrostatic charge.

Additionally, the equipment should only be cleaned with a damp cloth.

Limitations on use

1. The MicroFlow-i must be routinely inspected to avoid the build-up of dust

layers when installed in Zone 21 & Zone 22.

2. Electrostatic hazard – The MicroFlow-i must only be wiped with a damp or

antistatic cloth.

3. The outer enclosure is made from Valox357U, consider the performance of

this material with respect to chemicals that may be present in the hazardous

area.

Page 9

Hazardous Area Specific Power Supply and barrier Requirements

The MicroFlow-i operates from a DC supply of 10 – 28VDC and will typically

draw less than 22mA. When connecting sensor to the PC software with a HART

modem, it is recommended to use a supply of at least 18VDC.

The MicroFlow-i cable is a twisted pair with overall cable screen. The twisted

pair is red and black, connect the red to +ve and the black to -ve. The screen

should go to signal ground.

Typical wiring for the MicroFlow-i:

Important Information

In the case of the Ex ia version, the sensor must be powered from an

approved I.S. safety barrier or approved I.S. power supply with the

following limits:

Uo <= 28V, Io <= 162mA, Po <= 1.03W

V

24VDC

I.S. EARTH

PSU/SENSE

LOAD/SENSE

HAZARDOUS

AREA

SAFE AREA

SINGLE ZENNER BARRIER

Ex ia Version 4-20mA mode

SINGLE ZENNER BARRIER

CURENT SENSED IN +ve

Ui<=28V

Li<=162mA

Pi<=1.03W

+

-

Page 10

V

24VDC

I.S. EARTH

PSU/SENSE

LOAD/SENSE

HAZARDOUS

AREA

SAFE AREA

DUAL ZENNER BARRIER

Ex ia Version 4-20mA mode

DOUBLE ZENNER BARRIER

CURENT SENSED IN +ve

Ui<=28V

Li<=162mA

Pi<=1.03W

+

-

V

PSU/SENSE

HAZARDOUS

AREA

SAFE AREA

GALVANIC ISOLATOR

Ex ia Version 4-20mA mode

GALVANIC ISOLATOR

Ui<=28V

Li<=162mA

Pi<=1.03W

CURRENT

SENSE

+

-

Page 11

Location

When choosing a location to mount the bracket and MicroFlow-i, note the

following:

• For optimum readings, it is recommended that the MicroFlow-i should be

positioned at a 45° angle to the surface of the material being measured.

• The mounting surface must be vibration-free.

• The ambient temperature should be between -20ºC and 60ºC.

Mounting

For the best results it is highly recommended to use the MicroFlow-i angled

bracket, which is available from your Pulsar distributor, which will ensure that the

MicroFlow-i can be correctly installed. The bracket can be used if the MicroFlow-

i sensor is to be mounted on its own in a specific location or along with a Pulsar

dBi or dB level transducer. Please see ‘Angled Mounting Bracket’ for

dimensions of this bracket, please note that the drawing is not to scale.

‘Mounting sensor to a bracket’ illustrates how you would install the sensor to

one of Pulsar’s angled brackets.

The MicroFlow-i angled bracket should be mounted by marking and drilling the

holes suitable for fixing your screws/bolts (length to suit your application) and

then fixing the bracket in place.

Important Information

When installing the MicroFlow-i it is recommended that it is mounted at

least 1m away from moving persons or machinery.

All electronic products are susceptible to electrostatic shock,

so follow proper grounding procedures during installation.

Page 12

Angled Mounting Bracket

Part number: dBA0008MF

45

o

Side view

176mm

22mm

R20mm

12mm

100mm

90mm

130mm

Top view

100mm

Page 13

Important Information

Using a spirit level, ensure that the Mounting Bracket is level before

attaching the sensor to the bracket.

R20mm

4 off 12mm

14mm

100mm

60mm

20mm

100mm

60mm

26mm

Rear view

Page 14

MicroFlow-i sensor

The dimensions of the sensor body are shown below in Fig.1 and Fig.2:

BOTTOM

90 mm

1” BSP

78 mm

39mm

140 mm

To obtain the most accurate results, ensure the device is mounted at

a 45° angle to the surface being measured.

45°

Surface of measurement

73 mm

M i

Green ‘Dot’ to be

positioned on top of sensor.

Fig.1

Fig.2

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Pulsar MicroFlow-i User manual

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