DTFXL Installation and Operation Manual

DTFXL Installation and Operation Manual
MODEL TFXL
ULTRASONIC FLOW METER
Installation and Operating Instructions
1
2
TABLE OF CONTENTS
•
Quick Start Instructions
4
•
Introduction
6
•
Specifications
7
•
Symbol Explanations
7
•
Components and Terminology
8
•
Flow Meter Mounting Procedure
11
•
Electronic Connections
14
•
4-20mA Output Connections
16
•
Pulse Output Connections
18
•
Applying Power
20
•
Software Utility
22
•
Maintenance
37
•
Troubleshooting Guide
38
•
Warranty
39
•
Service Instructions
40
•
Drawings
41
•
Notes
42
3
QUICK-START INSTRUCTIONS
This manual contains detailed operating instructions for the TFXL instrument.
The following condensed instructions are provided to assist an experienced
operator in basic operation of the instrument. If the operator is unfamiliar with
this type of instrument, refer to the detailed explanations located on pages 1032.
A. Select a flow meter mounting location with at least 10 pipe
diameters upstream and 5 diameters downstream from the
meter with no flow disturbances (i.e. elbows, tees, needle
valves, etc.). See Figure 1.
Figure 1
B. On horizontal pipe, choose a flow meter mounting location
within approximately 45-degrees of the side of the pipe. See
Figure 2. Locate the flow meter so that the pipe will be
completely full of liquid when flow is occurring in the pipe.
Avoid mounting on vertical pipes where the flow is moving in
a downward direction.
NO
45°
Figure 2
YES
YES
45°
NO
FLOW METER MOUNTING ORIENTATION
4
C. Remove rust, scale and paint from the flow meter mounting
location. Clean to bare metal. Plastic pipes do not require
preparation.
D. Apply a thin, even layer of silicone grease to the two
transducer faces. Ensure that air bubbles are not present
over the two brown plastic sound-guides. Place the electronic
portion of the flow meter onto the prepared area of pipe,
making sure that the flow direction arrow is pointing in the
direction of flow. Place the clamp portion opposite the flow
meter and secure with the enclosed screws. Only moderate
torque is required on the screws—DO NOT OVER TIGHTEN
and DO NOT ROTATE the flow meter on the pipe once the
screws have been tightened.
E. Connect 11-30 Vdc to the power terminals within the TFXL
transmitter. Ensure that the power supply is capable of
sourcing a minimum of 0.25 Amps. Observe polarity.
F. Connect either the 4-20mA, pulse output or both outputs to
the data acquisition or monitoring system as required.
G. Apply power.
H. If the pipe is full of liquid, a flow rate reading will appear. If
the pipe is empty or partially empty, a ERROR 0010 will be
shown on the display. The error will clear when flow resumes
and the pipe fills up with water.
I.
Configuration changes and advanced troubleshooting can be
accomplished using the UltraLink software utility, a PC
computer and a PC interface cable.
5
INTRODUCTION AND OPERATING THEORY
TFXL transit time flow meters measure flow velocity by sending
pulses of ultrasound energy back and forth between two
piezoelectric devices. See Figure 3. The piezoelectric components
are located behind the oval-shaped, dark plastic sound guides that
are embedded in the flow sensor clamp. If the liquid inside of the
pipe is moving, the sound will travel faster when it is sent in the
direction of liquid flow than it will
Figure 3
when it is sent against the liquid
flow. The TFXL microprocessor
generates the pulses and
measures the elapsed time
required for the sound to travel
between the piezoelectric
TFXL
devices. Liquid velocity is
Sound Path
proportional to the difference in
time between upstream and downstream time measurements. The
TFXL compensates for gas content in the liquid and will remove
gaseous content from flow rate and totalizer readings. Outputs from
the flow meter include 4-20 mA analog, turbine frequency output/
pulse output.
