dynasonics Fusion User manual

Water Flow Meter
Installation and Operating Instructions

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TABLE OF CONTENTS
• Quick Start Instructions 4
• Operating Theory 6
• Specifications 7
• Mounting Location 9
• Plumbing 10
• Electronic Connections 12
• Power-Up and Operation 19
• Configuration 20
• Configuration—Advanced 25
• KeypadMenu 36
• Troubleshooting 39
• Hazardous Area Installation 40
• Service and Repair 41
• Warranty Statement 42

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QUICK-START INSTRUCTIONS
This manual contains detailed operating instructions for the FU-
SION flow meter. The following condensed instructions are
provided to assist an experienced operator in basic operation of
the instrument. If the operator is unfamiliar with this type of
instrument, refer to the detailed explanations located on pages 9-
32.
1. MOUNTING LOCATION Determine the proper mounting lo-
cation for the flow meter by referring to Figure 1 below. The
pipe must be completely filled with liquid while measurements
are being made—avoid installations where pipes can become
partially filled. (It is acceptable to have the pipe drain out
when the pump or valve is turned off, so long as the pipe re-
fills completely when the pump or valve turns on.)
2. PLUMBING FUSION is equipped with an IN`directional arrow
pointing in the flow direction that will produce positive read-
ings with the FLO DIR set to POS. Mount the meter for best
viewing of the display regardless of the flow direction; the di-
rection can be changed in CONFIGURATION. The flow meter is
equipped with NPT female threads. Apply pipe sealant or tape
to mating components and tighten securely. For best accu-
racy, install a straight pipe nipple that is a minimum of 10
times the pipe ID immediately before the FUSION flow meter.
It is recommended that a pipe union be utilized near the flow
meter to facilitate easy removal of the meter for service.
Figure 1—Flow Meter Location

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3. ELECTRICAL CONNECTIONS Route 12-30 volt DC power
and earth ground through one of the FUSION conduit connec-
tions and secure at the 12-30 VDC In, Power Gnd and Earth
Gnd terminals. Ensure that electrical codes applicable to the
installation area are followed. An installation drawing cover-
ing Hazardous Area installations is located in the back of this
manual. (The FUSION meter contains several output options
that will be covered in detail in subsequent sections of this
manual.)
4. APPLY POWER After power is applied to the FUSION flow
meter, the display will illuminate and show the software ver-
sion that is running inside of the flow meter as Un.nn. The
flow meter will then conduct self-diagnostic, measurement
and buffering operations during an Auto Adjust countdown
that is shown on the display. These operations are also con-
ducted each time a user exits from the keypad configuration
menu.
5. OPERATION If the flow meter is started empty, the display
will indicate “EMPTY PIPE” until the flow meter fills with liquid.
If the flow meter is filled with liquid, the flow meter will dis-
play either DOPPLER or TRANSIT (indicating the mode of op-
eration that is supplying the flow readings to the display and
outputs).
6. CONFIGURATION There are seven parameters that are
configured in the field on a typical installation
A. RATE UNIT <GPM, BPD, LPM, M3/H>
B. TOTAL UNIT <GAL, BBL, LIT, M3>
C. FLOW DIRECTION <POS, NEG>
D. OUTPUT <4-20 mA, PULSE>
E. FULL FLOW <Maximum flow rate for span>
F. FLOW CUTOFF <Meter indicates zero below setting>
G. RESPONSE <SLOW, MEDIUM, FAST>
7. TOTALIZER RESET The flow totalizer can be reset to zero
by simultaneously pressing the MENU and ENTER keys or by
momentarily connecting the Reset Total In terminal to Power
Gnd terminal.

