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Compu-Flow™ Doppler Ultrasonic Flow Meter

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1. 3 After the update time is set the LCD screen will return to the rate and totalizer flow reading Hi Low Alarms To Set the High Low Alarms 1 Press the HI LO ALARM key Select Hi Lo or Both 2 Next enter the high limit alarm in your preselected engineering unit 3 Now enter the low limit alarm in your preselected engineering unit 4 After the high and low alarm parameters are set the LCD screen will return to the rate and totalizer flow reading Totalizer Reset To Reset the Totalizer While the Unit is Running 1 Press the TOT RESET key The totalizer reading will return to zero 2 The meter will begin taking totalizer readings from zero The rate reading remains unchanged 2 24 Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Normal Operation Once you have set up the Doppler flow meter for operation in your system you may virtually forget about it The system is maintenance free and does not require calibration since the readings do not drift over time In the event of a power interruption your parameters will be saved for up to 99 years in non volatile Flash Memory when you have activated the Secure On setting Portable Battery Operation Portable Units Only The LCD screen will flash LOW BAT every second when there is approximately one half hour of safe operation remaining Never totally discharge the gel cell battery The charger provided with the flow meter will recharge the
2. lt gt 33 78 mm heads JA Transducer head end view cable length cable length 5000 ft 12 ft 3 66 m 1524 m Figure 4 3 Dimensions of clamp on Doppler Specifications and Reference Information 4 7 Compu Flow Doppler Ultrasonic Flow Meter REFERENCE INFORMATION The following section provides reference information for setting up the Doppler flow meter in your system Standard Pipe Data on page 4 9 contains three tables to assist in pipe measurement Steel stainless steel and PVC on page 4 9 Cast iron pipe standard classes on page 4 10 Ductile iron pipe standard classes inside diameters on page 4 11 e Velocity Conversion Tables on page 4 12 contains three tables to assist in converting the default flow readings of meters per second or feet per second Velocity conversion table MPS to LPM and LPS on page 4 12 Velocity conversion table MPS to LPS and M3 Hr on page 4 12 Velocity conversion table FPS to GPM on page 4 13 Useful formulas for field calculations on page 4 14 4 8 Specifications and Reference Information Standard Pipe Data Table 4 4 Steel stainless steel and PVC Size Standard Schedules Inside Diameters Table 4 5 Cast iron pipe standard classes Nominal Class H Pipe Size Inches 54 56 66 53 96 57 10 54 00 57 80 54 00
3. 2 16 Installation and Operation Table 2 3 LED conditions and indications Compu Flow Doppler Ultrasonic Flow Meter Echo Yellow Flashing On llluminated steady Alarm High or Low Red On llluminated steady First Time Operation Power is not available to the unit If you have tried to power up your unit and this light is off see Troubleshooting the Unit on page 3 1 Is power available to unit Proceed with normal operation Consult Troubleshooting the Unit on page 3 1 Transducer signal is weak Consult Troubleshooting the Unit on page 3 1 Transducer signal is marginal Proceed with normal operation Transducer signal is normal Proceed with normal operation No alarm condition exists Your system is running at high or low alarm flow Adjust your flow levels or or your alarm settings consult Troubleshooting the Unit on page 3 1 Once you have successfully completed installation of the Doppler flow meter you are ready to configure your unit for operation using the front panel in the electronics enclosure Installation and Operation 2 17 2 18 Attention If your display flashes LOW BAT at any time during setup or programming consult Status of Unit Power on page 3 2 for troubleshooting information Note If you are switching from AC DC power to battery power and your battery may need charging To Operate Your Doppler Flow Meter for the First Time
4. 58 40 53 94 60 62 80 60 02 63 40 60 06 64 20 60 20 64 82 60 06 72 75 34 72 10 76 00 72 10 76 88 72 10 4 11 Compu Flow Doppler Ultrasonic Flow Meter Table 4 6 Ductile iron pipe standard classes inside diameters Outside Cement Lining Note 1 Diameter Standard Double Thickness Thickness Note 1 Reduce I D by dimension shown these figures also apply to C l pipe Specifications and Reference Information Compu Flow Doppler Ultrasonic Flow Meter Velocity Conversion Tables Table 4 7 Maketi conversion table MPS to LPM and LPS size 0 3 0 6 1 0 1 5 2 0 2 5 3 0 5 0 7 0 RET i ey a ac ry es a TT CTS KDS KTS B feo is ass as fso foe vas e or w fin fess fan ror o2 ne ese oo fss 20 ses 1190 1885 2827 s770 ariz fos 157_ 220 300 1272 2544 4241 6361 8482 10602 212 353 495 400 2262 4524 7539 11309 15078 18848 377 628 880 Table 4 8 Velocity conversion table MPS to LPS and M3 Hr size 0 3 0 6 1 0 1 5 2 0 255 3 0 5 0 7 0 CT EO NO Trrs Taro ES Esi Re o as io as aoe fse ror si as n9 100 ss 100 1767 2651 s534 418 sre sso Specifications and Reference Information 4 12 4 1 Table 4 9 Velocity conversion table FPS to GPM Nominal pipe Velocity in Feet Per Second fps size inches gt See E CO COR O E Ean 5 2 10 5 105 157 E
5. When the Doppler transducers are mounted on a horizontal pipe care should be taken to mount them in the 7 o clock to 10 o clock positions with the top of the pipe the side furthest from the Earth corresponding to the 12 o clock position If the transducer is mounted on the bottom of the pipe settling particles may attenuate the signals by introducing an additional sonic barrier Also air may agglomerate at the top of the pipe Since the ultrasonic frequencies used will not penetrate air efficiently the signal will be heavily attenuated so that the meter will not be able to render accurate results Horizontal Pipe Mounting The recommended placement of the Doppler transducers is a horizontal section of piping Figure 2 2 provides horizontal mounting examples Transducers Correct Incorrect Flow gt Ie K Side View i d F XQ Flow gt 2718 Figure 2 2 Horizontal pipe mounting examples Vertical Pipe Mounting Measuring flow at a vertical pipe run is not recommended If measuring flow in a vertical run can not be avoided we recommend you measure at a point where the direction of flow through the pipe is upwards to help ensure the pipe will remain full at all times Figure 2 3 However measuring flow even with an upward vertical pipe run will not address all the problems associated with this configuration Correct Incorrect Incorrect a Cc 1 Flow Side View i J Transducers Flow Flow
6. gt y 7 oo A XY Me O 2717 Figure 2 3 Vertical pipe mounting examples Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Compu Flow Transit Time Ultrasonic Flow Meters In the event the flow to be measured does not contain the minimum required particle size and or parts per million count and the transducer will not read you may want to consider the Compu Flow Transit Time ultrasonic flow meter for your application Contact your Compu Flow sales representative with your application questions See Compu Flow Systems Support on page 4 15 for contact information INSTALLATION PROCEDURES After you have performed the pre install check and determined that the Doppler flow meter will work for your application follow these steps to install your meter To Install the Compu Flow Doppler Ultrasonic Flow Meter 1 Mount and connect the transducers 2 Mount and connect power to the electronics enclosure see page 2 13 3 Turn on power to the electronics enclosure using the motherboard rear panel switch on the front panel for portable and follow display panel for meter set up see Operation on page 2 15 for more information on configuring your meter for operation Mounting and Connecting the Transducers The clamp on transducers are NEMA 6 rated and fully submersible For continuous submersion secure sensors to pipe with approved epoxy To Mount the Clamp On Transducers to th
7. measurable fluid 4 1 vertical pipe mounting 2 8 voltage selector switch 2 13 W warranty authorized returns 3 13 filing a claim 3 12 returning units 3 13 statement 3 13 web site 4 15 wedge material crystal 4 3 Notes
8. 1 Complete all the steps in Before Installing the Unit on page 2 1 2 Complete all the steps in Installation Procedures on page 2 9 3 Turn on power and observe the display panel LCD The display will show the model name and number of the unit 4 Following the prompts presented by the display panel LCD and making your entries using the keypad configure your unit for operation for English or Metric The LCD screen displays SELECT RATE Select the unit of measure for rate display All rate selections may be displayed in seconds minutes hours days Time elements 1 Sec 2 Min 3 Hr 4 Day Table 2 4 Rate selection English s A TT sop eee S e m areas OOOO O O C TC A oo pm eniemi S If you select FPS the flow meter will automatically begin measuring flow in feet per second If you select keys 1 through 6 the LCD screen will ask that you enter your pipe ID in inches If you select keys 7 through 9 the LCD screen will ask that you enter your pipe ID in millimeters See Standard Pipe Data on page 4 9 to estimate your pipe ID Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter After you enter your rate time element the LCD screen will then display SELECT TOTALIZER Select the unit of measure for totalizer display Table 2 5 Totalizer selection 5 BL Barrels44gah 6 ir Liters After you enter your totalizer selection the LCD screen will then display
9. adaptor 115 VAC 50 60 Hz 10 input delivering 12 VDC 500 mA output 8 W typical Analog output signal 4 20 mA at 24VDC 1200 Q maximum load resistance internally Carbon fused active amp passive modes Specifications and Reference Information 4 3 Compu Flow Doppler Ultrasonic Flow Meter Table 4 3 Functional specifications Continued RS232 output RS232 via DBO amp USB ports 9300 baud rate Terminal Emulation Software HyperTerminal for Windows ZTerm for Mac USB board mount or remote cable Power failure backup Allows the electronics assembly to retain all parameter information and current totalizer value for 99 yrs Standard interface LCD display 2 line 16 characters per line high resolution backlit LED indicators Yellow Echo signal received Red High alarm or low alarm activated Green Power available Keypad 12 keys tactile feedback Note Keypad lockout via front panel keyboard see To Save Your Programmed Flow Reading Settings on page 2 21 and figure 2 10 Display panel Rate selection totalizer selection K factor selection analog output low flow cutoff update time damping high low alarm fps or mps selection totalizer reset etc Output setting function 4 20mA output scaling from keypad in selected engineering units Alarm setting function High and low alarms set points entered in engineering units Rate indication 4 digit LCD velocity or volume user selectable English un
