dynasonics TFXD Series Manual

Series TFXD
Transit Time Ultrasonic Flow Meter
Operations & Maintenance
Manual
REV 5/07

Rev. 5/07 -1.1- TFXD
TABLE OF CONTENTS
Pages
Quick-Start Operating Instructions 1.3-1.5
Introduction
General 1.6
Applications 1.6
Product Matrix 1.7
Product Specifications 1.8
Transmitter Installation 1.9-1.10
Transducer and Power Connections 1.11-1.14
Input/Output Connections
General 1.15
4-20 mA Output 1.16
Dual Control Relays 1.17
Rate Pulse Output 1.18
RS232C 1.19
RS485 1.20
Data Logger 1.21
Heat Flow 1.22-1.23
Startup and Configuration 1.24
General 2.1
Mounting Location 2.2
Transducer Spacing 2.3-2.7
Transducer Mounting, Pipe Preparation 2.8
Transducer Mounting, V-Mount and W-Mount 2.9-2.11
Transducer Mounting, DTTS Small-pipe 2.12
Transducer Mounting, Z-Mount 2.13-2.15
Mounting Track Installation 2.16-2.17
RTD Installation 2.17-2.19
Part 1 -
Introduction
Connections
and Wiring
Part 2 -
Transducer
and RTD
Installation

Rev. 5/07 -1.2- TFXD
TABLE OF CONTENTS
Pages
General Programming Information 3.1-3.2
BASIC MENU 3.3-3.13
OUTPUT MENU 3.14-3.21
SENSOR MENU 3.22
SECURITY MENU 3.22
SERVICE MENU 3.23-3.28
Liquid Sound Speed 3.23
Signal Strength 3.23
Setting ZERO Flow 3.27
Correction Factor Entry 3.28
DISPLAY MENU 3.28-3.29
Software Utility Operation
UltraLink™4.1-4.21
Data Logger 4.21-4.24
Appendix
Keypad Interface Map
Fluid Characteristic Table
TFX Error Codes
Digital Communications Protocol
Pipe Dimension Chart: ST, SS, PVC
Pipe Dimension Chart: Copper
Pipe Dimension Chart: Cast Iron
Velocity to Volumetric Conversion
Statement of Warranty/Terms & Conditions
Customer Service
Temperature Values 3.25
Pipe Dimension Chart: Ductile Iron
Part 3 -
Programming
Part 4 -
Software
Utilities
Appendix

Rev. 5/07 -1.3- TFXD
This manual contains detailed operating instructions for all aspects
of the TFX 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.
1. TRANSDUCER LOCATION
A. In general, select a mounting location on the piping system
with a minimum of 10 pipe diameters (10 x the pipe inside
diameter) of straight pipe upstream and 5 straight diameters
downsteam. See Table 2.1 on page 2.4 for additional
configurations.
B. Select a mounting method for the transducers, based on pipe
size and liquid characteristics. See Table 2.2 on page 2.5.
Transducer configurations are illustrated in Figure 1.1.
C. Enter the following data into the TFX transmitter via the
integral keypad or UltraLink™software utility.
D. Record the value calculated and displayed as Transducer
Spacing/XDCR SPC.
Transducer
Location
QUICK-START OPERATING INSTRUCTIONS
1. Transducer mounting method
2. Pipe O.D. (outside diameter)
3. Pipe wall thickness
4. Pipe material
5. Pipe sound speed 1
6. Pipe relative roughness 1
7. Pipe liner thickness
8. Pipe liner material
9. Fluid type
10. Fluid sound speed
1
11. Fluid viscosity
1
12. Fluid specific gravity 1
1Nominal values for these
parameters are included
within the TFX operating
system.
The nominal values may
be used as they appear or
may be modified if exact
system values are known.
Figure 1.1
Transducer Mounting Configurations

