Dynasonics DFX Operating Manual

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Doppler Ultrasonic Flow Meters

Series DFX

DPP-UM-00256-EN-03 (August 2019)

User Manual

Doppler Ultrasonic Flow Meters, Series DFX

Page 2 August 2019DPP-UM-00256-EN-03

User Manual

CONTENTS

Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Terminology and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Quick-Start Operating Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transducer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pipe Preparation and Transducer Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transducer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Application Versatility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

User Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Data Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product Identication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DT9 Clamp-On Transducer Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DP7 Probe Transducer Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Transmitter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Transducer Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power Supply Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

AC Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DC Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Multiple Meter Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ISO Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4…20 mA Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Internal Power Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

External Power Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Doppler Ultrasonic Flow Meters, Series DFX

Control Relay Output Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rate Pulse Output Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Instrument Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Totalizer Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Hierarchy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Menu Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Module Conguration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Advanced Conguration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Startup and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

North American Pipe Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Part Number Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Scope of This Manual

SCOPE OF THIS MANUAL

This manual is divided into two main sections:

• “Quick-Start Operating Overview” on page6 is intended to help you get the DFX flow meter up and running quickly. Refer to the detailed instructions if you require additional information.

• The remaining chapters provide a detailed description of all software settings and hardware installation guidance.

MPORTANTI

Read this manual carefully before attempting any installation or operation. Keep the manual accessible for future reference.

UNPACKING AND INSPECTION

Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

SAFETY

Terminology and Symbols

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing death or serious personal injury.

Indicates a hazardous situation, which, if not avoided, could result in severe personal injury or death.

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing minor or moderate personal injury or damage to property.

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Quick-Start Operating Overview

QUICKSTART OPERATING OVERVIEW

This manual contains detailed operating instructions for all aspects of the DFX flow instrument. The following condensed instructions are provided to help you get the instrument up and running as quickly as possible. This pertains to basic operation of the clamp-on transducer only. If specific instrument features, a hazardous area installation or an alternate transducer style are to be used—or if you are unfamiliar with this type of instrument—see the appropriate section in the manual for complete details.

Transducer Location

Determine the appropriate mounting location for the transducers. (See Figure 1.) Pipe must be filled with liquid for proper operation.

FLOW

Figure 1: Transducer locations

45°

YES

45°

Figure 2: Transducer mounting configuration

Pipe Preparation and Transducer Mounting

Top View of Pipe

Top of

Pipe

W and V Mount

1. The piping surface, where the transducers mount, needs to be clean and dry. Remove loose scale, rust and paint for satisfactory acoustical bonds.

2. Connect the mounting straps around the pipe. Leave the strap loose enough to slip the transducers underneath.

3. Apply a liberal amount of couplant grease onto the transducer faces.

4. Place each transducer under the mounting strap, 180° apart on the pipe. Verify that the transducer cables are facing the same direction on the downstream side of the ow. See Figure 3.

5. Route the transducer cable back to the monitor, avoiding conduits that contain high voltage AC supply wires.

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Quick-Start Operating Overview

FLOW

Figure 3: Transducer direction

Top View

of Pipe

Transducer Connections

1. Mount the monitor within the length of the transducer cables.

2. Route the transducer cables through the center conduit hole in the bottom of the enclosure and connect to terminal block J4. The terminal blocks are a removable and can be disconnected to simplify wiring access. See the wiring diagram inside the door for reference.

Startup

Initial Settings and Powerup

1. Verify that the power supply jumper settings are properly congured for the power supply. See “Power Supply Wiring

Connections” on page 21 or the wiring and jumper selection diagram is located inside the door.

OTE:N Power supply selection is specified during order placement and appropriate jumpers are placed at the factory.

If power is changed from AC to DC or vice versa, the fuse requirement changes. Fuse ratings are listed on the transmitter’s door.

2. Route power connections through the conduit hole farthest to the left and in the enclosure. Then connect power to the J2 terminal block. See Figure 11 on page 17.

3. Apply power. On initial power-up, the DFX ow meter conducts a series of self-diagnostic tests and buering operations that take approximately 30 seconds.

4. Enter pipe internal diameter (Pipe ID), measuring units and output conguration.

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Introduction

INTRODUCTION

General

The DFX ultrasonic flow meter is designed to measure volumetric flow of solids-bearing or aerated liquid within a closed conduit. Transducers are available as non-contacting (DT9) or insertion probe (DP7) types. DT9 non-contacting transducers are strapped to the outside of a pipe and are suitable for most installations where the pipe material supports the transmission of ultrasound. Some pipe materials, such as concrete pressure pipe and some plastic lined pipes do not allow ultrasound to penetrate to the liquid inside. For these applications, use the DP7 insertion probe.

The flow meter operates by transmitting an ultrasonic sound from a transmitting transducer through the pipe wall or from the probe tip into the moving liquid. The sound is reflected by sonic reflectors suspended in the liquid and recorded by the receiving transducer. If the sonic reflectors are moving within the sound transmission path, sound waves are reflected at a frequency shifted (Doppler frequency) from the transmitted frequency. The shift in frequency 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.

The criteria for a good Doppler reflector are:

• The scattering material must have a sonic impedance (sound speed difference) at least 10% different from the fluid.

• There must be some particles large enough to cause longitudinal reflection—particles larger than 35 micron.

• For a given pipe size, the longitudinal reflection must have sufficient energy to overcome the Rayleigh (energy wasting) scattering caused by smaller particles.

• The reflecting material must travel at the same velocity as the fluid for good accuracy.

Application Versatility

The DFX flow meter can be successfully applied on a wide range of metering applications. The easy-to-program transmitter allows the standard product to be used on pipe sizes ranging from 1…120 in. (25…3050 mm) pipe ID. With the small pipe transducer option, the pipe size range is 0.25…1 in. (6…25 mm). A variety of liquid applications can be accommodated:

• Sewage

• River water

• Plant effluent

• Mining slurries

• Sludge

• Others

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 a pipe surface temperature of 250° F (121° C).

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Introduction

User Safety

The DFX flow meter employs modular construction and provides electrical safety for the operator. The enclosure is constructed from rugged polycarbonate plastic with UV inhibitors. The enclosure does not contain any conductive materials that can become energized while the door is closed. The keypad is made of polycarbonate and is designed for outdoor use. The AC power transformer provides 4000 Volts of isolation from the power supply mains. The display face contains voltages no greater than 24V DC. Output modules are optically isolated from external power supplies and provide a great degree of immunity to ground loops.

CAUTION

IF THE DFX FLOW METER IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.

Data Integrity

The DFX flow meter retains all user configuration data and totalizer accumulations in non-volatile FLASH memory indefinitely.

Product Identication

The serial number and complete model number of the transmitter are on the side of the monitor enclosure.

Figure 4: Product labels

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Transducer Installation

TRANSDUCER INSTALLATION

Unpacking and Inspection

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

Mounting Locations

The transducers contain piezoelectric crystals for transmitting and receiving ultrasonic sound energy through the pipe wall (DT9) and from the probe tip (DP7). Placement of the ultrasonic transducer is the most critical step in achieving an accurate and reliable flow reading. All flow meters of this type rely on a full-pipe of fluid that is flowing symmetrically (evenly) in the pipe. Flow in partially filled pipes and immediately downstream of elbows, valves and pumps is unstable and leads to unstable readings and non-linearity.

The DFX flow meter has software algorithms that assume a full pipe of liquid. Install only in locations where the pipe is filled at all times when flow measurements are required. Avoid partially filled pipes that can lead to very large flow measurement errors. See Figure 5 for possible pipe configurations.

Figure 5: Pipe configurations and installation recommendations

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Transducer Installation

Select a transducer mounting location with adequate straight runs of pipe, both upstream and downstream, to achieve stable readings1. See Figure 6 for examples of minimum upstream and downstream requirements.

Piping Conguration

and Transducer Positioning

Flow

Upstream

Pipe

Diameters

Downstream

Diameters

* **

Pipe

Flow

Figure 6: Upstream/Downstream Pipe Requirements

The DFX system provides repeatable measurements on piping systems that do not meet these requirements, but the

accuracy may be affected.

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Transducer Installation

Pipe Preparation

Before the transducer heads are mounted to the pipe surface, an area slightly larger than the flat surface of the transducer face must be prepared. If pipe insulation is present, it must be peeled back to expose the pipe surface. Use a wire brush to remove loose paint, rust, scale or dirt. Paint, if bonded well to the pipe surface, does not need to be removed. Any bumps present on ductile iron pipe do not need to be removed. Thoroughly dry the mounting surfaces so that the couplant grease bonds to the surface.

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

Couplant

Use a coupling compound to create an acoustically conductive path between the transducer and the prepared pipe surface. Clamp-on ultrasonic meters do not operate without coupling compound mounted between the pipe wall and the transducer face. Enclosed with the DFX system is a tube of coupling compound that is adequate for general purpose applications. Use a silicone-based valve grease or RTV (Room Temperature Vulcanizing) products or grease for Doppler installations as they operate over a very wide temperature range. In some installations, such as automotive, silicone is not permitted. Alternate petroleum-based products can be used, but verify that the grease is rated not to flow at the maximum surface temperature anticipated on the pipe.

In general, use the following couplants with these transducers:

Transducer Couplant

DT90, DT91, DT94, DT95 Dow 732 or Dow 111 (or equivalent) DT92, DT93, DT96, DT97 Krytox® LVP

DP7 Not applicable

Table 1: Transducer couplants

DT9 Clamp-On Transducer Mounting

Clamp-on transducers should be mounted on the pipe 180° apart and facing each other on the pipe, with the cables on the downstream side of the transducers. 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. See Figure 7. Orientation on vertical pipes does not matter.

FLOW

Figure 7: Transducer Placement

Large pipe installations use stainless steel straps to secure the transducers to the outside of the pipe. The DFX system is shipped with four 36 in. (900 mm) straps, which are suitable for pipes up to 39 in. (1000 mm) diameter.

1. Select the proper number of transducer straps to allow a complete strap to go around the circumference of the pipe. If a pipe is larger than 39 in. (1000 mm), use a single strap/buckle arrangement to reduce the number of strap connections. The straps can be connected together to make a continuous length. Small pipe installations use an integral clamping mechanism built into the transducer.

Pipe Size Straps Required

1…9 in. (25…225 mm) 1 10…19 in. (250…480 mm) 2 20…29 in. (500…740 mm) 3

30…39 in. (760…1000 mm) 4

Table 2: Straps required vs. pipe size

Top View

of Pipe

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Transducer Installation

2. Wrap the strap around the pipe where the transducers mount. Leave the strap loose enough to allow the transducers to be placed underneath. If multiple straps are being used, wrap electrical tape around all but one strap connection to secure the strap worm screws in place.

3. Spread an even layer of coupling compound, approximately 1/8 in. (3 mm) thick, to the prepared transducer mounting areas of the pipe.

4. Spread an even layer of coupling compound, approximately 1/8 in. (3 mm) thick, to the at face of the two transducers.

5. Place each transducer under the strap with the at face—amber plastic window—positioned towards the pipe. The notch on the back of the transducer provides a mounting surface for the strap. The transducer cables must be facing in the same direction and downstream of the transducers for proper operation.