Model Number Matrix
D T F X L
1
N N
Display Options
1)
2)
3)
4)
Output Options
ABS Enclosure-Blind (no display)
ABS Enclosure-Display (rate & total)
Polycarbonate Enclosure-Blind
Polycarbonate Enclosure-Display
1) 4-20 mA and Pulse
Connector Options
Pipe Size
A) ½” ANSI Pipe
B) ¾” ANSI Pipe
C) 1” ANSI Pipe
D) 1¼” ANSI Pipe
E) 1½” ANSI Pipe
F) 2” ANSI Pipe
G) ½” Copper
H) ¾” Copper
I) 1” Copper
J) 1¼” Copper
6
K)
L)
M)
N)
P)
Q)
R)
S)
X)
1½” Copper Pipe
2” Copper Pipe
½” Tubing
¾” Tubing
1” Tubing
1¼” Tubing
1½” Tubing
2” Tubing
Remote Transducer
(Not shown in this
manual)
N)
A)
C)
D)
½-inch Conduit Hole
Water-tight Cable Clamp
4-Pin Connector (male)
1/2 inch Flexible Conduit Connector
Accessories
Part Number
PC Cable w/Ultralink Software
90-240VAC Power Supply
D010-0204-001
D005-2502-005
SPECIFICATIONS/OPERATING CONDITIONS
For a complete table of specifications, see Series TFXL Data Sheet
Description
Specification
Input Voltage
11-30 VDC @ 0.25A
Flow Range Reference
Sch 40 ½” Pipe
Sch 40 ¾” Pipe
Sch 40 1” Pipe
Sch 40 1¼” Pipe
Sch 40 1½” Pipe
Sch 40 2” Pipe
0.1 to 40 FPS [0.03 to 12.4 MPS]
0.5 to 25 GPM [20 to 850 BPD]
1.0 to 55 GPM [40 to 1800 BPD]
2.0 to 100 GPM [80 to 3400 BPD]
4.0 to 150 GPM [170 to 5000 BPD]
5.0 to 220 GPM [170 to 7500 BPD]
8.0 to 400 GPM [275 to 13500 BPD]
Accuracy
±1% of rate above 1 FPS [0.3 MPS]
Environment
Indoor use
Ambient Temperature
General Purpose: 0 to +185°F [-20 to +85°C]
Hazardous Area: 0 to +105°F [-20 to +40°C
Altitude
Up to 2000 meters
Humidity
-20º to 31ºC; 80% max; decreasing linearly to
50% at 40ºC
Transient Overvoltages
According to installation category 1, in accordance with IEC 664
Pollution Degree
2 in accordance with IEC 664
Enclosure Material
ABS/Polycarbonate
Approvals
General Requirements: ANSI/ISA 82.02.01;
Hazardous Location: CSA C22.2 No. 213,
E79-15-95, ANSI/ISA 12.12.01
Class I Div 2, Groups C & D
(DTFXL3 & DTFXL4 models only)
4-20 mA Output
12-bit, sourcing, DC ground referenced
Pulse Output
Turbine Frequency Output/Pulse Output—
Switch Selectable, non-ground referenced AC/
Ground referenced square wave, 0-1,000 Hz,
100mVpp minimum/5VDC.
SYMBOL EXPLANATIONS
!
Caution—Refer to accompanying documents
7
FLOW METER COMPONENTS AND TERMINOLOGY
The pictures on the following two pages reference key
components and their respective terminology of the TFXL
flow meter. These terms are utilized throughout this
manual.
8
SOUND GUIDES
CLAMP
PC INTERFACE
CABLE
9
FLOW METER INSTALLATION
10
!
IMPORTANT NOTE:
Not following instructions properly may impair
safety of equipment and/or personnel.
!
IMPORTANT NOTE:
Must be operated by a power supply suitable
for the location.
!
IMPORTANT NOTE:
Do not connect or disconnect either power or
outputs unless the area is known to be nonhazardous.
!
IMPORTANT NOTE:
Do not connect the interface cable between a
TFXL and a personal computer unless the
area is known to be non-hazardous.
A. FLOW METER LOCATION
The first step in the installation process is the selection of an
optimum location for the flow measurement to be made. For this
to be done effectively, a basic knowledge of the piping system
and its plumbing is required.
An optimum location would be defined as a piping system that is
completely full of liquid when measurements are being taken and
has lengths of straight pipe such as those described in Figure 4.
The optimum straight pipe diameter recommendations apply to
pipes in both horizontal and vertical orientation.
Note: If adequate straight plumbing cannot be provided the
TFXL will operate repeatably, but will most likely not achieve
ideal accuracy.
Figure 4—Straight Pipe Recommendations
11
B. MOUNTING ORIENTATION ON THE PIPE
If the flow meter is applied to horizontal pipe, choose a mounting
position within approximately 45-degrees of 3 o’clock or 9 o’clock
on the pipe, assuming 12 o’clock to be to top of the pipe. These
positions provide optimum acoustic penetration into the moving
liquid. As illustrated in Figure 5, placement at the top or bottom
of the pipe can result in poor sound penetration due to air
pockets (on the top of the pipe) or sediment (at the bottom of the
pipe).
NO
45°
YES
YES
45°
Figure 5—
Mounting
Orientation on
Horizontal Pipes
NO
FLOW METER MOUNTING ORIENTATION
It is best to plumb and orient the piping system so that it will be
completely full of liquid at all times—whether the liquid is flowing
or not. Typically, by slightly sloping the pipe in the upward
direction or orienting the check valve judiciously within the piping
system this can be accomplished.
If the flow meter is applied to vertical pipe with flow moving in an
upward direction, radial orientation does not matter.