10. engineering unit 2 After the output level has been set the LCD screen will return to the rate and totalizer flow reading Low Flow Cutoff To Set the Low Flow Cutoff 1 Press the FPS 1 or MPS 7 key to obtain the current reading in feet per second or meters per second Press the key again to return to the flow reading parameters previously shown 2 Press the LFC 6 key Enter the cutoff in feet per second or meters per second If you enter a parameter that is too high the LCD screen will display the maximum allowable cutoff setting and then will return to the prompt for cutoff in feet per second Installation and Operation 2 23 3 After the low flow cutoff is set the LCD screen will return to the rate and totalizer flow reading Meters per Second Power Clear To Read Meters Per Second 1 Press the MPS 7 key The LCD will show the flow reading in meters per second on the upper line of the LCD screen replacing the rate parameter previously on the screen The totalizer reading remains the same parameter 2 To return to the previous flow rate reading press the MPS 7 key again Update Time To Set Update Time 1 Press the UT 9 key To enter the selection screen 1 1sec 2 10sec 3 auto Auto mode will update every second when the velocity change is gt 5 When the flow stabilizes to lt 5 change the update time resets to a 10 second running average 2 Enter the update time in 1 second 10 seconds or Auto
11. of Flow Reading Erratic on page 3 8 Yes If the flow reading appears too low or too high troubleshoot using Table 3 4 below 3 6 Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter Table 3 4 Status of flow reading troubleshooting checklist High or low Question Possible Cause Has the meter been properly programmed Has the meter been set up with sufficient straight run piping Are the transducers mounted properly on the pipe Has the pipe been cleaned down to bare metal before transducer placement Is this an old pipe Is the inside wall coated or Contaminated with build up Is the pipe diameter correct or has the pipe been expanded or flattened Does your Doppler show a flow reading that varies from the reading on your alternative measurement device Troubleshooting and Customer Support Corrective Action Using the display panel keypad and the LCD screen verify that the rate selection and totalizer selection are set correctly See To Operate Your Doppler Flow Meter for the First Time on page 2 18 Make sure that the transducers are properly placed for use with your Doppler flow meter See Straight Run Requirements on page 2 5 for more information on correct transducer placement in your system Make sure that the transducers have been mounted on a clean smooth pipe using the required coupling grease Ensure that the transducers are secu
12. on page 2 11 Are the transducers mounted Make sure that the transducers have been mounted on a properly on the pipe clean smooth pipe using the required coupling grease Ensure that the transducers are securely mounted flush with the pipe side by side See To Mount the Clamp On Transducers to the Pipe on page 2 9 Is there fluid in the pipe Is the Verify that the pipe is full of fluid and that the fluid is pipe full flowing above the minimum velocity specifications See Functional Specifications on page 4 3 for flow velocity specifications Have the transducers been Make sure that the transducers have been mounted in an placed in the recommended acceptable location location on the pipe Consider straight run requirements see Straight Run Requirements on page 2 5 for more information Make sure the transducers are mounted flush with the pipe facing the same direction See To Mount the Clamp On Transducers to the Pipe on page 2 9 for more details 3 4 Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter Table 3 2 Status of Echo light troubleshooting checklist Echo off Question Possible Cause Corrective Action Has the pipe been cleaned Make sure the pipe was cleaned with sandpaper prior to down to bare metal before transducer placement Also check to make sure the type of transducer placement Is this an pipe in your application i
13. particles 1 3 sonic 1 3 repeatability 4 2 returning units for repair 3 12 S sales contact information 4 15 sensitivity flow 4 1 setting parameters advanced 2 22 analog output 2 23 hi low alarms 2 24 K factor 2 22 low flow cutoff 2 23 read meters per second 2 24 sample setting 2 22 totalizer reset 2 24 update time 2 24 sonic reflectors 1 3 specifications flow sensitivity 4 1 fluid conditions 4 1 functional 4 3 input power requirements 4 3 performance 4 1 physical 4 2 pipe conditions 4 1 velocity of fluid 4 1 stainless steel pipe data 4 9 standard pipe data 4 9 steel pipe data 4 9 straight run examples 2 7 requirements 2 5 support customer support 4 15 system components 1 2 overview 1 1 T theory of operation 1 2 tools for installation 2 2 totalizer indication units of measure 4 5 reset setting 2 24 selection 2 19 transducers cable length 4 3 cabling 1 2 connecting to electronics enclosure 2 11 dimensions 4 2 housing material 4 2 mounting 2 9 placement guidelines 2 7 positioning guidelines 2 6 unstable readings 2 20 weight 4 2 troubleshooting additional information 3 9 Compu Flow Doppler Ultrasonic Flow Meter checklist 3 1 ECHO light flashing 3 5 erratic flow rate 3 8 flow rate high or low 3 6 no ECHO light 3 3 no power to unit 3 2 troubleshooting table 3 2 unstable readings 2 20 U unpacking the system 2 1 update time setting 2 24 V velocity conversion tables 4 12 velocity
14. power 2 13 DC input power 2 14 electronics board 2 12 input power 2 13 conversion tables velocity 4 12 correction factor 2 22 crystal wedge material 4 3 customer support 3 11 D DC power requirements 4 3 troubleshooting 3 2 dimensions 4 8 electronics enclosure 4 2 electronics enclosure illustration 4 6 Compu Flow Doppler Ultrasonic Flow Meter Index transducers 4 2 Doppler flow meter features 1 1 ductile iron pipe data 4 11 E ECHO LED flashing 3 5 off 3 3 unstable readings 2 20 electronics enclosure 4 2 ambient temperature range 4 2 board connections 2 12 dimensions 4 2 overview 1 2 weight 4 2 email customer support 4 15 F features 1 1 first time operation 2 17 flow requirements assessing profile 2 5 flow sensitivity specification 4 1 fluid conditions specifications 4 1 front panel 2 17 functional specifications 4 3 H hi low alarms setting 2 24 high flow rate reading troubleshooting 3 6 horizontal pipe mounting 2 8 2 9 illustrations clamp on transducer dimensions 4 8 electrical connections 2 12 electronics enclosure 4 6 electronics enclosure mounting 2 13 indications rate 4 4 totalizer 4 5 input power requirements 4 3 inside diameters pipes 4 9 installation horizontal pipe mounting 2 8 pre installation procedures 2 2 procedures 2 9 straight run requirements 2 5 tools required 2 2 vertical pipe mounting 2 8 introduction 1 1 K K factor setting 2 22 keypad lockout sw
15. the installation process To Perform the Doppler flow meter Pre installation Check 1 Mount the transducers side by side between 7 o clock and 10 o clock on the pipe see Mounting and Connecting the Transducers on page 2 9 for more information 2 If not already connected connect the transducers to the electronics enclosure see Mounting and Connecting the Transducers on page 2 9 3 Connect AC or DC power to the flow meter see Mounting and Connecting Power to the Electronics Enclosure on page 2 13 4 Turn on the power using the switch on the display panel 5 After the electronics enclosure powers up and the front display panel lights up press soft key 1 to select FPS feet per second o Estimate your expected flow rate and compare it to the reading in feet per second on the display panel 2 2 Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter If the reading on the display appears to be accurate continue to the next step If you do not see a flow reading on the LCD screen at all or if the flow reading is much lower or higher than expected try repositioning the transducers If this does not help see Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 and consult Troubleshooting the Unit on page 3 1 7 Observe the yellow Echo LED on the display panel If the Echo LED is on steady and the flow rea
16. 0 F to 200 F 40 C to 93 C temperature range 500 F Option with Heat Sinks Velocity range 0 1 fps to 50 fps 0 04 mps to 15 25 mps Flow sensitivity 0 01 fps 0 04 mps Piping conditions Pipe diameter range Velocity amp Volumetric indication 0 5 to 999 13 mm to 9999 mm diameter Including but not limited to carbon steel stainless steel ductile iron cast iron FRP PVC PVDF PE 100 fiberglass teflon and most concrete lined or coated pipes Pipe lining Including but not limited to tar epoxy mortar rubber teflon PVC and glass Specifications and Reference Information 4 1 Table 4 1 Performance specifications Continued Measurement Accuracy Accuracy Typically 1 to 3 of full scale NIST Cent Available See Table 2 2 on page 2 6 for straight run requirements and specific accuracies Note Accuracy is a function of flow profile 0 5 of full scale Repeatability 0 1 of full scale PHYSICAL SPECIFICATIONS Table 4 2 Physical specifications Specification Electronics Enclosure Dimensions 7 75 X 4 25 X 2 50 inch Note See Figure 4 1 on page 4 6 for dimensional illustrations 4 Ibs C6D_8 Ibs C6P Materials Enclosure Molded ABS FR plastic Meets Nema type 4 4X 12 amp 13 Meets IP 66 Meets UL 94 V 01 6 Flammability rating Light gray RAL 7035 Environmental rating NEMA 4X IP65 Ambient temperature 13 F to 132 F 25 C to 55 C range Ambient humidi
