Dynasonics 902, 903 User Manual

Series 902/903

Portable Doppler Ultrasonic Flow Meter

Operations & Maintenance

Manual

REV 10/08

BEFORE OPERATING THE D902/3

Important Notice!

The D902/3 flow meter is equipped with a Lead Acid Gel
Cell battery. This battery will require charging before initial
operation.

Apply AC power, utilizing the enclosed line power cord, to
the D902/3 for a period of 16-24 hours prior to using the
product for the first time. The line cord connects to the
socket connection located on the side of the enclosure.

Do not allow the battery to completely discharge.
(Discharging the battery to the point where the LOW
BATTERY indicator illuminates will not damage the
battery. Allowing the battery to stay discharged for long
periods of time can degrade the storage capacity of the
battery.) When not in use, continually charge the battery
by keeping it plugged into line power. The D902/3 has an
integral charging circuit that prevents overcharging. The
instrument can be permanently connected to AC line power
without damaging the flow meter or the battery.

Rev. 10/08 - 1 - D902/3

TABLE OF CONTENTS

Part 1 - Introduction

Part 2 - Installation

Quick-Start Operating Instructions 4-5

Introduction

General 6

Applications 6

Model Matrix 7

Product Specifications 8

Bench Test Procedure 9

Installation

Transducer Mounting Locations 11-12

Pages

Pipe Preparation 13

Transducer Mounting 13-15

Electrical Connections 16-17

Battery Charging and Maintenance 18-19

Part 3 - Startup and
Configuration

Rev. 10/08 - 2 - D902/3

Instrument Startup and Configuration

Initial Settings 20

Modes of Operation 21

Pipe I.D. Input 22

Full Scale Input 23

Totalizer Exponent Input 24

Engineering Units Input 25

TABLE OF CONTENTS

Part 4 - Troubleshooting

Instrument Startup and Configuration

CAL. Constant Input 25

Display Damping 26

TEST Diagnostic Key 26

System and Totalizer RESET 27

Totalizer Reset 27

FLOW ANALYZER Indicator 27

Troubleshooting Guide 28-29

Appendices 31+

Spare Parts Listing

Mechanical Drawing

Pages

Fluid Sound Speed Conversion Chart

Clean Liquid Installation Guide

Pipe Dimension Chart: Cast Iron

Pipe Dimension Chart: ST, SS, PVC

Velocity to Volumetric Conversion

Statement of Warranty

Customer Service

Rev. 10/08 - 3 - D902/3

Location

QUICK-START OPERATING INSTRUCTIONS

This manual contains detailed operating instructions for all
aspects of the D902/3 instrument. The following condensed
instructions are provided to assist the operator in getting
the instrument started up and running as quickly as
possible. This pertains to basic operation only. If specific
instrument features are to be used or if the installer is
unfamiliar with this type of instrument, refer to the
appropriate section in the manual for complete details.

1. TRANSDUCER LOCATION

A. Determine the appropriate mounting location for the

transducers by referring to Figure 1.

TOP VIEW OF PIPE

Pipe Preparation
and Mounting

RECEIVING

TRANSDUCER

TRANSMITTING

TRANSDUCER

90° ELBOW

Fluid Velocity ∝ Г - Г2

Clean, Non-aerated Liquids Liquids with Suspended Solids or Aeration

Figure 1 Transducer Locations

2. PIPE PREPARATION AND TRANSDUCER
MOUNTING

A. The piping surface, where the transducers are to be

mounted, needs to be clean and dry. Remove
loose scale, rust and paint to ensure satisfactory
acoustical bonds.

B. Connect the elastic mounting strap around the pipe.

Leave the strap just loose enough to slip the
transducers underneath.

C. Apply a liberal amount of silicone grease (enclosed)

onto the transducer faces and the prepared areas of
the pipe.

Rev. 10/08 - 4 - D902/3

QUICK-START OPERATING INSTRUCTIONS

D. Place each transducer under the mounting strap, 180°

apart on the pipe. Ensure that the transducer cables
are facing the same direction. See Figure 2.