OTE:N Large pipes may require two people for this procedure.

6. Tighten the strap enough to hold the transducers in place, but not so tight that all of the couplant squeezes out of the gap between the transducer face and pipe. Make sure that the transducers are squarely aligned on the pipe and 180° apart. If RTV is used, avoid moving the transducers during the curing time (typically 24 hours) as bubbles may form between the transducer and pipe that can reduce ultrasonic signal transmission to unsatisfactory levels.

7. Route the transducer cables back to the area where the transmitter mounts, avoiding high voltage cable trays and conduits. While transducer cable extension is not generally recommended, if additional transducer cable length is required, use cable and connectors of the correct type and impedance. In many cases, especially if a splice my be exposed to water or other liquids, it may be more eective to replace the entire cable. Transducers use RG59, 75 Ohm coaxial cable or Twinax (Belden #9463) or (Belden # 9463DB) 78 Ohm two conductor cable.

8. If the transducers are permanently mounted using Dow 732, the RTV must be completely cured before proceeding to Instrument Startup. Make sure that no relative motion between the transducer and pipe occurs during the 24 hour curing process. If Dow 111 grease was used for temporary operation of the DFX system, proceed with the Startup procedures.

DP7 Probe Transducer Mounting

The DP7 insertion transducer that is used by the DFX flow meter contains piezoelectric crystals for transmitting and receiving ultrasonic sound energy. The black Ultem® plastic tip of the DP7 transducer contains these crystals, which are designed to be inserted just into the path of the flowing liquid.

Select a transducer mounting location that is completely filled with liquid when flow measurements are made (see

Figure 5) and with adequate straight runs (without disturbances) of pipe, both upstream and downstream, to achieve stable

and accurate readings. Examples of minimum upstream and downstream requirements are included in Figure 5 on page 10.

Figure 8: Installation locations

When installing the DP7 transducer in a horizontal pipe, the preferred orientation is at least 20 degrees from the top or bottom of the pipe. Verify that the mounting location allows for adequate clearance to install and retract the probe fully from the pipe.

The following instructions cover hot tapping applications where the installation or removal of the transducer probe must be done without shutting down the process pressure. If the product is being installed without an isolation valve, ignore the steps that pertain to its installation. Figure 9 illustrates an exploded view of an isolation valve assembly and names the various components.

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Transducer Installation

Seal

Fitting

Full Port

Ball Valve

Nipple

Weld

Coupling

Figure 9: Hot tap installation

The Bronze Hot Tap Kit (p.n. D030-1006-001) and the Stainless Steel Hot Tap Kit (p.n. D030-1006-002) include an isolation valve assembly and are designed for installation in pipes under pressure, up to 700 psi (48 bar) at 70° F (21° C).

All items required for installation are provided with the kit, except for the 1-1/2 in. NPT weld coupling or service saddle and the drilling and welding equipment. These instructions call for the use of a drilling machine designed for operations under pressure (for example, Mueller Co., Water Products Division).

1. Verify that the pipe’s line pressure is within the rated limits of the pressure drilling machine being used.

2. Grind o paint or other coatings from the pipe in the DP7 probe mounting area.

3. Tack weld a 1-1/2 in. NPT weld coupling to the pipe or install a service saddle according to the supplier’s instructions. The coupling or saddle must be aligned perpendicular to the pipe axis and square to its plane.

4. Complete welding. A water tight, 0.25 in. minimum weld bead is recommended.

5. Install the close nipple (supplied with assembly) into the weld coupling. Use appropriate pipe sealants.

6. Install the isolating ball valve on the close nipple. Verify that the valve is in the fully open position.

7. Install drill bit and adapter into the pressure drilling machine. Then attach the machine to the isolation valve.

8. Drill through the pipe wall in accordance with the instructions supplied with the drilling machine.

9. Withdraw the drill bit through the isolating valve.

10. Close the valve and remove the drilling machine.

11. Check for leakage at valve and connections.

12. Place pipe sealant on the 1-1/2 in. NPT threads of the insertion tting assembly.

13. Screw the assembly into the isolation valve and tighten with a 2-1/2 in. pump wrench.

Page 14 August 2019DPP-UM-00256-EN-03

Transducer Installation

Probe Cables

Before inserting the probe into the pipe, the sensor cables should be routed to the transmitter location. Verify that the supplied cable length is sufficient to meet the installation requirements. While transducer cable extension is not generally recommended, if additional transducer cable length is required, use cable and connectors of the correct type and impedance. In many cases, especially if a splice my be exposed to water or other liquids, it may be more effective to replace the entire cable. Transducers use RG59, 75 Ohm coaxial cable, Twinax (Belden #9463) or (Belden # 9463DB) 78 Ohm two-conductor cable.

CAUTION

THE PROBE CABLES ARE DESIGNED TO CARRY LOW LEVEL SIGNALS THAT ARE DEVELOPED BY THE SENSOR. CARE SHOULD BE TAKEN IN ROUTING THE CABLES. AVOID RUNNING CABLES NEAR SOURCES OF HIGH VOLTAGE OR EMI/RFI. ALSO AVOID ROUTING THE CABLES IN CABLE TRAY CONFIGURATIONS, UNLESS THE TRAYS ARE SPECIFICALLY USED FOR OTHER LOW VOLTAGE, LOW LEVEL SIGNAL CABLES.

CAUTION

THE INTERNAL DP7 PROBE WIRING IS EPOXY ENCAPSULATED TO SEAL IT FROM MOISTURE. THE DP7 PROBE IS PROVIDED WITH TWO COAXIAL CABLES TO SHIELD THE LOW LEVEL SIGNALS AND MUST BE CONTINUOUS TO THE DP7 PROBE TRANSMITTER. EXCESS WIRE MAY BE CUTOFF OR SIMPLY COILED NEAR THE DFX FLOW METER.

Probe Retraction Procedure

1. Retract the probe by loosening the upper jam nuts counterclockwise as viewed from the top of the probe using the proper size wrench. If the pipe is under pressure, the nuts must be turned alternately about two turns at a time to prevent binding as a result of non-equal seal loading. In many cases, the line pressure causes the probe to retract. Should the probe bind, use the retraction nuts on the lower side of the probe ange to assist in the probe retraction. Continue this procedure until the probe is fully retracted into the isolation valve.

CAUTION

DO NOT RUN THE DRIVE NUTS OFF THE RODS UNTIL THE ISOLATION VALVE IS FULLY CLOSED.

2. After the probe is retracted past the “ball” in the isolation valve, the isolation valve may be closed to isolate the probe from the line so the probe can be removed entirely.

CAUTION

IF THE INSERTION PROBE IS NOT ABOVE THE “BALL” OF THE ISOLATION VALVE, THE VALVE CANNOT BE CLOSED. IF THE VALVE WILL NOT CLOSE SMOOTHLY, THE BODY OR TIP OF THE PROBE IS MOST LIKELY NOT ABOVE THE “BALL”. ATTEMPTING TO FORCE THE VALVE INTO THE CLOSED POSITION MAY RESULT IN DAMAGE TO THE PROBE.

Page 15 August 2019 DPP-UM-00256-EN-03

Transducer Installation

Probe Insertion

Before inserting the DP7 probe into the piping system, calculate the probe insertion depth. Refer to the paragraphs that follow and Figure 10 on page 17 for information regarding this process. The variables required are:

• The overall probe length

• Pipe internal diameter (ID)

• Pipe wall thickness

• The length of the valve stack

• Amount of straight pipe diameters in the system

To Calculate Insertion Depth

Using this information and referring to Figure 10, proper insertion depth can be determined.

• Measurement A — The typical depth that the DP7 probe tip is inserted into the piping system is 1/8 (12.5%) of the pipe internal diameter.

• Measurement B — Pipe wall thickness. This information can be obtained from standard pipe wall charts (see

“Specifications” on page40) or ideally can be measured using an ultrasonic wall thickness gauge.

• Measurement C — Measure the distance that is going to be taken up by the pipe tap, nipple, full-flow ball valve and the insertion fitting. DP7 probes use 1-1/2 in. NPT hardware and the insertion fitting is approximately 2-1/2 in. in height.

• Measurement D — The length of DP7 probe that protrudes from the insertion fitting after it is inserted to the proper depth in the fluid stream.

• Measurement E — This is the overall length of the probe measured from the black measurement tip to the top flange on the probe.

Measure and record the following linear dimensions.

A = 0.125 x Pipe OD = B = Pipe Wall Thickness = C = Seal Fitting to Pipe Wall = D = E - C - B - A D = E = Probe Length =

Page 16 August 2019DPP-UM-00256-EN-03

Transducer Installation

Full Port

Ball Valve

Seal

Fitting

DP7 Probe

Pipe WallB

1/8 Pipe

Diameter

DP7

Length

Insertion

Measurement

Valve and

Seal Stack

Internal

Diameter

OTE:N For some low pressure/low temperature applications less than 30 psi (2.1 bar) and less than 100° F (38° C), the probe

may be pushed in by hand to decrease the insertion time.

Figure 10: Installation measurements

Flow Direction

Arrow

Figure 11: Flow direction arrow

1. Lubricate the O-rings located within the DP7 probe seal tting so that the seals are not damaged during probe insertion.

2. Run the lower jam nuts down to a point that approximates the nal insertion position or at least far enough to allow insertion into the insertion tting.

3. Using the threaded rods as a guide, position the probe in the insertion tting. Continue to insert the probe into the isolation assembly until the probe tip comes in contact with the closed “ball” in the isolation valve.

CAUTION

DO NOT FORCE THE PROBE TIP AGAINST THE “BALL”, AS DAMAGE TO THE PROBE TIP MAY RESULT.

4. Replace the upper jam nuts (2 on each rod) and the cotter pins. The nuts should be run down to the top side of the retaining collar and the cotter pins replaced.

5. Orient the probe in the direction of ow as indicated by the ow direction arrow located on the top of the probe ange.

6. Lock the probe in position with the enclosed Allen wrench.

CAUTION

THE NUTS ON BOTH ENDS OF THE RETAINING RODS MUST ALWAYS BE IN PLACE AS A SAFETY MEASURE TO PREVENT POSSIBLE PROBE BLOW OUT. INSERTING COTTER PINS IS A FURTHER SAFETY MEASURE.

7. Slowly open the isolation valve. When the valve is fully open, use the proper size wrench on the insertion nuts, alternately tightening each nut about two complete turns to avoid uneven seal loading.

Page 17 August 2019 DPP-UM-00256-EN-03

Transmitter Installation

TRANSMITTER INSTALLATION

Unpacking and Inspection

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

Mounting Location

The enclosure should be mounted in an area that is convenient for servicing, calibration and for observation of the LCD readout.

1. Locate the transmitter within the length of transducer cable that was supplied with the DFX system. If this is not possible, exchange the cable for one that is of proper length. While transducer cable extension is not generally recommended, if additional transducer cable length is required, use cable and connectors of the correct type and impedance. In many cases, especially if a splice my be exposed to water or other liquids, it may be more eective to replace the entire cable. Transducers use RG59,75 Ohm coaxial cable or Twinax (Belden #9463) or (Belden # 9463DB) 78 Ohm two-conductor cable.