12
C. PIPE PREPARATION
Before the transducer face can be coupled to a pipe surface, an
area slightly larger than the flat surface of the transducer must be
cleaned to bare metal on the pipe. Remove all scale rust and
paint. Thoroughly dry and clean the mounting surface.
Note: For plastic pipes, such as PVC or PVDF, pipe
preparation is typically not required.
D. APPLYING ACCOUSTIC COUPLANT
To assure an acoustically conductive path between the
transducer face and the prepared pipe surface, a coupling
compound is employed. Enclosed with the TFXL flow meter is a
tube of silicone based grease. This grease is adequate for the
majority of installations. If an alternate grease is utilized, the
grease must be specified not to flow at the temperature of the
pipe surface or the ambient conditions.
Apply an even layer of grease, approximately 1/16” [1.5 mm]
thick to the entire inside surface of the transducer. See Figure 6.
Figure 6—
Applying
Acoustic Couplant
Apply silicone grease
to both surfaces
13
E. MOUNTING THE FLOW METER
Place the flow meter on the prepared area of the pipe, observing
the flow direction arrow on the side of the flow meter enclosure.
Place the flow meter clamp on the backside of the pipe and
secure with the two enclosed screws. Tighten only enough to
hold the flow meter in place and to squeeze some of the acoustic
couplant from the mounting faces. Over tightening may strip the
threads and is unnecessary for flow meter operation.
IMPORTANT NOTE: Do not rotate the TFXL flow meter on the
pipe once the screws have been tightened, as the acoustic
grease may be disturbed. If the grease layer between the sound
guides and the pipe obtains an air pocket, the flow meter signal
strength and, hence, operation may be compromised.
If upon power up the flow meter indicates ERROR 0010 and the
pipe is full of liquid, reapplication of the acoustic grease will be
necessary.
F. FIELD WIRING—GENERAL
The TFXL is equipped with a single conduit hole located in the
flow meter enclosure that should be suitable for most
installations. A sealed cord grip or conduit connection should be
utilized to retain the NEMA 3 integrity of the flow meter
enclosure. Failure to do so will void the manufacturers warranty
and can lead to product failure.
For hazardous area installation, see drawing at back of this manual (D091-1054-001). For non-hazardous location installations,
flow meter power and output signals can be carried by a single
cable with multiple conductors. Select a 20-24 AWG shielded
cable with an external jacket suitable for the installation environment and either 2, 4, or 6 conductors—dependent on the electronic output requirements.
Wiring methods and practices are to made in accordance with
the NEC—National Electric Code and/or other local ordnances
that may be in affect. Consult the local electrical inspector for
information regarding wiring regulations.
When making connections to the field wiring terminals inside of
the flow meter, strip back the wire insulation approximately 0.25
14
inches [6 mm]. Stripping back too little may cause the terminals
to clamp on the insulation and not make good contact. Stripping
back too much insulation may lead to a situation where the wires
could short together between adjacent terminals. Wires should
be secured in the Field Wiring Terminals using a screw torque of
between 0.5 and 0.6 Nm.
G. FIELD WIRING—POWER
!
IMPORTANT NOTE:
Must be operated by a power supply
suitable for the location.
!
IMPORTANT NOTE:
Do not connect or disconnect either power
or outputs unless the area is known to be
non-hazardous.
Power for the TFXL flow meter is obtained from a direct current
DC power source. The power source should be capable of
supplying between 11 and 30 Vdc at a minimum of 0.25 Amps or
250 milliamps. With the power from the DC power source
disabled or disconnected, connect the positive supply wire and
ground to the appropriate field wiring terminals in the flow meter.
See Figure 7. A wiring diagram decal is located on the inner
cover of the flow meter enclosure.
If the flow meter is only to be utilized as a flow rate indicator or
totalizer, no further wiring will be required. Skip to step J.
DC Ground
11-30 VDC
11 to 30 Vdc
Figure 7
DC Power Connection
15
H. CONNECTING THE 4-20 mA OUTPUT
The TFXL is equipped with a ground-referenced 4-20 mA
output—the output shares a common ground with the power
supply. The output transmits a continuous current output that is
proportional to liquid flow rate. The output was scaled at the
Dynasonics factory and the scaling information is recorded on
the label located on the side if the TFXL enclosure. To ensure
that the instrument or data acquisition system that is receiving
the 4-20 mA signal responds properly, it must be spanned
identically to the TFXL.
The 4-20 mA output is designed to source current across a loop
resistance that is typically located within a data acquisition
system or other receiving instrument. The maximum resistance
that the TFXL can accommodate is directly related to the DC
power source that is powering the flow meter and the 4-20 mA
loop. Chart 1 illustrates the range of load resistance that can be
used with a given power supply voltage. Ensure that the loop
load resistance is within the shaded region of the graph, or nonlinearity and transmitting errors will occur.
