Operating Instructions DU04 - PKP Prozessmesstechnik GmbH
Contents
1. 15 25 1 0 NPT or BSP 050 40 T30 150 1 50 NPT or SP 025 60 270 25 150 6 30 575 3 ASME Cass T50 Flange 248 707 907 750 80 mm DIN Class 150 Flange H 4 96 107 7800 7507 Other FS ranges can be specified DIMENSIONS 3 920 234 1 62 41 10 2 06 5230 6 40 163 2 40 61 00 1 12 amp 2 9 88 251 2 75 69 90 2 51 63 80 6 40 163 2 40 61 00 3 80 mm Pipe ASME 150 amp DIN 3 ASME 150 280 190 8400 165 F2. Around method to launch and receive pulses each received pulse initiating the next transmitted pulse On any one measurement a number of such cycles are used to accumulate the individual transit times which are then divided by the number of cycles to give an average of these measurements A microprocessor provides the following functions Control and calibration of the ASIC Calculations required to convert the measured times to flow rate Setting of the 4 20 mA loop current to represent flow rate Response to User selectable switch settings Fault reporting via an optically isolated open collector output INSTALLATION The DU04 may be installed in any orientation although it is recommended that in horizontal pipe runs an orienta tion which positions the electrical enclosure vertically be avoided if possible The reason for this caution is that with any transit time meter erratic behavior may result if bubbles are allowed to accumu late in the sound path A mounting orientation of the electrical enclosure 90 from vertical is recommended DYNAMIC PERFORMANCE The Model 0004 is designed to react to abrupt changes in flow rate During steady flow the Model 2004 updates the 4 20 loop current at a rate determined by the update time as selected by SWS position 2 fig 3 This update rate will either be every 10 sec onds if SLOW response has been set or every 2 seconds if the FAST is set How
3. PKP Process Instruments Inc 10 Brent Drive Hudson MA 01749 Tel 1 978 212 0006 Fax 1 978 568 0060 PKP Prozessmesstechnik GmbH Borsigstrasse 24 D 65205 Wiesbaden Nordenstadt Tel 06122 7055 0 Fax 06122 7055 50 Operating Instructions DU04 Ultrasonic Flow Transmitter MODEL DU04 Rev012008 USER MANUAL MODEL DU04 The Model 0004 an ultrasonic transit time flow meter designed to accurately and reliably report the flow of non compressi ble fluids in pipe diameters ranging from inch to 3 inches It is a 2 wire device reporting flow in the industry standard 4 20 mA proto col The meter introduces no pressure drop other than the pipe sec tion which provides the means to position the ultrasonic transducers and to connect to the user s piping system The small electronic board which implements all the func tions to measure and report the flow is housed in the integral brass meter body and is sealed so as to protect the electronics from the environment THEORY OF OPERATION Two ultrasonic transducers are positioned and angled so as to transmit and receive sound pulses that are launched at flat reflec tion point located on the opposing side of the pipe The flight time of the sound pulse from the transmitting transducer to the receiving transducer will be shortened if the pulse is launched in the direction of flow and increased if launched opposite to the direction of flow By alternating the transmitting and
4. ction An optically isolated sink output is activated under certain detectable fault conditions such as transducer failure or overly noisey output due to flow stream anomalies as might be seen due to excessive bubble entrainment The optional Fault output is an optically isolated NPN transistor capable of sinking up to 10 mA from a voltage source of no more than 48 VDC Caution There is no current limiting on this output so care must be exercised to limit the sink current to less than 25 ma and insure that proper polarity as shown in Fig 1 is observed else permanent damage may result Direction of Flow Optional output to indicate direction of flow is available Activation or deactivation of an optically isolated 10 mA max 48V no load voltage sink output indicates flow direction rror detection is not available when this option is ordered WIRING LOOP RESISTANCE Vs SUPPLY VOLTAGE Loop RESISTANCE onms FIG2 RESET 542 Response Full lt Seale BOARD LOCATIONS OF REFERENCED USER FUNCTIONS Range Switch Position Response time See Standard Models Table 10 Seconds ow Standard Range F 2 seconds igh Standard Range STANDARD MODELS il Field Selectable 988 Selectable Model Pipe Size Thread Size Full Full Scale Ranges Max Min Max e 018 75 072 EJ 20 Le Host 25 120 100 038 30 138 1
5. ever if a flow rate is measured that is greater than plus or minus 10 of the current rate the Model DU04 will invoke the 2 second update mode for the duration of the transient change after which it will revert to the selected update rate This feature is seen as advantageous when the DU04 is used as the feedback transducer in a process control loop while at the same time the normal update rate has been selected to be the 10 second rate In the case of eight or more consecutive bad measurements as might be experienced if excessive bubble volume is entrained in the flow the 0004 will activate the FAULT output opto isolator and simultaneously set the loop current to 3 ma to indicate fault con dition This fault condition will be maintained until eight consecutive good measurements are made at which time the Model DUO4 will revert to its normal mode EXCEPTIONAL BEHAVIOR AND FAULT REPORTING Two fault conditions can be detected and are reported via the Fault output provided FIG 1 Failure of the ASIC to perform necessary internal calibrations Failure to make reliable measurements The ASIC must upon initialization be able to send and receive sound pulses of a minimum strength If it cannot no measurements can be made This may come about for two reasons most likely reason the ASIC cannot be calibrated is because of a sound path that is not completely through the fluid This would be the case if the pi
