Dwyer UFC User Manual

Series UFC Ultrasonic Flowmeter Kit Installation and Operating Instructions

Bulletin F-UFC

DWYER INSTRUMENTS, INC.

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, USA

Phone: 219/879-8000 www.dwyer-inst.com

Fax: 219/872-9057 email: info@dwyer-inst.com

Table of Contents

1: General Description 1

1.1 Introduction 1

1.2 Principles of Operation 2

1.3 Supplied Hardware 3

1.4 UFC Instrument 4

1.4.1 Connections 4

1.4.2 Keypad 5

1.4.3 Power supply 6

2: Installation 7

2.1 Safety Precautions and Warnings 7

2.2 Installing the UFC Instrument 7

2.2.1 Positioning the instrument 7

2.2.2 Mounting the instrument 8

2.2.3 Connecting the instrument 9

2.3 Installing the Ultrasonic Transducers 10

2.3.1 Transducer positioning 10

2.3.2 Transducer attachment 11

2.3.3 Attaching the transducer holder to the pipe 12

2.3.4 Fitting the transducers 12

2.3.5 Transducer attachment (diagonal mode) 14

3: Operating Procedures 16

3.1 Setting-up the Instrument 17

3.1.1 Using the instrument for the first time 17

3.1.2 Changing the user language 18

3.1.3 Changing the date and time 18

3.2 Using the Quick Start Menu 18

3.3 Instrument Calibration 22

3.3.1 Adjusting the zero cut-off 22

3.3.2 Adjusting the set zero flow offset 22

3.3.3 Adjusting the calibration factor 23

3.3.4 Adjusting the roughness factor 25

3.3.5 Adjusting the damping factor 25

3.4 Outputs 27

3.4.1 Current output 27

3.4.2 Pulse output 29

3.4.3 Alarm outputs 30

3.5 How to Measure Totalized Flows (manually) 33

3.6 Display of totalizers 34

3.7 Operation with an Energy Meter 34

3.7.1 Pulse output 34

3.7.2 Configuring the UFC 34

4: Data Logging 36

4.1 How to Set Up the Basic Logging Application to Memory 36

4.2 How to Set Up Automatic (Timed) Logging Mode 38

4.3 How to Download Logged Data 39

5: Maintenance & Repair 41

5.1 Introduction 41

5.2 General care 41

5.3 Warranty / Return 41

6: Troubleshooting 42

6.1 Overview 42

6.2 General Troubleshooting Procedure 43

6.3 Warning and Status Messages 44

6.4 Diagnostics Display 46

7: Options 48

7.1 Large Pipe Diameter Transducers 48

7.2 Transducer Holder Options 48

7.3 Extended Signal Cable Options 48

8: Specification 49

1: General Description

1.1 Introduction

This manual describes the operation of the Dwyer UFC flowmeter. The flowmeter is designed to work with clampon transducers to enable the flow of a liquid within a closed pipe to be measured accurately without needing to insert any mechanical parts through the pipe wall, or protrude into the flow system.

Using ultrasonic transit time techniques, the UFC is controlled by a micro-processor system which contains a wide range of data that enables it to be used with pipes having an outside diameter ranging from 0.5 to 79 inches (13 to 2000 mm) and constructed of almost any material. This can be extended to pipes of up to 197 inches (5000 mm) using the optional type D sensors. The instrument will also operate over a wide range of fluid temperatures.

UFC standard features:

• Large, easy to read graphic display with backlight.

• Simple to follow, dual function keypad.

• Simple ‘Quick Start’ set up procedure.

• Continuous signal monitoring.

• Isolated pulse output (volumetric or frequency).

• Isolated current output (4 to 20 mA, 0 to 20 mA, or 0 to 16 mA).

• 2x Isolated programmable alarm outputs.

• Password-protected menu operation for secure use.

• Signal diagnostics.

• Multi-function alarm outputs.

• Operates from Mains, 24 Vac, or 24 Vdc.

• Logging of Flows and Volume total.