2. Mount the DFX ow meter in a location that is:

• Free of vibration

• Protected from falling corrosive fluids

• Within ambient temperature limits – 40…185° F (– 40…85° C)

• Out of direct sunlight. Direct sunlight may increase transmitter temperature to above the maximum limit

3. See Figure 12 for enclosure and mounting dimension details. Make sure there is enough room for door swing, maintenance and conduit entrances. Secure the enclosure to a at surface with four appropriate fasteners.

4. Use conduit hubs where cables enter the enclosure. Seal unused holes with plugs.

OTE:N Use NEMA 4 (IP-65) rated fittings/plugs to maintain the watertight integrity of the enclosure. Generally, the left

conduit hole (viewed from front) is used for line power, the center conduit hole for transducer connections and the right hole is used for ISO-MOD I/O wiring.

5. If additional holes are required, drill the appropriate size hole in the enclosure’s bottom. Use extreme care not to run the drill bit into the wiring or circuit cards.

Page 18 August 2019DPP-UM-00256-EN-03

Dimensions

7.00"

(177.8)

RUN PROGRAM RELAY 1 RELAY 2

5.75"

(146.1)

Transmitter Installation

4.25"

(108.0)

3.93"

(99.8)

Power

Connection

Transducer

Connection

PANEL MOUNT (OPTION)

0.07”(1.8)

Maximum

Radius

5.19"

(131.8)

PANEL CUT-OUT

Panel Thickness: 0.5” (12) Max

Input/Output

Connection

WALL MOUNT (OPTION)

6.25”

(158.8)

Figure 12: DFX transmitter installation dimensions

(3) ½” (m20) Conduit

Holes

1.99”

(50.5)

3.31

(84.1)

1.70”

(43.2)

6.08"

(154.4)

6.65"

(169.0)

Page 19 August 2019 DPP-UM-00256-EN-03

Transmitter Installation

Transducer Wiring Connections

To access terminal strips for electronic connectors, loosen the two screws in the enclosure door and open the door.

1. Guide the transducer connectors through the middle conduit hole located of the transmitter enclosure. Secure the transducer cable with the supplied conduit nut (See Figure 13).

JP1

Figure 13: Transducer cable installation

The terminals within the DFX flow meter are removable. They can be unplugged, wired and then plugged back in.

2. Connect the wires to J4 at the corresponding screw terminals in the transmitter. See Figure 14 or the Wiring Diagram located inside the door of the transmitter.

OTE:N The transducer cable carries low level, high frequency signals. While transducer cable extension is not generally

recommended, if additional transducer cable length is required, use cable and connectors of the correct type and impedance. In many cases, especially if a splice my be exposed to water or other liquids, it may be more effective to replace the entire cable. Transducers use RG59, 75 Ohm coaxial cable or Twinax (Belden #9463) or (Belden # 9463DB) 78 Ohm two conductor cable. Cable lengths up to 990 feet (300 meters) are available.

Transducer

Connections

JP3

241

VPP12-800

CLASS B

VDE

JP2

JP1

Grounding

Wire

Lock Nut

Figure 14: Transducer connections

Page 20 August 2019DPP-UM-00256-EN-03

Transmitter Installation

Power Supply Wiring Connections

Connect power to the screw terminal block marked J2 through the conduit hole on the left side of the enclosure. See Figure 15 for AC power supplies and Figure 16 for DC power supplies. Use wiring practices that conform to local and national codes (for example, The National Electric Code Handbook in the U.S.).

CAUTION

ANY OTHER WIRING METHOD MAY BE UNSAFE OR CAUSE IMPROPER OPERATION OF THE INSTRUMENT.

TO AVOID SERIOUS INJURY OR DAMAGE, DISCONNECT ELECTRICAL POWER BEFORE SERVICING THIS METER.

OTE:N This instrument requires clean electrical line power. Do not operate this unit on circuits with noisy components (such

as fluorescent lights, relays, compressors or variable frequency drives). Do not run line power with other signal wires within the same wiring tray or conduit.

WIRING DIAGRAM

CAUTION! To avoid serious injury or damage,

disconnect electrical power before servicing this meter

JP3

Connections

2 1

115 VAC

4 3 2 1

230 VAC

4 3 2 1

9-28 VDC

4 3

JP1/JP2

Connections

AC DC

2 1

115/230

VAC

9-28 VDC

JP3 2 1

4 3

JP2

2 1

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

GND

JP1

EARTH EARTH

SYNC SELECT

INT

MODULE #2

MODULE #1

RED BLK

BLU CLR

Receive Transmit

REDBLK BLUCLR

GND

EXT SYNC

EXT

Figure 15: DFX flow meter wiring diagram

Page 21 August 2019 DPP-UM-00256-EN-03

Transmitter Installation

AC Power Supply Connections

LINE VOLTAGES MAY BE PRESENT WITHIN THE ENCLOSURE. THERE IS A RISK OF SHOCK, SPARKS AND DEATH IF THIS PRODUCT IS HANDLED IN AN UNSAFE WAY. SERVICE SHOULD ONLY BE DONE BY QUALIFIED PERSONNEL.

1. Verify that the jumpers at JP3 are properly oriented for the power supply. See Figure 15.

2. Verify that the jumpers at JP1 and JP2 are not present.

3. Connect L1, L2 and EARTH to the terminals referenced in Figure 15. Phase and neutral connections to L1 and L2 are not polarized. Do not operate without an earth ground connection.

4. See Figure 16 for AC connection schematic. Wire gauges up to 14 AWG can be accommodated in the DFX ow meter’s terminal blocks.

OTE:N A switch or circuit breaker is required in the installation. The switch or circuit breaker must be in close proximity

of the DFX flow meter and within easy reach of the operator. The switch or circuit breaker must be marked as the disconnect device for the DFX flow meter.

JP1

AC Power

Connections

Figure 16: DFX flow meter AC power connection

50/60 Hz

17 Watts Maximum

DC Power Supply Connections

The DFX flow meter may be operated from a 12…28V DC source, as long as the source is capable of supplying 7 Watts.

• 12V DC Supply @ 600 mA minimum

• 24V DC Supply @ 300 mA minimum

1. Verify that the jumpers are properly placed. See the wiring diagram inside the door of the DFX ow meter enclosure or see

Figure 15. The jumpers at JP3 should not be present and the jumpers at JP1 and JP2 should be in place.

2. Connect the DC power source as illustrated in the schematic in Figure 17 on page 23. Wire up to 14 AWG can be accommodated in the DFX ow meter terminal blocks.

OTE:N A switch or circuit breaker is required in the installation. The switch or circuit breaker must be in close proximity

of the DFX flow meter and within easy reach of the operator. The switch or circuit breaker must be marked as the disconnect device for the DFX flow meter.

Page 22 August 2019DPP-UM-00256-EN-03

Transmitter Installation

JP1

DC Power

Connections

12 to 28 VDC

7 Watts Maximum

Figure 17: DC power connection

Multiple Meter Installations

The DFX flow meter contains a provision for synchronizing multiple DFX flow meters together. Synchronization is required when more than one DFX flow meter is mounted on a common pipe or header system. If the meters are not synchronized, a phenomena called “cross-talk” can occur between meters, which can lead to erroneous readings or no readings at all. Cross-talk results from the small differences in transmitted frequency generated from two or more different ultrasonic flow meters. By synchronizing the transmitted ultrasonic energy, cross-talk caused by differences in transmitted frequency is eliminated.

The DFX flow meter synchronization circuit is designed to interconnect up to four DFX flow meters over a cable length of 100 feet (30 meters). Use 20-22 AWG twisted-pair shielded interconnection wire for this purpose. See Figure 18.

4 3

2 1

GND

SYNC SELECT

EARTH EARTH

2 1

INT EXT

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

RED BLK BLU CLR

Receive Transmit

EXT SYNC

REDBLK BLUCLR

GND

9-28 VDC

JP1/JP2

Connections

115/230

VAC

9-28 VDC

AC DC

Synchronization

Selection

(Connect one end only to earth ground)

Twisted Pair

Shield

Figure 18: Meter synchronization detail

To Synchronize Multiple Meters

1. Remove power from the DFX ow meters.

2. Daisy-chain connect the EXTernal SYNChronization and GND terminal blocks together between the meters to be synchronized, using the twisted-pair cable described previously. The terminal block is located on the circuit board that is mounted on the door of the meter’s monitor. See Figure 15 on page 21 or the Wiring Diagram inside the door of the DFX monitor.

3. At a single point, connect the shield drain wire from the interconnection cable to earth ground.

4. Congure the SYNC SELECT jumpers on the DFX ow meters. One DFX ow meter should be congured for INT and the remaining units congured for EXT (see Figure 19).

5. Apply power to the DFX system.

Page 23 August 2019 DPP-UM-00256-EN-03

Transmitter Installation

MODULE #2

MODULE #1

JP1/JP2

Connections

115/230

VAC

JP2

JP1

JP3

9-28 VDC

2 1

4 3 2 1

4 3

2 1

4 3

2 1

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

Receive Transmit

RED BLK BLU CLR

REDBLK BLUCLR

EXT SYNC

SYNC SELECT

INT EXT

GND

ACDCEARTH

EARTH

GND

230 VAC

115 VAC

Connections

JP3

WIRING DIAGRAM

CAUTION! To avoid serious injury or damage,

disconnect electrical power before servicing this meter

Master Meter Slave Meter Slave Meter

WIRING DIAGRAM

CAUTION! To avoid serious injury or damage,

disconnect electrical power before servicing this meter

JP3

Connections

2 1

115 VAC

4 3 2 1

230 VAC

4 3 2 1

9-28 VDC

4 3

JP1/JP2

Connections

115/230

VAC

2 1 2 1

9-28 VDC

2 1

ACDCEARTH

4 3

JP1

2 1

EARTH

GND

SYNC SELECT

INT EXT

JP2

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

MODULE #2

MODULE #1

RED BLK BLU CLR

Receive Transmit

EXT SYNC

REDBLK BLUCLR

GND

WIRING DIAGRAM

CAUTION! To avoid serious injury or damage,

disconnect electrical power before servicing this meter

JP3

Connections

2 1

115 VAC

4 3 2 1

230 VAC

4 3 2 1

9-28 VDC

4 3

JP1/JP2

Connections

115/230

VAC

2 1 2 1

9-28 VDC

2 1

ACDCEARTH

L1 +V

4 3

JP1

2 1

EARTH

GND

SYNC SELECT

INT EXT

JP2

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

MODULE #2

MODULE #1

RED BLK BLU CLR

Receive Transmit

EXT SYNC

REDBLK BLUCLR

GND

Twisted Pair

Master Meter

Set to Internal

Synchronization

Shield

(Connect one end

only to earth ground)

Slave Meters

Set to External

Synchronization

Twisted Pair

Wire

Slave Meters

Set to External

Synchronization

Figure 19: DFX flow meter synchronization connections

ISO Modules

The DFX flow meter uses ISO-MODs for input and output functions. ISO-MODs are epoxy encapsulated electronic input/ output modules that are simple to install and replace in the field. See Figure 20. All modules are 2500 V optically isolated from the DFX flow meter’s power and earth grounds. This eliminates the potential for ground loops and reduces the chance of severe damage in the event of an electrical surge.