TFXL Loop Resistance
Loop Load: Ohm s
1400
1200
1000
800
600
Operate in the
Shaded Region
400
200
0
15
17
19
21
23
25
Supply: Vdc
Chart 1
4-20 mA Loop Load
16
27
29
The 4-20 mA output is polarized and since the output shares the
DC common with the power supply, reversing the connections
can cause a short circuit in the DC power circuit. Figure 8
shows a block diagram of how the 4-20 mA interfaces with the
receiving device.
TFXL Flow Meter
Receiving Device
Meter Power
11 to 30 Vdc
4-20 mA
4-20 mA Output
Loop Resistance
4-20 mA Ground
Power Supply
Ground
Figure 8
4-20 mA Block
Diagram
Connect the wires to the appropriate Field Wiring Terminals
within the TFXL enclosure. See Figure 9.
4-20 mA Ground
4-20 mA Output
Figure 9
4-20 mA Connections
17
I. CONNECTING THE PULSE OUTPUT
The TFXL is equipped with a circuit that outputs a pulse
waveform that varies proportionally with flow rate. The
quantity of pulses per unit volume of liquid is described by the
K-factor that is recorded on the side of the flow meter
enclosure. To ensure that accurate readings are being
recorded by the receiving instrument, the TFXL and the
receiving instrument must have identical K-factor values
programmed into them.
Two pulse output options are available with the TFXL:
♦
Turbine meter simulation—This option is utilized when a
receiving instrument is capable of interfacing directly with a
turbine flow meter’s magnetic pickup. The output is a
relatively low voltage AC signal that is not ground
referenced. The minimum AC amplitude is approximately
500 mV peak-to-peak. The TFXL is configured for turbine
simulation if the third character after the first dash number
in the model number is a “1”. Dip switch SW1 must be in
the off or open position.
♦
TTL pulse frequency—This option is utilized when a
receiving instrument requires that the pulse voltage level
be either of a higher potential and/or referenced to DC
ground. The output is a square-wave with a peak-to-peak
voltage swing of 5 volts. The TFXL is configured for TTL
pulse frequency if the third character after the first dash
number in the model number is a “2”. Dip switch SW1
must be in the on or closed position.
18
Turbine Meter Simulation Output Connection
Connection of the turbine meter simulation output is simply a
matter of connecting the two Field Wiring Terminals to the
turbine meter input terminals on the receiving instrument and
verifying that the K-factor listed on the side of the TFXL
enclosure is programmed into the receiving instrument. This
output is not referenced to DC ground and is not polarized, so
wiring polarity is not important. See Figure 10.
Turbine Output
TURBINE SIMULATION
Turbine Output
Figure 10
Turbine Meter
Simulation Connections
19
TTL Pulse Frequency Connection
Connection of the TTL pulse frequency output is a matter of
connecting the two Field Wiring Terminals to the frequency
input terminals on the receiving instrument and verifying that
the K-factor listed on the side of the TFXL enclosure is
programmed into the receiving instrument. This output is
referenced to DC ground and is polarized. Connect the TTL
Pulse plus (+) field terminal in the flow meter to the frequency
input on the receiving instrument. Connect the TTL Pulse
negative (-) field terminal to the frequency input negative or DC
common connection in the receiving instrument. See Figure
11.
TTL Output (+)
TTL Output (-)
Figure 11
TTL Pulse Output
Connections
J. APPLYING POWER TO THE TFXL
The TFXL flow meter requires a full pipe of liquid before a
successful startup can be completed. Do not attempt to make
adjustments or change configurations until a full pipe is verified.
1. Verify that all wiring is properly connected and routed as
described in Steps A though I of this manual.
2. Verify that the flow sensor is properly mounted and that the
acoustic grease is intact between the transducer faces and
the pipe.
3. Apply power. The display of the TFXL2 (with a display) will
display a display test where all segments will illuminate in
20
succession and then the software version will be displayed.
The meter will then enter RUN Mode. If the flow meter is a
TFXL1 (without a display) verify that one of the red LEDs
on the main printed circuit board is illuminated continuously
and that the other one begins to blink.
4. Upon entering RUN Mode, the TFXL2 will provide one of
the following responses:
♦
♦
The display may indicate ERROR 0010, which indicates
low signal strength. Low signal strength is caused by
one of the following:
⇒
an empty pipe (gas locked)
⇒
gas content in the liquid that exceeds 50%
⇒
inadequate acoustic grease between the flow
meter transducer and the pipe
⇒
a broken connection between a transducer and the
main circuit board—check wire terminations under
the display.
The display may indicate a flow rate.
⇒
If 0.000 is indicated, it means that the meter is
operating properly, but that the liquid is not moving.
⇒
A negative value would indicated that flow is
moving backwards—against the flow direction
arrow. A standard TFXL will not output flow signals
under this condition.