• Output to USB pen

Volumetric flow rates are displayed in L/h, L/min, L/sec, gal/min, gal/h, USgals/min, USgals/h, Barrel/h, Barrel/ day, m³/s, m³/min, m³/h. Linear velocity is displayed in meters or feet per second. When operating in the ‘Flow Reading’ mode the total volumes, both positive and negative, are displayed up to a maximum 12-digit number.

The flowmeter can be used to measure clean liquids or oils that have less than 3% by volume of particulate content. Cloudy liquids such as river water and effluent can be measured along with cleaner liquids such as demineralized water. In addition, the UFC can function as a data logger. When operating in this mode the logged data, which includes the flow rates and totalizers, is stored in memory and can then be transfe rred to a USB memory stick. Typical UFC applications include:

• Sea or River water.

• Potable water.

• Demineralized water.

• Treated water.

The UFC is available in two model options. Model UFC-A is supplied with type ‘A’ transducers which are designed to work with pipe diameters between 0.5 to 4.5 inches (13 to 115 mm). Model UFC-B is supplied with type ‘B’ transducers which are designed to work with pipe diameters between 2 to 79 inches (50 to 2000 mm). Both sets of transducers use a common mounting system for pipe attachment, and throughout this manual any reference to ‘UFC’ applies to both ‘A’ and ‘B’ model variants unless otherwise stated.

1: General Description

Fluid flow

Separation

Distance

Separation

Distance

Separation

Distance

Separation

Distance

Reflex mode

Reflex mode (double bounce)

Reflex mode (triple bounce)

Diagonal mode

This is the mode most commonly used. The two transducers (U & D) are attached to the pipe in line with each other and the signals passing between them are reflected by the opposite pipe wall. The separation distance is calculated by the instrument in response to entered data concerning the pipe and fluid characteristics.

In this mode the separation distance is calculated to give a double bounce. This is most likely to occur if the pipe diameter is so small that the calculated reflex mode separation distance would be impractical for the transducers in use.

This illustration goes one step further to show a triple bounce situation. This would normally apply when working with very small pipes relative to the transducer range in use.

This mode might be selected by the instrument where relatively large pipes are concerned. In this mode the transducers are located on opposite sides of the pipe but the separation distance is still critical in order for the signals to be received correctly.

This mode can be used with the standard ‘A’ & ‘B’ transducer sets but for really large pipe installations the optional transducer set ‘D’ might be recommended.

Upstream

transducer

Note: In addition to the 'A' and 'B' type sensors, type 'D' sensors (option) are available for use on pipes up to 197 inches (5000 mm). These sensors have a different mounting method. See Paragraph 1.3 for further details.

1.2 Principles of Operation

When ultrasound is transmitted through a liquid, the speed at which the sound travels through the liquid is accelerated slightly if it is transmitted in the same direction as the liquid flow, and decelerated slightly if transmitted against it. The difference in time taken by the sound to travel the same distance but in opposite directions is therefore directly proportional to the flow velocity of the liquid.

The UFC system employs two ultrasonic transducers attached to the pipe carrying the liquid and compares the time taken to transmit an ultrasound signal in each direction. If the sound characteristics of the fluid are known,

Figure 1.1 Operating modes

the instrument’s microprocessor can use the results of the transit time calculations to compute the fluid flow

Acoustic

Steel

T ransducer

Transducers (Sensors)

UFC Instrument

Mounting

High

Transducer Cables (x2)

User Documentation

holder

Temperature Interface Cables (x2)

Couplant Applicator

(Ax2, or Bx2)*

Clamps (x2)

Bands (x2)

velocity. Once the flow velocity is known the volumetric flow can be easily calculated for a given pipe diameter. The system can be set up to operate in one of four modes, determined mainly by the pipe diameter and th e type

of transducer set in use. The diagram in Figure 1.1 illustrates the importance of applying the correct separation distance between the transducers to obtain the strongest, and therefore most reliable, signal.

