Series D601 Doppler Ultrasonic Flow Meter Operations & Maintenance Manual REV 4/00
PART 1 - TABLE OF CONTENTS Description Pages Quick Start Installation 1.2-1.3 Operating Theory 1.4 Product Limitations 1.5 Model Number Matrix 1.6 Specifications 1.7 Transducer Installation 2.1-2.5 Pre-Installation Functional Test 3.1-3.2 Transmitter Installation 3.3-3.4 Power Source Jumper Settings 3.5 Electrical Connections 3.5-3.6 Power Up and Configuration 3.7 Keypad Operations 3.8-3.19 Trouble Shooting 3.20-3.
PART 1 - QUICK START This manual contains detailed operating instructions for all aspects of the D601 instrument. The following condensed instructions are provided to assist the operator in getting the instrument started up and running as quickly as possible. This pertains to basic operation only. If specific instrument features are to be used or if the installer is unfamiliar with this type of instrument, refer to the appropriate section in the manual for complete details. General 1.
PART 1 - QUICK START 3. TRANSDUCER/POWER CONNECTIONS A. Do not attempt to add additional cable to the transducers. B. Refer to the DIAGRAMS in Figure 1.2 for proper power and transducer connections. Verify proper jumper selections are in place for the power source. See Figure 3.4. 4. INITIAL SETTINGS AND POWER UP IMPORTANT! In order to successfully complete the configuration of the D601 flow meter, the transducer must be mounted on a pipe which is full of a flowing liquid.
PART 1 - GENERAL General The Dynasonics D601 flowmeter is designed to measure the flow of liquids and slurries in full-pipe closed systems. The transmitter is field configured to measure flow on a variety of pipes and liquids. The standard product is typically used on pipe sizes ranging from 1 - 120 inch [ 25 - 1524 mm ] pipe I.D. (With the small pipe transducer option, the pipe size range is 0.25 - 1 inch [ 6 - 25 mm]).
PART 1 - GENERAL Measuring Limits The flowmeter is typically used as a unidirectional meter and is most accurate when the transducer is mounted in the orientation detailed in this manual. But, the meter will measure flow in both directions — although flow direction will not be indicated or totalized properly.
PART 1 - GENERAL The D601 employs modular construction and provides electrical safety for the operator. The display face contains voltages no greater than 9 Vdc and any exposed metal work is electrically connected to Earth Ground. The display face swings open to allow access to user connections. Serial Number The serial number and complete model number of your D601 is located on the inside of the transmitter front cover.
PART 1 - GENERAL Rev. 4/00 -1.
PART 2 - TRANSDUCER INSTALLATION Transducer Mounting Locations The following list outlines how to install the DT6 transducer for optimal performance, highest reliability and greatest accuracy: 1. Select a transducer site at least 10 pipe diameters downstream from bends, or fittings and 5 pipe diameters upstream. A symmetrical flow pattern is necessary for accuracy and repeatability over the Table 2.
PART 2 - TRANSDUCER INSTALLATION Transducer Cable 2. FLOW 3. Figure 2.2 Top View of Pipe 4. 5. 6. 7. Rev. 4/00 operating range of the meter. Down stream from pump or orifices, etc., locate at least 20 diameters. See Table 2.1 On horizontal pipe, select a position that is between 2 and 4 o’clock on the pipe, with 12 o’clock representing the top.
PART 2 - TRANSDUCER INSTALLATION permanently mounted. Under flowing liquid conditions, adequate signal is indicated when the Signal Strength indicates between 000125 and 000200 counts. Acoustic Couplant Types For proper operation, there cannot be air voids between the traducer face and pipe. The space must be filled with a material which is a good transmitter of sound energy such as: SILICONE GREASE: Dow Corning 111 R or comparable (-100 to +450 F.
PART 2 - TRANSDUCER INSTALLATION Intrinsic Safety Installations Installations requiring intrinsic safety should refer to the Appendix drawings covering these applications. 1. Pipe Preparation: For permanent silicone adhesive mounting, after determining the transducer location, some attention must be given to the pipe condition. Before the transducer head is bonded to the pipe surface, an area slightly larger than the flat surface to the transducer head (black rectangle) must be cleaned to bare metal.