17. 20 Installation and Operation 2 19 IF YOU EXPERIENCE UNSTABLE READINGS A steady display and solid illuminated Echo lamp indicates a good signal An erratic display and or a flashing Echo lamp indicates a poor signal Reposition the transducer heads until readings are steady and the Echo lamp is illuminated solid or select another position to mount the sensors Possible reasons for poor signals are e Partially full pipe Extreme aeration Insufficient suspended particles minimum particle size and concentration are 40 microns at 35 ppm and greater than 0 2 density difference Any fluids with particle size concentration less than the requirement listed above should be measured with a transit time flow meter Extreme turbulence Interference from electric motors or motor controllers If your meter readings do not stabilize see Troubleshooting the Unit on page 3 1 and Echo LED Light Considerations on page 3 9 for further assistance Advanced Configuration Options The display panel keypad has a secondary menu for advanced configuration options the keypad toggle menu You may want to use this menu to set 4 20mA analog output set up bar graph select HI LO alarm set points and configure batch control To access the secondary menu press appropriate key until the display changes To exit press the key again Figure 2 10 on page 2 21 provides a visual representation of the toggle menu e Table 2 6 lists t
18. Enter Pipe ID If you select keys 1 through 5 the LCD screen will ask that you enter your pipe ID in inches If you select keys 6 through 7 the LCD screen will ask that you enter your pipe ID in millimeters See Standard Pipe Data on page 4 9 to estimate your pipe ID Your Doppler flow meter is now configured to measure the flow parameters you have set After you set the flow reading parameters you need for your system you can secure these settings so they are saved in the event of power loss to the electronics enclosure Note To clear the rate and totalizer parameters you have set select 0 reset or switch the power off using the on off switch on the display panel Until settings are saved using Key 8 Secure On the security switch turning off power clears all previously set parameters When you turn on power again the LCD screen will prompt you to restart programming To Save Your Programmed Flow Reading Settings Using the Secure Function 1 Complete setting the flow reading parameters see First Time Operation on page 2 17 to set parameters 2 Press and hold key 8 for 5 seconds until Secure On appears on the LCD display Note If you need to change your programming press and hold key 8 Secure until Secure Off appears on the LCD display If you wish to further customize your flow meter system for operation in your process continue on to Advanced Configuration Options on page 2
19. See To Connect Input Power to the Electronics Enclosure on page 2 13 and Figure 2 8 on page 2 14 for the location of the switch Is there a LOW BAT flashing in If you are switching from BATTERY DC power to AC the display power and the module does not match your incoming power you may see a LOW BAT warning in the front panel display Select the correct incoming power level 12VDC and this warning should disappear If you are using the battery DC power to power the unit your battery may be low See Portable Battery Operation Portable Units Only on page 2 25 Is there a blown input power All fuses are carbon pile auto resettable guick trip fuses fuse that require no service STATUS OF ECHO LED On or OFF Is the Echo LED on steady Yes If the Echo LED is on steady or is flashing continue on to Status of Echo LED Flashing on page 3 5 Note If the Echo LED is off troubleshoot using Table 3 2 below Note See Additional Troubleshooting Information on page 3 9 for additional information about the Echo LED indicator Troubleshooting and Customer Support 3 3 Table 3 2 Status of Echo light troubleshooting checklist Echo off Question Possible Cause Corrective Action Are the transducers properly Make sure the transducer wires are connected correctly to connected to the processor the processor board board See To Connect the Transducers to the Electronics Enclosure
20. There are only a few circumstances that might merit adjusting the default K Factor setting on your Doppler flow meter Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter If the flow rate readings are not as expected these are factors that may be contributing 1 The meter is measuring flow with a high level of turbulence which may be caused by too short of a straight run for proper transducer placement 2 The liquid being measured has high viscosity is too thick or contains sound absorbing materials for example homogenous drilling mud or roofing tar If either of these conditions exist and your flow readings appear inaccurate then you may need to adjust the K Factor correction factor to get the desired flow rate Note The K Factor is linear Increase the K Factor to lower the flow rate or decrease the K Factor to increase the flow rate by the percentage that the flow is off Again for most applications the default K Factor setting ensures the most accurate reading by your Doppler flow meter Consult Troubleshooting the Unit on page 3 1 to troubleshoot inaccurate flow readings before making this adjustment To Set the K Factor 1 Press the K FACTOR 3 key 2 Enter Hz FPS If you want to keep the default setting enter 090 3 The LCD screen will return to the rate and totalizer flow reading Analog Output To Set the Analog Output 1 Press the MA 4 key Enter the full scale preselected
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22. battery fully in approximately 8 hours You may leave the battery on the charger overnight since prolonged charging periods will not damage the battery The POWER switch on the flow meter front panel must be in the OFF position in order for the internal battery to charge If the internal battery has been deep discharged it will be necessary to charge the battery for a minimum of 30 minutes before the front panel POWER switch is turned ON Installation and Operation 2 25 2 26 Compu Flow portable display Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Chapter 3 Troubleshooting and Customer Support The following sections provide useful information for troubleshooting your Compu Flow Doppler ultrasonic flow meter and process as related to your flow meter Product warranty return policy and customer support information appears near theend of this chapter TROUBLESHOOTING THE UNIT If you suspect your Doppler flow meter is malfunctioning please perform the following checks before calling Compu Flow Systems Support 1 Make sure that the unit is properly connected to input power See Mounting and Connecting Power to the Electronics Enclosure on page 2 13 Also see Status of Unit Power on page 3 2 2 Make sure that the transducers are properly connected to the electronics enclosure and that they are properly mounted See Mounting and Connecting the Transducers on pag
23. ch a wide fluctuation in liquid characteristics Extreme cases may require the use of both a transit time flow meter as well as a Doppler flow meter For example river water may require a meter which is capable of measuring both clean and dirty liquids Depending on conditions the river may vary considerably in suspended solid content In this situation contact your rep and ask about the Compu Flow Hybrid System PROCESS CHANGES Changes in the process may cause the meter to cease proper operation For example a Doppler meter had been operating satisfactorily for a long time in a certain installation and then suddenly it stopped functioning The problem was eventually traced to a particle filter that had recently been placed before the transducers effectively eliminating the reflectors from the stream Process changes in the other direction are also possible The meter responds to bubbles up to a point but if the liquid starts to foam there may be too many air bubbles to allow the ultrasonic beam to adequately penetrate the flow stream This may cause the Doppler flow meter to produce erroneous flow readings Similarly a sludge may become too dense to allow proper penetration Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Assessing Pipe Material and Condition Doppler flow meter performance is best maximized by using piping that is sonically conductive The Doppler flow meter assumes that the path by which th
24. ch to 999 inches inside diameter The Doppler flow meter is well suited for flow measurement applications such as sludges slurries aerated liquids sewage dredges pulp plastics and activated sludges The Doppler flow meter features clamp on transducers and a rugged NEMA 4X enclosure and is a long term maintenance free solution for your high solid flow measurement requirements Features of the Compu Flow Doppler Ultrasonic Flow Meter The Doppler flow meter features AC or DC operation Isolated Regulated Module Smart LCD screen featuring high resolution 32 character 2 line alphanumeric providing rate and totalization simultaneously in Metric and English units Splash proof NEMA 4X case protected from moister and caustic chemicals Easy configuration for set up and operation with on screen prompting quick scrolling menus display panel keypad and color coded LEDs Non invasive Submersible Clamp on transducers RS232 via DB9 PORT 9600 Baud Batch Control Isolated Output for Dry Contact Relay Separate High and Low Alarm outputs for Dry Contact Relay with LED status Data Logger 1 32 GB memory USB Flash Drive data transfer Wireless Signal option from Sensors and or Receiver sensor singular Optional signal cable lengths up to 5000 ft No Tuning required e High accuracy even in turbulent flows Wide pipe diameter range 0 50 999 inches Maintenance free modular construction simplifying fi