1.3 Supplied Hardware

The supplied UFC components are shown in Figure 1.2.

1: General Description

UFC Standard equipment

• Instrument with backlit graphic display.

• Transducer cables (x2) 16.5 feet (419 mm) in length.

• High temperature interface cables (x2).

• Transducers ‘A-ST’ x2 (UFC-A) for use with pipes ranging 0.5 to 4.5

• Transducers ‘B-ST’ x2 (UFC-B) for use with pipes ranging 2 to 79 Inches (50 to 2000 mm).

• Transducer holder for use with ‘A’ or ‘B’ transducers.

• Steel bands used to secure the transducer holder to the pipe.

• Acoustic couplant applicator.

• USB Memory stick.

• User documentation.

UFC Optional equipment

• Transducer set 'D' can be used for monitoring pipes of 59 inches to 197 inches (1500 to 5000 mm) outside diameter, over a temperature range -4°F to +176°F (-20°C to +80°C). This optional kit is supplied in a

Figure 1.2 Standard UFC equipment

inches (13 to 115 mm).

1: General Description

Keypad

LCD Display

Coaxial cables to transducers

Cable glands for

Small & Large Glands for power connection

Alarms & I/O connections

Blue = Downstream Red = Upstream

USB Connector

(for memory key)

separate case and includes the type 'D' transducers together with ratchet straps and holders for attaching the transducers to the pipe.

1.4 UFC Instrument

The UFC is a microprocessor controlled instrument operated through a menu system using an inbuilt LCD display and keypad. It can be used to display the instantaneous fluid flow rate or velocity, together with totalized volumes. The instrument also provides an isolated current output, or variable pulse output, that is proportional to the measured flow rate and can be scaled to suit a particular flow range. Two isolated alarm outputs are provided which can be configured in a number of ways. For example, to operate when the flow rate exceeds a specified maximum or minimum value.

1.4.1 Connections

Transducer connections

The transducers are connected to two coaxial sockets located on the bottom left-hand of the instrument. The silkscreen above these connectors show a red and blue triangle and a direction of flow symbol. For a positive flow reading, it is important that the upstream transducer is connected to the RED socket and the downstream transducer to the BLUE one. It is safe to connect or disconnect these cables while the instrument is switched on.

4 to 20 mA, ‘Pulse’, and Alarm I/O connections

The 4 to 20 mA, ‘pulse’, and alarm I/O cables, enter the bottom of the instrument via two cable glands and connected internally to a terminal block. Full details of the terminal connections are provided in Chapter 2

(Installation).

Power supply

Two cable glands located on the bottom right-hand side of the instrument are available for the power supply cable. Two sizes of glands are provided to accept cables of different diameters.

Figure 1.3 Instrument details

1.4.2 Keypad

Scroll UP

ENTER (SELECT)

Scroll DOWN

Scroll LEFT

Scroll RIGHT

Numerical keypad with dual function keys

The instrument is configured and controlled via a 15-key tactile membrane keypad, as shown in Figure 1.4.

Menus and the menu selection keys

1: General Description

Figure 1.4 UFC Keypad

Note: As a security measure, once the instrument has been set-up for the first time, a password is required to

gain subsequent access to the operating menus (see page 21).

The UFC menus are arranged hierarchally with the MAIN MENU being at the top level. Menu navigation is achieved by three keys located on the right hand side of the keypad which are used to scroll UP and DOWN a menu list and SELECT a menu item. When scrolling through a menu, an arrow-shaped cursor moves up and down the left hand side of the screen to indicate the active menu choice, which can then be selected by pressing the ENTER (SELECT) key.

Some menus have more options than can be shown on the screen at the same time, in which case the overflowed choices can be brought into view by continuing to scroll DOWN past the bottom visible item. Menus generally ‘loop around’ if you scroll beyond the first or last items.

If you select Exit on any menu it usually takes you back one level in the menu hierarchy, but in some cases it may go directly to the ‘Flow Reading’ screen.

