Trimec DUALPULSE 490 User manual

IMDP000-3310
DUALPULSE
LOCK
DUALPULSE
INSTRUCTION MANUAL
BI-DIRECTIONAL INSERTION FLOW TRANSDUCER

1.1 General arrangement
Thank you for purchasing a Dualpulse Flowmeter. It is important that you read this
manual to gain a full understanding of the capability and operational aspects of the
equipment you are about to install.
This information is provided only to assist in the installation of the product and
does not diminish your obligation to read the manual.
1. Select a location that meets the requirements as illustrated on the guideline
sheet (yellow pages located in the center of this manual). An ideal installation
would provide for 25 diameters of straight pipe upstream from the meter and 10
diameters downstream.
You will also need to know the pipe internal diameter (NB ) and pipe wall thickness
for calculation of the insertion depth. (refer page 5.) Non ideal installations may
require in-situ calibration (refer to the factory for details).
2. After screwing the Dualpulse in place ensure the flow alignment mark located
on the top positioning collar of the meter aligns with the flow in the pipe (refer
page 5). This ensures the paddle is correctly aligned to the flow.
Note. the meter is bi-directional so a flow direction arrow is not provided.
3. Calculate and adjust the height of the Dualpulse (refer page 5).
4. Electrical Installation depends on the model you have purchased.
If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser
or rate totaliser please refer to the appropriate manual and Page 10 of this
manual. For pulse output meters, select the appropriate output and wire to your
receiving device. (refer pages 7 to 9).
5. Calculate the Dualpulse K (scale) factor to suit the installation. For ideal
installations refer to page 11 or 12 or 13 of the Dualpulse Manual. Fo r non ideal
installations the K-factor may be calculated by performing an in-situ calibration.
Enter the appropriate K-factor into your receiving instrument.
Contents 1
CONTENTS PAGE
1.0 INTRODUCTION
1.1 General arrangement 2
1.2 Overview 3
1.3 Operating principal 3
1.4 Specifications 3
2.0 INSTALLATION
2.1 Meter location 4
2.2 Meter installation & orientation 4
2.3 Height adjustment 5
2.4 Flow direction orientation 5
2.5 Hot tap installations 6
3.0 ELECTRICAL CONNECTIONS
3.1 Standard outputs 7
3.2 Optional Reed switch output 7
3.3 Instrument cable installation requirements 8
3.4 Pulse output selection ( standard outputs ) 8
3.5 QP Quadrature pulse output option 9
3.6 Bi-directional flow using QP option 9
3.7 Connection to family instruments 10
4.0 CALIBRATION ( K- factor for meter )
4.1 K-factors for common pipe ID sizes <575mm 11
4.2 K-factors for large pipe ID >460mm 11
4.3 Calculating K-factors ( metric units – litres or M3 ) 12
4.4 Calculating K-factors ( US gallons ) 13