25. ct to misuse negligence or accident or that have been altered or repaired by anyone other than the seller or the seller s duly authorized agent This warranty is expressly made in lieu of any and all other warranties express or implied unless otherwise agreed to in writing The warranty period is 18 months after the date the goods are shipped or 12 months after installed for service In all cases the seller has sole responsibility for determining the cause and nature of the failure and the seller s determination with regard thereto shall be final Troubleshooting and Customer Support 3 13 Compu Flow Doppler Ultrasonic Flow Meter Gm GE G5 Gi Sooo GS OS GS A Troubleshooting and Customer Support 3 14 Compu Flow Doppler Ultrasonic Flow Meter Chapter 4 Specifications and Reference Information The following sections provide specification and accessory information for the Compu Flow Doppler ultrasonic flow meter as well as useful pipe and conversion data PERFORMANCE SPECIFICATIONS Table 4 1 Performance specifications Fluid conditions Measured fluid Homogenous liquids with Newtonian flow profiles sludges slurries sewage wastewater and other fluids containing suspended particles State of flow Axis symmetric flow in pipe filled with fluid Fluid type Liquids containing suspended particles of at least 35 ppm at 40 microns at 0 2 density of undissolved solids or air bubbles Measurable fluid 4
26. dequately insuring the unit Authorized Returns Before returning any product for repair and or adjustment call Compu Flow Systems Support and discuss the problem with them Be prepared to provide the model number and serial number of the unit as well as the reason for the proposed return This consultation call will allow Compu Flow System Support to determine if the unit must actually be returned for the problem to be corrected Such technical consultation is always available at no charge Units that are returned without authorization from Compu Flow Systems Support and that are found to be functional will not be covered under the warranty see warranty statement below That is you will have to pay a retest and calibration fee and all shipping charges Warranty Statement The seller makes no express or implied warranty that the goods are merchantable or fit for any particular purpose except as specifically stated in printed Compu Flow specifications The sole responsibility of the Seller shall be that it will manufacture the goods in accordance with its published specifications and that the goods will be free from defects in material and workmanship The seller s liability for breach of an expressed warranty shall exist only if the goods are installed started in operation and tested in conformity with the seller s published instructions The seller expressly excludes any warranty whatsoever concerning goods that have been subje
27. ding appears to be accurate your Doppler flow meter is ready for operation See Normal Operation on page 2 25 to configure the flow meter for operation with your system If the Echo LED is flashing or not illuminated see Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 and consult Troubleshooting the Unit on page 3 1 DETERMINING IF YOUR PROCESS OR INSTALLATION IS RIGHT FOR A DOPPLER FLOW METER Accurate operation of a Doppler flow meter depends upon your application and installation site Doppler flow meters offer many advantages over other flow meter models when flows are viscous turbulence is minimal and piping materials are appropriate When conditions are adverse to Compu Flow Doppler ultrasonic flow meter operation the Compu Flow Transit Time flow meter may offer an excellent alternative Contact Compu Flow Systems Support on page 4 15 for more information about this transit time meter To determine which flow meter is appropriate for your process and specific installation consider the following The presence of reflective particles in the flow The pipe material and condition of pipe housing the flow The flow profile meaning that you are able to provide acceptable straight run requirements to ensure more accurate readings The following sections discuss these considerations Installation and Operation 2 3 Assessing Particles or Ai
28. e 2 9 3 Ensure input power is on and power is within specifications See Functional Specifications on page 4 3 for power requirements 4 Is the Echo LED light flashing or off See Status of Echo LED Flashing on page 3 5 or Status of Echo LED Off on page 3 3 for troubleshooting information 5 Does your Doppler flow meter flow rate reading appear too low too high or erratic but your Echo light is on See Status of Flow Reading High or Low on page 3 6 or Status of Flow Reading Erratic on page 3 8 for troubleshooting information Also consult Echo LED Light Considerations on page 3 9 for more information about the Echo light 6 Have you performed the above checks and you still have no flow reading If you have performed all the above checks and followed troubleshooting procedures in the Flow Meter Troubleshooting Tables on page 3 2 and your unit is still malfunctioning contact Compu Flow Systems Support on page 3 11 Troubleshooting and Customer Support 3 1 Flow Meter Troubleshooting Tables Follow these tables in sequential order for the best use Answer the heading question in bold at the beginning of each section before continuing on to the next section STATUS OF UNIT POWER Is the unit receiving power Is the green Power light on Yes If the unit is receiving power continue on to Status of Echo LED Off on page 3 3 No If the unit
29. e Pipe 1 Ensure the pipe surface is clean Use sandpaper to remove all paint and scale from the pipe surface if necessary 2 Apply sonic gel to the transducer lenses For best results in most weather conditions and heat use Dow Corninge High Vacuum Grease or the supplied Novagard grease G661 N Attention Always apply sonic gel to the transducer lenses before placing on the pipe The sonic gel must be used to transmit the energy from the transducer crystals through the pipe wall and into the flow to be measured Installation and Operation 2 9 3 Place the transducers side by side between 7 o clock and 10 o clock on the pipe as shown in Figure 2 4 Place the transducers flush to the pipe facing the same direction See Figure 2 5 for an example Note Be careful with transducer placement Air bubbles near the top of the pipe or sediment on the bottom of the pipe can hinder successful flow readings Place the transducers as shown in Figure 2 4 Electronics enclosure Transd 12 o clock position Cross section of pipe with mounted transducers 6 o clock position Figure 2 4 Clamp on transducer placement 4 Use the supplied chain and bungee cord to strap the transducers in place securing them tightly to the pipe Figure 2 5 provides an example of two properly mounted clamp on transducers 5 Small pipes below 2 do not permit side by side mounting Pipes 2 1 diameter mount sensors 90 apar
30. e to defects in material and workmanship for 18 months after they are shipped from the factory or 12 months in service please see warranty statement below for details In order to claim shipping or handling damage you must inspect the delivered goods and report such damage to us within 30 days of your receipt of the goods Please note that failing to report any damage within this period is the same as acknowledging that the goods were received undamaged For a warranty claim to be valid it must Be made within the applicable warranty period Include the product serial number and a full description of the circumstances Have been assigned a return material authorization RMA number see below by Compu Flow Systems Support All warranty work will be performed at an authorized Compu Flow service center see list of contacts at the beginning of this chapter You are responsible for obtaining authorization see details below to return any defective units prepaying the freight 3 12 Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter costs and ensuring that the units are returned to an authorized Compu Flow service center Compu Flow will return the repaired unit freight prepaid to you by second day air shipment or ground carrier for local returns repair parts and labor will be provided free of charge Whoever ships the unit either you or CF is responsible for properly packaging and a
31. e ultrasonic beam enters the pipe and returns to the transducer is ultrasonically homogenous which means that you must use your flow meter with pipes with non porous smooth pipe walls Concrete lined pipes old or crystallized cast iron pipes hand wrapped fiberglass pipe and old piping with air inclusions do not exhibit the required homogeneity Avoid using the Doppler flow meter for flow measurement on these pipes unless proper operation is proven by the manufacturer through demonstration Contact Compu Flow Systems Support on page 4 15 for more information on an alternate meter if your application is not suitable for the Doppler flow meter Note No clamp on meter will operate properly if the liner is not solidly attached to the pipe wall because of the probability of an air gap Pipe Vibration Moderate pipe vibration does not usually adversely affect the Doppler flow meter since the vibration of the piping is at a significantly lower frequency than the ultrasonic beam used to measure flow However in situations where the transducer signal strength is low because of fluid piping or other environmental factors measurement accuracy may be further decreased by pipe vibration In these situations your display panel may register flow when there is none due to the vibration If you can not bracket the pipe to reduce vibration you may be able to rectify the problem by relocating the transducer to a pipe location with less vibration As
32. ears correct the Doppler is the best meter for your application There may be an inadequate level of reflective materials in the flow to ensure correct flow readings Move the transducers until you get a steady light or replace your Doppler meter with a transit time meter There may be an inadequate level of reflective materials in the flow to ensure correct flow readings Replace your Doppler meter with a transit time meter Clamp on transducers may not be able to provide accurate flow readings in your application 3 9 SUSPENDED PARTICLE TEST FOR DOPPLER SIGNALS Particles in a liquid may be either in suspension or dissolved Dissolved particles will not reflect Doppler signals because there is no physical dimension nor density difference to return the sound to the receiver Suspended particles generally will return the Doppler signal if there are enough present and their size is sufficient to meet the requirements of the transmitted frequency Materials such as wood pulp algae moss onion skins fine sand or other materials that do not meet the 35 ppm 40 micron 0 2 density difference minimum requirements will not reflect sounds Instead the signal simply passes through this material as if it were water Usually these materials have a specific gravity of 0 999 or 1 001 This is almost exactly the same as water itself and therefore will neither rise nor fall in the solution These materials will move about almost anyw