Some screens require you to move the cursor left and right along the display as well as up and down. This is achieved using keys 5 (scroll LEFT) and 6 (scroll RIGHT).

Dual function numerical keypad

The block of keys shown in the center of the keypad in Figure 1.4 are dual function keys. They can be used to enter straight-forward numerical data, select the displayed flow units, or provide quick access to frequently required control menus.

1: General Description

1.4.3 Power supply

Mains supply

As standard, the UFC instrument is designed to work with a mains supply of 86 to 236 Vac and 50/60 Hz. A mains supply fuse is located adjacent to the mains power connection (see Figure 2.2).

24V Supply

An alternative 24 V (ac/dc) power supply module is available as a factory fitted option.

Power failure

The instrument will automatically power-up and become operational when the input power is applied. In the event of a power failure, the instrument’s configuration parameters are stored in non-volatile memory which then allows the instrument to return to normal operation immediately power is restored. A real time clock (RTC) records the date and time of any power disruptions, and time-stamps any such occurrence in the output log. All data logging ceases while power is unavailable.

2: Installation

WARNING

Caution

2.1 Safety Precautions and Warnings

You may be exposed to potentially lethal (mains) voltages

when the terminal cover of this instrument is removed.

Always isolate the supply to this instrument before removing

This instrument must be installed by an electrically qualified

technician aware of the potential shock hazards presented

when working with mains powered equipment.

2: Installation

LETHAL VOLTAGES

the terminal cover.

LETHAL VOLTAGES

If the equipment is powered from a 24 Vac supply then the

Blanking plugs are fitted to the cable glands on leaving the manufacturer.

In order to preserve the enclosure’s IP65 rating, ensure that the blanking plugs

2.2 Installing the UFC Instrument

2.2.1 Positioning the instrument

The UFC instrument should be installed as close as conveniently possible to the pipe-mounted ultrasonic sensors. Standard transducer cables are 16.5 ft (5 m) in length with 33 ft (10 m) cables being optionally available. Where, for operational reasons, it is not possible to mount the instrument this close to the sensors, bespoke cables of up to 328 ft (1000 m) can be provided. Consult Dwyer for further information and availability.

A suitable mains supply must be available to power the instrument (an optional 24V (ac/dc) supply module is available). The external supply must be suitably protected and connected via an identifiable isolator. A 500 mA fuse is fitted internally in the instrument’s input supply line.

SUPPLY EARTHING

supply must be isolated from earth.

IP65 Enclosure Protection

remain fitted in any unused cable gland.

2: Installation

GND

TxD

RxD

mA+

mA-

PULSE+

PULSE-

AL1+

AL1-

AL2+

AL2-

IO1

IO2

IO3

IO4

IO5

IO6

IO7

IO8

IO9

IO10

IO11

IO12

24V

+ -

230V AC

L N E

4.5in

7.8in

Screw Slot

Keyhole

Mounting Details

The instrument should be securely wall-mounted using the three fixing points shown.

Cable connections

All power and control cables enter through cable glands located on the bottom of the instrument and connect to terminal blocks as shown.

GND

TxD

RxD

mA+

mA-

PULSE+

PULSE-

AL1+

AL1-

AL2+

AL2-

IO1

IO2

IO3

IO4

IO5

IO6

IO7

IO8

IO9

IO10

IO11

IO12

24V

230V AC

LNE

2.2.2 Mounting the instrument

Ideally, the UFC enclosure should be fixed to a wall using three screws – see Figure 2.2.

1. Remove the UFC terminal cover.

2. Fix a screw into the wall at the required point to align with the mounting keyhole on the back of the enclosure.

3. Attach the enclosure to the wall using the keyhole screw mounting.

4. Align the enclosure then mark out the positions for the two remaining screw fixings through the slots near the

bottom corners of the enclosure. Then remove the enclosure, and drill (and plug) the two fixing points.