FLOW
DIRECTION

Figure 2 Transducer Cable Direction

E. Route the transducer cable back to the transmitter,

avoiding locations near high voltage supply wires.

Connections

Startup

3. TRANSDUCER CONNECTION

A. Connect the transducer plug to the appropriate mating

socket on the side the D902/3 enclosure.

4. INITIAL SETTINGS AND POWER UP

A. Set the SENSITIVITY control to -2.

B. Press the POWER button. The POWER indicator will

illuminate.

C. If the pipe is full of a flowing liquid

STRENGTH meter will indicate and the READ
indicator will illuminate.

D. Adjust the SENSITIVITY control so that the right-most

green LED just comes ON.

E. The default display indicates fluid velocity as either

FPS or MPS. Refer to the appropriate place in this
manual for specific features and options.

, the SIGNAL

Rev. 10/08 - 5 - D902/3

PART 1 - INTRODUCTION

General

Application Versatility

The D902/3 ultrasonic flow meter is designed to measure
the fluid velocity of liquid within closed conduit. The
transducers are a non-contacting, clamp-on type, which
will provide benefits of non-fouling operation and ease of
installation.

The flow meter operates by transmitting an ultrasonic
sound from its transmitting transducer through the pipe
wall into the flowing liquid. The sound will be reflected by
suspended particles or bubbles within the liquid and
recorded by the receiving transducer. A frequency shift
(Doppler effect) will occur that is directly related to the
speed of the moving particle or bubble. This shift in
frequency is interpreted by the instrument and converted to
various user defined measuring units.

A unique feature of this product is that it employs a
proprietary digital filtering system and recognition circuit.
This feature allows the instrument to measure fluid
velocities of clean liquids if the transducers are mounted
downstream from a 90° elbow. The non-symmetrical
hydraulic turbulence which occurs downstream of an elbow
is captured, linearized and can be displayed as liquid
velocity and volume. This capability is not available in
conventional Doppler technology.

The D902/3 flow meter can be successfully applied on a
wide range of metering applications. The simple to program
transmitter allows the standard product to be used on pipe
sizes ranging from 1 - 120 inch (25 - 3048 mm) pipe I.D.
With the small pipe transducer option, the pipe size range
is 0.25 - 1 inch (6 - 25 mm). A variety of liquid applications
can be accommodated: raw sewage, reclaimed water,
cooling water, river water, plant effluent, mining slurries,
sludge, etc. Because the transducers are non-contacting
and have no moving parts, the flow meter is not affected
by system pressure, fouling or wear. Standard transducers
are rated to 250 °F (121 °C). Optional high temperature
transducers are rated to operate to 400 °F (204 °C).

Rev. 10/08 - 6 - D902/3

PART 1 - INTRODUCTION

User Safety

Battery Backup

Product Identification

The D902/3 employs modular construction and provides
electrical safety for the operator. The display face contains
voltages no greater than 9 Vdc and the metal work is
electrically connected to earth ground. All user connections
are made through sealed, bulk-head plugs located on the
side of the D902/3 enclosure.

A rechargeable nickel-cadmium battery on the back of the
display board retains all user-entered configuration values
in memory for several years (at 25 °C), even if power is
lost or turned off. The ten year battery is continually trickle
charged whenever line power is applied. A completely
discharged battery recharges fully after 48 hours of
instrument operation.

The serial number and complete model number of the
D902/3 are located on the inside of the transmitter cover.
Should technical assistance be required, please provide
the Dynasonics Customer Service Department with this
information.

Product Matrix

D 9

Measuring Units/
Transducer Type

02) U.S.

03) Metric

12) U.S. (High Temp)

13) Metric (High Temp)

22) U.S. (Small Pipe)

23) Metric (Small Pipe)

32) U.S. (High Temp &

Small Pipe)

33) Metric (High Temp &
Small Pipe)

* High Temp (+400 °F)
Small Pipe (1/4" - 1")

*

Power Supply

A) 115 VAC
B) 230 VAC
C) 100 VAC
D) 200 VAC
E) 12 VDC

1 N A

Output 2

N) None

Output 1

1) 4-20 mA

Totalizer

A) Six digit

resettable

NOTE: The Series D902 is shipped with one set of
standard transducers, acoustic couplant, two mounting
straps, power cord and a 4-20 mA cable.