Rev. 5/07 -1.4- TFXD
2. TRANSDUCER/POWER CONNECTIONS
A. Route the transducer cables from the transducer mount
location back to the TFX enclosure. If additional cable and
connections are required, ensure that they are RG59 75 Ohm
compatible. Connect the transducer wires to the terminal
block J4 in the TFX enclosure. A wiring diagram is located on
the inner door label.
NOTE: The transducer cable carries low level, high frequency
signals. In general, it is not recommended to add additional cable to
the cable supplied with the DTTN, DTTH or DTTS transducers. If
additional cable is required, contact the Dynasonics factory to
arrange an exchange for a transducer with the appropriate length of
cable. Cables to 990 feet [300 meters] are available. If additional
cable and connections are added, ensure that they are RG59
75 Ohm compatible.
B. Verify that power supply jumpers are properly configured.
Reference the wiring diagram located on the TFX inner door.
Connect power to the TFX flow meter.
3. PIPE PREPARATION AND TRANSDUCER MOUNTING
DTTN and DTTH Transducers
A. Place the flow meter in signal strength measuring mode. This
value is available on the TFXD2 display (Service Menu) or in
the Data display of the UltraLink™software utility.
B. The piping surface, where the transducers are to be mounted,
must be clean and dry. Remove loose scale, rust and paint
to ensure satisfactory acoustical bonds. Grind rough
surfaces of pipes to smooth bare metal. Plastic pipes do not
require preparation other than cleaning.
C. Apply a single 1/2" [12 mm] bead of couplant grease to the
upstream transducer and secure it to the pipe with a
mounting strap.
D. Apply acoustic couplant grease to the downstream transducer
and press it onto the pipe using hand pressure at the lineal
distance calculated in Step 1.
E. Move the transducer slowly around the mount area until the
highest signal strength is observed. Secure with a mounting
strap at this location.
Connections
QUICK-START OPERATING INSTRUCTIONS

Rev. 5/07 -1.5- TFXD
DTTS Transducers
A. Place the flow meter in signal strength measuring mode.
This value is available on the TFXD2 display (Service Menu)
or in the Data display of the UltraLink™software utility.
B. The pipe surface, where the transducers are to be mounted,
must be clean and dry. Remove loose scale, rust and paint
to ensure satisfactory acoustical bonds. Grind rough
surfaces of pipes to smooth bare metal. Plastic pipes do not
require preparation other than cleaning.
C. Apply a single 1/2" [12 mm] bead of acoustic couplant grease
to the top half of the transducer and secure it to the pipe with
bottom half or U bolts.
D. Tighten the wing nuts so that the grease begins to flow out
from the edges of the transducer and from the gap between
the transducer halves. Do not over tighten.
4. INITIAL SETTINGS AND POWER UP
A. Verify that SIG STR is greater than 2.0%.
B. Verify that measured liquid SSPD is within 3% of the
configuration value.
C. Input proper units of measure and I/O data.
Startup
QUICK-START OPERATING INSTRUCTIONS

Rev. 5/07 -1.6- TFXD
PART 1 - INTRODUCTION
The TFXD ultrasonic flow meter is designed to measure the fluid
velocity of liquid within closed conduit. The transducers are a non-
contacting, clamp-on or clamp-around type, which will provide
benefits of non-fouling operation and ease of installation.
The TFX family of transit time
flow meters utilize transducers
that function as both ultrasonic
transmitters and receivers.
DTTN and DTTH transducers
are clamped on the outside of a
closed pipe at a specific distance
from each other. The transducers can be mounted in V-Mount
where the sound transverses the pipe two times, W-Mount where
the sound transverses the pipe four times, or in Z-Mount where the
transducers are mounted on opposite sides of the pipe and the
sound crosses the pipe once. This selection is based on pipe and
liquid characteristics.
DTTS (Small Pipe Transducers) have both transmit and receive
crystals imbedded in a single clamp-around transducer so no
measurement between transducers is required.
The flow meter operates by alternately transmitting and receiving a
frequency modulated burst of sound energy between the two
transducers and measuring the time interval that it takes for sound
to travel between the two transducers. The difference in the time
interval measured is directly related to the velocity of the liquid in the
pipe.
The TFXD flow meter can be successfully applied on a wide range
of metering applications. The simple-to-program transmitter
allows the standard product to be used on pipe sizes 1/2 inch
[12 mm] and larger. (Transducers sets from 1/2 to 1-1/2 inch
require 2 MHz transmitters and dedicated pipe transducers.) A
variety of liquid applications can be accommodated:
Because the transducers are non-contacting and have no moving
parts, the flow meter is not affected by system pressure, fouling or
wear. The DTTN transducer set is rated to a pipe surface
General
Application
Versatility
ultrapure liquids sewage cooling water
potable water reclaimed water river water
chemicals plant effluent others