⇒
The flow meter indicates flow rate. This verifies
that signal strength is adequate and that the flow is
moving in the direction that the flow arrow signifies.
5. TFXL1 Responses—The TFXL1 is not equipped with a
display, so troubleshooting requires the use of a computer
and a PC interface cable. See pages 22-28.
21
ULTRALINK COMPUTER SOFTWARE
The UltraLink utility has been designed to provide the TFXL
user with a powerful and convenient way to configure,
troubleshoot and calibrate TFXL flow meters. Several
operating features can be setup or revised from factory set
values using the UltraLink utility.
Minimum PC Requirements
Computer type - PC, operating system: Windows 95/98/2000/
ME/XP, an RS232 serial communications port, hard disk and
CD-ROM drive.
Installation
1. Place the enclosed diskette or CD-ROM into the diskette or
PC CD-ROM drive.
2. If the CD drive is setup to automatically launch setup files
when it is closed, the installation Unwise® Installation
Wizard window will appear and prompt the installer. If the
program is initialized from a diskette or if the CD-ROM drive
is not setup for automatic launch, press the START/RUN
button, select ULSetup.exe from the diskette or the CDROM drive and click OK.
3. UlSetup will automatically extract and install on the hard
disk and place two short-cut icons on the desktop.
4. Most PCs will require a restart after a successful
installation.
22
UltraLink Initialization
!
IMPORTANT NOTE:
Do not connect the interface cable between
a TFXL and a personal computer unless the
area is known to be non-hazardous.
1. Connect the PC to the TFXL flowmeter by connecting the
PC interface cable between a COM port on the PC and the
PC Interface connection within the TFXL flow meter—See
Page 8 for location of the connector.
2. Double-click on the UltraLink icon. If it is the first time that
UltraLink has been run on the computer, UltraLink will test
Communications Port 1 for connection with the TFXL
meter. If Comm port 1 is already in use by another
application, UltraLink will prompt for another Comm port
number. Once UltraLink has established communications,
it will default to that setup upon program launch.
Data Trend Minutes
Data Trend Flow Rate
Figure 12
UltraLink Data Screen
23
3. The opening screen, shown in Figure 12, is called the Data
Screen. It contains a large data trend chart that can be
adjusted for both the X(time) and Y(flow rate) axis. This
screen also contains real-time information regarding flow
rate, totalizer accumulations, system signal strength and
diagnostic data. The indicator in the lower right-hand corner
will indicate communications status. If a red ERROR appears, click on the Communications button on the top bar.
Click on Initialize. Choose the appropriate COM port and
RS232. Proper communications are established when a
green OK is indicated in lower right-hand corner of the PC
display.
NOTE: Power on unit may need to be cycled in order to establish communication.
4. Click on the button labeled Configuration for updating flow
range, liquid, pipe and I/O operating information. The first
screen that appears after clicking the Configuration button
is the BASIC tab. See Figure 13.
5. BASIC TAB—See Figure 13
•
General Units allows selection of either English (U.S.) or
Metric units of measure. If measurements of the pipe are to
be entered in inches, select English. If pipe measurements
Figure 13 — Basic Tab
24
are to be entered in millimeters, select Metric. It is
recommended that if the General Units are altered from
those at instrument startup, that the Download button be
pressed on the lower right-hand portion of the screen and
that the TFXL have its power cycled.
•
Standard Configurations contains the most popular
applications for the TFXL. The TFXL has been constructed
and configured at the Dynasonics factory for a specific pipe
size. If the Standard Configuration does not match the pipe
schedule or material, select the proper configuration from
the drop down list. If the pipe schedule is not listed or if the
liquid is not water, select Other on the drop down list and
fill in the proper information on the setup screen.
TFXL flow meters are constructed and configured at the
Dynasonics factory for a single pipe size. Altering pipe
material and schedule is possible, but do not change pipe
size or the meter may not operate or may operate with a
large error.
6. FLOW Tab—See Figure 14
•
Flow Rate Units are selected from the pull down lists.
Select an appropriate rate unit and rate time-base from the
two lists.
•
Totalizer Units are selected from pull down lists. Select an
appropriate totalizer unit and totalizer exponent. The
totalizer exponents are in Scientific Notation and permit the
eight digit totalizer to accumulate very large values before
the totalizer “rolls over” and starts again at zero. Table 1
illustrates the Scientific Notation values and their respective
decimal equivalents.
•
MIN Flow is used by the TFXL to establish filter settings in
its operating system. Enter a flow rate that is the minimum
flow rate anticipated within the system. For uni-directional
systems, this value is typically zero. For bi-directional
systems this value is set to a negative number that is equal
to the maximum negative flow rate that is anticipated within
the system.