PART 2 - TRANSDUCER INSTALLATION adhesive (Dow-732). Spread a bead of the adhesive on the flat surface of the transducer face, covering well. Now spread a bead to the prepared pipe surface and press the head lightly to the pipe. Let the adhesive flow enough to fill in all the area beneath the head. At the same time, clamp (clamp supplied) into place until the silicone has set up. Taping along the edges of the head will hold the adhesive in place.
PART 3 - PRE-INSTALLATION CHECKOUT Unpacking Functional Test After unpacking, it is recommended to save the shipping carton and packing materials in case the instrument is stored or re-shipped. Inspect the equipment and carton for damage. If there is evidence of shipping damage, notify the carrier immediately. The D601 flow meter can be checked for basic functionality using the following Bench Test procedure. It is recommended that this operation be performed before permanently installing the system.
PART 3 - PRE-INSTALLATION CHECKOUT forth with your thumb using moderate pressure. The cycle time should be 1-2 times per second. 8. Verify that signal strength increases with frequency of the rubbing. Typical increases will range from 20-30 counts. 9. Verify that signal strength decreases when rubbing ceases. Bench Test is Complete Rev. 4/00 -3.
PART INSTALLATION PART32- -TRANSMITTER ELECTRICAL CONNECTIONS Transmitter Installation 1. Place the D601 transmitter in a location that is: ♦ Where little vibration exist. ♦ Protected from falling corrosive fluids. ♦ Within ambient temperature limits - 22 to 122°F [-30 to 50°C] ♦ Out of direct sunlight. Direct sunlight may increase temperatures within the transmitter to above maximum limit. 2. Mounting: Refer to Figure 3.3 for enclosure and mounting dimension details.
PART INSTALLATION PART 32 -- TRANSMITTER SERVICE AND MAINTENANCE FIGURE 3.3 Important ! Rev. 4/00 NOTE: The transducer cable carries low level signals. Do not attempt to add additional cable to the factory supplied transducer cable. -3.
PART INSTALLATION PART 32 -- TRANSMITTER SERVICE AND MAINTENANCE 4-20mA OUTPUT The 4-20mA output is proportional to the flow rate measuring scale and can drive a load of up to 1000 ohms. The output is isolated from earth ground and circuit low. Connect the load to the 4-20 mA connection terminals located on the inside of the D601 enclosure, matching polarity as indicated. Power Connections Line power is connected by supplying power to the appropriate terminals located inside of the D601 enclosure.
PART 3 - TRANSMITTER INSTALLATION Transducer Connections 1. Guide the transducer terminations through the transmitter conduit hole located on the left side of the enclosure. Secure the transducer cable with the supplied conduit nut. 2. The terminals on the transducer cable are coded with wire markings. Connect the appropriate wires to the corresponding screw terminals in the transmitter. NOTE: The transducer cable carries low level signals.
PART 3 - STARTUP AND CONFIGURATION Before Starting the Instrument Note: The D601 flow meter system requires a full pipe of flowing liquid before a successful startup can be completed. Do not attempt to make adjustments or change configurations until a full pipe is verified. Instrument Startup Procedure: 1. Verify that all wiring is properly connected and routed. 2. Apply power. 3. Adjust the GAIN control [R13] to 1/4 turn from full counter-clockwise rotation. 4. Apply power to the instrument. 5.
PART 3 - KEYPAD CONFIGURATION After a successful flow meter installation and startup (covered in the previous sections of this manual) the D601 can be keypad configured to provide select engineering unit readings of flow and a scaled 4-20mA output. Configuration inputs are made via the keypad and are stored by the microprocessor. The entries are retained by the flow meter’s E2PROM memory in the event of power failure.
PART 3 - KEYPAD CONFIGURATION F1 and F2 Not utilized. RESET Caution: Conducts a system reset. All configuration constants will be lost and the D601 will load default values for all constants. I.D. Allows entry of a pipes internal diameter. Internal diameters must be entered if volumetric flow rates are to be displayed. ! If a UNITS code for U.S. measurements was made the I.D. value will be entered in inches. Valid ranges for this entry are 0.25 to 120.00 inches.