33. eeseneeeeeeneeeeenaeeeeee 3 9 Echo LED Light Considerations L L kasai sanis inne saiko 3 9 Suspended Particle Test For Doppler Signals c eeeeee 3 10 Compu Flow Systems Support sskssteiniais inst i ia i se a 4 15 Returning Units for Repair cecceeseeeeeesccceeeeseceeeeseneceeneneceenansenenensenensanenenseneneesanes 3 12 Wanay erate peereereretereperererereer aa a go a a ae ra a mercer 3 12 Authorized Returns 0 0 0 kia aaa aaaa a aaaa aa aeaaa a aaa aa aaa aaa aaa aaa aaa 3 13 Warranty Statement L sc caste ai sis God is iiin a SRi 3 13 Chapter 4 Specifications and Reference Information Performance Specifications E E E ee eee A 4 1 Physical Specifications sssi sias baisiai i i i ss eee 4 2 Functional Specifications vsuietusasessoss Iris uostais i a ao o i it a 4 3 Dimensional Drawings S 4 6 Electronics Enclosure Dimensions kaka aa aaa aa kaa aaa kaka aaa 4 6 Clamp On Transducer and Digitizer Dimensions cece eee eee e 4 8 Reference Information cccesceeceesneeeeeeneceeeneenensaeenesanecneneneesenaneeseseaeenenanseneeeanens 4 8 Standard Pipe Data eee ee ar sias ree eet ne mene Es ce a a a eer i 4 9 Velocity Conversion Tables Assis sinias sans ss sis iii ia i az 4 12 vi Chapter 1 Introduction and Theory of Operation INTRODUCTION The Compu Flow Doppler ultrasonic flow meter provides an accurate and easy to use measuring system for high solid fluid flow through pipes 0 50 in
34. eld service Introduction and Theory of Operation 1 1 Components of the Compu Flow Doppler Ultrasonic Flow Meter System A typical Doppler flow meter system is comprised of an electronics enclosure with a display panel and two clamp on transducers ELECTRONICS ENCLOSURE AND DISPLAY PANEL The display panel in the electronics enclosure features an easy to read LCD screen a keypad and LEDs to interface with the flow meter The Doppler flow meter can be wall mounted for permanent installation or a portable option is also available TRANSDUCERS AND CABLING The Doppler flow meter is configured with clamp on transducers When installed the sensors gather fluid flow data through a pipe and send this information to the system electronics The electronics then convert transmit and display the received data The clamp on transducers allow you to install the Doppler flow meter without shutting down flow and are ideal for smooth clean pipe walls The transducers are NEMA 6 rated and fully submersible Contact Compu Flow Systems Support on page 4 15 for information on configuring your meter for continuous submersion The standard cable length between the electronics enclosure and the transducers is 25 feet Custom cable lengths up to 5000 feet are available Wireless Sensor to Display where applicable See Compu Flow Systems Support on page 4 15 for contact and ordering information THEORY OF OPERATION 1 2 The Compu Fl
35. f pr m ind A 1 R pi Compu Flow Doppler Ultrasonic Flow Meter COPYRIGHT This manual and the information herein is the proprietary property of Compu Flow No Part of this manual may be reproduced or copied without the express written permission Any unauthorized use of this manual or its contents is strictly prohibited Copyright January 2010 All rights reserved DISCLAIMER AND LIMITATION OF LIABILITY The information contained in this manual is subject to change without prior notice Compu Flow makes no warranty of any kind whatsoever either expressed or implied with respect to the information contained herein Compu Flow shall not be liable for damages of whatever kind as a result of the reliance on or use of the information contained herein INTERPRETING THE MANUAL The following sections explain the document type conventions and the danger warning and caution boxes that provide information about the specific levels of hazard seriousness TYPE CONVENTIONS Please note the following type conventions Pin and signal names appear in capitalized italics POWER ON New terms appear in italicized text Unit labels switches indicators and so on appear in boldface text ECHO Commands 162 and command names set point appear in boldface lowercase text CAUTION AND ATTENTION BOXES This symbol represents important notes concerning potential harm to people this unit or N associa
36. f needed connect the DC power cable wires to the 12 VDC PWR section of the processor board using Figure 2 6 and Figure 2 8 as a guide Use a Nema 4Xcable gland and a cable backing nut to securely fasten the input power cable to the electronics enclosure 2 14 Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Move the switch to the on position See Figure 2 8 for the switch location 3 Continue on to First Time Operation on page 2 17 OPERATION The following sections describe the display panel in the electronics enclosure first time operation and normal operation of your Doppler flow meter Display Panel The display panel in the Doppler flow meter electronics enclosure provides an interface for monitoring and controlling the flow meter The high resolution 2 line 16 digits per line display shows operating information and configuration menu prompts You may use the 12 key tactile feedback keypad to make selections when prompted by the configuration menu prompts th C F 8 9 ME Installation and Operation 2 15 Compu Flow Doppler Ultrasonic Flow Meter LED INDICATORS If your Doppler flow meter is working properly with your system when you power up the flow meter you should see the green Power LED and the yellow Echo LED illuminate If this is not the case consult the table 2 3 and see Troubleshooting the Unit on page 3 1 Figure 2 9 Display panel
37. he advanced configuration options accessible from the display panel keypad 2 20 Installation and Operation High Low alarm Compu Flow Doppler Ultrasonic Flow Meter Bar graph BAR K FACTOR FPS PWR clear 2 K factor reset 1 to 256 GRAPH VEL 5 6 Low flow cutoff 4 20 mA maximum 2 5 fps SIM SECURE UPDATE Set update time MPS PWR clear 1sec 10sec auto avg Totalizer reset Figure 2 10 Display unit keypad Table 2 6 Keyboard Toggle Menu Key Selection Functional Specifications Feet per second clear pwr 2 Bargraph Analog 16pt bar graph n a with batch 3 KFactor Select K factor while running 6 Low Flow Cut Off Set low flow cut off maximum 2 5 fps E a 8 Secure Secure parameters On Off 9 Update Time Set update time 0 to 99 sec Reset Recall Pipe ID Recall pipe ID configure batch system reset az HI LO ALARM Set up HI LO limit alarms reset cursor a TOT RESET Reset totalizer while running reset cursor Installation and Operation 2 21 2 22 BEFORE SETTING ADVANCED PARAMETERS The default setting for secondary keyboard functions is feet per second fps or meters per second mps if the flow meter is configured for metric units Once the flow meter is operational and you wish to activate the analog bar graph 4 20 mA output batch control high or low alarm or low flow cut off options consult advanced parameter setting Sample Parameter Setting You have a
38. here in the solution controlled only by the motion of the liquid itself Be aware that slow flows carry heavy particulate may allow the reflectors to settle out even though you have flow This generally does not occur on flows over 1 fps A simple test requires a clear glass container and a sample of the liquid you wish to measure with the Doppler sensors Stir the liquid and watch it for about 3 to 5 minutes If the visible particles in suspension neither rise nor fall they are most likely the same specific gravity as water and may not reflect Doppler signals If these particles are the same specific gravity as water but do have a membrane or shell around them that is at least 0 2 density difference than the water molecules than the signals should be strong enough for the Doppler to report correct flow readings If the particles rise or fall in the solution they should provide adequate sonic reflection as long as they meet the specified quantity size and density requirements for the Doppler see Specifications and Reference Information on page 4 1 for more information Rising particles Floating particles Falling particles Figure 3 1 Suspended particle test Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter Full Function Field Test System Integrity Figure 3 2 Bucket test In figure 3 2 above the Compu Flow portable Doppler system is being field tested With the sensors connec
39. ht run requirements from any disturbance of flow are 10 diameters upstream and 20 diameters downstream Introduction and Theory of Operation 1 3 APPLICATIONS Some of the materials the Compu Flow Doppler ultrasonic flow meter is well suited for measuring include Ag water Abrasives Asphalts Concrete Dredge flows Drilling mud Large contaminates Extremely viscous substances Grout Hazardous wastes Municipal sludges and wastes Paper pulp Rendering products Reservoirs Rivers and streams Runoffs Sludges Slurries Suspended solids Most all liquids containing suspended particles or air bubbles 1 4 Introduction and Theory of Operation Chapter 2 Installation and Operation BEFORE INSTALLING THE UNIT Before installing your Compu Flow Doppler ultrasonic flow meter follow the steps listed below 1 See Unpacking the Unit on page 2 1 2 Make sure you have performed the Pre installation Procedures and Checks on page 2 2 3 Determine if your process installation is compatible with the requirements of Doppler flow meter See Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 4 Proceed to Installation Procedures on page 2 9 Unpacking the Unit Unpack and inspect the unit carefully looking for obvious physical damage If no damage is apparent locate and save all documentation and then c