Three ISO-MOD options are available: 4…20 mA, dual-relay and rate pulse. The DFX flow meter supports any two ISO-MOD input/output modules. All modules are field-configurable by using the keyboard interface. Field wiring connections to ISO-MODs are quick and easy using removable wiring terminals. Configuration and connection of the various ISO-MODs are described on the following pages.

ISO Module Replacement

To remove an ISO-MOD, remove the two machine screws that secure the module in place and pull the module straight out of the enclosure. A 10-pin connection is on the bottom of the module that mates with the circuit board underneath. To install and ISO-MOD, push the module into the 10-pin connector and tighten the two machine screws. Re-calibrate the parameters if the 4…20 mA modules are replaced. See “Module Configuration Parameters” on page 35 for instructions.

WIRING DIAGRAM

CAUTION! To avoid serious injury or damage,

disconnect electrical power before servicing this meter

JP3

Connections

2 1

115 VAC

4 3 4 3 2 1

230 VAC

JP1 4 3 2 1

9-28 VDC

4 3

JP1/JP2

Connections

115/230

VAC

2 1

9-28 VDC

2 1

Page 24 August 2019DPP-UM-00256-EN-03

ACDCEARTH

EARTH

GND

SYNC SELECT

MODULE #2

JP2

2 1

MODULE #1

Fuse (5x20mm) AC: 0.25 A/250V Delay DC: 1.0 A/250V Delay

RED BLK

REDBLK

BLU CLR

BLUCLR

Receive Transmit

GND

EXT SYNC

INT EXT

Figure 20: Two ISO-MOD I/O modules installed

JP3

241

VPP12-800

CLASS B

VDE

JP2

JP1

OUT (-)

IN (+)

JP2 JP1

b NO

b CM

b NC

a NO

a CM

a NC

INT PWR EXT PWR

I/O: RELAY

P.N. D020-1045-102

I/O: 4-20 mA

P.N. D020-1045-100

ISO-MOD

Transmitter Installation

4…20 mA Output Module

The 4…20 mA Output Module interfaces with most recording and logging systems by transmitting an analog current signal that is proportional to system flow rate. Configure the 4…20 mA ISO-MOD via jumper selections for an internally powered (Figure 22) or externally powered (Figure 23) module. Do not exceed the maximum load for a particular supply voltage. See Figure 21.

Supply Voltage - 7 VDC

1100

1000

900

800

700

600

500

400

Loop Load (Ohms)

300

200

100

12 14 16 18 20 22 24 26 28

0.02

Supply Voltage (VDC)

Figure 21: Maximum 4…20 mA loads

= Maximum Loop Resistance

Operate in the

Shaded Regions

Internal Power Conguration

Verify that jumpers are in place at JP1 and JP2 on the module. See Figure 22 . In this configuration, the 4…20 mA output is driven from a +24V DC source located within the DFX flow meter. The 24V DC source is isolated from the DC ground and earth ground connections within the DFX flow meter. The module can accommodate loop loads up to 800 Ohms in this configuration.

OTE:N The +24V internal supply, if configured to power the 4…20 mA output, shares a common ground with another

ISO-MOD (if installed). If another module is connected to earth ground, a ground loop may occur. The solution to this problem is to configure the 4…20 mA module for external power and use an external isolated supply to power the 4…20 mA loop.

4-20 mA IN (+)

4-20 mA OUT (-)

RTU/PLC

MONITOR

Figure 22: Internally powered 4…20 mA

OUT (-)

IN (+)

INT PWR EXT PWR

JP2 JP1

Use Both

Jumpers

I/O: 4-20 mA

P.N. D020-1045-100

ISO-MOD

Page 25 August 2019 DPP-UM-00256-EN-03

Transmitter Installation

External Power Conguration

Remove the two jumpers located at JP1 and JP2 on the module. See Figure 23. In this configuration, the 4…20 mA module requires power from an external DC power supply. The voltage of the external power source must be sufficient to power the module and drive the loop load. The loop loss attributed to the ISO-MOD is 7V DC, so the minimum voltage required to power a loop can be calculated using the following formula: Loop voltage (min) = (loop load Ohms × 0.02) + 7

I/O: 4-20 mA

OUT (-)

IN (+)

INT PWR EXT PWR

JP2 JP1

Jumpers

P.N. D020-1045-100

ISO-MOD

Remove

4-20 mA IN (+)

4-20 mA OUT (-)

RTU/PLC

MONITOR

Figure 23: Externally powered 4…20 mA

Page 26 August 2019DPP-UM-00256-EN-03

Transmitter Installation

Control Relay Output Module

Two independent SPDT (single-pole, double-throw, Form C) relays are contained in this module. The relay operations are user configured via the front panel to act in either a flow rate alarm, error alarm or totalizing pulse. The relays are rated for 200V AC maximum and have a current rating of 0.5 A resistive load (175V DC @ 0.25 A resistive). Use a secondary relay whenever the Control Relay ISO-MOD is used to control inductive loads such as solenoids and motors.

Typical relay connections are illustrated in Figure 24. The reed relays located within the relay module can interface directly with small pilot lights, PLCs, electronic counters and SCADA systems.

Figure 25 shows the connection of an external power relay to the Relay ISO-MOD. Use external power relays whenever the

load to be switched exceeds the switch rating of the reed relays, or if the load is inductive in nature.

FLOW OK

LOW F LOW

EXTERNAL

TOTALIZER/SAMPLER

Figure 24: Typical relay connections

INTERNAL

CURCUIT

b NO

b CM

b NC

a NO

a CM

a NC

I/O: RE L A Y

P.N. D020-1045-102

ISO-MOD

POWER

RELAY

b NO

b CM

b NC

a NO

a CM

a NC

POWER

SOURCE

Figure 25: External relay connections

I/O: RELAY

P.N. D020-1045-102

ISO-MOD

Page 27 August 2019 DPP-UM-00256-EN-03

Instrument Programming

Rate Pulse Output Module

The Rate Pulse Output Module is used to transmit information to external counters and PID systems via a frequency output that is proportional to system flow rate. The frequency output range of the Rate Pulse Module is 0…2500 Hz. This module has two types of outputs: one simulates the output of the coil of a turbine flow meter and the other is an open-collector type that does not source voltage at its output. Both outputs may be connected simultaneously.

The turbine meter output creates a 500 mV peak-to-peak saw-tooth waveform that is not referenced to ground. This output can be run to electronic monitors that are compatible with variable reluctance outputs from coils, such as those found in turbine and paddle-wheel flow meters. The input impedance of the receiving device should not be smaller than 2000 Ohms.

The standard pulse output does not output a voltage, but acts as an open-collector output requiring an external power source and pull-up resistor. See Figure 26. The MOSFET in the Rate Pulse Module can support loads of 100V @ 1 A. Resistor selection is based on the input impedance of the receiving device. Select a resistor that is a maximum of 10% of the input impedance of the receiving device, but does not exceed 10k Ohms.

500 mV

p-p

TURBINE IN

RTU/PLC

MONITOR

+V EXT SENSOR

RTU/PLC

MONITOR

500 mVpp

PULSE IN

GND

Figure 26: Rate pulse module

I/O: 0-2.5KHz

P.N. D020-1045-207

TURBINE - B TURBINE - A OUT (-) IN (+)

ISO-MOD

TIME

Page 28 August 2019DPP-UM-00256-EN-03

Instrument Programming

INSTRUMENT PROGRAMMING

General

The DFX flow meter is configured through the keypad interface. All entries are saved in non-volatile FLASH memory that is retained indefinitely in the event of power loss.

Keypad Operation

The DFX flow meter contains a four-key tactile feedback keypad interface that lets you view and change configuration parameters used by the meter’s operating system.

Figure 27: Keypad layout

The DFX flow meter has two basic sets of programming procedures: list item selection and numeric value entry.

OTE:N While in RUN mode, simultaneously press the UP and DOWN keys to display the current firmware version.

List Item Selection Procedure

OTE:N If you are in PROGRAM mode and the selection to be viewed or changed is displayed, proceed to step 3 below. If

you are in PROGRAM mode and the selection to be viewed or changed is not displayed, press UP or DOWN until the selection appears. Proceed to step 3.

1. Press MENU. PROGRAM appears in the lower left-hand corner and ID UNITS appears on the lower line of the display.

2. Press DOWN to move to the selection.

3. Press ENTER to view the current selection.

4. If the current selection is correct, press ENTER to conrm. The unit automatically advances to the next selection.

5. To change the current selection, press UP to scroll through the available choices. Press ENTER to conrm your selection. The unit automatically advances to the next selection.

6. To exit the programming mode, press MENU. Depending on your position in the programming mode, up to three MENU presses may be required to exit. The display changes to RUN mode.

OTE:N While in RUN mode, simultaneously press the UP and DOWN keys to display the current firmware version.

Numeric Value Entry Procedure

OTE:N If you are in PROGRAM mode and the selection to be viewed or changed is displayed, proceed to step 3 below. If

you are in PROGRAM mode and the selection to be viewed or changed is not displayed, press UP or DOWN until the selection appears. Proceed to step 3.

1. Press MENU. PROGRAM displays in the lower left corner and ID UNITS displays on the lower line.

2. Press DOWN until the correct selection displays. The current numeric value for this selection displays on the upper line.

3. If the current value is correct, press ENTER. The left-most programmable number ashes. Press ENTER again to conrm and keep the current numeric value. The unit automatically advances to the next menu selection.

4. To change the current selection, press ENTER. The left-most programmable number ashes. Press UP to scroll through the digits 0…9. Press DOWN to move the active digit to the right. Continue until all digits are selected.

5. Press ENTER to conrm your selection. The unit automatically advances to the next selection.

6. To exit the programming mode, press MENU. Depending on your position in the programming mode, up to three MENU presses may be required to exit. The display changes to RUN mode.

Totalizer Reset

Press ENTER and MENU simultaneously when in the RUN mode to reset the totalizer. The message TOTAL RST displays for a few seconds to indicate that the totalizer had been cleared. If a password has been set, you must enter the password to clear the totalizer.

Page 29 August 2019 DPP-UM-00256-EN-03

Menu Structure

MENU STRUCTURE

Hierarchy

The DFX flow meter has a hierarchical menu structure. See “Menu Maps” on page31 for a visual path to the configuration parameters. Use the table below as a quick reference guide to the pages with detailed information on each parameter.

