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

4
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.

6
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.

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For best measurement accuracy and reading stability, mount the
meter with the minimum lengths of straight pipe described in
Figure 4. The optimum straight pipe diameter recommendations
apply to pipes in both horizontal and vertical orientation.
Note: If adequate straight plumbing
cannot be provided the FUSION will
operate repeatably and reliably, but
will not achieve optimum accuracy.
Outdoor Installations
In outdoor installations, mount
the flow meter with the dis-
play/keypad facing 9-10 o'clock
to prevent water from collect-
ing in the keypad recess and
water running down the cables
to the conduit connections.
Refer to FIGURE 5.

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3. ELECTRICAL CONNECTIONS
The FUSION flow meter is equipped with three threaded conduit
holes located on the bottom of the flow meter enclosure that are
suitable for routing of field wiring. A sealed cord grip or sealed
threaded conduit connection should be utilized to retain the
NEMA 4 integrity of the flow meter enclosure. Failure to do so
will void the manufacturers warranty and can lead to product
failure.
For hazardous area installation, see drawing number D091-1054-
002 located in the back of this manual. For non-hazardous loca-
tion installations, flow meter power and output signals can be
carried by a single cable with multiple conductors. Select a 20-
24 AWG shielded cable with an external jacket suitable for the
installation environment an appropriate number of conductors.
The number of conductors can range from 3-11 depending on the
number of input/output connections that will be utilized.
Wiring methods and practices are to made in accordance with the
NEC—National Electric Code and/or other local ordnances that
may be in affect. Consult the local electrical inspector for
information regarding wiring regulations.
When making connections to the field wiring terminals inside of
the flow meter, strip back the wire insulation approximately 0.25
inches [6 mm]. Stripping back too little may cause the terminals
to clamp on the insulation and not make good contact. Stripping
back too much insulation may lead to a situation where the wires
could short together between adjacent terminals. Wires should
be secured in the Field Wiring Terminals using a screw torque of
between 0.5 and 0.6 Nm.
!
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.
!
!

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POWER CONNECTIONS
Power for the FUSION flow
meter is obtained from a DC
(direct current) power source.
The power source should be
capable of supplying between
12 and 30 Vdc at a minimum of
0.1 Amps or 100 milliamps.
With the power from the DC
power source disabled or
disconnected, connect the
positive supply wire and ground
to the appropriate field wiring
terminals in the flow meter.
See Figure 7. A wiring
diagram decal is located adja-
cent to the field wiring termi-
nals within the FUSION enclosure.
If the flow meter is only to be utilized as a flow rate indicator or
totalizer, no further wiring will be required. Skip to the Flow Me-
ter Configuration section of this manual (see page 20).

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4-20mA CONNECTION
The FUSION is equipped with a ground-referenced 4-20 mA
output—the output shares a common ground with the power
supply. The output transmits a continuous current output that is
proportional to liquid flow rate. The output was scaled at the
Dynasonics factory and the scaling information is recorded on the
label located outside of the FUSION enclosure. To ensure that
the instrument or data acquisition system that is receiving the 4-
20 mA signal responds properly, the receiving device must be
spanned identically to the FUSION.
IMPORTANT: The RATE PULSE and 4-20mA outputs cannot be
operated simultaneously. Select the desired output type from the
OUTPUT menu. Details of this selection are covered in the Flow Me-
ter Configuration section of this manual.

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The 4-20 mA output is designed to source current across a loop
resistance that is typically located within a data acquisition
system or other receiving instrument. The maximum resistance
that the FUSION can accommodate is directly related to the DC
power source that is powering the flow meter and the 4-20 mA
loop. Figure 8 illustrates the range of load resistance that can be
used with a given power supply voltage. Ensure that the loop
load resistance is within the shaded region of the graph, or non-
linearity and transmitting errors will occur.
The 4-20 mA output is polarized and since the output shares the
DC common with the power supply, reversing the connections
can cause a short circuit in the DC power circuit. Figure 9 shows
a block diagram of how the 4-20 mA interfaces with the receiving
device.
FUSION Flow Meter Receiving Device
Meter Power 12 to 30 Vdc
Power Supply
Ground
Loop Resistance
4-20 mA
4-20 mA Output
Signal Ground
Figure 9
4-20 mA Block
Diagram

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RATE PULSE OUTPUT
The FUSION is equipped with an open-collector transistor circuit
that outputs a pulse waveform that varies proportionally with
flow rate—from 0 Hz at zero flow rate to 1,000 Hz at full flow rate
(configuration entry FULL FLOW described in detail in the flow me-
ter configuration section of this manual). To ensure that
accurate readings are being recorded by the receiving
instrument, the FUSION and the receiving instrument must have
identical K-factor values programmed into them. Unlike standard
mechanical flow meters such as turbines, gear or nutating disk
meters, the K-factor of the FUSION meter can be changed by
modifying the FULL FLOW flow rate value. Please refer to the
equations on the following page for the Full Flow / K-factor Calcu-
lation.
Two pulse output options are available with the FUSION:
♦ Turbine meter simulation—This option is utilized when a
receiving instrument is capable of interfacing directly with a
turbine flow meter’s magnetic pickup. The output is a
relatively low voltage AC signal whose amplitude swings
above and below the signal ground reference. The minimum
AC amplitude is approximately 500 mV peak-to-peak. To ac-
tivate the turbine output circuit, turn on SW1-2 and turn off
SW1-3.
♦ Square-wave (TTL) frequency—This option is utilized when a
receiving instrument requires that the pulse voltage level be
either of a higher potential and/or referenced to DC ground.
The output is a square-wave with a peak-to-peak voltage that
swings to the DC supply rail when the SW1-2 in ON or to an
alternate voltage level if SW1-2 is turned OFF and an external
pull-up resistor and power source are utilized.
IMPORTANT: The RATE PULSE and 4-20mA outputs cannot be
operated simultaneously. Select the desired output type from the
OUTPUT menu. Details of this selection are covered in the Flow Me-
ter Configuration section of this manual.

