Compu-Flow C6 User manual

Operator’s Manual
Rev 1.6.1
Compu-Flow™ C6 Doppler Ultrasonic Flow Meter

DISCLAIMER AND LIMITATION OF LIABILITY
Compu - Flow™ Doppler Ultrasonic Flow Meter
COPYRIGHT
The information contained in this manual is subject to change without prior notice.
Compu-Flow™ makes no warranty of any kind whatsoever, either expressed or implied,
with respect to the information contained herein. Compu-Flow™ shall not be liable for
damages, of whatever kind, as a result of the reliance on or use of the information
contained herein.
INTERPRETING THE MANUAL
The following sections explain the document type conventions and the danger, warning,
and caution boxes that provide information about the specific levels of hazard
seriousness.
TYPE CONVENTIONS
Please note the following type conventions:
• Pin and signal names appear in capitalized italics (POWER_ON).
• New terms appear in italicized text.
• Unit labels (switches, indicators, and so on) appear in boldface text (ECHO).
• Commands (162) and command names (set point) appear in boldface, lowercase text.
CAUTION AND ATTENTION BOXES
This symbol represents important notes concerning potential harm to people, this unit, or
associated equipment. Compu-Flow includes this symbol in Warning, Caution, and Attention
boxes to identify specific levels of hazard seriousness.
iii
This manual and the information herein is the proprietary property of Compu-Flow™.
No Part of this manual may be reproduced or copied without the express written
permission. Any unauthorized use of this manual or its contents is strictly prohibited.
Copyright© January 2010. All rights reserved.

Compu-Flow™ Doppler Ultrasonic Flow Meter
Table of Contents
Chapter 1: Introduction and Theory of Operation
Introduction ................................................................................................................. 1-1
Features of the Compu-Flow™ Doppler Ultrasonic Flow Meter ................. ....1-1
Components of the Compu-Flow™ Doppler Ultrasonic Flow Meter System….1-2
Electronics Enclosure and Display Panel ........................................1-2
Transducers and Cabling ......................................... ……………….1-2
Theory of Operation ..................................................................................................... 1-2
Sonic Reflectors ........................................................................................ ..….1-3
Accuracy ...........................................................................................................1-3
Summary ................................................................................................. ….....1-3
Applications ............................................................................................... ………….....1-4
Chapter 2: Installation and Operation
Before Installing the Unit .............................................................................................. 2-1
Unpacking the Unit ........................................................................................ 2-1
Included Equipment ......................................................................... 2-1
Tools Required for Installation ..........................................................2-2
Pre-installation Procedures and Checks ....................................................... .2-2
Determining if Your Process/Installation is Right for a Doppler Flow Meter ..................2-3
Assessing Particles or Air Bubbles ................................................................. 2-4
Fluctuations in Flow Content ............................................................ 2-4
Process Changes ..............................................................................2-4
Assessing Pipe Material and Condition ..................................................... …..2-5
Assessing Flow Profile ................................................................................... .2-5
Straight Run Requirements ...............................................................2-5
Transducer Placement ......................................................................2-7
Compu-Flow™ Transit Time Ultrasonic Flow Meters ................................ …..2-9
Installation Procedures ................................................................................. …………..2-9
Mounting and Connecting the Transducers .................................................... 2-9
Mounting and Connecting Power to the Electronics Enclosure .....................2-13
Operation .............................................................................................................. ..….2-15
Display Panel ................................................................................................ 2-15
LEDs ........................................................................................... ....2-16
First Time Operation ..................................................................................... 2-17
If You Experience Unstable Readings .............................................2-20
Advanced Configuration Options ............................................................. …..2-20
Primary and Secondary Keyboard Functions …………………………………………… .2-21
Before Setting Advanced Parameters .............................................2-22
Setting Advanced Parameters .........................................................2-22
Normal Operation .................................................................................... .…2-25
Portable Battery Operation (Portable Units Only) .........................................2-25
v