40. is not receiving power troubleshoot using Table 3 1 below Table 3 1 Status of unit power troubleshooting checklist Question Possible Cause Corrective Action Is AC or BATTERY DC Ensure that input power is properly connected power properly connected to the processor board See To Connect Input Power to the Electronics Enclosure on page 2 13 Is the battery charged if you are If you are using DC battery power make sure your battery using BATTERY DC power is charged and that the power cables are securely or is the AC power module connected plugged in if you are using AC power If you are using AC power make sure your AC power is correct and the module is plugged in See To Connect Input Power to the Electronics Enclosure on page 2 13 and Portable Battery Operation Portable Units Only on page 2 25 for more information Is the power switch on the Front Ensure the power switch on the rear display panel is in the display panel on Portable on position Is the power switch on the rear See Display panel on page 2 16 for the location of this Display panel on Dedicated switch 3 2 Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter Table 3 1 Status of unit power troubleshooting checklist Question Possible Cause Corrective Action Is the power switch set correctly Make sure the switch is in the on position BATTERY 12 VDC input battery power
41. itch 4 4 B LCD display rate selection 2 18 totalizer selection 2 19 LEDs ALARM 2 16 ECHO 2 20 indications 2 16 POWER 2 16 specifications 4 4 lockout switch keypad 4 4 low flow cutoff setting 2 23 specifications 4 5 low flow rate reading troubleshooting 3 6 M main components 1 2 measurement accuracy 4 2 meters per second reading 2 24 mounting horizontal pipe 2 8 vertical pipe 2 8 N normal operation 2 25 O operating temperature range electronics enclosure 4 2 transducers 4 3 operation first time 2 17 normal 2 25 portable battery 2 25 output signals alarms 4 4 analog output 4 3 P performance specifications 4 1 physical specifications 4 2 pipe conditions specifications 4 1 pipe data 4 9 cast iron pipe 4 10 ductile iron pipe 4 11 PVC 4 9 stainless steel 4 9 steel 4 9 pipe material assessing condition 2 5 portable battery operation 2 25 power adaptor 4 3 power failure backup 4 4 power requirements AC 4 3 DC 4 3 procedures connecting power to electronics enclosure 2 13 connecting transducers to electronics enclosure 2 11 first time operation 2 18 mounting the electronics enclosure 2 13 mounting transducers 2 6 mounting transducers to the pipe 2 9 process determining application requirements 2 3 product introduction 1 1 PVC pipe data 4 9 R rate indications units of measure 4 4 rate selection 2 18 reference pipe data 4 9 velocity conversion tables 4 12 reflectors air bubbles and
42. its feet per second fps gallons Gal cubic feet CF and million gallons MG SMHD Metric units meters M liters LT and cubic meters CM SMHD Note Gallons refers to U S gallons BBL 44gallon SMHD Seconds Minutes Hours Days Totalizer indication 12 digit LCD English units gallons cubic feet acre feet barrels and millions of gallons Metric units liters and cubic meters Note Gallons refers to U S gallons BBL 44gallon Update time damping Entered from keypad 1sec 10sec Auto Running Avg 75 1sec Low flow cutoff default is 90 Hz correction factor for version 6 0 Doppler sensor Totalizer reset Key function 0 Key fuction Resume Reset D a 8 Key function 2 key function Setup 16 point Bar Graph tracks 4 20mA output n a with Batch 4 4 Specifications and Reference Information Specifications and Reference Information Compu Flow Doppler Ultrasonic Flow Meter 4 5 Compu Flow Doppler Ultrasonic Flow Meter DIMENSIONS Electronics Enclosure Dimensions Inches 7 87L X 4 33W X 2 36D mm 160 130 60 Figure 4 1 Front view of the electronics enclosure C6 display panel 4 6 Specifications and Reference Information Compu Flow Doppler Ultrasonic Flow Meter Figure 4 2 Bottom view of the electronics enclosure Wall mount dimensions 179 X 54 mm CLT V 5 6 Clamp On Transducer Dimensions 113 0 mm 123 2 mm 4 45 aera e 485 Transducer
43. lectronics Enclosure The fixed Doppler flow meter model electronics enclosure is wall mounted for permanent installation The portable meter model does not need to be mounted To Mount the Fixed Electronics Enclosure 1 Locate the four mounting holes on the base of the electronics enclosure Figure 2 7 Wall mounting of the electronics enclosure 2 Using the reinforced holes in the enclosure base securely mount the electronics enclosure to the wall To Connect Input Power to the Electronics Enclosure Note You can either use AC power or DC battery power to operate your Doppler flow meter 1 If you are using AC power wall module only If not already connected supply input power to the electronics enclosure by routing the power cable through the appropriate enclosure base opening see Bottom view of the electronics enclosure on page 4 7 Use a Nema 4Xcable gland and a cable backing nut to securely fasten the input power cable to the electronics enclosure Plug AC Power Module into the appropriate outlet Installation and Operation 2 13 Bch Low o ALARMS O Figure 2 8 Another view of processor board connections 2 If you are using DC battery power If not already connected supply input power to the electronics enclosure by routing the power cable through the appropriate opening see Bottom view of the electronics enclosure on page 4 7 I
44. leshooting Information ECHO LED LIGHT CONSIDERATIONS Compu Flow Doppler ultrasonic flow meters require suspended solids or air bubbles to operate The strict requirement is that sonic discontinuities exist If the speed of sound in the solids and liquids are identical then there are no sonic discontinuities which act as ultrasonic reflectors and most Doppler flow meters will not function Some bacterial slurries and chemical slurries may have suspended solids but cannot be measured with a Doppler flow meter for this reason The behavior of the Echo light on the display panel of your Doppler flow meter electronics enclosure may provide indication as to whether the Doppler flow meter is the correct one for your application If after troubleshooting your unit the Echo light does not remain on steady while you are operating your unit you may need to consider changing the meter to a transit time meter See Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 and Troubleshooting the Unit on page 3 1 if you are having trouble maintaining a steady Echo light during operation of your flow meter Table 3 6 Echo light scenarios Echo light Flow rate Applicable Meter Solution condition reading Illuminated steady Flashing Yes Doppler flow meter or Transit time meter Doppler flow meter Pf o O Troubleshooting and Customer Support If the Echo light is on and the flow reading app
45. m ef fe fa fete fete ET LE EES EEE ESS ps fs to fio fzo o ast si ver oon 1882 iso Ps e faz 46 oe 70 fos 128 ise 2 a ee 4S p p ee r e 422 e i266 iess feno 232 sss 4220 esso 8wo 2 2791 3489 4187 5582 6978 10466 13955 Fase oor Tazas am Tos ese sens eoe ora soe Tarsi ee a k RE ss fas s470_ 10940 1609 are7a_ 27849 s2sio asse sasos s2047 109896 o M esi A aus _ avean_fassro ias ss se cama ones soos 4192 8395 16769 25154 33538 41923 50307 67076 83845 125768 167690 Compu Flow Sales TEKSCO USA 1920 Loop 499 107 Harlingen TX 78550 Phone USA 1 800 649 5331 Tel 956 421 4585 Fax 956 421 4586 Email sales advancedflow net support advancedflow net Website www compuflow com Compu Flow Doppler Ultrasonic Flow Meter Compu Flow SYSTEMS SUPPORT The complete Compu Flow product line for liquid includes turbine electromagnetic and clamp on ultrasonic flow products For more information refer to the Compu Flow website http Awww compuflow com Specifications and Reference Information 4 15 OPTIONS Data Logger Option 1 32 GB Flash drive Built in or remote systems Extremely user friendly keypad setup data storage and transfer On board or remote cable USB terminal access Wireless Option Wireless option for receivers and transmitters Short and long range Global signal transmission via internet Wireles
46. ng Power to the Electronics Enclosure 4 2 13 IDBTALUO sce is ia i i ii i a i A i alae i eee 2 15 Display PANG iai e TS 2 15 LEDS Pe S 2 16 First Time DOT AUION sine setae asis esa asis an i es o ass aa 2 17 If You Experience Unstable Readings ceeeeeesseeeeeeeeeeeenees 2 20 Advanced Configuration Options ccc nana knisa iii i i i sense 2 20 Primary and Secondary Keyboard Functions cccceeeeeeeeeeeeeeeeeeeeeeeeeeees 2 21 Before Setting Advanced Parameters ccesscesseeeeeeeeeeseeeeeeeees 2 22 Setting Advanced Parameters csscsesceesseetsseeeesaeeeseeesseeeeeaees 2 22 Normal Operation scares esis sno ge ace oaks fas ede eee ceee et dade dbdouteeacnatetmotatanaes 2 25 Portable Battery Operation Portable Units Only c cccececeeeeeeteeeeeees 2 25 Chapter 3 Troubleshooting and Customer Support Troubleshooting the Unit ws ccncnniesedwiieccdauin needs i ai ina ein 3 1 Flow Meter Troubleshooting Tables cecseeeeseeeeeeeneeeeeeeeeeeeeeeeeeseeeeeea 3 2 Status of Unit POWeT Aciiticssee Asesinas 3 2 Status of Echo LED Off ore en ee nee Peery ee ias rer Tere eter 3 3 Status of Echo LED Flashing sssssnkinusisni i sns iii iii 3 5 Status of Flow Reading High or LOW eseceeeeteeeeeteeeeeeeteeee aes 3 6 Status of Flow Reading Erratic Las knssnikanakans sns sai ce 3 8 Additional Troubleshooting Information 0 ccccecseeeeeeeee
47. ontinue with the following procedures If you see signs of shipping damage contact your supplier for product support see Compu Flow Systems Support on page 4 15 for contact information Save the shipping container for submitting necessary claims to the carrier INCLUDED EQUIPMENT Table 2 1 lists the standard items that ship with Compu Flow Doppler Ultrasonic Flow Meter systems Installation and Operation 2 1 Table 2 1 Items shipped with the flow meter system Dedicated unit C6D model Portable unit C6P model Electronics enclosure Electronics enclosure Two transducers and a 25 cable std e Two transducers and a 25 cable std Sensor Strap Kit Sensor Strap Kit e Sonic coupling gel Sonic coupling gel User manual User manual e 12 V 1 2 AH battery Smart 110 VAC battery charger Auxiliary transport handle Padded Field transport case Custom lengths up to 5000 min 25 adder TOOLS REQUIRED FOR INSTALLATION Sandpaper to clean the pipe surface to bare pipe Tape measure to measure pipe size Pre installation Procedures and Checks Before you install your Doppler flow meter there is a pre install check you should perform to ensure that this is the appropriate meter to use for your application If you encounter any difficulties during the pre installation procedures see Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 before proceeding with