5. Clear the site of any dust/debris, then mou n t the enclosure on the wall.

Figure 2.1 UFC Mounting and connection details

2.2.3 Connecting the instrument

WARNING

All cables enter the instrument through the (4) cable glands located at the bottom of the instrument and are connected by means of screwed terminals to a number of plug-in connectors – see Figure 2.1.

Control & monitoring cables

Depending on the fitted options, any of the following control and monitoring ca bles may be required:

• Current output – a 4 to 20 mA, 0 to 16 mA, or 0 to 20 mA monitoring signal is output at terminal mA+ and mA-. (mA+ is the current output terminal and mA- is the return terminal).

• Pulse output – an opto-isolated pulse output is available at terminals PULSE+ and PULSE- (PULSE+ is the pulse output terminal and PULSE- is the return terminal).

• Alarm Outputs – two programmable, multifunction alarm outputs are available using MOSFET, SPNO relays. The relays, which are rated at 48 V/500 mA continuous load, are connected to terminals ALARM1+, ALARM1-, ALARM2+ and ALARM2- respectively.

• Expansion ports – terminals IO1 to IO12 are used for I/O connections to a number of optional expansion boards that may be fitted to the UFC expansion slot.

1. Remove the terminal block cover.

2. Route the control and monitoring cables through the two smaller cable glands.

3. Cut the wires to length, strip back the insulation by approximately 0.4in (10 mm) and connect them to the required terminals identified in Figure 2.1.

4. On completion, tighten the cable glands to ensure the cables are held securely.

Power connections

2: Installation

LETHAL VOLTAGES

Ensure the power cable is isolated from the mains supply.

Do not apply mains voltage with the terminal cover removed.

SUPPLY EARTHING

If the equipment is powered from a 24V AC supply then the

supply must be isolated from earth.

The UFC instrument can be powered from a mains supply (86 to 264 Vac, 47 to 63 Hz) or from a 24 V(ac/dc) supply if it is fitted with a 24 V supply module.

1. Route the power cable through one of the two cable glands located below the power connection terminals, using the gland most suitable for the power cable diameter.

2. Cut the wires to length, strip back the insulation by approximately 0.4 inches (10mm), and connected to them to the correct power supply terminals identified in Figure 2.1.

3. On completion, tighten the cable glands to ensure the cables are held securely.

4. Refit the terminal block cover.

2: Installation

The UFC equipment expects a uniform flow profile as a distorted flow will produce unpredictable measurement errors. Flow profile distortions can result from upstream disturbances such as bends, tees, valves, pumps and other similar obstructions.

To ensure a uniform profile, the transducers must be mounted a sufficient distance away from any cause of distortion.

Flow

Valid transducer location

10 x Diameter 20 x Diameter

45°

Uniform Flow Profile Distorted Flow Profile

Possible sludge

Air

Flow

Transducer Holder

45°

In many applications an even flow velocity profile over a full 360° is unattainable due to, for example, air turbulence at the

top of the flow and possibly sludge in the bottom of the pipe. Experience has shown that the most consistently accurate

results are achieved when the transducer holders are mounted at 45° with respect to the top of the pipe.

Possible sludge

Air

Reflex Mode

Diagonal Mode*

Transducer

Transducer Holder 2

Transducer Holder

Transducer Holder 1

Transducer Holder 2

45°

*Note: when using the UFC in the ‘diagonal’ mode an additional transducer holder and fixing kit is required.

Holder

Holder 1

2.3 Installing the Ultrasonic Transducers

2.3.1 Transducer positioning

Figure 2.2 Locating the transducers

Figure 2.3 Transducer holder attachment (reflex vs. diagonal mode)

2: Installation

Rectangular

Upstream

Downstream

Stainless steel bands

transducer

opening

transducer

Nylon Flag Transducer

Cable Connector

Thumb screw

Transducer Holder

To obtain the most accurate results, the condition of both the liquid and the pipe wall must be suitable to allow the ultrasound transmission along its predetermined path. It is important also that the liquid flows uniformly within the length of pipe being monitored and that the flow profile is not distorted by any upstream or downstream obstructions. This is best achieved by ensuring there is a straight length of pipe upstream of the transducers of at least 20 times the pipe diameter and 10 times the pipe diameter on the downstream side, as shown in Figure 2.2. Flow measurements can be made on shorter lengths of straight pipe, down to 10 diameters upstream and 5 diameters downstream, but when the transducers are positioned this close to any obstruction the resulting errors can be unpredictable.