2 Introduction
1.1 General arrangement
Thank you for purchasing a Dualpulse Flowmeter. It is important that you read this
manual to gain a full understanding of the capability and operational aspects of the
equipment you are about to install.
This information is provided only to assist in the installation of the product and
does not diminish your obligation to read the manual.
1. Select a location that meets the requirements as illustrated on the guideline
sheet (yellow pages located in the center of this manual). An ideal installation
would provide for 25 diameters of straight pipe upstream from the meter and 10
diameters downstream.
You will also need to know the pipe internal diameter (NB ) and pipe wall thickness
for calculation of the insertion depth. (refer page 5.) Non ideal installations may
require in-situ calibration (refer to the factory for details).
2. After screwing the Dualpulse in place ensure the flow alignment mark located
on the top positioning collar of the meter aligns with the flow in the pipe (refer
page 5). This ensures the paddle is correctly aligned to the flow.
Note. the meter is bi-directional so a flow direction arrow is not provided.
3. Calculate and adjust the height of the Dualpulse (refer page 5).
4. Electrical Installation depends on the model you have purchased.
If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser
or rate totaliser please refer to the appropriate manual and Page 10 of this
manual. For pulse output meters, select the appropriate output and wire to your
receiving device. (refer pages 7 to 9).
5. Calculate the Dualpulse K (scale) factor to suit the installation. For ideal
installations refer to page 11 or 12 or 13 of the Dualpulse Manual. Fo r non ideal
installations the K-factor may be calculated by performing an in-situ calibration.
Enter the appropriate K-factor into your receiving instrument.
Introduction 3
1.2 Overview
Dualpulse insertion flow transducers provide a cost effective and simple means of
measuring the flow of a wide range of low viscosity liquids. Installation is quick and
inexpensive for pipe diameters ranging from 40mm to 900mm (1.5-36") and up to 2500mm
(100") nominal bore for the Hot tap capable model DP525.
Dualpulse has a linear measuring range of 0.3~10.0 metres/sec. (1~33 ft/sec.). Minimum
detectable flow velocity is 0.15 m/sec. (0.5 ft/sec.). When used in conjunction with the RT12
flow rate totaliser NLC feature the linear flow range is extended down to 0.15 m/sec. (0.5
ft/sec.) with an improved linearity.
The Dualpulse is constructed from 316 L (1.4404) stainless steel enabling use in many
applications for metering water and low viscosity chemicals.
Two independent pulse outputs are standard & can directly input to a wide range of
ancillary instruments, PLC’s and computers. Both pulse outputs have a high level of
immunity to electrical interference. Options include a reed switch.
1.3 Operating principle
Flow passes through a pipe causing the rotor to spin. Magnets installed in the rotor pass by
pulse sensors within the transducer body & inturn this produces frequency outputs
proportional to flow rate.
1.4 Specifications ( subject to change without notice )
Model
490 525
Suits pipe sizes
40mm - 900mm 50mm - 2500mm
( 1.5 – 36 inches ) ( 2 – 100 inches )
Flow range
0.25 - 6300 litres/sec. 0.4 - 49000 litres/sec.
( 4-99600 USGPM ) ( 6-780000 USGPM )
Process connections
1.5" or 2” NPT or BSPT 2" NPT or BSPT
Velocity range
0.3 - 10 metres/sec. ( 1 - 33 feet/sec.)
Linearity
typically  1.5%
Repeatability
typically  0.5%
Pressure (max)
80 Bar ( 1200PSI )
Temperature range
-40C to 100C (-40F to 212F ) – refer options
Body material
316L stainless steel (1.4404)
Rotor materials
PEEK rotor w ith graphite-PTFE impregnated PEEK bearing
O-Ring material
VITON - options available
(a) Voltage output (to 125C)
1.5volt x 10 sec pulse w idth, self -generated (2 wire)
(b) Square wave ( Hall Effect )
5-24vdc, 3wire NPN open collector (20mA max. current sink)
(c) Reed Sw itch (to 100°C)
30vdc max. x 20mA max. (output freq. is 1/3 std. K-factor)
Output freq. @ max. velocity
( a & b ) outputs 220~240 Hz ( c ) output 73~80 Hz
Output options
Ultra high temp. coil 204C (400F) or non magnetic
Transmission distance
1000 metres ( 3300 feet ) maximum
Wiring (standard)
5 core, screened cable, length 3 metres ( 10 feet )
Protection class
IP68 submersible ( Nema 6X )
Conduit entry (terminal box)
3/8" NPT or PG9
Shipping Weight
1.2 kg ( 2.7 lbs.) 1.5 kg ( 3.3 lbs.)

4 Installation
2.1 Meter location
Choose an appropriate section of horizontal or vertical pipe as per the guidelines below.
With vertical pipe installations the media should be pumped up through the pipe past the
flow sensor so that any entrained air will pass freely.
The DP flow sensor requires a fully developed turbulent flow profile to ensure maximum
measurement accuracy and repeatability. This can be achieved by installing the DP in a
straight run of pipe. We recommend at least 10 but ideally 25 straight pipe diameters
upstream & at least 5 but ideally 10 pipe diameters downstream of the Dualpulse. Major
obstructions such as pumps, valves or strainers will require longer straight runs before and
after the Dualpulse.
2.2 Meter installation & orientation
Cut a 40mm diameter hole (1.6") on either the 2, 10 or 12 o’clock positions of the pipe. If
there is any likelihood of air entrainment in a horizontal pipe do not locate the flow
transducer in the 12 o’clock position.
Install a female threaded weld on fitting (threadolet) or service saddle.
Wrap the threads of the Dualpulse with Teflon tape or sealing compound & screw the unit
into the installed fitting.
Installation 5
2.3 Height adjustment calculation
Calculate the adjustment height A for DP490 (or AA for the DP525) as follows:
A ( for DP490 ) = 175mm ( 6.9") - ( B + C + D )
AA ( for DP525 ) = 420mm (16.5") - ( B + C + D )
Where :
B = Distance between the top of the pipe & the top of the hex adaptor.
C = Pipe wall thickness
D = Insertion depth ( pipe ID ÷ 8 )
Examples of insertion depth D :
For 40mm pipe ID ( D= 5.0 mm )
For 50mm pipe ID ( D= 6.25 mm )
For 100mm pipe ID ( D= 12.5 mm )
For 400mm pipe ID ( D= 50.0 mm )
Turn the height adjustment nuts (1) as required so that the distance between the top of the
hex adaptor (2) and the top of the positioning collar (3) equals your calculated distance A
(for DP490) or AA for model DP525. Retighten the height adjustment nuts (1).
2.4 Flow direction orientation
The unit is bi-directional however the paddle must be aligned with the direction of flow.
Using a 2mm hex key (Allen key), unlock the locking screw located on the positioning collar
(3) then insert the hex key (as a lever) in the body rotating hole located above the collar,
turn the body until the alignment slot is parallel with the direction of pipe. Retighten the
locking screw.
12 o’clock
2 o’clock
Other positions
around the pipe are
acceptable
10 pipe dia. minimum
25 pipe dia. prefered
5 pipe dia. min.
10 pipe dia. prefered
FLOW
Major obstructions such as
pumps,v alv es,reducers or strainers
to be kept well outside the straight
run pipe sections
D
3
2
A (AA)
B
C
LOCK
C
1
ALIGNMENT SLOT TO
PARRALLEL PIPE