Rev. 5/07 -1.7- TFXD
PART 1 - INTRODUCTION
The TFX employs modular construction and provides electrical
safety for the operator. The display face contains voltages no
greater than 10 Vdc. The display face swings open to allow access
to user connections. Disconnect electrical power before opening the
instrument enclosure.
Non-volatile FLASH memory retains all user-entered configuration
values in memory for several years (at 25 °C), even if power is lost
or turned off. Password protection is provided as part of the
Security menu and prevents inadvertent configuration changes or
totalizer resets.
The serial number and complete model number of the TFX is
located on the inside of the transmitter’s front cover. Should
technical assistance be required, please provide the Dynasonics
Customer Service Department with this information.
User Safety
Data Integrity
Product
Identification
Product Matrix
Transmitter
temperature of 300 °F [150 °C]. High temperature DTTH transducers
can operate to a pipe surface temperature of 380 °F [193 °C].
The DTTS series of small pipe transducers can be used to a
pipe surface temperature of 185 °F [85 °C].

Rev. 5/07 -1.8- TFXD
PART 1 - PRODUCT SPECIFICATIONS
TRANSMITTER
Power Requirements 115/230 VAC 50/60 Hz ±15% at 5 VA max or 10-28 VDC at 3.0 W
Velocity Range -40 to +40 FPS [-12 to +12 MPS]
Input/Output Bays 2
Options All modules optically isolated from earth and system ground
4-20 mA 800 Ohm max; 12-bit resolution, internal or external power
Dual Relay 2 separate Form C relays, 200 VAC max at 0.5 A [resistive]
Rate Pulse Open collector, 0 to 2,500 Hz max; 1.0 A max
RS232C Data rate to 57.6k
RS485 Supports up to 126 drops on a two-wire network
Data Logger 200k events in 30k pages, 16-bit, integral DB-9 RS232C connection
Heat Flow (RTD) Supports two 1000 Ohm RTDs, multiplexed, 12-bit resolution
Display
(DTFXD2 only)
2 line x 8 character backlit LCD; 8 digit rate, 8 digit re-settable totalizer
Top row: 7 segment, 0.7" [18 mm] high, numeric
Bottom row: 14 segment, 0.35" [9mm] high alpha-numeric
Units User configured
Rate Gal, liters, million gal, ft³, m³, acre-ft, oil barrels [42 gal], liquid barrels [31.5 gal], ft, m, lb, kg, BTU, MBTU,
MMBTU, kJ, kCal, ton
Time Seconds, minutes, hours, days
Totalizer Gal, liters, million gal, ft³, m³, acre-ft, oil barrels [42 gal], liquid barrels [31.5 gal], lb, kg, BTU, MBTU, MMBTU,
kJ, kCal, ton
Mode Forward, reverse, net, batch
Ambient Conditions -40 °F to +185 °F [-40 °C to +85 °C], 0 to 95% relative humidity [non-condensing]
Enclosure NEMA 4X [IP-66], polycarbonate, SS, brass, plated steel
Size 7.00" H ×5.75" W ×3.88" D [178 mm H × 146 mm W ×99 mm D]
Flow Rate Accuracy ±1% of reading for velocities > 1 FPS [0.3 MPS]; ±0.5% of reading for field calibrated units
±0.1 FPS [0.03 MPS] for velocities < 1 FPS [0.3 MPS]
Flow Sensitivity 0.001 FPS [0.0003 MPS]
Repeatability ±0.01% of reading
Response Time (Flow) 0.3 to 30 seconds, user configured, for 10% to 90% step change in flow
Security Keypad lockout, user selected 4 digit access code
Approvals Ordinary areas
Software UltraLink™, compatible with Window®95/98/2000/XP
Liquid Types Most non-aerated, clean liquids
Cable Length Up to 990 ft [300 meters]; standard lengths 20, 50, 100 ft [6, 15, 30 meters]
Pipe Sizes DTTN / DTTH: 2 inch and larger
DTTS [small pipe]: 1/2", 3/4", 1", 1-1/4", 1-1/2" [ANSI pipe, copper tube, tube]
Environment NEMA 6
Pipe Surface
Temperature
DTTN:
-40 °F to +300 °F [-40 °C to +150 °C]
DTTS:
-40 °F to +185 °F [-40 °C to +85 °C]
DTTH:
-40 °F to +380 °F [-40 °C to +193 °C]
Ambient Conditions -40 °F to +185 °F [-40 °C to +85 °C]
Housing Material DTTN: CPVC, Ultem®, and nylon
DTTS: PVC, Ultem®, and nylon
DTTH: PTFE, Vespel®, and nickel-plated brass
Approvals Standard: None
Optional - DTTN only: CSA Class I, Div 1, Groups C & D; requires intrinsically safe transducer kit with barrier
TRANSDUCERS