Rev. 10/08 - 7 - D902/3

N

Approvals

N) None

Options

N) U.S. Power Cord
E) U.K. Power Cord
G) Euro Power Cord

PART 1 - SPECIFICATIONS

TRANSMITTER

DESCRIPTION SPECIFICATION

Power Requirements

Flow Range

Outputs

Indicators

Display

Units

Rate U.S. (Metric) FPS, GPM, MGD (MPS, LPM, M

Totalizer U.S. (Metric) Gallons (liters, M3)

Ambient Conditions

Enclosure

Internal Lead Acid Gel Cell battery provides 8 hours of continuous operation. AC charging:
(Std) 115/230 VAC 50/60 Hz ±10%. (Opt) 100/200 VAC 50/60 Hz ±10%. (Opt) 12 VDC.

0.5 to 20 FPS (0.15 to 6 MPS)

4-20 mA, 600 Ohms max. isolated

Power, Signal Strength, Flow Analyzer, Read Fault, Overrange, Charging and Low Battery

2 line × 20 character alphanumeric LCD (backlit).
Digit height 0.2 inches (5 mm), 6 digit rate, 6 digit totalizer (resettable)

User configured

-20 to +160 °F (-30 to +70 °C), 0-95% relative humidity, non-condensing

NEMA 4, (IP-65) ABS with SS hardware. 11W × 17L × 8D inches (279W × 432L × 203D mm)

3

/hr)

Accuracy

Sensitivity

Repeatability

Response Time

±2% Full Scale

0.4% of Full Scale

±0.4% of Full Scale

5-50 seconds, user configured, to 90% of value, step change in flow

TRANSDUCERS

DESCRIPTION SPECIFICATION

Liquid Requirements

Transducer Cable

Pipe Sizes

Housing Material

25 ppm of 30 micron size suspended solids or entrained gases.

(Std) 20 feet (6 m), retractable cord.

(Std) 1 inch (25 mm) and above
(Small pipe) 1/4 to 1 inch (6 to 25 mm)

Standard Clamp-On: NEMA 6P (IP-68) - 40 °F to +210 °F (- 40 °C to +100 °C)
CPVC, Ultem

High Temp Clamp-On: NEMA 4 (IP-65) - 40 °F to +400 °F (- 40 °C to +200 °C)
Vespel

®

, Nylon, PVC (Cable Jacket), Aluminum (small pipe)

®

, Anodized Aluminum, Nickel-plated brass, Teflon® (Cable Jacket)

Rev. 10/08 - 8 - D902/3

PART 2 - PRE-INSTALLATION CHECKOUT

Unpacking

Functional Test

Transducer Connection

After unpacking, it is recommended to save the shipping
carton and packing materials in case the instrument is
stored or re-shipped. Inspect the equipment and carton for
damage. If there is evidence of shipping damage, notify
the carrier immediately.

The D902/3 flow meter can be checked for basic
functionality using the following Bench Test procedure. It
is recommended that this operation be performed before
each day of operation.

Procedure:

1. Open the D902/3 transmitter cover.

2. Connect the transducer cable connector plug to the
corresponding connector socket located on the side of
the D902/3 enclosure. See Figure 3.

3. Set the transmitter SENSITIVITY control (located on
the front panel) to -2.

4. Apply power.

5. Hold the transducers, the flat sides facing each other,
approximately 6 - 8 inches (150 - 200 mm) apart.

6. Move the transducers towards and away from each other
1 inch (25 mm) for several cycles at approximately 1
second intervals.