Key Point: Do not expect to obtain accurate results if the transducers are positioned close to any obstructions that distort the uniformity of the flow profile.

Preparation

Before you attach the transducers you shoul d first e nsure that the proposed location satisfies the distance requirements shown in Figure 2.2, otherwise the resulting accuracy of the flow readings may be affected.

Prepare the pipe by degreasing it and removing any loose material or flaking paint in order to obtain the best possible surface. A smooth contact between the pipe surface and the fa ce of the transducers is an important factor in achieving a good ultrasound signal strength, and therefore maximum accuracy.

2.3.2 Transducer attachment

Figure 2.4 Transducer attachment (completed assembly)

2: Installation

Figure 2.5

Figure 2.6

Type ‘A’ or ‘B’ transducers are attached to the pipe using the adjustable transducer holder assembly shown in Figure 2.4. The transducer holder itself is secured to the pipe using two wrap-around steel bands. For user convenience, an imperial ruler (inches) is etched on the top side plate and a metric (millimeters) ruler is etched on the bottom side plate – as shown in Figure 2.4. Once the transducer holder assembly is fully assembled, the transducers are locked into position by tightening two thumb screws which are themselves then secured by locking nuts.

Note: When using the UFC in the diagonal or reflex mode on pipes over 16 inches diameter, two transducer holders are required with one transducer mounted in each – see Paragraph 2.3.5 for diagonal mode details.

2.3.3 Attaching the transducer holder to the pipe

1. Remove the two nylon flag s from t he t ran sdu cer

holder.

2. Position the transducer holder horizontally on

the pipe at 45° to the horizontal and secure it in position using the stainless steel banding, as shown in Figure 2.5.

Note: In the following procedure the transducer holder is installed with the rectangular opening facing towards the upstream end of the pipe.

2.3.4 Fitting the transducers

1. Attach the nylon flags to the two

transducers, as shown in Figure

2.6.

2. Using a syringe applicator, apply a

narrow bead (0.1in) of acoustic couplant to the base of both transducers.

3. Insert the downstream transducer

cable (blue) through the holder’s end plate and up through the rectangular opening at the lefthand side of the transducer holder, as shown in Figure 2.7.

Note: When carrying out the following steps, handle the transducer assembly with care to avoid smearing the acoustic couplant on the pipe while attaching the transducer to the transducer holder.

4. Connect the downstream cable (blue) to one of the transducers, then lower the transducer and cable through

the rectangular opening as shown in Figure 2.8.

5. Align the slots in the sides of the nylon flag with the edges on the top of the transducer holder, then carefully

slide the transducer assembly to the middle of the holder.

6. Tighten the thumb screw (clockwise) until the transducer is locked to the top of the transducer holder. This is

done to prevent the acoustic couplant from touching the pipe.

2: Installation

Figure 2.9

‘0’ on ruler scale

Calculated Separation

Distance

Figure 2.7

Figure 2.8

7. Connect the upstream signal cable (red) to the other transducer, then lower the transducer assembly through the rectangular opening, as shown in Figure 2.9.

8. Position the upstream transducer so that its leading face aligns with ‘0’ on the ruler scale (Figure 2.10), then lower the transducer onto the pipe by turning the thumb screw anti-clockwise.

9. As shown in Figure 2.11, align the leading face of the right-hand (downstream) transducer at the appropriate separation distance mark on the ruler scale, then lower the transducer onto the pipe by turning the thumb screw anti-clockwise until firm contact with the pipe is made.

Note: The correct separation distance can be found using the ‘Quickstart’ menu described in Paragraph 3.2.

Figure 2.10

Figure 2.11

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