Setup

Parameters

ID UNIT → INCH 33 AD SETUP → YES 36 CFG MOD1 → YES 34

DISPLAY → RAT E 33 HIGH 36 NO 35

RATE UNT → GALLONS 33 LOW 36 RELAY 27, 35

RATE INT → SEC 33 FLOW 0HZ → (numeric entry) 35

TOTL UNT → GALLONS 33

TOTL MUL → X PT 01 33

SP GRAV → (numeric entry) 33 FL C OFF → (numeric entry) 33

SCALE F → (numeric entry) 34

DAMPING → (numeric entry) 34

PASSWORD → (numeric entry) 34

Options

MM 33 NO 36 NO 34

ID → (numeric entry) 33 AGC MODE → NORMAL 36 CFG MOD2 → YES 35

TOTAL 33 MANUAL 36 MOD TYPE → NONE 35 BOTH 33 GAIN POT → (numeric entry) 36 4-20MA 25, 35 DIA 33 FILTER → NONE 36 R ATE 28, 35

LITERS 33 MEDIUM 36 FLOW 4MA → (numeric entry) 35 MGAL 33 HIGH 36 FLOW 20MA → (numeric entry) 35 CUBIC FT 33 XDCR TYP → DT90 36 4-20 CAL? → YES 35 M CU FT 33 PROBE 36 NO 35 CUBIC ME 33 C FACTOR → (numeric entry) 36 4MA OUT → (numeric entry) 35 MEG LTRS 33 LINEAR → YES 36 20MA OUT → (numeric entry) 35 ACRE FT 33 NO 36 4-20TEST → (numeric entry) 35 OIL BARR 33 NUM PTS → (numeric entry) 36 RATE → NONE 35 LIQ BARR 33 FREQ n → (numeric entry) 36 TOTA L 35 LBS 33 COEFF n → (numeric entry) 36 FLOW 35 KGS 33 ERRORS 35 VEL FT 33 n OFF → (numeric entry) 35 VEL MTRS 33 n ON → (numeric entry) 35

MIN 33 FLOW MAXHZ → (numeric entry) 35 HOUR 33 RATE TST → (numeric entry) 35 DAY 33 RATE PCT → (numeric entry) 35

LITERS 33 MGAL 33 CUBIC FT 33 M CU FT 33 CUBIC ME 33 MEG LTRS 33 ACRE FT 33 OIL BARR 33 LIQ BARR 33 LBS 33 KGS 33 VEL FT 33 VEL MTRS 33

X PT 1 33 X 1 33 X 10 33 X 100 33 X 1000 33 X 10000 33 X 100000 33 X 10000000 33

For Details,

see page

Advanced

Setup

Parameters

Options

For Details,

see page

Module

Configuration

Parameter

Options

For Details,

see page

Page 30 August 2019DPP-UM-00256-EN-03

Menu Maps

Menu Structure

To Module Conguration

NUM PTS

Number of Linearization Points

Numeric Entry (0 to 10)

AGC MODE

Automatic Gain Control

NORMAL

FL C-OFF

Low Flow Cuto

Numeric Entry

HIGH

FREQ n

MANUAL

SCALE F

COEFF n

Frequency of Point (n)

Numeric Entry

depending on the number

May require up to 10 cycles

of linear points chosen.

Coecient of Point (n)

Numeric Entry

From Module Conguration

Numeric Entry

DAMPING

Damping Percentage

Numeric Entry

FILTER

Hardware Filter

NONE

CFG MOD 1

Congure Module 1

LOW

MEDIUM

YES

HIGH

XDCR TYP

Transducer Type

CFG MOD 2

Congure Module 2

YES

GAIN POT

4 mA Flow Value

Scale Factor

Numeric Entry

DT90

PROBE

C FACTOR

Correction Factor

PASSWORD

LINEAR

Linearization?

YES

AD SETUP

Advanced Setup

YES

Numeric Entry

Password Entry

Numeric Entry

RATE INT

START

V1.16

SETUP MENU

Rate Inter val

SEC

MIN

I D UNIT

Pipe Measurement Units

HOUR

DAY

INCH (Inches)

MM (Millimeters)

TOTL UNT

Totalizer Units

Pipe Inside Diameter

GALLONS

LITERS

NUMERIC ENTRY

MGAL

CUBIC FT

M CU FT

CUBIC ME

DISPLAY

Display Choices

(42 Gal)

MEGL TRS

ACRE FT

OIL BARR

LIQ BARR (31.5 Gal)

LBS

KGS

RATE UNT

BOTH

DIAGNOSTICS

RAT E

TOTA L

Figure 28: Menu Map 1

VEL FEET

Flow Rate Units

VEL MTRS

GALLONS

LITERS

MGAL

TOTL MUL

Totalizer Multiplier

X PT 01(÷100)

CUBIC FT

M CU FT

X PT 1 (÷10)

X 1 (X1)

CUBIC ME

MEGL LTRS

ACRE FT

X 10 (X10)

X 100 (X1,00)

(42 Gal)

OIL BARR

LIQ BARR (31.5 Gal)

X 1000 (X1,000)

LBS

X 10000 (X10,000)

X 100000 (X100,000)

KGS

X 1000000 (X1,000,000)

VEL FEET

VEL MTRS

SP GRAV

Specic Gravity

Numeric Entry

Specic Gravity only appears

when LBS or KGS are selected

in either Rate Unit or Total Unit

Page 31 August 2019 DPP-UM-00256-EN-03

Menu Structure

MOD TYPE

Numeric Entry

RATE TST

n OFF <

Relay (n) O

Select Rate Test Function

FLOW 0HZ

Flow Rate at 0 Hz

RELAY n

Relay Functions

Numeric Entry

TOTAL

NONE

FLOW

FL MAXHZ

Flow Rate at 2500 Hz

ERRORS

Numeric Entry

Module Type

4-20 MA

NONE

RATE

RELAY

For Test Press Enter

n ON >

Relay (n) On

RATE PCT

10% Increments

Numeric Entry

1 & 2 are in

n = the relay

number 1, 2, 3 ,4

module 1.

3 & 4 are in

module 2.

To Password

4MA OUT

FLOW 4MA

4 mA Flow Value

FLOW 20MA

20 mA Flow Value

Numeric Entry

4-20 CAL?

4-20 Calibration?

YES

Numeric Entry

From Module Conguration

Figure 29: Menu map 2

Page 32 August 2019DPP-UM-00256-EN-03

4 mA DAC Value

20MA OUT

20 mA DAC Value

Numeric Entry

4-20TEST

4-20 mA Output Test

Numeric Entry

PARAMETERS

The following tables list and explain the parameters. The tables are divided into three main sections:

• Setup parameters

• Module configuration parameters

• Advanced setup parameters

Setup Parameters

The setup menu contains all of the configuration parameters necessary to make the transmitter operational.

Parameter Function Options Description

ID UNITS

DISPLAY Display mode

RATE UNT

RATE INT

TOTL UNT Totalizer units

TOTL MUL

SP GRAV

FL COFF Low flow cutoff (Enter a numeric value)

Measurement standard

Pipe inside diameter

Engineering units for flow rate

Time interval for flow rate

Flow totalizer multiplier value

Fluid specific gravity

ENGLSH (Inches) METRIC (Millimeters)

(Enter a numeric value)

RAT E TOTAL BOTH DIA

Select an engineering unit for flow rate measurements. When Pounds (LBS) or Kilograms (KGS) is selected, the specific gravity for the fluid type must be entered for the SP GRAV setup parameter.

Measurement Selection Measurement Selection

Pounds LBS Cubic Meters CUBIC ME

Kilograms KGS Millions of Metric Liters MEGLTRS

Gallons GALLONS Acre Feet ACRE FT

Liters LITERS Oil Barrels (42 Gallons) OIL BARR

Millions of Gallons MGAL Liquor Barrels (31.5 Gallons) LIQ BARR

Cubic Feet CUBIC FT Velocity in Linear Feet VEL FEET

Millions of Cubic Feet M CU FT Velocity in Linear Meters VEL MTRS

SEC Seconds MIN Minutes HOUR Hours DAY Days

Select an engineering unit for flow totalizer measurements. When Pounds (LBS) or Kilograms (KGS) is selected, the specific gravity for the fluid type must be entered for the SP GRAV setup parameter.

Measurement Selection Measurement Selection

Pounds LBS Cubic Meters CUBIC ME

Kilograms KGS Millions of Metric Liters MEGLTRS

Gallons GALLONS Acre Feet ACRE FT

Liters LITERS Oil Barrels (42 Gallons) OIL BARR

Millions of Gallons MGAL Liquor Barrels (31.5 Gallons) LIQ BARR

Cubic Feet CUBIC FT Velocity in Linear Feet VEL FEET

Millions of Cubic Feet M CU FT Velocity in Linear Meters VEL MTRS

0.01…1,000,000

(Enter a numeric value)

Selects the unit of measure for pipe ID entry.

Enter the pipe inside diameter in inches if ENGLSH was selected as UNITS; in millimeters if METRIC was selected.

To display only the Flow Rate, select R ATE . To display only the Flow Total, select TOTAL . To alternately display the Flow Rate and the Total, select BOTH. By selecting BOTH, the display switches between RATE and TOTAL every 7 seconds.

The DIA selection places the display in the diagnostics mode. When selected, the display shows the measured frequency, the gain setting and the signal strength.

Select a time interval for flow rate measurements.

Used for setting the flow totalizer exponent. This feature is useful for accommodating a very large accumulated flow. The exponent is a ×10n multiplier, where “n” can be from -2 (×0.01) to +6 (×1,000,000). Reference the table below for valid entries and their influence on the DFX meter display.

Exponent Display Multiplier

× PT 01 2 × 0.01

× PT 1 1 × 0.1

×1 0 × 1

×10 1 × 10

×100 2 × 100

×1000 3 × 1000

×10000 4 × 10,000

×100000 5 × 100,000

×1000000 6 × 1,000,000 Allows adjustments to be made to the specific gravity (density relative to water) of the liquid. If Pounds (LBS) or Kilograms (KGS) is selected for either the RATE UNT or the TOTL UNT, a specific

gravity must be entered for the correct mass flow to be calculated. A list of fluids and their associated specific gravities is located in “Specifications” on page40.

A Low Flow Cutoff entry is provided to allow very low flow rates (that can be present when pumps are off and valves are closed) to be displayed as Zero flow. The value entered is in actual

rate units.

Parameters

Page 33 August 2019 DPP-UM-00256-EN-03

Parameters

Parameter Function Options Description

The SCALE F function applies a correction factor/multiplier to the readings and outputs so the DFX system can agree with a different or reference flow meter, or to compensate for an installation where there is inadequate straight pipe to obtain a laminar flow profile. A factory

SCALE F Scale factor value (Enter a numeric value)

DAMPING

CFG MOD1

CFG MOD2

System damping percentage

Configure I/O Module

(Enter a numeric value 0…99%)

YES or NO

calibrated system should be set to 1.000. The range of settings for this entry is 0.5000…5.000. The following example describes using the SCALE F entry.

The DFX meter is indicating a flow rate that is 4% higher than another flow meter located in the same pipe line. To have the meter indicate the same flow rate as the other meter, enter a SCALE F of 0.960, to lower the readings by 4%.

Flow Filter Damping establishes a maximum adaptive filter value. Under stable flow conditions (flow varies less than 10% of reading), this adaptive filter increases the number of successive flow readings that are averaged together up to this maximum value. If flow changes outside of the 10% window, the Flow Filter adapts by decreasing and allows the meter to react faster. Increasing this value tends to provide smoother steady-state flow readings and outputs.

This prompt lets you access the setup parameters associated with installation of the optional ISO-MOD interface modules. If NO is selected, the unit skips ahead to CFG MOD2. If YES is selected, configuration and calibration of the module installed in the first position is accessible.