7. If unit is functioning properly, the READ LED will
illuminate and the rate display will indicate flow
readings.

Bench Test is Complete

Figure 3

Rev. 10/08 - 9 - D902/3

PART 2 - TRANSDUCER INSTALLATION

Transducer Mounting
Considerations

Step A -
Mounting
Locations

CASE 1:

Figure 4

The transducers that are utilized by the D902/3 contain
piezoelectric crystals for transmitting and receiving
ultrasonic sound energy through the pipe wall.

The transducers can be mounted in three different
configurations. The selection of the proper configuration is
dependent on the characteristics of the liquid to be
measured.

The three liquid characteristics, which will affect mounting
location and orientation, are as follows:

CASE 1: Liquid that contains 25 to 10,000 PPM (1%) of
30 micron or larger suspended solids or aeration.

CASE 2: Liquid that contains greater than 10,000 PPM
(1%) of 30 micron or larger suspended solids or aeration.

CASE 3: Liquid that contains fewer than 25 PPM of 30
micron or larger suspended solids or aeration and
suspended solids and aeration content which is smaller
than 30 microns.

Liquid that contains 25 to 10,000 PPM (1%) of 30
micron or larger suspended solids or aeration.

Select a transducer mounting location with adequate
straight runs of pipe, both upstream and downstream, to
achieve stable readings. Examples of minimum upstream
and downstream requirements are included in Table 1.

Mount the transducers 180° apart and facing each other on
the pipe. If the pipe is horizontal, the preferred mounting
orientation is 3 and 9 o’clock, with 12 o’clock being the top
of the pipe. Orientation on vertical pipes does not matter.
See Figure 4.

Rev. 10/08 - 10 - D902/3

PART 2 - TRANSDUCER INSTALLATION

Table 1

1

1

The D902/3 system will provide repeatable measurements on piping systems
that do not meet these requirements, but the accuracy of these readings may
be influenced to various degrees.

Rev. 10/08 - 11 - D902/3

PART 2 - TRANSDUCER INSTALLATION

CASE 2:

Liquid that contains greater than 10,000 PPM (1%) of
30 micron or greater suspended solids or aeration.

The mounting location and straight pipe requirements for
CASE 2 liquid characteristics are the same as those
described in CASE 1. The difference will be in the location
of the transducers on the pipe. As the discontinuities
(suspended solids or aeration) reach a level of
approximately 1% or 10,000 PPM, sound can no longer be
reliably transmitted through the liquid as it has a tendency
to scatter and absorb into the high concentration of
discontinuity. To compensate for this, the D902/3
transducers can be located on the same region of the pipe.
In a horizontal pipe, mount the transducers at 2 o’clock
and 4 o’clock positions. (Assuming 12 o’clock as the top of
the pipe.) See Figure 5.

Figure 5

CASE 3:

Rev. 10/08 - 12 - D902/3

Liquid that contains fewer than 25 PPM of 30 micron or
larger suspended solids or aeration. Or, liquid that
contains solids or aeration which is smaller than 30
microns.

The transducers will be mounted 1 to 3 pipe diameters
downstream from a 90° elbow. The orientation of the
transducers on the pipe will be 180° apart and facing each
other and 90° out of the plane of the elbow. See Figure 6
on page 13.

PART 2 - TRANSDUCER INSTALLATION

Step B -
Pipe Surface
Preparation

Step C -
Transducer
Mounting

Figure 6

Before the transducer heads are bonded to the pipe
surface, an area slightly larger than the flat surface of the
transducer must be cleaned to bare metal on the pipe.
(Plastic pipes do not require preparation beyond removal
of paint.) Remove all scale, rust and paint. Thoroughly
dry and degrease the mounting surfaces.

NOTE: Small pits in the piping surface typically do not
significantly impact ultrasonic transmission or signal
reception.

After selecting the applicable mounting location and
preparing the piping surface as detailed in Steps A and B,
the transducer can be mounted to the pipe.

NOTE: High Temperature transducer installations require
specialized mounting hardware and instructions. For
drawings detailing installation of this option, contact
the factory.

Steps A and B, Mounting Locations and Pipe Preparation
sections of this manual apply to the High Temperature
option. Reference these sections as required.

Rev. 10/08 - 13 - D902/3