25
Figure 14
Flow Tab
TABLE 1—Totalizer Exponent Values
Exponent
Display Multiplier
E-1
X 1 (No multiplier)
E0
X 1 (No multiplier)
E1
X10
E2
X100
E3
X1,000
E4
X10,000
E5
X100,000
E6
X1,000,000
26
•
MAX Flow is used by the TFXL to establish filter settings in
its operating system.
Enter a flow rate that is the
maximum, positive flow rate anticipated within the system.
•
The Damping value is increased to intensify stability of the
flow rate readings. Damping values are decreased to allow
the flow meter to react faster to changing flow rates.
•
Low Flow Cutoff is entered as a percentage of MAX Flow
and influences how the flow meter will act at flows very
near zero. Generally, an entry of 1% provides for a stable
zero indication, while providing a 100:1 turndown ratio for
measurements.
•
Low Signal Cutoff is a relative value that should be
entered after a successful flow meter startup. For an initial
value, enter 5% [Signal Strength indications below 3% are
considered to be below the noise ceiling and should not be
indicative of a successful flow meter startup.] The entry has
three purposes: provides an error indication—Low Signal
Strength [Error 0010 on the TFXL display] when liquid
conditions in the pipe have changed to the point where flow
measurements may not be possible, warns if the pipe’s
liquid level has fallen below the level of the transducers,
and signals that something with the flow meter installation
or configuration may have changed. Examples would
include such things as the couplant used to mount the
transducer has become compromised, a cable has become
disconnected or a pipe size setting has been altered.
•
Substitute Flow is used to provide an indication and output
that signifies that an error exists with the flow meter or its
setup. It is set as a percentage between MIN Flow and
MAX Flow. In a uni-directional system this value is typically
set to zero, to indicate zero flow while in an error condition.
In a bi-directional system, the percentage can be set such
that zero is displayed in a error condition. To calculate out
where to set the Substitute Flow value in a bi-directional
system perform the following operation:
SUBSTITUTE FLOW =
100 -
100 x MAX Flow ____
MAX Flow - MIN Flow
27
•
Vol. Correction Sig. Str. Limit is a feature used to provide
volumetric compensation for gas bubbles that can be
present in liquid systems. The TFXL measures the velocity
of the liquid in the pipe and converts that velocity to volume
by multiplying the velocity by the cross-sectional area of the
pipe. If there are gas bubbles within the liquid, the gas is
displacing some of the liquid and errors can occur. When
Vol. Correction Sig. Str. Limit is set to zero, the
compensation function is not operational. To use the
feature, enter the maximum Signal Strength observed on
the flow meter after installation. The maximum signal
strength should occur with the pipe completely full of liquid
and the flow stopped. Signal Strength can be observed on
the UltraLink Data Screen. See Figure 12.
•
Entry of data in the Basic and Flow tabs are all that is
required to provide flow measurement functions to the flow
meter. If the user is not going to utilize input/output
functions, click on the Download button to transfer the
configuration to the TFXL instrument.
7. ADVANCED TAB—See Figure 15
The Advanced TAB contains several filter settings for the TFXL
flow meter. These filters can be adjusted to match response
times and data “smoothing” performance to a particular
application.
The factory settings are suitable for most
installations.
•
Time Domain Filter adjusts the number of raw data sets
(the wave forms viewed on the UltraLink Diagnostics
Screen) that are averaged together. Increasing this value
will provide greater damping of the data and slow the
response time of the flow meter.
This filter is not
adaptive—it is operational to the value set at all times.
•
Low Signal Cutoff is a duplicate entry from Page 27.
Adjusting this value adjusts the value on the Flow TAB.
•
Substitute Flow is a duplicate entry from Page 27.
Adjusting this value adjusts the value on the Flow TAB.
•
Short Pulse Duration is a function used on pipes larger
than 8 inches [200 mm]. Set this value to zero to disable
the function. Do not select the Auto Short Pulse box.
28
Figure 15
Advanced Tab
•
Flow Filter Damping establishes a maximum adaptive filter
value. Under stable flow conditions (flow that varies less than
the Flow Filter Hysteresis entry) this adaptive filter will
increase the number of successive flow readings that are
averaged together up to this maximum value. If flow changes
outside of the Flow Filter Hysteresis window, the Flow Filter
adapts by decreasing and allows the meter to react faster.
Increasing this value tends to provide smoother steady-state
flow readings and outputs.
•
Flow Filter Hysteresis creates a window around the average
flow measurement reading whereby if the flow varies within
that window, greater Flow Filter Damping will occur. The
filter also establishes a flow rate window where
measurements outside of the window are captured by the
Bad Data Rejection Filter. The value is entered as a
percentage of actual flow rate.
Example:
If the average flow rate is 100 GPM and the Flow Filter
Hysteresis is set to 5%, a filter window of 95-105 GPM is
established. Successive flow measurements that are
measured within that window are recorded and averaged
in accordance with the Flow Filter Damping setting.
