Badger Meter Dynasonics DFX Series User manual

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
Page 3August 2019 DPP-UM-00256-EN-03
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

Doppler Ultrasonic Flow Meters, Series DFX
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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

Scope of This Manual
Page 5August 2019 DPP-UM-00256-EN-03
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.

Quick-Start Operating Overview
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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.
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FLOW
Top View of Pipe
Figure 1: Transducer locations
45°
45°
YES
W and V Mount
Top of
Pipe
Figure 2: Transducer mounting configuration
Pipe Preparation and Transducer Mounting
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.

Quick-Start Operating Overview
Page 7August 2019 DPP-UM-00256-EN-03
FLOW Top View
of Pipe
Figure 3: Transducer direction
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.

Introduction
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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).

Introduction
Page 9August 2019 DPP-UM-00256-EN-03
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

Transducer Installation
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TRANSDUCER INSTALLATION
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:NIf 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.
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Figure 5: Pipe configurations and installation recommendations