6. lects this actual diameter rather than the nominal diameter This method of calibration removes an otherwise indeterminate error The error resulting from the thermal expansion of the diame ter over the specified temperature range would however result in the flow rate being under reported by 0 1 SPECIFICATIONS GENERAL Flow Range Bi directional field selectable per Standard Models fable Accuracy 0 75 of full scale Operating Temperature 40 to 180 F 40 to 82 20 Response Time User Selectable 2 or 10 seconds Viscosity Range 0 2 to 150 cSt 0 2 to 150 mPas Liquid Density 30 6 to 74 9 Ib cu ft 490 to 200 kg m Max Working Pressure 250 PSI 17 2 bars Pipe Sizes 3 4 1 2 3 Pipe Connections izes 3 4 to 2 Female NPT BSP Size 3 ASME 150 DIN 16 Flange Electrical Enclosure Integral to casting with gasketed cover One 1 2 NPT conduit connection plugged when model ordered with metric threads and one M16 x 1 5 connection plugged when model ordered with NPT threads Electrical Connections Screw terminal connections on PC board Enclosure Rating NEMA 4 IP 65 Power 18 to 36 VDC WETTED MATERIALS Ultrasonic Transducers ULTEM Encapsulated Seals EPDM Buna N FKM or other Body Material Brass UNS 83600 OUTPUT Analog 2 wire 4 20 mA output Output is 4 mA from zero to min flow see Standard Model table Loop Resistance See FIG 2 Error Dete
7. lting in the case of steady flow a more constant reported flow rate See the Specification section for details o In the case where the Model DUO4 is to be used as a feedback transducer in a control loop a faster response time may be desirable Use If either the Full scale or Response Time switch has been changed since the last Reset or power cycle then the DU04 must be reset using the Reset switch or else power cycled CALIBRATION As mentioned in the Theory of Operation and the Imple mentation sections the 0004 employs the Sing Around method of determining transit times This method results in a meas urement of fluid velocity which is independent of the speed of sound through the fluid and hence its dependence on temperature This speed of sound independence removes all need for field calibration However to report volumetric flow rate this velocity must be multi plied by the cross sectional area through which the velocity was measured This area is set by the internal pipe diameter D Any uncertainty in D translates directly to an uncertainty in flow rate Q Quantitatively Q error 200 d D where d is the tolerance of D an example 01 inch uncertainty the nominal diameter of a 2 inch pipe would result in a 1 error in reported flow rate Q At PKP Instruments each meter is calibrated against a traceable standard meter and a constant set in software which ref
8. pe were not completely filled with fluid Although the pipe may be properly filled bubbles of air trapped near transducer would also preclude calibration Lastly and of least likelihood would be a system failure Such a failure may be a degraded transducer Less likely may be a failure in the control electronics Watchdog Timer The software includes a Watchdog timer which will cause a software reset should for whatever reason the code is not being normally exercised for more than about 2 seconds This reset will nor mally be transparent to the user Should permanent damage to the unit have occurred the normal fault reporting cannot be invoked and the Model DU04 will have to be replaced USER SELECTABLE OPTIONS There are three switches FIG 3 accessible when the controller board is exposed Their functions are as follows Reset This is small push button switch which when activated resets the software as would occur if the unit were power cycled Full Scale o This is a dip switch setting that allows the User to select between two pre programmed full scale values for the pipe diameter currently used the Specification section for detail Response Time This switch setting allows the User to select two different update rates In many applications longer update rate is desired and acceptable With this slow er update rate the DU04 will average read ings over a longer time resu
9. receiving transducers the differ ence in these transit times can be used to calculate the velocity of the flow which when multiplied by the area of the pipe results in a measure of volumetric flow rate which then used to set the current in the 4 20 ma loop proportional to the full scale value of the meter The path of this sonic pulse traverses the pipe diameter twice and because of the generous spacing between transducers the volume of fluid which influences the time of flight of this pulse is commensurate with the scale of the turbulence features in the flow Turbulence by its nature has chaotic velocity components and by directing the sonic pulse through a volume comparable to the scale of this chaos the effect on the flight time on any single measure ment are much reduced resulting in measurements that show less variation from the average Stating it another way a measure of the Standard Deviation of a number of measurements will be reduced resulting in less uncertainty in the currently reported flow rate IMPLEMENTATION The accuracy and precision of the determined flow rate ultimately determined by the accuracy and precision with which one can measure the transit times The 2004 incorporates a proprietary ASIC Application Specific IC which provides all the functions required to alternately transmit and receive sonic pulses and measure the transit times to picosecond accuracy The ASIC implements the Sing
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