48. ow Doppler ultrasonic flow meter measures flow velocity by sensing signals from reflective materials within a liquid and measuring the frequency shift due to the motion of these reflective materials The Doppler effect states that the received frequency is a function of the transmitted frequency and the relative motion between transmitter and the receiver The classic example of the Doppler effect is the train whistle increasing in pitch to the listener at the station as the train approaches then decreasing in pitch as the train moves away from the station To the person riding on the train the pitch remains the same The increasing pitch is due to phase front compression and the decreasing pitch is due to phase front expansion The Doppler flow meter uses this effect to measure the velocity of a liquid through a pipe wall Introduction and Theory of Operation Compu Flow Doppler Ultrasonic Flow Meter Sonic Reflectors The Doppler flow meter requires sonic reflectors in order to operate These reflectors may consist of particles or air bubbles within the flow to be measured Your readings may vary slightly with changes in concentration or size of these reflectors as well as the pipe condition and size Note Glycerin is the only known industrial liquid today that is not sonically conductive The Doppler flow meter uses two similar transducers to sense flow in a pipe These transducers are mounted on the outside of a pipe This configu
49. pe runs especially downhill pipe runs Table 2 2 Transducer distance from turbulence and reading accuracy 20 diameters 10 diameters 1 to 3 of full scale 10 diameters 3 to 5 of full scale Accuracy is dependant on flow profile and is related to the percentage of sound reflectors and their size variation and distribution Figure 2 1 provides straight run examples Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter D Nominal pipe diameter 20xD 10xD T 15xD 5xD lt 9xD fen BMD a lt 9xD jae 30xD 5xD SIDE VIEW 30xD 5xD eS 2716 Figure 2 1 Straight run examples TRANSDUCER PLACEMENT You should always avoid measuring liquids in vertical downward flows with any flow meter In the case of Doppler flow meters vertical downward flows cause erroneous readings by introducing air bubbles Excessive air bubbles attenuate the measurement signal by hampering penetration of the ultrasonic beam into the fluid Bubbles will tend to rise against the flow and since the Doppler flow meter is capable of totalizing in both directions this will cause erroneous flow measurements as the meter factors in the backward flow of the bubbles Additionally in vertical flows it may be difficult to keep the pipe full allowing pockets of air into the pipe This will drastically reduce the transducer s ability to penetrate the flow and produce a readable signal Installation and Operation 2 7
50. r Bubbles 2 4 The ultrasonic beam from the transducer is transmitted through the pipe wall into the liquid The particles air bubbles suspended in the liquid have to be large enough to act as reflectors to return the signal back to the transducer so that a measurement may be taken It is important to understand that the ultrasonic beam from the Doppler flow meter does not penetrate air very well A few bubbles will not affect flow meter performance but too many bubbles may cause the meter to malfunction See Suspended Particle Test For Doppler Signals on page 3 10 for information on how to assess the particulate content of your flow Note At a frequency of roughly 650 kHz the minimum particle which can be sensed is 40 microns 35 parts per million ppm and at least 0 2 density difference from the liquid N Attention The flow to be measured must always have a sufficient number of sonic reflectors of ample size in order to provide reflection of the transmitted sound If the reflectors do not have sufficient density difference they will neither rise nor fall in the solution but remain suspended The specific gravity will also affect the ability of a particle to reflect sound A good example of a reflector is a sand particle or an air bubble A poor example is algae or onion skins FLUCTUATIONS IN FLOW CONTENT Wide fluctuations in flow suspended solids content can only be handled by an instrument capable of monitoring su
51. ration presents no obstruction to flow and will not cause associated pressure drops Accuracy The Doppler flow meter output signal is linear as opposed to square root which means that accuracy is not a function of flow rate Within certain application limits the meter is ideal because it is not affected by changes of pressure within the process nor by changes of viscosity temperature specific gravity sound velocity or electrical conductivity Summary The Doppler flow meter is a non intrusive flow meter system which operates by sensing the frequency shifts of signals reflected from particles air bubbles or density differences within a liquid producing a linear signal proportional to the flow of the liquid within the pipe No pipe section is required to install the meter The meter is not affected by changes in temperature viscosity specific gravity or the speed of sound within the liquid The liquid does not have to be electronically conductive e A minimum particle concentration of 35 ppm 40 micron of suspended solids or air bubbles is required The reflector must have at least a 0 2 density difference than the liquid medium e For accurate volumetric measurement the pipe must be full at all times The transducers are normally coupled to the outer pipe wall with greaser sonic gel or epoxy In order to obtain accurate measurements adequate upstream and downstream pipe runs are required Recommended straig
52. rely mounted side by side See To Mount the Clamp On Transducers to the Pipe on page 2 9 Make sure the pipe was cleaned with sandpaper prior to transducer placement Also check to make sure the type of pipe in your application is suitable for use with a Doppler flow meter See Assessing Pipe Material and Condition on page 2 5 1 Pipe wall build up reducing Ida Incorrect ID due to erroneous data collapsed pipe or swollen pipe due to pressure Verify that pumps are operating and that valve settings are correct Compare the velocity reading with an alternative type of flow meter If the flow reading on your Doppler is similar to the reading on your alternative meter the Doppler is probably reading correctly If the flow reading on your Doppler varies from the reading on the alternative meter you may need to adjust the K Factor accordingly to correct the flow reading See K Factor Correction Factor on page 2 22 for information on adjusting your K Factor STATUS OF FLOW READING ERRATIC Is the flow reading showing an erratic rate Yes If the flow reading appears erratic troubleshoot using Table 3 5 below UNo If you have followed all the troubleshooting steps and procedures and your Doppler is still not working correctly contact Compu Flow Systems Support on page 4 15 for information on how to proceed Table 3 5 Status of flow reading troubleshoo
53. s radio transducer to receiver available for Doppler Magnetic Mechanical and Hybrid optional 2 4gHz wireless good for 14km LOS Heat Sink Option Hi temp Doppler sensor heat sinks allows continuous operation up to 500 F 4 14 Specifications and Reference Information CUSTOMER FEEDBACK Compu Flow s technical writing staff has carefully developed this manual using research based document design principles However improvement is ongoing and the writing staff welcomes and appreciates customer feedback Please send any comments on the content organization or format of this user manual to info Ocompuflow com To order a manual please contact Technical Support info Ocompuflow com Or download this pdf file from the Compu Flow website http compuflow com For more Compu Flow brand product line information visit the Compu Flow website ehttp www compuflow com 4 16 Specifications and Reference Information Numerics 4 20 mA output specifications 4 3 A AC power requirements 4 3 troubleshooting 3 2 accuracy 4 2 adaptor battery 4 3 alarm output specifications 4 4 analog output setting parameters 2 23 signals 4 3 assessing flow profile 2 5 B battery operation 2 25 power adaptor charger 4 3 before installing the unit 2 1 C cables transducers 1 2 4 3 cast iron pipe data 4 10 charger battery 4 3 checklist for troubleshooting 3 1 clamp on transducers dimensions 4 8 connecting AC input
54. s suitable for use with a Doppler old pipe flow meter See Assessing Pipe Material and Condition on page 2 5 Is the measured fluid too clean Verify that suspended solid content of fluid is at least 40 or is the particle content microns 35 ppm with at least a 0 2 density difference fluctuating below readable from the liquid specifications See Suspended Particle Test For Doppler Signals on page 3 10 to check your fluid for particle content and also consult Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 Note Use a transit time meter if the fluid does not meet the suspended solid specifications of a Doppler flow meter Contact Compu Flow Systems Support on page 4 15 for more information STATUS OF ECHO LED FLASHING Is the Echo LED flashing No If the Echo LED light is on steady continue on to Status of Flow Reading High or Low on page 3 6 Yes If the Echo LED light is flashing troubleshoot using Table 3 3 below Note Review the three questions in Table 3 3 If you can answer yes to all three and you have determined that you do not have a power issue you may have an application that would be better suited for a transit time meter See Determining if Your Process Installation is Right for a Doppler Flow Meter on page 2 3 and Additional Troubleshooting Information on page 3 9 Troubleshooting and Customer S
55. sessing Flow Profile STRAIGHT RUN REQUIREMENTS As with other flow meters such as vortex or magnetic flow meters the Doppler flow meter needs a well developed flow profile to ensure accurate flow measurement To assure a well developed profile choose a measurement point on a long run of pipe well away from elbows valves pumps flanges and other possible sources of turbulence The ideal placement of the Doppler flow meter is with 20 diameters of straight run upstream and 10 diameters of straight run downstream between the transducers and any disturbance of the flow Most typical flow meter applications use 10 diameters of straight run upstream and 5 diameters downstream from any disturbance of the flow Installation and Operation 2 5 2 6 However when the measured fluid is too clean to provide the proper number of reflective particles one may position the transducer near the pump or source of turbulence in such a manner as to obtain stable readings in a continuous flow full pipe situation Using a transit time meter may be another viable option if the Doppler flow meter is not performing ideally A point to remember is that turbulence is a non linear function of flow so turbulence can create reflected signals Interpret readings near turbulent flows with caution Sources of turbulence are elbows flanges valves orifices wedges pumps pipe openings and pipe irregularities rust corrosion and buildup Try to avoid vertical pi