Chapter 3: Troubleshooting and Customer Support
Troubleshooting the Unit .............................................................................................. 3-1
Flow Meter Troubleshooting Tables ............................................................... .3-2
Status of Unit Power .........................................................................3-2
Status of Echo LED: Off ....................................................................3-3
Status of Echo LED: Flashing ...........................................................3-5
Status of Flow Reading: High or Low ........................................... …3-6
Status of Flow Reading: Erratic .................................................... ....3-8
Additional Troubleshooting Information .............................................................3-9
Echo LED Light Considerations .........................................................3-9
Suspended Particle Test For Doppler Signals ............................... ..3-10
Compu-Flow™ Systems Support ..................................................................................4-15
Returning Units for Repair .............................................................................................3-12
Warranty ........................................................................................................... ……….3-12
Authorized Returns ......................................................................................... .3-13
Warranty Statement ................................................................................ ……..3-13
Chapter 4: Specifications and Reference Information
Performance Specifications ...........................................................................................4-1
Physical Specifications ..................................................................................................4-2
Functional Specifications .................................................................................. ……….4-3
Dimensional Drawings ................................................................................. …..…..…..4-6
Electronics Enclosure Dimensions ...................................................... ..………4-6
Clamp-On Transducer and Digitizer Dimensions ..............................................4-8
Reference Information ................................................................................................. .4-8
Standard Pipe Data .......................................................................................... 4-9
Velocity Conversion Tables .......................................................................... ..4-12
vi

• Wireless Signal option from Sensors and/or Receiver (sensor singular)
Chapter
1
Introduction and Theory of
Operation
INTRODUCTION
The Compu-Flow™ Doppler ultrasonic flow meter provides an accurate and easy-to-use
measuring system for high-solid fluid flow through pipes 0.50 inch to 999 inches
(inside diameter). The Doppler flow meter is well suited for flow measurement
applications such as sludges, slurries, aerated liquids, sewage, dredges, pulp, plastics,
and activated sludges. The Doppler flow meter features clamp-on transducers and a
rugged NEMA 4X enclosure, and is a long-term, maintenance-free solution for your
high-solid flow measurement requirements.
Features of the Compu-Flow™ Doppler Ultrasonic Flow Meter
The Doppler flow meter features:
• AC or DC operation, Isolated, Regulated, Module
• Smart LCD screen featuring high-resolution, 32 character, 2-line alphanumeric
providing rate and totalization simultaneously—in Metric and English units
• Splash proof NEMA 4X case protected from moister and caustic chemicals
• Easy configuration for set up and operation with on-screen prompting, quick
scrolling menus, display panel keypad, and color coded LEDs
• Non- invasive, Submersible, Clamp-on transducers
• RS232 via DB9 PORT 9600 Baud
• Separate High and Low Alarm outputs for Dry Contact Relay with LED status
• Optional signal cable lengths up to 5000 ft. No Tuning required.
• High accuracy even in turbulent flows
• Wide pipe diameter range 0.50 - 999 inches
• Maintenance-free modular construction simplifying field service
Introduction and Theory of Operation
1-1
• Data Logger 1 – 32 GB memory USB Flash Drive data transfer
• Batch Control, Isolated Output for Dry Contact Relay

Components of the Compu-Flow™ Doppler Ultrasonic
Flow Meter System
A typical Doppler flow meter system is comprised of an electronics enclosure, with a
display panel, and two clamp-on transducers.
ELECTRONICS ENCLOSURE AND DISPLAY PANEL
The display panel in the electronics enclosure features an easy-to-read LCD screen, a
keypad, and LEDs to interface with the flow meter. The Doppler flow meter can be
wall mounted for permanent installation or a portable option is also available.
TRANSDUCERS AND CABLING
The Doppler flow meter is configured with clamp-on transducers. When installed, the
sensors gather fluid flow data through a pipe and send this information to the system
electronics. The electronics then convert, transmit, and display the received data.
The clamp-on transducers allow you to install the Doppler flow meter without shutting down flow
and are ideal for smooth, clean pipe walls. The transducers are NEMA 6-rated and fully
submersible. Contact “Compu-Flow Systems Support” on page 4-15 for information on configuring
your meter for continuous submersion.
The standard cable length between the electronics enclosure and the transducers is 25
feet. Custom cable lengths up to 5000 feet are available. Wireless Sensor to Display where
applicable. See “Compu-Flow Systems Support” on page 4-15 for contact and ordering
information.
THEORY OF OPERATION
The Compu-Flow™ Doppler ultrasonic flow meter measures flow velocity by sensing
signals from reflective materials within a liquid and measuring the frequency shift due
to the motion of these reflective materials. The Doppler effect states that the received
frequency is a function of the transmitted frequency and the relative motion between
transmitter and the receiver.
The classic example of the Doppler effect is the train whistle increasing in pitch to the
listener at the station as the train approaches, then decreasing in pitch as the train
moves away from the station. To the person riding on the train, the pitch remains the
same. The increasing pitch is due to phase-front compression and the decreasing pitch
is due to phase-front expansion. The Doppler flow meter uses this effect to measure
the velocity of a liquid through a pipe wall.
1-2
Introduction and Theory of Operation