Rev. 5/07 -1.9- TFXD
PART 1 - TRANSMITTER INSTALLATION
After unpacking, it is recommended to save the shipping carton and
packing materials in case the instrument is stored or reshipped.
Inspect the equipment and carton for damage. If there is evidence
of shipping damage, notify the carrier immediately.
The enclosure should be mounted in an area that is convenient for
servicing, calibration or for observation of the LCD readout (if so
equipped).
1. Locate the transmitter within the length of transducer cable that
was supplied with the TFXD system. If this is not possible, it is
recommended that the cable be exchanged for one that is of
proper length.
NOTE: The transducer cable carries low level, high frequency
signals. In general, it is not recommended to add additional cable to
the cable supplied with the DTTN, DTTH or DTTS transducers. If
additional cable is required, contact the Dynasonics factory to
arrange an exchange for a transducer with the appropriate length of
cable. Cables to 990 feet [300 meters] are available. If additional
cable and connections are added, ensure that they are RG59
75 Ohm compatible.
2. Mount the TFX transmitter in a location that is:
• Where little vibration exists.
• Protected from corrosive fluids.
• Within ambient temperature limits -40 to 185 °F [-40 to 85 °C].
• Out of direct sunlight. Direct sunlight may increase transmitter
temperature to above the maximum limit.
3. Mounting: Refer to Figure 1.2 on page 1.10 for enclosure and
mounting dimension details. Ensure that enough room is
available to allow for door swing, maintenance and conduit
entrances. Secure the enclosure to a flat surface with four
appropriate fasteners.
4. Conduit holes: Conduit hubs should be used where cables enter
the enclosure. Holes not used for cable entry should be sealed
with plugs.
Transmitter
Installation

Rev. 5/07 -1.10- TFXD
PART 1 - TRANSMITTER INSTALLATION
Figure 1.2
TFX Transmitter Installation Dimensions

Rev. 5/07 -1.11- TFXD
NOTE: Use NEMA 4 [IP-65] rated fittings/plugs to maintain the
watertight integrity of the enclosure. Generally, the left conduit hole
(viewed from front) is used for line power; the center conduit hole for
transducer connections and the right hole is utilized for ISO-MOD
I/ O wiring.
5. If additional holes are required, drill the appropriate size hole in
the enclosure’s bottom. Use extreme care not to run the drill bit
into the wiring or circuit cards.
To access terminal strips for electronic connectors, loosen the two
screws in the enclosure door and open the door.
1. Guide the transducer terminations through the transmitter
conduit hole located in the bottom-center of the enclosure.
Secure the transducer cable with the supplied conduit nut (if
flexible conduit was ordered with the transducer).
2. The terminals within the TFX are a pluggable type –they can be
removed, wired and then plugged back in. Connect the
appropriate wires to J4 at the corresponding screw terminals in
the transmitter. Observe UP/DN Str Xdcr orientation. See
Figure 1.3 on page 1.12 and Figure 1.4 on page 1.13 or the
wiring diagram located on the inner door of the transmitter.
NOTE: The transducer cable carries low level high frequency
signals. In general, it is not recommended to add additional cable to
the cable supplied with the DTTN, DTTH or DTTS transducers. If
additional cable is required, contact the Dynasonics factory to
arrange an exchange for a transducer with the appropriate length of
cable. Cables to 990 feet [300 meters] are available. If additional
cable and connections are added, ensure that they are RG59
75
Ohm compatible.
Connect power to the screw terminal block marked J2 in the TFX
transmitter. See Figure 1.3 and Figure 1.4. Utilize the conduit hole
on the left side of the enclosure for this purpose. Use wiring
practices that conform to local and national codes (e.g., The
National Electric Code Handbook in the U.S.)
CAUTION: Any other wiring method may be unsafe or cause
improper operation of the instrument.
PART 1 - TRANSDUCER AND POWER CONNECTIONS
Transducer
Connections
Transmitter
Power
Connections