56. t Pipes below 1 diameter mount sensors 180 apart 2 10 Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Transducers Figure 2 5 Clamp on transducers secured with a bungee and chain To Connect the Transducers to the Electronics Enclosure 1 Ensure AC or battery DC input power is turned off 2 Connect the transducer cable to the electronics enclosure by routing the cable through the appropriate opening see Bottom view of the electronics enclosure on page 4 7 for location of cable access openings Use a Nema 4Xcable gland and a cable backing nut to securely fasten the trasnducer cable to the electronics enclosure 3 Connect the transducer wires to the processor board as shown in Figure 2 6 on page 2 12 for correct placement The transducer 4 wire connection is as follows White Digital signal output 0 V to 12 V pulse train Green Echo good logic signal when used Red 12 VDC at 100 mA nominal power in Black Ground Common Note Do not connect bare shield wire to black common ground Installation and Operation 2 11 Compu Flow Doppler Ultrasonic Flow Meter o 4 ALARMS Figure 2 6 Main electronics board connections 4 Continue with Mounting and Connecting Power to the Electronics Enclosure on page 2 13 Installation and Operation Compu Flow Doppler Ultrasonic Flow Meter Mounting and Connecting Power to the E
57. ted eguipment Compu Flow includes this symbol in Warning Caution and Attention boxes to identify specific levels of hazard seriousness AN WARNING This box identifies hazards or unsafe practices that could result in personal injury AN CAUTION This box identifies hazards or unsafe practices that could result in product or property damage Attention This box identifies important information It calls attention to a procedure practice or condition which is important to highlight TRADEMARKS Compu Flow is a trademark of Teksco USA Dow Corning is a registered trademark of Dow Corning Corporation Novagard is a registered trademark of Foam Seal Inc NSCG Inc G661 is a trademark of Foam Seal Inc NSCG Inc Swagelok is a registered trademark of Swagelok Company Compu Flow Doppler Ultrasonic Flow Meter Table of Contents Chapter 1 Introduction and Theory of Operation INTOQUCTION vice iii sis Si a si ii Hable bo aka si E i i andesite eats 1 1 Features of the Compu Flow Doppler Ultrasonic Flow Meter 1 1 Components of the Compu Flow Doppler Ultrasonic Flow Meter System 1 2 Electronics Enclosure and Display Panel sessen 1 2 Transducers and Cabling Lisisissiinionnssukssassas i i eisi a sias Theory of Operation session o aa oe a Aa ss 1 2 70191 doe i toj PT 1 3 ACCUFaCY siiis si itas Gabo a ia iso ies idan P E i i ai ui 1 3 li l P STS 1 3 Applications 22 L sisisti aiss
58. ted to the display insert the sensors into a container of water Turn on the display and select FPS or MPS Stir the water and watch the display to verify readings on the LCD screen and a solid echo light This confirms complete system integrity If you still do not get good readings after testing your unit then you should reconfirm the flow information or select a different type of flow meter for the application Troubleshooting and Customer Support 3 11 RETURNING UNITS FOR REPAIR Before returning any product for repair and or adjustment first follow all troubleshooting procedures If after following these procedures you still have a problem or if the procedure instructs you to contact Compu Flow Systems and discuss the problem with a representative See also Authorized Returns on page 4 15 A WARNING All returns to Compu Flow Systems support must be free of harmful corrosive radioactive or toxic materials and have purge documentation when appropriate If you return a unit without first getting authorization from Comp Flow Systems Support and that unit is found to be functional you will be charged a retest and calibration fee plus shipping charges To ensure years of dependable service Compu Flow products are thoroughly tested and designed to be among the most reliable and highest quality systems available worldwide WARRANTY Compu Flow products are warranted to be free from failures du
59. ting checklist Erratic Question Possible Cause Corrective Action Have the transducers been placed in Make sure that the transducers have been mounted in the recommended location on the an acceptable location pipe Consider straight run requirements see Straight Run Requirements on page 2 5 for more information Make sure the transducers are mounted side by side See To Mount the Clamp On Transducers to the Pipe on page 2 9 for more details Has the pipe been cleaned down to Make sure the pipe was cleaned with sandpaper prior bare metal before transducer to transducer placement Also check to make sure the placement Is this an old pipe type of pipe in your application is suitable for use with a Doppler flow meter See Assessing Pipe Material and Condition on page 2 5 Is the unit near an electric motor or Move the transducers away from interference and see motor controller if the flow readings become more stable Is your update time allowing for Change your flow meter update time and see if the erratic flow readings flow readings become more stable See To Set Update Time on page 2 24 Can you adjust Analog damping to No there are no analog damping settings other than provide a more accurate reading update time adjustment See To Set Update Time on page 2 24 3 8 Troubleshooting and Customer Support Compu Flow Doppler Ultrasonic Flow Meter Additional Troub
60. ty Less than 100 RH Transducers Dimensions Transducer heads 4 85 L x 1 33 W x 1 35 D 123 mm x 33 8 mm x 34 3 mm Note See Figure 4 3 on page 4 8 for the dimensional illustration 1 0 Ib 0 455 kg 4 2 Specifications and Reference Information Compu Flow Doppler Ultrasonic Flow Meter Table 4 2 Physical specifications Continued Housing material Nylon Hi Density Mounting Mounted to the outside of pipe by strap and gear clamps nylon belts bungee and steel chain or epoxy Crystal wedge material Epoxy resin all transducer models Environmental rating NEMA 6 IP67 Continuous Submersible to 200 Ambient temperature 20 F to 200 F 29 C to 93 C range 20 F to 500 F with optional heat sinks Ambient humidity Less than 100 RH Transducer cable Standard cable 25 7 6 m 2 twisted pairs 24 AWG belfoil shield Note Custom cable lengths are available min 25 5000 1524 m Wireless Optional FUNCTIONAL SPECIFICATIONS Table 4 3 Functional specifications Specification Dedicated units Isolated Regulated Module 100 240 VAC 300mA 12VDC 12 VDC DC operation enabled by barrier strip terminals see Figure 4 4 on page 4 14 for switch location Portable units Internal gel cell 4 hour continuous operation built in battery without backlight Recharge time is 8 hours using the external power adaptor charger or DC auto cigarette lighter Portable battery charger Standard
61. upport 3 5 Table 3 3 Status of Echo light troubleshooting checklist Echo flashing Question Possible Cause Corrective Action Have the transducers been Make sure that the transducers have been mounted in an placed in the recommended acceptable location location on the pipe Try moving the transducers Consider straight run requirements when deciding where they need to be mounted see Straight Run Requirements on page 2 5 for more information Make sure the transducers are mounted side by side flush with the pipe Make sure the exterior of the pipe was cleaned prior to mounting the transducers See To Mount the Clamp On Transducers to the Pipe on page 2 9 for more details Have you performed the See Suspended Particle Test For Doppler Signals on suspended particle test to see if page 3 10 the liquid in the flow is compatible with Doppler operation Have you consulted the Echo See Echo LED Light Considerations on page 3 9 for light consideration section information on whether the Doppler is the right meter for your application A transit time meter may work better for your application if the Echo light continues flashing STATUS OF FLOW READING HIGH OR LOW Is the flow reading showing a rate that is lower or higher than expected No If the flow reading is erratic rather than low or high or you are experiencing another issue continue on to Status
62. velocity of 5 fps and you would like the 4 20 mA output to be 12 mA or 50 of scale Push and hold the MA 4 key until the screen changes and then release the key Enter a scale value of 10 fps via the keypad The screen will automatically return the display to volumetric indication The 4 20 mA output will read 12 mA at the terminal strip located on the right side of the main electronics circuit board You may check your 4 20mA output setting via the bar graph Note Never adjust any of the potentiometers on the main processor board These settings are to be performed by authorized personnel only SETTING ADVANCED PARAMETERS This section explains how to set advanced parameters using the keyboard on the front panel of the unit Bar Graph To Set the Analog Bar Graph of Flow Rate n a with batch 1 Press the Bar Graph 2 key Enter the desired full scale flow rate in the indicated engineering unit 2 To return to the rate and totalizer flow reading press the Graph 2 key again 3 To return to the graph press the Graph 2 key again and select OK Batch Control 1 To configure batch control press 0 key and select Batch 2 Select Enable and choose 1 Pulse 2 Batch 3 Select Batch volume in preselected engineering units K Factor Correction Factor The default K Factor on the Doppler flow meter is set at 90 hZ fps for CLT V 6 0 Doppler Sensors For nearly all applications this default K Factor setting should be adequate

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