29
Flow readings outside of the window are held up in
accordance with the Bad Data Rejection Filter.
•
Flow Filter MinHysteresis sets a minimum hysteresis
window that is invoked at low flow rates, where the “of rate”
Flow Filter Hysteresis is very small and ineffective. This
entry is entered in pico-seconds and is differential time. This
value is factory set and should not be altered without
consulting the Dynasonics technical services department.
•
Flow Filter Sensitivity allows configuration of how fast the
Flow Filter Damping will adapt in the positive direction.
Increasing this value allows greater damping to occur faster
than lower values. Adaptation in the negative direction is not
user adjustable.
•
Bad Data Rejection is a value related to the number of
successive readings that must be measured outside of the
Flow Filter Hysteresis and Flow Filter MinHysteresis windows
before the flow meter will use that flow value. Larger values
are entered into the Bad Data Rejection when measuring
liquids that contain gas bubbles, as the gas bubbles tend to
disturb the ultrasonic signals and cause more extraneous
flow readings to occur. Larger Bad Data Rejection values
tend to make the flow meter more sluggish to rapid changes
in actual flow rate.
8. Output TAB—See Figure 16
The entries made in the Output TAB establish range factors for
the 4-20 mA and frequency outputs on the meter. The 4-20mA
is calibrated at the Dynasonics factory and cannot be altered in
the field. However, the range of the output can be altered.
The unit has been factory calibrated to output 1KHz at the maximum flow rate. To change the frequency output at full scale, the
value for the “Flow @1KHz” must be altered. This may be required when installing the meter to replace a turbine style flow
meter. This example shows how to change the frequency output
to match that of a turbine style flow meter.
Max flow rate
Flow @1KHz
————————————— = ———————
Required frequency @max flow
1000Hz
30
Figure 16
Output Tab
1) To determine the frequency out of a turbine meter at maximum flow, convert the maximum flow rate to gallons/second,
then multiply by the nominal K-factor (pulses/gallon).
2) Calculate the flow rate that corresponds to 1000Hz. Multiply
the maximum flow rate times 1000Hz, then divide by the required frequency at maximum flow.
3) Enter this value in the “Flow @1KHz” field.
Example:
Maximum Flow Rate = 400 GPM
Desired K-factor = 52 pulses/gallon
400 gallons/minute = 6.67 gallons/second
6.67 gallons/second x 52 pulses/gallons = 346.67Hz
Therefore:
(400 GPM X 1000Hz) / 346.67Hz = 1153.83 GPM
Enter 1153.83 into the “Flow @1KHz” field.
31
To adjust the range of the 4-20mA output, simply enter the flow
rate that corresponds to 4mA output in the “Flow @0Hz” field.
Enter the flow rate that corresponds to 20mA output in the “Flow
@ 1KHz” field.
9. Display TAB—See Figure 17
The Display TAB permits configuration of the flow meter display.
Display
•
Select Flow to display flow rate only on the display.
•
Select Total to display the flow accumulator only on
the display.
•
Select Both to periodically toggle between rate and
accumulated flow displays.
Display Total
32
•
Select Net to display the accumulated difference
between the positive and negative totalizers. This
feature will subtract backflow (drain back) from the
totalizer value.
•
Select Positive to display only flows moving in the
forward direction.
•
Select Negative to display only flows moving in the
backwards direction.
Display Dwell Time
•
Enter a value between 1 and 10 seconds to establish
how long the flow meter will display flow rate, then
accumulated total, then rate and so on.
Figure 17
Display Tab
33
Setting Zero and Calibration
UltraLink contains a powerful multi-point calibration routine that
can be used to calibrate the TFXL flow meter to a primary
measuring standard in a particular installation. To initialize the
three step calibration routine, press the Calibration button located
on the top of the UltraLink Data Screen. The display shown in
Figure 18 will appear. The first step in the calibration process is
the selection of the engineering units that the calibration will be
performed with. Select the units and press the Next button at the
bottom of the window.
NOTE: Changes here will invalidate the current calibration.
Figure 18
Calibration Units
34
The second screen, Figure 19, establishes a baseline zero flow
rate measurement for the instrument. To zero the flow meter,
establish zero flow in the pipe (turn off all pumps and close a
dead-heading valve). Wait until the delta-time interval shown in
Figure 19 is stable (and typically very close to zero). Press the
Set button. Press the Next button when complete, then press
the Finish button on the Calibration Screen. If the Set button
was pressed, do not proceed with Flow Rate Calibration before
pressing the Finish button to save the Zero setting.
Wait for Stable Reading
Figure 19
Setting Zero Flow
35
Enter Actual Flow Rate
Figure 20
Flow Rate Calibration
The screen shown in Figure 20 allows multiple actual flow rates
to be run past the meter and the values recorded by the TFXL.