PART 3 - KEYPAD CONFIGURATION second). Valid ranges for this entry are 0.00 to 30.00 FPS. Two useful equations that relate liquid velocity to volume: GPM = 2.45 X I.D.2 X FPS FPS = ( GPM X 0.408) / I.D.2 I.D. in inches ! If a UNITS code for metric measurement was made the I.D. value will be entered in MPS (meters per second). Valid ranges for this entry are 0 to 10.00 MPS. Two equations that relate liquid velocity to volume are LPM = 0.047 X I.D.2 X MPS MPS = ( LPM X 21.28) / I.D.2 I.D.
PART 3 - KEYPAD CONFIGURATION Table 3.1 UNITS Code Flow Rate Rev. 4/00 Totalizer 0 FPS (feet per sec) 1 GPM (gallons per min) GALLONS 2 GPH (gallons per hr) GALLONS 3 MGD (millions of gal pre day) GALLONS 4 CFM (ft.3 per min) CF 5 MPS (meters per sec) N/A 6 CMH (m3 per hr) m3 7 LPM (liters per min) Liters 8 MLD (millions of liters Liters per day) 9 BPM (barrels per min) BARRELS 10 BPH (barrels per hr) 11 BPD (barrels per day) BARRELS -3.
PART 3 - KEYPAD CONFIGURATION HIGH ALARM (Labeled RELAY-1 on the Main PCB) Controls the set-point of the SPDT relay labeled RELAY-1 on the Main PCB. Enter a liquid velocity at which a relaycontact action is desired. Relay contacts are utilized for signaling flow rate conditions that are higher of lower than a desired set point. If a relay setting is made very close to a nominal liquid velocity, relay “chatter” ( rapid opening and closing of the relay ) may result. ! If a UNITS code for U.S.
PART 3 - KEYPAD CONFIGURATION The External Counter output, available at the two terminals labeled CTR on the Main PCB, is influenced by the TOTAL MULT value. Since the output is designed to operate electromechanical accumulators, large flow rates will require that the TOTAL MULT be set to a value usable by these types of counters (typically speeds no faster than 3 cps). The following chart tabulates suggested settings vs.
PART 3 - KEYPAD CONFIGURATION (continued) Third press Restarts the internal totalizer/external CTR (The internal totalizer starts from zero.) If inhibiting (pausing) the totalizer is necessary, there are two methods suggested: 1. Connect and external totalizer to the CTR terminals. See the section of this manual related to CTR electrical connections for connection parameters. 2. To inhibit the internal totalizer without resetting the accumulation, press the TEST key to pause the accumulation.
PART 3 - KEYPAD CONFIGURATION of correction factors located in the Appendix of this manual for Liquid Sound Speed and their associated correction factors. ! Transducer mounted in non-recommended locations. By applying a CAL value other than 100%, the factorycalibrated readings will be altered by the percentage entered. This CAL value will be reflected in the display, 420mA and CTR outputs and relay settings.
PART 3 - KEYPAD CONFIGURATION 2nd FUNCT - SERVICE MODE {2nd FUNCT} SIGNAL STR Displays the raw Doppler signal strength value. This value will increase as the velocity of the liquid increases. Typically, a liquid flowing at a velocity greater than 0.2 FPS [0.06 MPS], with adequate suspended solids (100 ppm or 100 micron or larger solids) or aeration, will produce SIGNAL STR readings of at least 000125 counts. NOTE: If the liquid is not flowing a low SIGNAL STR reading is non-conclusive.
PART 3 - KEYPAD CONFIGURATION {2nd FUNCT} 4 mA The 4-20mA output on standard D601 flow meters is scaled at zero flow equals 4mA and 20 FPS (6.08 MPS) equals 20mA. The 4mA key allows fine adjustments to be made to the “zero” of the 4-20mA output or allows offset to be placed on the 4-20mA output. To adjust the 4mA output, an ammeter or reliable reference connection to the 4-20mA output must be present. Procedure: 1.