Compu-Flow™ Doppler Ultrasonic Flow Meter
Sonic Reflectors
The Doppler flow meter requires sonic reflectors in order to operate. These reflectors
may consist of particles or air bubbles within the flow to be measured. Your readings
may vary slightly with changes in concentration or size of these reflectors as well as
the pipe condition and size.
Note: Glycerin is the only known industrial liquid today that is not sonically
conductive.
The Doppler flow meter uses two similar transducers to sense flow in a pipe. These
transducers are mounted on the outside of a pipe. This configuration presents no
obstruction to flow, and will not cause associated pressure drops.
Accuracy
The Doppler flow meter output signal is linear (as opposed to square root), which
means that accuracy is not a function of flow rate. Within certain application limits,
the meter is ideal because it is not affected by changes of pressure within the process
nor by changes of viscosity, temperature, specific gravity, sound velocity, or electrical
conductivity.
Summary
The Doppler flow meter is a non-intrusive flow meter system which operates by
sensing the frequency shifts of signals reflected from particles, air bubbles, or density
differences within a liquid, producing a linear signal proportional to the flow of the
liquid within the pipe.
• No pipe section is required to install the meter.
• The meter is not affected by changes in temperature, viscosity, specific gravity, or
the speed of sound within the liquid.
• The liquid does not have to be electronically conductive.
• A minimum particle concentration of 35 ppm @ 40 micron of suspended solids or
air bubbles is required.
• The reflector must have at least a 0.2% density difference than the liquid medium.
• For accurate volumetric measurement the pipe must be full at all times.
• The transducers are normally coupled to the outer pipe wall with greaser, sonic gel or epoxy.
• In order to obtain accurate measurements adequate upstream and downstream
pipe runs are required. Recommended straight-run requirements from any
disturbance of flow are 10 diameters upstream and 20 diameters downstream.
Introduction and Theory of Operation
1-3

APPLICATIONS
Some of the materials the Compu-Flow™ Doppler ultrasonic flow meter is well-suited
for measuring include:
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Ag water
Abrasives
Asphalts
Concrete
Dredge flows
Drilling mud
Large contaminates
Extremely viscous substances
Grout
Hazardous wastes
Municipal sludges and wastes
Paper pulp
Rendering products
Reservoirs
Rivers and streams
Runoffs
Sludges
Slurries
Suspended solids
Most all liquids containing suspended particles or air bubbles
1-4
Introduction and Theory of Operation

Chapter
2
Installation and Operation
BEFORE INSTALLING THE UNIT
Before installing your Compu-Flow™ Doppler ultrasonic flow meter,
follow the steps listed below:
1. See “Unpacking the Unit” on page 2-1.
2. Make sure you have performed the --“Pre-installation Procedures and Checks” on
page 2-2.
3. Determine if your process/installation is compatible with the requirements of
Doppler flow meter. See --“Determining if Your Process/Installation is Right for a
Doppler Flow Meter” on page 2-3).
4. Proceed to “Installation Procedures” on page 2-9.
Unpacking the Unit
Unpack and inspect the unit carefully, looking for obvious physical damage. If no
damage is apparent, locate and save all documentation and then continue with the
following procedures.
If you see signs of shipping damage, contact your supplier for product support.
(see “Compu-Flow Systems Support” on page 4-15 for contact information). Save the
shipping container for submitting necessary claims to the carrier.
INCLUDED EQUIPMENT
Table 2-1 lists the standard items that ship with Compu-Flow™ Doppler Ultrasonic
Flow Meter systems.
Installation and Operation
2-1