If NO was selected at CFG MOD1, CFG MOD2 becomes active. This prompt lets you access the setup parameters associated with installation of the optional ISO-MOD interface modules. If NO is selected, the unit skips ahead to PASSWORD. If YES is selected, configuration and calibration of the module installed in the second position is accessible.

Page 34 August 2019DPP-UM-00256-EN-03

Module Conguration Parameters

When YES is selected at CFG MOD1 or CFG MOD2, these MOD TYPE parameters become available:

• NONE

• 4…20 mA

• RATE

• RELAY Once the module is configured, the menu moves to the PASSWORD parameter.

MOD TYPE Function Options Description

NONE

420MA

RAT E

RELAY

No module is installed

4…20 mA type module

Rate pulse output module

Relay 1 and Relay 2 configuration

NONE Select NONE (no module installed) to move to the PASSWORD parameter.

FLOW 4MA Enter the flow rate that corresponds to 4 mA. The units are equal to the units set in RATE UNT. FLOW 20MA Enter the flow rate that corresponds to 20 mA. The units are equal to the units set in RATE UNT.

Select NO to move to the PASSWORD parameter. Select YES to adjust the “zero” and span of the 4…20 mA output.

To adjust either the 4 mA or 20 mA output, connect a milliammeter or reliable

4MA OUT

4-20 CAL?

20MA OUT

4-20TEST

FLOW 0Hz Enter the flow rate that corresponds to 0 Hz. The units are equal to the units set in RATE UNT. FL MAXHZ Enter the flow rate that corresponds to 2500 Hz. The units are equal to the units set in RATE UNT. RATE TST Simulate a pulse output. Moves to RATE PCT entry.

Allows a simulated value to be output from the rate pulse output. By incrementing this value, the rate pulse output transmits the indicated frequency in terms of percentage of the maximum

RATE PCT

NONE Select NONE (no Relay 1 installed) to move to the Relay 2 parameter.

TOTAL

FLOW

ERRORS

output frequency. For example, if the maximum output frequency is 2500 Hz, increment the displayed value to 50 to

output a test frequency of 1250 Hz.

TOTAL mode configures the relay to output a 50 m/s pulse (contact changeover) each time the display totalizer increments. Select TOTAL to configure the relay for Totalizer Relay and move to the PASSWORD menu.

Flow Rate Relay configuration permits relay changeover at two separate flow rates allowing operation with an adjustable switch deadband. Figure 30 on page 37 illustrates how the setting of the two set points influences Rate Alarm operation.

A single-point flow rate alarm would place the ON> setting slightly higher than the OFF< setting—allowing a switch deadband to be established. If a deadband is not established, switch chatter (rapid switching) may result if the flow rate is very close to the switch point.

When a relay is set to ERROR mode, the relay activates when any error occurs in the flow meter that has caused the meter to stop measuring reliably. See “Startup and Troubleshooting” on

page38 for a list of potential errors.

reference to the output.

1. Disconnect one side of the current loop and connect the milliammeter in series (disconnect either wire at the terminals labeled +/– on the ISOMOD 4…20 mA module).

2. Using the arrow keys, increase the numerical value to increase the current in the loop to the output. Decrease the value to decrease the current in the loop to output. The value range for 4MA OUT is 40…80 counts. The value range for 20MA OUT is 3700…3900 counts.

3. Re-connect the 4…20 mA output circuitry as required.

Outputs a simulated value from the 4…20 mA output. By incrementing this value, the 4…20 mA output transmits the indicated current value.

Parameters

Page 35 August 2019 DPP-UM-00256-EN-03

Parameters

Advanced Conguration Parameters

Parameter Function Options Description

By changing the Security Password from 0000 to some other value (any value between 0001…9999), configuration parameters are not accessible without first entering that value when prompted. If the value is left at 0000, no security is invoked and unauthorized changes could be made. Access to resetting of the Totalizer is also protected by this password.

PASSWORD

AD SETUP (continued on next page)

Change the security password

Advance setup mode

Select YES to access these parameters: AGC MODE GAIN POT FILTER LINEAR

(continued on next page)

0…9999

AGC MODE – Automatic Gain Control Mode of Operation NORMAL – Standard Configuration HIGH – Used for low signal strength MANUAL – AGC disabled GAIN POT – Digital Gain Control FILTER – Hardware Filter Control

Select the mode of operation. A basic understanding of the AGC logic is required in order to know when to use any selection other than NORMAL.

When the unit is powered up, there is a delay before the unit begins transmitting sound into the pipe. During this time, the signal strength is measured and a base signal level is obtained. Typically this is a value of about 20. The unit measures flow by measuring the Doppler frequency shift. The frequency shift is approximately 70 Hz per foot per second. For every foot per second increase in velocity, the signal strength should increase by 1. The unit automatically adjusts the gain and selects the proper hardware filter for the measured velocity. The control can be observed when the DISPLAY mode is set to DIAG. See Figure 31 on page 38.

Manual Operations

When NORMAL is selected, the unit automatically controls the gain and front end hardware filter for optimum measurement of the Doppler signal.

Select HIGH for applications where the unit reads flow rates consistently, but much lower than the actual flow rate. This may be required when sound is not getting through the pipe as well. Selecting HIGH causes the unit to look for the signal strength to increase by 2 for every foot per second increase in flow rate. Basically, the gain is doubled, but still automatically controlled.

Select the MANUAL mode for applications where the flow is constant but there is extraneous noise to filter out. Typically, this would only be required at very low flow rates. When MANUAL mode is selected, the GAIN POT and FILTER settings are manually set. Automatic control is disabled.

Gain Control

GAIN POT – Digital Gain Pot 0…64 Using the arrow keys, increase or decrease the numerical value to set the signal gain level. Typically, optimum flow measurement is made when this value is 10…50. Use the lowest value that provides an accurate and stable flow reading. This adjustment must be made in conjunction with the FILTER setting.

Page 36 August 2019DPP-UM-00256-EN-03

Parameter Function Options Description

Hardware Filter

FILTER – Hardware Filter Selection NONE – No Filter LOW – (1600 Hz Cutoff) MEDIUM – (350 Hz Cutoff) HIGH – (250 Hz Cutoff) Select the hardware filter with a cutoff frequency that is above the Doppler shift frequency to be measured. The Doppler shift frequency is found by multiplying the flow velocity (in FPS) by 80. For example, if the flow velocity is 4 FPS then the cutoff frequency is 4 × 80 or 320 Hz. The filter with the next highest frequency would be 350 Hz. Transducer Type

XDCR TYPE – Transducer Type

DT9 – Clamp-on Transducers PROBE – DP7 Insertion Probe Transducer

Select the appropriate transducer type to be connected to the DFX transmitter. The selection invokes optimum hardware and software settings unique to the transducer architecture. Correction Factor C FACTOR – Transducer Type

0.01…5.00 This value is established at the factory during calibration. If a new set of transducers or insertion probe is connected , the new correction factor should be entered. The correction factor values can be found on transducers or probes labels.

Linearization

LINEAR – Entry of Linearization Data

The Linearization feature corrects flow readings influenced by non-linear flow measurement. This typically occurs when there is insufficient straight piping before or after the location where the transducers are mounted.

Up to 10 linearization points may be entered. The microprocessor performs a linear interpolation between data points entered in the linearization table and apply the associated correction factor to the measured flow rate.

AD SETUP (continued from previous page)

Advance setup mode

Select YES to access these parameters: AGC MODE GAIN POT FILTER LINEAR

(continued from previous page)

1. Enter the number of linearization points at the NUM PTS prompt. If a value of 00 is entered, linearization is disabled. The unit prompts for FREQ 1 to be entered.

2. Enter the measured frequency corresponding to the ow rate for the rst point. This can be obtained by running actual ow with the DISPLAY mode set to DIAG and reading the measured frequency, or by calculating the frequency if the ow rate in feet per second is known using the following formulas:

DT9 CLAMPON TRANSDUCER: FREQ = VELOCITY FPS × 80 HZ

DP7 INSERTION PROBE TRANSDUCER: FREQ = VELOCITY FPS × 80 HZ

The unit prompts for COEFF 1 to be entered. This is the multiplication factor for the measured flow rate.

3. Enter the coecient or correction factor to be applied. The value entered must be between 0.5…1.5.

4. Repeat this procedure for all of the linearization points. When all of the points have been entered, the unit returns to the NUM PTS prompt.

5. Press MENU to return to the main menu LINEAR prompt. Then press UP or DOWN to move to the next setup parameter.

Parameters

Minimum

Flow

Set OFF

Set ON

Output OFF

Deadband

Figure 30: Single point alarm operation

Maximum

Flow

Output ON

Page 37 August 2019 DPP-UM-00256-EN-03

Startup and Troubleshooting

Gain

RUN

Frequency

Signal

Strength

51000

0 0

MEM

AUTO

AutoHOLD FAST MIN MX LOGGING YES

HOLD MIN MAX REL

CANCEL SAVE NO

Hz % ms RANGE

SETUP

°F

°C

ac+dc

OFF

VIEW MEM

CLEAR MEM

COM

µA

10A MAX

CAT III

400mA

FUSED

I/O: 4-20 mA

P.N. D020-1045-100

OUT (-)

IN (+)

INT PWR EXT PWR

JP2 JP1

MANUAL

µA

ac+dc

µA

ac+dc

TEMPERATURE

1000V

ISO-MOD

Figure 31: Diagnostic display

Figure 32: 4…20 mA calibration setup

STARTUP AND TROUBLESHOOTING

OTE:N The DFX flow meter system requires a full pipe of flowing liquid before a successful startup evaluation can be

completed. Do not attempt to make adjustments or make manual configuration changes until a full pipe of flowing liquid is verified.

OTE:N If an RTV sealant was used to couple the transducers to the pipe, the sealant must fully cure before power is applied

to the instrument. Most RTVs require 24 hours to cure satisfactorily. It is very important that the transducers are not moved during the curing process. Air bubbles can form between the transducer and the pipe wall and influence performance. If silicone grease was used as a couplant, the curing time is not required.

Startup

1. Verify that the DT9 or DP7 transducer has been properly installed and wired. See “Transducer Installation” on page 10.

2. Verify that the power supply jumper settings are properly congured for the power supply. See “Power Supply Wiring

Connections” on page 21.

3. Verify that the meter is properly programmed. See “Instrument Programming” on page 29.

4. Apply power.

5. On initial powerup, the DFX meter’s microprocessor conducts a series of self-diagnostic tests, baseline measurements and begins to buer liquid velocity data. During this 30-second startup, ow rate readings and outputs are inhibited.

6. After the startup routine has completed running, the meter begins to display ow rate and/or total as congured.

7. If an ERROR appears on the monitor’s lower display, see “Troubleshooting” on page 39.

Page 38 August 2019DPP-UM-00256-EN-03

Troubleshooting

Symptom Cause/Resolution

• Insufficient power to monitor. Measure voltage at J2.

• Power supply not properly wired to J2. See “Power Supply Wiring Connections” on page 21.

Display does not light up

ERROR on the DFX flow meter display

Unstable flow reading

Inaccurate flow reading

Analog output does not match data collection system

Rate Pulse output does not match data collection system

DFX flow meter does not capture short flow pulses

• Fuse F1 is open or not installed.