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Rate Pulse Output Connection
Figure 10 illustrates the field wiring terminals and switch set-
tings utilized for the rate pulse output.
Full Flow / K-factor Calculation
The Rate Pulse output generates 1,000 Hz (pulses per second) at
full flow. To adjust the K-factor of the meter, adjust the full
flow entry. Two examples of this conversion are listed below.
Example 1
K-factor (pulses/gallon) = 1,000 ÷ (Full Flow GPM ÷ 60)
K-factor (pulses/gallon) = 60,000 ÷ Full Flow GPM
Example, K-factor = 1,200 if full flow = 50 GPM
Example 2
K-factor (pulses/gallon) = 1,000 ÷ (Full Flow BPD ÷ 2057)
K-factor (pulses/gallon) = 2,057,000 ÷ Full Flow BPD
Example, K-factor = 1,143 if full flow = 1,800 BPD

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TOTAL PULSE OUTPUT
The FUSION is equipped with an open-collector transistor circuit
that outputs a 33 millisecond pulse each time the flow meter to-
talizer display increments—i.e. one pulse for every gallon or bar-
rel. Adjustment of the Total Unit and Total Exponent parameters
influences the frequency of the total pulse output.
Figure 11 illustrates common wiring configurations of the Total
Pulse output feature. The output is a square-wave with a peak-
to-peak voltage that swings to the DC supply rail when the SW1-
1 is ON or to an alternate voltage level if SW1-1 is turned OFF
and an external pull-up resistor and power source are utilized.
The output will remain in a “high” state and pulse low for 33
mSec when the totalizer increments.
Total Pulse output examples,
Example 1: If the Total Unit is set to Gallons and the Total Multi-
plier is set to E0 (x1), the FUSION will output one pulse for every
gallon of liquid that passes through the meter.
Example 2: If the Total Unit is set to Gallons and the Total Multi-
plier is set to E1 (X10), the FUSION will output one pulse for
every ten gallons of liquid that passes through the meter.
Example 3: If the Total Unit is set to Barrels and the Total Multi-
plier is set to E-1 (x 0.1), the FUSION will output one pulse for
every 0.1 barrels of liquid that passes through the meter.
Figure 11—
Totalizer Pulse
Output

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4. FUSION POWER-UP
FUSION Firmware Version
After power is applied to the FUSION flow meter, the display will
illuminate and show the software version that is running inside of
the flow meter as Ux.xx. Have the firmware version available
when contacting factory technical support personnel so that more
effective service can be provided.
Initialization
After power-up or after exiting Keypad Configuration, the flow
meter will conduct self-diagnostic, measurement and buffering
operations. During this time, the flow meter display will show
AUTO ADJ and will count down from 10.
Total Flow Backup
The accumulated flow, indicated on the bottom line of the LCD, is
backed up into FLASH memory once every 10 minutes. On
power-up, the last value written to memory is restored on the
LCD and new accumulations are added as they are recorded.
5. FUSION OPERATION
Normal Operation
If the flow meter is filled with liquid, the flow meter will display
either DOPPLER or TRANSIT on the upper right side of the LCD—
indicating the mode of operation that is supplying the flow read-
ings to the display and outputs. When operated in AUTO mode,
the FUSION continuously dwells between transit time and Doppler
flow measurement circuits and determines the better measure-
ment based on the present liquid conditions.
Positive and Negative Flow
Fusion, when operated in AUTO mode, will measure positive and
negative flow rate—so long as the liquid is relatively clean and the
unit is operating in Transit mode. Negative flow will not influence
the 4-20mA or pulse outputs, but will show on the LCD as a nega-
tive flow rate. (Faulty check valves are the primary reason for
negative flow indication.) FUSION will also indicate negative flow
if the flow direction through the meter does not match the FLO DIR
selection parameter that has been entered—see page 23 for de-
tails.

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6. CONFIGURATION
The FUSION meter has two basic sets of programming proce-
dures: list item selection and entering of numeric values. It also
has two configuration menus—Basic and Advanced.
List Item Selection Procedure
Note: If you are already in PROGRAM mode and the selection to
be viewed or changed is already displayed, proceed to step 3 be-
low. If you are in PROGRAM mode and the selection to be viewed
or changed is not displayed, press the ▲or ►arrow keys and
repeat pressing until the desired selection appears. Proceed to
step 3.
1. To access the Basic menu, press the MENU key for less than
three seconds and release the key. The unit will enter the
Basic menu. To access the Advanced menu, press and hold
the MENU key for more than three seconds and release the
key.
2. Press the
►key to move to the desired selection.
3. Press ENTER to view the current selection.
4. If the current selection is desired, press ENTER to confirm.
The unit will automatically advance to the next selection.
5. If the current selection must change, press the ►key and
repeat pressing to scroll through the available choices. Press
ENTER to confirm your selection. The unit will automatically
advance to the next selection.
6. To exit programming mode, press the MENU key. Depending
on your position in the programming mode, up to three MENU
key presses may be required to exit. The display will change
to RUN mode.
Important: The FUSION software is structured using two
menus—a Basic menu and an Advanced menu. Pressing the
MENU key for less than three seconds places the user into the
basic menu. Pressing and holding the MENU key for more than
three seconds will place the user into the advanced menu. A
Map of the user interface is included in the Appendix of this man-
ual. The Map provides a visual path to the configuration parame-
ters that users can access. This tool should be employed each
time configuration parameters are accessed or revised.