PART 3 - KEYPAD CONFIGURATION {2nd FUNCT} 20mA The 4-20mA output on standard D601 flow meters is scaled at zero flow equals 4mA and 20 FPS (6.08 MPS) equals 20mA. The 20mA key allows fine adjustments to be made to the “span” of the 4-20mA output. To adjust the 20mA output, an ammeter or reliable reference connection to the 4-20mA output must be present. Procedure: 1.
PART 3 - KEYPAD CONFIGURATION {2nd FUNCT} INPUT F.S. This key is used to select a maximum velocity that the instrument will operate. Choices are 10, 20 and 30 FPS. It is not recommended to deviate alter this value from factory settings, as certain spans have been set that correlate to the set maximum velocity. Consult the Dynasonics factory for adjustment procedures. {2nd FUNCT} DAC 3 This key is not used. {2nd FUNCT} BACK LIGHT Toggles the electro-luminescent LCD back lighting ON and OFF.
PART 3 - TROUBLE SHOOTING CONDITION POSSIBLE CAUSE Unit does not turn “ON” when power is applied • Verify that AC power source is live. • Test the fuse • Verify that proper power supply jumpers are in place. • Fault conditions can arise from several causes: electrical surges, short circuits, open circuits, etc. To clear a “Fault Condition”, press 2nd Function then press Reset. Use the arrow keys to change the Fault code number to “0”. Press Enter.
PART 3 - TROUBLE SHOOTING Stability of flow readings are unsatisfactory • Increase the DAMP constant from keypad. • Move transducers to a location further from piping tees, elbows, valves, filters, Erroneous Reading • Transducer mounted incorrectly or not true to the pipe. • Another local ultrasonic instrument is operating at about the same frequency [ consult the Dynasonics factory]. • Presence of large amounts of suspended solids or aeration. Use CAL constant to compensate.
APPENDIX Appendix Fluid Sound Speed Conversions Pipe Dimension Chart: Ductile Iron Pipe Dimension Chart: Cast Iron Pipe Dimension Chart: Steel, SS, PVC Velocity to Volumetric Conversion Chart Intrinsic Safety Connections Statement of Warranty Customer Service Rev. 4/00 -3.
Fluid Sound Speeds Original Date: Revision: Revision Date: File: Fluid Acetate, Butyl (n) Acetate, Ethyl Acetate, Methyl Acetate, Propyl Acetone Alcohol Alcohol, Butyl (n) Alcohol, Ethyl Alcohol, Methyl Alcohol, Propyl (I) Alcohol, Propyl (n) Ammonia (35) Anlline (41) Benzene (29,40,41) Benzol, Ethyl Bromine (21) n-Butane (2) Butyrate, Ethyl Carbon dioxide (26) Carbon tetrachloride Chloro-benezene Chloroform (47) Diethyl ether Diethyl Ketone Diethylene glycol Ethanol Ethyl alcohol Ether Ethyl ether Ethyle
Linseed Oil Methanol (40,41) Methyl alcohol (40,44) Methylene chloride (3) Methylethyl Ketone Motor Oil (SAE 20/30) Octane (23) Oil, Castor Oil, Diesel Oil (Lubricating X200) Oil (Olive) Oil (Peanut) Paraffin Oil Pentane Petroleum 1-Propanol (46) Refrigerant 11 (3,4) Refrigerant 12 (3) Refrigerant 14 (14) Refrigerant 21 (3) Refrigerant 22 (3) Refrigerant 113 (3) Refrigerant 114 (3) Refrigerant 115 (3) Refrigerant C318 (3) Silicone (30 cp) Toluene (16,52) Transformer Oil Trichlorethylene 1,1,1-Trichloro-etha
Ductile Iron Pipe Standard Classes Pipe Outside Size Diameter (inches) (inches) Class 50 Class 51 Class 52 Class 53 Class 54 Class 55 Class 56 ID Wall ID Wall ID Wall ID Wall ID Wall ID Wall ID Wall 0.25 0.26 0.28 0.30 0.32 0.34 3.40 4.22 6.28 8.39 10.40 12.46 0.28 0.29 0.31 0.33 0.35 0.37 3.34 4.16 6.22 8.33 10.34 12.40 0.31 0.32 0.34 0.36 0.38 0.40 3.28 4.10 6.16 8.27 10.28 12.34 0.34 0.35 0.37 0.39 0.41 0.43 3.22 4.04 6.10 8.21 10.22 12.28 0.37 0.38 0.40 0.42 0.44 0.46 3.