Rev. 5/07 -1.12- TFXD
NOTE: This instrument requires clean electrical line power. Do not
operate this unit on circuits with noisy components (i.e., fluorescent
lights, relays, compressors, or variable frequency drives). It is
recommended not to run line power with other signal wires within
the same wiring tray or conduit.
AC POWER CONNECTIONS
PART 1 - TRANSDUCER AND POWER CONNECTIONS
Figure 1.3
TFXD Wiring Diagram

Rev. 5/07 -1.13- TFXD
1. Verify that the jumpers at JP3 are properly oriented for the power
supply. Verify that the jumpers at JP1 and JP2 are not present.
2. Connect L1, L2 and earth to the terminals referenced in Figure
1.3 on page 1.12. Phase and neutral connections to L1 and L2 are
not polarized. Do not operate without an earth ground
connection.
3. See Figure 1.4 for AC connection schematic. Wire gauges up to
14 AWG can be accommodated in the TFX terminal blocks.
PART 1 - TRANSDUCER AND POWER CONNECTIONS
AC Power
Supply
Figure 1.4
AC Power Connection

Rev. 5/07 -1.14- TFXD
DC Power
Supply
DC POWER CONNECTIONS
The TFX may be operated from a 9-28 Vdc source, as long as the
source is capable of supplying a minimum of 3 Watts.
1. Verify that the jumpers are properly placed. See the wiring
diagram located on the inside door of the TFX enclosure or see
Figure 1.3 on page 1.12. The jumpers at JP3 should not be
present and the jumpers at JP1 and JP2 will be in place. The
jumper located beneath the microprocessor protection shield –
the panel with the wiring diagram label mounted on it – should be
positioned at JP2 for 9-16 Vdc input power and in JP1 position
for 16-28 Vdc input power.
2. Connect the DC power source as illustrated in the schematic in
Figure 1.5. Wire up to 14 AWG can be accommodated in the
TFX terminal blocks.
PART 1 - TRANSDUCER AND POWER CONNECTIONS
Figure 1.5
DC Power Connection

Rev. 5/07 -1.15- TFXD
The TFXD utilizes ISO-MODs for input and output functions. ISO-
MODs are epoxy encapsulated electronic input/output modules that
are simple to install and replace in the field. See Figure 1.6. All
modules are 2,500 V optically isolated from TFXD power and earth
grounds. This eliminates the potential for ground loops and reduces
the chance of severe damage in the event of an electrical surge.
Seven ISO-MOD options are available, including: 4-20 mA, dual-
relay, rate pulse, RS232C, RS485, BTU and 200k point data logger.
The TFXD supports any two ISO-MOD input/output modules. All
modules are field configurable by utilizing the keyboard or
UltraLink™interface. Field wiring connections to ISO-MODs are
quick and easy using removable plug-in terminals. Configuration
and connection of the various ISO-MODs are described on the
following pages.
To remove an ISO-MOD, remove the two machine screws that
secure the module in place and pull the module straight out of the
enclosure. A 10-pin connection is on the bottom of the module that
mates with the circuit board underneath. Installation of a module is
simply the reverse operation of removal. 4-20 mA modules will
require calibration parameters to be entered if the module is
replaced. See Part 3 of this manual for instructions on entry of
calibration parameters.
PART 1 - INPUT/OUTPUT CONNECTIONS
General
Figure 1.6
Two ISO-MOD I/O
Modules Installed
ISO-MOD
Replacement