• Power supply jumpers are not installed properly. See “Power Supply Wiring Connections” on page 21..

• Ribbon cable between the door and enclosure back is not fully engaged into the two sockets.

• Transducers not properly coupled to the pipe. Couplant is not present or pipe not properly prepared.

• Transducer not properly wired to the J4 Terminal block inside the meter. Review the Wiring Diagram on the inside door of the DFX meter.

• More than one DFX meter is installed on the piping system. See “Multiple Meter Installations” on page 23.

• Insufficient particles over 35 microns. Inject air upstream of the transducers.

• Too many particles that are smaller than 35 micron prevent ultrasonic meters from operating.

• Transducer failure. Unplug transducer cable from J4, measure capacitance between blue/clear or red/ black Receive and Transmit. Verify that the capacitance on each set is approximately 2 nF (nano Farads) and within 0.02 nF of each other.

• Relocate transducer to a pipe position with less hydraulic disturbance.

• Increase Damping value.

• Ensure that ground connection is properly connected to meters earth ground. See Figure 13.

• Verify that pipe ID is entered correctly.

• Verify that an erroneous Scale Factor has not been entered.

• Verify that erroneous Linearization values have not been entered.

• Verify that AGC is set to Normal.

• Verify that the transducers are mounted square and 180 degrees apart on the pipe.

• Relocate transducer to a pipe position with greater straight run length.

• DP7 Probe not aligned in the pipe.

• Verify 4…20 mA calibration.

• Verify 4 mA and 20 mA flow settings. Verify that the loop load is within the supply voltage range

• Run 4…20mA TEST feature to verify that mA outputs coincide with expected data collection system readings.

• Verify 0 Hz and MAX Hz flow settings.

• Place oscilloscope or frequency counter on the Rate Pulse module outputs and verify frequency output.

• Run output TEST feature to verify that the Hz output coincides with expected data collection system readings.

• Verify that the K-factor has been calculated correctly: K-factor = Hz/(flow/second) Example: Max Hz (2500 Hz) = 10,000 Gallons/Minute K-factor = 2,500 Hz / 166.7 Gallons/Second K-factor = 15 pulses/gallon

• Verify that the data collection system is accepting the pulses from the meter. Connect to Turbine OUT or OUT/IN as required.

When run in AUTO mode, the meter uses a series of filters that optimize readings for a particular flow range. The flow meter takes several seconds to adjust to a step change in flow. To make the flow meter respond quickly to changes in flow, decrease DAMPING, place the meter into MANUAL AGC and lock the FILTER at NONE.

Startup and Troubleshooting

Page 39 August 2019 DPP-UM-00256-EN-03

Specications

SPECIFICATIONS

Velocity Range 0.15…30 fps (0.05…9 mps) Accuracy ±2% full scale, over calibrated span

Liquid Types

Monitor Enclosure

Power Supply 115/100/230V AC 50/60 Hz ±15% @ 17V A max; 12…28V DC @ 7V A max Display 2-line × 8 character LCD; LED backlighting; 8-digit rate, 8-digit total (resettable)

Units

Rate Interval Second, minute, hour, day. Totalizer exponent: E-2 to E+6 (x ¹/100 to x 1,000,000) Response Time User selectable: 6…60 seconds

Output Options

Multiple Meters

Keypad 4-key, tactile Ambient Conditions –40…185º F (–40…85º C); 0…95% relative humidity (non-condensing) Approvals (Std.) General Safety US and Canada. Certified to UL 61010-1 and CSA C22.2 No. 61010-1 Transducer Type Compression-mode Ultrasonic; 625 kHz

Construction

Pipe Sizes

Liquids containing a minimum of 100 ppm of useful sonic suspended reflectors greater than 35 micron size, and at least 25% of the overall particle volume is larger than 100 microns

NEMA 4X (IP 66), polycarbonate, stainless steel, brass, plated-steel mounting brackets 7.00 in. H × 5.75 in. W × 3.88 in. D (178 mm × 146 mm × 99 mm)

User configured: Feet, US gallons, ft³, Mil-gal, meters, liters, Mil-ft³, m³, Mil-liters, acre-feet, oil barrels (42 US gallons), liquid barrel (32.5 US gallons), lb, Kg

4…20 mA 800 ohms max, internal or external power supply, 12-bit resolution

Optically Isolated Dual Relay

Rate Pulse

Synchronization provision included—utilized for multiple meter, single pipe/manifold system. Up to four meters may be interconnected, up to 100 feet (30 meters) apart

Standard Clamp-On

Optional Flexible Armored Conduit Zinc-plated steel, PVC Standard Clamp-On Transducers 1 inch (25 mm) and above Small Pipe Clamp-On Transducers 0.25…1 inch (6…25 mm) Standard Lengths 20, 50 and 100 foot (6.1, 15 and 30 meter), 78 Ohm twinax cable Optional Lengths To 990 feet (297 meters), 75 Ohm RG59 cable

500 mV AC 2500 Hz max, 12-bit resolution, 500 mV AC into 2 K Ohm minimum; Open collector 2500 Hz max, 1 A at 100 V max

Independently configured; Form C, 200V AC @ 0.5 A resistive; rate alarm, totalizer pulse, error

Type 6* (IP 67) –40…194º F (–40…90º C) CPVC, Ultem®, Nylon, PVC (Cable Jacket), Aluminum (small pipe) *Depth of 1 meter for 30 minutes

Page 40 August 2019DPP-UM-00256-EN-03

NORTH AMERICAN PIPE SCHEDULES

Steel, Stainless Steel, PVC Pipe, Standard Classes

North American Pipe Schedules

NPS

in.

1 1.315

1.25 1.660 1.278 0.191 1.278 0.191 1.160 0.250

1.5 1.900 1.500 0.200 1.500 0.200 1.338 0.281 2 2.375 1.939 0.218 1.939 0.218 1.687 0.344

2.5 2.875 2.323 0.276 2.323 0.276 2.125 0.375 3 3.500 2.900 0.300 2.900 0.300 2.624 0.438

3.5 4.000 4 4.500 3.826 0.337 3.826 0.337 3.624 0.438 3.438 0.531 5 5.563 4.813 0.375 4.813 0.375 4.563 0.500 4.313 0.625 6 6.625 5.761 0.432 5.761 0.432 5.501 0.562 5.187 0.719 8 8.625 7.813 0.406 7.625 0.500 7.625 0.500 7.437 0.594 7.178 0.719 6.183 1.221

10 10.75 9.750 0.500 9.75 0.500 9.562 0.594 9.312 0.719 9.062 0.844 8.500 1.125 12 12.75 11.626 0.562 11.75 0.500 11.37 0.690 11.06 0.845 10.75 1.000 10.12 1.315 14 14.00 12.814 0.593 13.00 0.500 12.50 0.750 12.31 0.845 11.81 1.095 11.18 1.410 16 16.00 14.688 0.656 15.00 0.500 14.31 0.845 13.93 1.035 13.56 1.220 12.81 1.595 18 18.00 16.564 0.718 17.00 0.500 16.12 0.940 15.68 1.160 15.25 1.375 14.43 1.785 20 20.00 18.376 0.812 19.00 0.500 17.93 1.035 17.43 1.285 17.00 1.500 16.06 1.970 24 24.00 22.126 0.937 23.00 0.500 21.56 1.220 20.93 1.535 20.93 1.535 19.31 2.345 30 30.00 36 36.00 35.00 0.500 42 42.00 41.00 0.500 48 48.00 47.00 0.500

in.

SCH 60 X STG. SCH 80 SCH 100 SCH 120/140 SCH 180

in.

—

Wall

in.

0.957 0.179 0.957 0.179

3.364 0.318 3.364 0.318

29.00 0.500

Wall

in.

Wall

in.

— — — —

in.

Wall

in.

— —

—

in.

Wall

in.

— —

ID in.

0.815 0.250

Wall

in.

Table 3: Steel, stainless steel, PVC pipe, standard classes

Page 41 August 2019 DPP-UM-00256-EN-03

North American Pipe Schedules

Steel, Stainless Steel, PVC Pipe, Standard Classes (continued)

SCH 10

(Lt Wall)

ID in.

13.50 0.250 13.37 0.315 13.25 0.375 13.25 0.375 13.124 0.438

29.37 0.315 29.00 0.500 29.00 0.500 29.25 0.375 29.25 0.375

Figure 18: Steel, stainless steel, PVC pipe, standard classes (continued)

Wall

in.

— — —

SCH 20 SCH 30 STD SCH 40

in.

Wall

in.

— —

in.

Wall

in.

1.049

3.548 — 3.548 0.226

41.25 0.375 41.25 0.375

Wall

in.

—

ID in.

1.049 0.133

Wall

in.

ID in.

SCH 5

Wall

in.

—

NPS

in.

1 1.315 1.185 0.065 1.097 0.109

1.25 1.660 1.53 0.065 1.442 0.109 1.380 1.380 0.140

1.5 1.900 1.77 0.065 1.682 0.109 1.610 1.610 0.145 2 2.375 2.245 0.065 2.157 0.109 2.067 2.067 0.154

2.5 2.875 2.709 0.083 2.635 0.120 2.469 2.469 0.203 3 3.500 3.334 0.083 3.260 0.120 3.068 3.068 0.216

3.5 4.000 3.834 0.083 3.760 0.120 4 4.500 4.334 0.083 4.260 0.120 4.026 0.237 4.026 0.237 5 5.563 5.345 0.109 5.295 0.134 5.047 0.258 5.047 0.258 6 6.625 6.407 0.109 6.357 0.134 6.065 0.280 6.065 0.280 8 8.625 8.407 0.109 8.329 0.148 8.125 0.250 8.071 0.277 7.981 0.322 7.981 0.322

10 10.75 10.482 0.134 10.42 0.165 10.25 0.250 10.13 0.310 10.02 0.365 10.02 0.365 12 12.75 12.42 0.165 12.39 0.180 12.25 0.250 12.09 0.330 12.00 0.375 11.938 0.406 14 14.00 16 16.00 15.50 0.250 15.37 0.315 15.25 0.375 15.25 0.375 15.000 0.500 18 18.00 17.50 0.250 17.37 0.315 17.12 0.440 17.25 0.375 16.876 0.562 20 20.00 19.50 0.250 19.25 0.375 19.25 0.375 19.25 0.375 18.814 0.593 24 24.00 23.50 0.250 23.25 0.375 23.25 0.375 23.25 0.375 22.626 0.687 30 30.00 36 36.00 35.37 0.315 35.00 0.500 35.00 0.500 35.25 0.375 35.25 0.375 42 42.00 48 48.00 47.25 0.375 47.25 0.375

in.

Page 42 August 2019DPP-UM-00256-EN-03

Copper Tubing, Copper and Brass Pipe, Aluminum

North American Pipe Schedules

Nominal

Diameter

0.5

0.6250

0.75

1.25

1.5.

2.5

Copper Tubing

in.