Cast Iron Pipe Standard Classes CLASS A Size O.D. (Inches) Inch CLASS B CLASS C CLASS D CLASS E I.D. O.D. Wall Inch Inch I.D. O.D. Wall Inch Inch I.D. O.D. Wall Inch Inch I.D. O.D. Wall Inch Inch CLASS F CLASS G CLASS H I.D. O.D. Wall Inch Inch I.D. O.D. Wall Inch Inch I.D. O.D. Wall Inch Inch I.D. Inch Wall 3 3.80 3.02 0.39 3.96 3.12 0.42 3.96 3.06 0.45 3.96 3.00 0.48 4 4.80 3.96 0.42 5.00 4.10 0.45 5.00 4.04 0.48 5.00 3.96 0.52 6 6.90 6.02 0.44 7.10 6.14 0.48 7.10 6.08 0.
Steel, Stainless Steel, P.V.C. Standard Schedules Nominal OUTSIDE Pipe Size DIAMETER Inches SCH. 5 SCH. 10 (LTWALL) SCH. 20 SCH. 30 ID ID ID Wall ID Wall Wall Wall STD. ID Wall SCH. 40 SCH. 60 ID Wall ID Wall X STG. SCH. 80 SCH. 100 SCH. 120 SCH. 140 SCH. 180 ID ID ID ID Wall 0.815 1.160 1.338 1.687 2.125 2.624 0.250 0.250 0.281 0.344 0.375 0.438 ID Wall ID Wall 1 1.25 1.5 2 2.5 3 1.315 1.660 1.900 2.375 2.875 3.500 1.185 1.530 1.770 2.245 2.709 3.334 0.065 0.
FPS TO GPM CROSS - REFERENCE (Schedule 40) Nominal I.D. Pipe INCH (Inches) 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 1 1.05 2.6989 4.0484 5.3978 6.7473 8.097 9.4462 10.796 12.145 13.490 14.844 16.190 17.540 18.890 20.240 21.590 22.941 24.290 1.25 1.38 4.6620 6.9929 9.3239 11.655 13.99 16.317 18.648 20.979 23.310 25.641 27.970 30.300 32.630 34.960 37.300 39.627 41.958 1.5 1.61 6.3454 9.5182 12.691 15.864 19.04 22.209 25.382 28.555 31.730 34.900 38.070 41.250 44.420 47.
FPS TO GPM CROSS - REFERENCE (Schedule 40) Nominal I.D. Pipe INCH (Inches) 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 18 16.88 697.52 1046.3 1395.0 1743.8 2093.0 2441.3 2790.1 3138.8 3488.0 3836.3 4185.0 4534.0 4883.0 5231.0 5580.0 5928.9 6277.7 20 18.81 866.14 1299.0 1732.0 2165.3 2598.4 3031.5 3464.6 3897.6 4330.7 4763.8 5196.8 5629.9 6063.0 6496.0 6929.1 7362.2 7795.3 24 22.63 1253.7 1880.0 2507.0 3134.1 3761.0 4387.8 5014.6 5641.5 6268.3 6895.1 7522.0 8148.8 8775.6 9402.
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Limited Warranty and Disclaimer Dynasonics, div. of Racine Federated Inc. warrants to the end purchaser, for a period of one year from the date of shipment from our factory, that all new transmitters and transducers manufactured by it are free from defects in materials and workmanship. This warranty does not cover products that have been damaged due to normal use, misapplication, abuse, lack of maintenance, or improper installation.
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