Rev. 5/07 -1.16- TFXD
4-20 mA
Output
The 4-20 mA Output Module interfaces with most recording and
logging systems by transmitting an analog current signal that is
proportional to system flow rate. The 4-20 mA ISO-MOD may be
configured via jumper selections for either an internally powered
mode (current sourcing) Figure 1.7A or externally powered mode
(current sinking) Figure 1.7B.
Internal Power Configuration: Ensure that jumpers are in place
at JP1 and JP2 on the module. See Figure 1.7A. In this
configuration the 4-20 mA output is driven from a +24 Vdc source
located within the TFX flow meter. The 24 Vdc source is isolated
from DC ground and earth ground connections within the TFX
instrument. The module can accommodate loop loads up to 800
Ohms in this configuration.
NOTE: The +24 internal supply, if configured to power the 4-20 mA
output, shares a common ground with another ISO-MOD (if
installed). If another module is connected to earth ground, as is the
case with a PC connection to an RS232 module or data logger, a
ground loop may occur. The solution to this problem is to configure
the 4-20 mA module for external power and utilize an external
isolated supply to power the 4-20 mA loop.
External Power Configuration: Remove the two jumpers located
at JP1 and JP2 on the module. See Figure 1.7B. In this
configuration the 4-20 mA module requires power from an external
DC power supply. The voltage of the external power source must
PART 1 - INPUT/OUTPUT CONNECTIONS
Figure 1.7A
Internally Powered
4-20mA
Figure 1.7B
Externally Powered
4-20mA

Rev. 5/07 -1.17- TFXD
Control
Relays
be sufficient to power the module and drive the loop load. The loop
loss attributed to the ISO-MOD is 7 Vdc, so the minimum voltage
required to power a loop can be calculated using the following formula:
Loop voltage (min) = (loop load Ohms x 0.02) + 7
Two independent SPDT (single-pole, double-throw) Form C relays
are contained in this module. The relay operations are user
configured via software to act in either a flow rate alarm, signal
strength alarm or totalizer/batching mode. The relays are rated for
200 Vac maximum and have a current rating of 0.5 A resistive load
[175 Vdc @ 0.25 A resistive]. It is highly recommended that a
secondary relay be utilized whenever the Control Relay ISO-MOD is
used to control inductive loads such as solenoids and motors.
Typical relay connections are illustrated in Figure 1.8A. The reed
relays located within the relay module can interface directly with
small pilot lights, PLCs, electronic counters and SCADA systems.
Figure 1.8B describes the connection of an external power relay to
the Relay ISO-MOD. It is recommended that external power relays
are utilized whenever the load to be switched exceeds the switch
rating of the reed relays, or if the load is inductive in nature.
PART 1 - INPUT/OUTPUT CONNECTIONS
Figure 1.8A
Typical Relay
Connections
Figure 1.8B
Slave Relay
Connections
POWER
SOURCE

Rev. 5/07 -1.18- TFXD
Rate Pulse The Rate Pulse Output Module is utilized to transmit information to
external counters and PID systems via a frequency output that is
proportional to system flow rate. The frequency output range of the
Rate Pulse Module is 0–2,500 Hz. This module has two types of
outputs: one simulates the output of the coil of a turbine flow meter,
and the other is an open-collector type that does not source voltage
at its output. Both outputs may be connected simultaneously.
The turbine meter output creates a 500 mV peak-to-peak saw-tooth
waveform that is not referenced to ground. This output can be run
to electronic monitors that are compatible with variable reluctance
outputs from coils, such as those found in turbine and paddle-wheel
flow meters. The input impedance of the receiving device should
not be smaller than 2,000 Ohms.
The standard pulse output does not output a voltage, but acts as an
“open-collector” output requiring an external power source and pull-
up resistor. See Figure 1.9. The MOSFET in the Rate Pulse
Module can support loads of 100 V @ 1A. Resistor selection is
based on the input impedance of the receiving device. Select a
resistor that is a maximum of 10% of the input impedance of the
receiving device, but do not exceed 10k Ohms.
PART 1 - INPUT/OUTPUT CONNECTIONS
Figure 1.9
Rate Pulse Module