K L M K L M

OD 0.625 0.625 0.625 0.840

ID 0.527 0.545 0.569 0.625 ID 3.385 3.425 3.459 3.500

OD 0.750 0.750 0.750

Wall 0.049 0.042 0.030 Wall 0.134 0.110 0.095 0.095 0.250

ID 0.652 0.666 0.690 ID 3 857 3.905 3.935 3.935 4.000

OD 0.875 0.875 0.875 1.050

Wall 0.065 0.045 0.032 0.114 Wall 0.250

ID 0.745 0.785 0.811 0.822 ID 4.500

OD 1.125 1.125 1.125 1.315

Wall 0.065 0.050 0.035 0.127 Wall 0.160 0.125 0.109 0.250 0.063

ID 0.995 1.025 1.055 1.062 ID 4.805 4.875 4.907 5.063 4.874

OD 1.375 1.375 1.375 1.660

Wall 0.065 0.055 0.042 0.146 Wall 0.192 0.140 0.122 0.250 0.063

ID 1.245 1.265 1.291 1.368 ID 5.741 5.845 5.881 6.125 5.874

OD 1.625 1.625 1.625 1.900

Wall 0.072 0.060 0.049 0.150 Wall 0.282 0.078

ID 1.481 1.505 1.527 1.600 ID 7.062 6.844

OD 2.125 2.125 2.125 2.375

Wall 0.083 0.070 0.058 0.157 Wall 0,271 0.200 0.170 0.313 0.094

ID 1.959 1.985 2.009 2.062 ID 7.583 7.725 7.785 8.000 7.812

OD 2.625 2.625 2.625 2.875 2.500

Wall 0.095 0.080 0.065 0.188 0.050 Wall 0.338 0.250 0.212 0.094 —

ID 2.435 2.465 2.495 2.500 2.400 ID 9.449 9.625 9.701 9.812 —

OD 3.125 3.125 3.125 3.500 3.000

Wall 0.109 0.090 0.072 0.219 0.050 Wall 0.405 0.280 0.254 — —

ID 2.907 2.945 2.981 3.062 2.900 ID 11.315 11.565 11.617 — —

Type Type

Copper & Brass

Pipe

in.

— — 4 in.

Alum.

in.

—

— 5 in.

— 6 in.

— 7 in.

— 8 in.

Nominal

Diameter

in.

OD 3.625 3.625 3.625 4.000

3-1/2

in.

OD 4.125 4.125 4.125 4.500 4.000

4-1/2

in.

OD 5.125 5.125 5.125 5.563 5.000

OD 6.125 6.125 6.125 6.625 6.000

OD 8.125 8.125 8.125 8.625 8 000

OD 10.125 10.125 10.125 10 000 —

10 in.

OD 12.125 12.125 12.125 — —

12 in.

Copper Tubing

in.

— — — —

— — —

Copper & Brass

Pipe

in.

7.625 7.000

Alum.

in.

—Wall 0.049 0.040 0.028 0.108 Wall 0.120 0.100 0.083 0.250

5.000

Table 4: Copper tubing, copper and brass pipe, aluminum

Page 43 August 2019 DPP-UM-00256-EN-03

North American Pipe Schedules

Cast Iron Pipe, Standard Classes, 3…20 inch

Size

in.

OD 3.80 3.96 3.96 3.96

ID 3.02 3.12 3.06 3.00

OD 4.80 5.00 5.00 5.00

ID 3.96 4.10 4.04 3.96

OD 6.90 7.10 7.10 7.10 7.22 7.22 7.38 7.38

Wall 0.44 0.48 0.51 0.55 0.58 0.61 0.65 0.69

ID 6.02 6.14 6.08 6.00 6.06 6.00 6.08 6.00

OD 9.05 9.05 9.30 9.30 9.42 9.42 9.60 9.60

Wall 0.46 0.51 0.56 0.60 0.66 0.66 0.75 0.80

ID 8.13 8.03 8.18 8.10 8.10 8.10 8.10 8.00

OD 11.10 11.10 11.40 11.40 11.60 11.60 11.84 11.84

Wail 0.50 0.57 0.62 0.68 0.74 0.80 0.86 0.92

ID 10.10 9.96 10.16 10.04 10.12 10.00 10.12 10.00

OD 13.20 13.20 13.50 13.50 13.78 13.78 14.08 14.08

Wall 0.54 0.62 0.68 0.75 0.82 0.89 0.97 1.04

ID 12.12 11.96 12.14 12.00 12.14 12.00 12.14 12.00

OD 15.30 15.30 15.65 15.65 15.98 15.98 16.32 16.32

Wall 0.57 0.66 0.74 0.82 0.90 0.99 1.07 1.16

ID 14.16 13.98 14.17 14.01 14.18 14.00 14.18 14.00

OD 17.40 17.40 17.80 17.80 18.16 18.16 18.54 18.54

Wall 0.60 0.70 0.80 0.89 0.98 1.08 1.18 1.27

ID 16.20 16.00 16.20 16.02 16.20 16.00 16.18 16.00

OD 19.50 19.50 19.92 19.92 20.34 20.34 20.78 20.78

Wall 0.64 0.75 0.87 0.96 1.07 1.17 1.28 1.39

ID 18.22 18.00 18.18 18.00 18.20 18.00 18.22 18.00

OD 21.60 21.60 22.06 22.06 22.54 22.54 23.02 23.02

Wall 0.67 0.80 0.92 1.03 1.15 1.27 1.39 1.51

ID 20.26 20.00 20.22 20.00 20.24 20.00 20.24 20.00

A B C D E F G H

Class

in.

— — — —Wall 0.39 0.42 0.45 0.48

— — — —Wall 0.42 0.45 0.48 0.52

Table 5: Cast iron pipe, standard classes, 3…20 inch

Page 44 August 2019DPP-UM-00256-EN-03

Cast Iron Pipe, Standard Classes, 24…84 inch

North American Pipe Schedules

Size

in.

Wall

O D

Wall

Class

in.

A B C D E F G H

25.80 25.80 26.32 26.32 26.90 26.90 27.76 27.76

0.76 0.98 1.05 1.16 1.31 1.45 1.75 1.88

24.28 24.02 24.22 24.00 24.28 24.00 24.26 24.00

31.74 32.00 32.40 32.74 33.10 33.46

0.88 1.03 1.20 1.37 1.55 1.73

29.98 29.94 30.00 30.00 30.00 30.00

37.96 38.30 38.70 39.16 39.60 40.04

0.99 1.15 1.36 1.58 1.80 2.02

35.98 36.00 35.98 36.00 36.00 36.00

44.20 44.50 45.10 45.58

1.10 1.28 1.54 1.78

42.00 41.94 42.02 42.02

50.55 50.80 51.40 51.98

1.26 1.42 1.71 1.99

47.98 47.96 47.98 48.00

56.66 57.10 57.80 58.40

1.35 1.55 1.90 2.23

53.96 54.00 54.00 53.94

62.80 63.40 64.20 64.28

1.39 1.67 2.00 2.38

60.02 60.06 60.20 60.06

75.34 76.00 76.88

1.62 1.95 2.39

72.10 72.10 72.10

87.54 88.54

1.72 2.22

84.10 84.10

—

Table 6: Cast iron pipe, standard classes, 24…84 inch

Page 45 August 2019 DPP-UM-00256-EN-03

Part Number Construction

PART NUMBER CONSTRUCTION

DDFX Digital Doppler Ultrasonic Flow Transmitter

D D F X D 2

Transmitter Type Power Supply Input/Output 1 Input/Output 2 Totalizer Approvals Options

2) Rate and Totalizer A) 115V AC N) None N) None A) Eight digit B) 230V AC 1) 4 C) 100V AC 2) Dual Relay 2) Dual Relay E) 9

  

…20 mA 1) 4…20 mA

…28V DC 3) Rate Pulse 3) Rate Pulse

resettable

N N

N) General safety

to US/Canadian standards

DT9 Doppler Ultrasonic Transducer Set

D T 9

Piping Environment* Cable Length Conduit Type Conduit Length Options

4) Std temp/Std pipe 020) 20 ft (6 m) N) None 000) 0 ft (0 m) N) General safety

5) Std temp/small pipe 050) 50 ft (15 m) 020) 20 ft (6 m)

*Std Temp: Maximum (+194° F) (+90° C) Small Pipe: 1/4…1 in. (6…25 mm) Std. Pipe: 1 in. (25 mm) and above



  

100) 100 ft (30 m) 050) 50 ft (15 m)

Max. length: 990 ft (297 m) in 10 ft (3 m) increments

NOTE: All DT9 transducers include acoustic couplant. DT94 includes four (4) 36 in. (890 mm) mounting straps.

   - 

A) Flexible Armored

100) 100 ft (30 m)

Max. length: 990 ft (297 m) in 10 ft (3 m) increments

DP7 Insertion Doppler Ultrasonic Probes

DP7

N) None

to US/Canadian standards

Probe Length

1) 8 in. (203 mm)*

2) 18 in. (457 mm)

3) 28 in. (711 mm)

4) 38 in. (965 mm)

5) 48 in. (1220 mm)

Consult factory for longer lengths.

Cable Length

020) 20 ft (6 m)

050) 50 ft (15 m)

100) 100 ft (30 m)

Maximum length: 990 ft (297 m) in 10 ft (3 m) increments.

Conduit Type

N) None A) Flexible Armored

*Cannot be used with hot tap assembly.

OTE:N All DP7 probes include a seal fitting for mounting in 1-1/2 in. NPT ports. Isolation valve kits are available for hot-tapped applications.

Conduit Length

000) 0 ft (0 m)

020) 20 ft (6 m)

050) 50 ft (15 m)

100) 100 (30 m)

Maximum length: 990 ft (297 m) in 10 ft (3 m) increments.

Options

N) None B) 1-1/2 in. RF ange

Page 46 August 2019DPP-UM-00256-EN-03

INTENTIONAL BLANK PAGE

User Manual

Page 47 August 2019 DPP-UM-00256-EN-03

Doppler Ultrasonic Flow Meters, Series DFX

Control. Manage. Optimize.

Dynasonics is a registered trademark of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2019 Badger Meter, Inc. All rights reserved.

www.badgermeter.com

Dynasonics DFX Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Scope of This Manual

UNPACKING AND INSPECTION

SAFETY

Terminology and Symbols

Quick-Start Operating Overview

Transducer Location

Pipe Preparation and Transducer Mounting

Transducer Connections

Startup

Introduction

General

Application Versatility

User Safety

Data Integrity

Transducer Installation

Unpacking and Inspection

Mounting Locations

Pipe Preparation

DT9 Clamp-On Transducer Mounting

DP7 Probe Transducer Mounting

Transmitter Installation

Unpacking and Inspection

Mounting Location

Dimensions

Transducer Wiring Connections

Power Supply Wiring Connections

AC Power Supply Connections

DC Power Supply Connections

Multiple Meter Installations

ISO Modules

4…20 mA Output Module

Control Relay Output Module

Rate Pulse Output Module

Instrument Programming

General

Keypad Operation

Totalizer Reset

Menu Structure

Hierarchy

Menu Maps

PARAMETERS

Setup Parameters

Startup and Troubleshooting

Startup

Troubleshooting

SPECIFICATIONS

NORTH AMERICAN PIPE SCHEDULES

Part Number Construction