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OPERATING THEORY
The FUSION ultrasonic flow meter is designed to measure volu-
metric flow of clean, solids-bearing or aerated liquid on full pipes.
There are no moving parts to jam or wear and the product can-
not be damaged by gas pockets, particulate or high flowing con-
ditions. The unit contains several input/output options for inte-
gration with monitoring and control systems.
The flow meter’s patent pending operation consists of continu-
ously measuring flow using both transit time and Doppler ultra-
sonic sound techniques, and using the better of the two signals
to calculate the flow rate.
When in transit time mode, the flow meter transmits an ultra-
sonic sound from the upstream transducer into the flowing liquid.
The travel time to the downstream transducer is measured. The
flow meter then transmits an ultrasonic sound from the down-
stream transducer into the flowing liquid. The travel time to the
upstream transducer is measured. The difference between the
two travel times is then used to calculate the measured flow rate.
When in Doppler mode, the flow meter transmits an ultrasonic
sound from its transmitting transducer into the flowing liquid.
The sound will be reflected by sonic reflectors (gas bubbles or
particulate) suspended within the liquid and recorded by the
receiving transducer. If the sonic reflectors are moving within
the sound transmission path, sound waves will be reflected at a
frequency shifted (Doppler frequency) from the transmitted fre-
quency. The shift in frequency will be 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.
FUSION retains all user configured data and accumulated flows
(totalizers) in non-volatile Flash memory indefinitely.

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Description Specification
Input Voltage 12-30 VDC @ 100 mA Max
Flow Range
1-Inch 0.7—60 GPM [24-2057 BPD] 3-230 LPM [0.18-13.8 M3/H]
Accuracy 1% of Rate over the top 10:1 measuring
range; 0.1% of full scale at rates less than
this range
Pressure
Temperature 300 PSI [2,070 kPa] -30 to +160 F [-34 to +70 C]
Outputs
4-20mA
Rate Pulse
Total Pulse
RS485
(FUSION cannot output 4-20mA and Rate Pulse simul-
taneously. Only one can be selected.)
12-bit; source from DC supply voltage
0-1,000 Hz; open collector; internal/
external pull-up; TTL square-wave or tur-
bine simulation; 50% duty cycle, sink
100mA max
Open collector, internal/external pull-up;
33 mSec duration, sink 100mA max
1/4-node; 128 drop, Modbus command set
Rate Units
Total Units GPM, BPD, LPM, M3/H GAL, BBL, LIT, M3
Wetted Materials 316 SS, polyetherimide, Buna-N
Enclosure
Ports
NEMA 4; powder coated aluminum, SS,
polycarbonate, urethane, PVC
(2) 1/2” NPT and (1) 3/4” NPT
Display Flow Rate: auto ranging 4-digit LCD
Flow Total: 8-digit, E-2 to E+3
Approvals
(pending) Class I Division 2 Groups C, D; CSA 22.2 No. 142 & 213; UL 916, ISA 12.12.01; File
215035
Protection Reverse polarity; auto-reset polyfuse;
transient voltage suppression
PRODUCT SPECIFICATIONS

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SYMBOL EXPLANATIONS
FLOW METER INSTALLATION
!Caution—Refer to accompanying documents
IMPORTANT NOTE:
Not following instructions properly may impair
safety of equipment and/or personnel.
IMPORTANT NOTE:
Must be operated by a power supply suitable for
the location.
IMPORTANT NOTE:
Do not connect or disconnect either power or
outputs unless the area is known to be non-
hazardous.
IMPORTANT NOTE:
Do not connect the interface cable between a
FUSION flow meter and a personal computer
unless the area is known to be non-hazardous.
!
!
!
!

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1. MOUNTING LOCATION
The first step in the installation process is the selection of an
optimum location for the flow measurement to be made. For this
to be done effectively, a basic knowledge of the piping system
and its plumbing is required.
The pipe must be completely filled with liquid while measurements
are being made—avoid installations where pipes can become par-
tially filled for long periods of time. It is acceptable to have the
pipe drain out when the pump turns off or a valve closes, so long
as the pipe refills completely when the pump turns on or the valve
opens. Refer to Figure 2 for unacceptable and acceptable piping
configurations.
Figure 2—Proper Mounting Locations

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2. PLUMBING
FUSION is equipped with an IN`directional arrow pointing in the
flow direction that will produce positive readings with the FLO DIR
set to POS. Mount the meter for best viewing of the display re-
gardless of the flow direction; the direction can be changed in
CONFIGURATION (see page 23).
If flow through the system is in the direction of the IN`arrow, the
FLO DIR should be set to POS.
If flow through the system is opposing the IN`arrow, the FLO DIR
should be set to NEG.
Selection of POS and NEG flow direction is covered in detail in the
CONFIGURATION section of this manual.