To calibrate a point, establish a stable, known flow rate (verified
by a real-time primary flow instrument), enter the actual flow rate
in the Figure 20 window and press the Set button. Repeat for as
many points as desired. Note: If only one point is to be used, it
is preferred that a flow rate as high as anticipated in normal
operation is used as the calibration point. If an erroneous data
point is collected, the point can be removed by pressing the Edit
button, selecting the bad point and selecting Remove.
!
WARNING:
Do not enter a zero point on this screen. A
zero will cause the TFXL to read no flow.
Press the Finish button when all points have been gathered.
36
Saving Meter Configuration on a PC
The complete configuration of the flow meter can be saved from
the Configuration screen. Select Save and name the file. This
file may be transferred to other flow meters or may be recalled
should the same pipe be surveyed again or multiple meters
programmed with the same information.
Printing Out a Flow Meter Configuration and Calibration
Report
Select File from the upper task bar and Print to print out a
calibration/configuration information sheet for the flow meter
installation.
Maintenance
No periodic maintenance is required for this product.
37
TROUBLESHOOTING GUIDE
Unit does not turn “ON”
when power is applied
•
Verify that voltage in the range of 1130 Vdc is present at the field terminals
•
If the voltage is present and neither
LED on the main printed circuit board
is illuminated, return the flow meter to
the Dynasonics factory for evaluation.
Unit reads zero flow when •
flow is actually running
•
Verify that the Maximum Flow Rate
value is not set to a very high value
and causing the Flow Cutoff percent
entry to drive the readings to zero.
Decrease Max Flow setting or
decrease Flow Cutoff percentage.
Verify that a zero was not entered on
page 3 of the calibration screen.
ERROR 0010 is Displayed •
on the Screen
The flow meter is not mounted onto
the pipe using an acoustic couplant.
•
The acoustic couplant is not uniform
between the flow meter transducer
and the pipe.
•
The liquid contains more than 50%
suspended gas bubbles.
•
The pipe is full of gas—gas locked.
Flow Meter Reads
Negative Flow Readings
•
Flow is running backwards when
compared to the FLOW DIRECTION
arrow located on the side of the flow
meter enclosure.
Flow Meter is Reading
Flow, But Output Is Not
Transmitting
•
Verify that one of the LEDs on the
main printed circuit board is flashing—
if not, return the flow meter to the
Dynasonics factory.
•
Verify connections and polarity of
wiring.
•
Test output with a milliamp meter,
oscilloscope or other test instrument
•
Verify that the output is configured for
RATE (Figure 16)
38
STATEMENT OF WARRANTY
Dynasonics Division, Racine Federated, Inc. (hereinafter “the
Company”) warrants its products under normal use and service to be
free of defects in material and workmanship for a period of twelve
(12) months from date of shipment (the “Warranty Period”).
This Warranty does not apply to defects caused by acts of God,
abuse, misuse, vandalism or improper installation or operation.
Further, this Warranty does not apply to products that have been
altered or improperly repaired by a party other than the Company or
its authorized agents.
To make claim under this Warranty, the Customer must notify the
Company in writing within the Warranty Period. The Company may
either repair or replace, at its option, any products found to be
defective. Return to the Customer of repaired items will be shipped
freight prepaid by the Company. Any repaired products shall be
warranted for the remainder of the unexpired Warranty Period plus
the amount of time the product was under repair, or for a period of 90
days, whichever is longer.
This Warranty is in lieu of all other warranties, express or implied,
including, without limitation, any implied warranty of merchantability or
fitness for a particular purpose. The sole and exclusive liability of the
Company hereunder shall be to repair or replace a defective product
or part, or if unable to do so, refund the purchase price of the product
at the Company’s option.
In all events, the Company shall not be liable for special, indirect,
incidental or consequential losses or damages of any kind or nature
whatsoever, even if the Company has been advised of the possibility
of such loss or damage. No waiver, alteration or modification of this
Warranty shall be binding against the Company unless in writing and
signed by an authorized executive officer of the Company.
39
SERVICE AND REPAIR
When returning equipment, it is necessary for you to contact our
service department at (800) 535-3569 or (262) 639-6770 to
obtain an RGA number for the authority and tracking of your
material and its proper inspection and return. All returns of
equipment must go to the following address:
Dynasonics
Attn: RGA#xxxx
8635 Washington Avenue
Racine, WI 53406
40
41
NOTES
42
43
8635 WASHINGTON AVENUE
RACINE, WI 53406
TOLL-FREE IN NORTH AMERICA.:
TEL: (800) 535-3569 FAX: (800) 732-8354
TEL: (262) 639-6770 FAX: (262) 639-2267
URL: www.dynasonics.com
44
TFXL O&M REV 03/07
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