6 Installation Electrical connections 7
3.0 ELECTRICAL CONNECTIONS
( see page 9 for QP outputs )
3.1 Standard outputs
3.2 Optional Reed switch output
HAZ ARDOUS ARE AS
The REED SWI TCH output is classed as a
“simple apparatus“ as def ined in the
CENELEC standard EN50020 &
recognized IEC & ATE X d irectiv e. It can
be connected to an ap prov ed I.S.
secondary instrument with both being
located in the hazardous area.
The Re ed Switch may also be connected
through an approv ed I.S. barrier.
Note: The Reed switch produces 1/3rd
the normal pulse output v alue
( eg. 1/3 the standard K-f actor )
Conductor color coding also applies to the N on-magnetic
sensor and high temper ature output options
A1
A2
B2
B1
b1
VOLTAGE PULSE
OUTPUT
Screen
Yellow ( + )
Green ( - )
SQUARE WAVE
PULSE OUTPUT
Red ( VDC suppl y )
White ( + Sig. output )
Black ( -0v ground )
Termi nal box option
terminal connections
Pull up resistor
required, they are
generally incor porated
in most receivi ng
instruments
Hex adapt or
Rotor
Body
Positioni ng
collar
Height
adjustment
nuts
1.5” or 2” BSPT
or NPT
DUALPULSE
LOCK
REED SWITCH
OUTPUT
To -0V
Screen
Yellow
Green
DUALPULSE
LOCK
CAUTION : Hot tap installation
should only be performed by
qualified personal. Installation
procedures should be in accordance
with the safety rules, regulations and
requirements applying to the territory
in w hich the flow transducer is being
installed.
If necessary extend valve
port using a 2” nipple &
socket combination to
ensure the paddle is clear
of the ball valve.
2.5 Hot tap installation
( model DP525 )
IMPORTANT
Before removing the
DP525 from the
installation first
withdraw the
transducer body to
the maximum
distance allowed by
the three height
adjusting threaded
rods. This will enable
the isolating valve
to be fully closed
without damaging the
paddle.
FLOW
2" Nipple
2" Weld-O-let
( threadolet )
2" ball or gate
isolation valve.
(Allow min. 40mm I.D. to
clear metering head)
Clean & lubricate screw
threads before
withdrawing the
transducer body in order
to avoid nut seizure
Hot tap clearance hole in
pipe w all to be a minimum
of 40mm diameter (1.6").

8 Electrical connections
3.3 Instrument cable installation requirements
Use twisted multi-core low capacitance shielded instrument cable (22 AWG ~ 7x 0.3
stranded) for electrical connection between the flow meter and the remote instrumentation.
The screen should be earthed at the readout instrument end only to protect the transmitted
signal from mutual inductive interference.
The cable should not be run in a common conduit or parallel with power and high inductive
load carrying cables as power surges may induce erroneous noise transients onto the
transmitted pulse signal. Run the cable in separate conduit or with other low energy
instrument cables .
3.4 Pulse output selection ( standard outputs )
The standard flowmeter has two independent pulse output signals that are linearly
proportional to volumetric flow rate. Pulse transmission can be up to 1000 metres (3300 ft ).
An optional I.S. Reed Switch output is available (see page 7).
Voltage pulse (pulse wire) output & Optional Reed Switch
A self generating pulse output which produces a strong 1.5 volt voltage spike of
approximately 10 micro/second duration with no dependence on rotor speed.
Square Wave Pulse (Hall sensor) ( also applies to non-magnetic & QP Hall outputs )
An NPN open collector transistor pulse output produced by a solid state Hall Effect device.
This three wire device requires 5~24vdc and produces an NPN square wave output (20mA
max. sink), pulse width is 2~75 mSec. The Hall output requires a pull up resistor, these are
generally incorporated in most receiving instruments. For (QP) Quadrature pulse output
refer details page 9.
Electrical connections 9
3.5 Quadrature outputs
DP series flowmeters supplied with the QP option produce two NPN open collector pulse
outputs from two Hall Effect sensors. The outputs are “ phase offset ” in their timing so that
external electronics are able to differentiate. These outputs may be used to assure output
signal integrity or to measure bi-directional flow.
3.6 Bi-directional flow
The DP flow transducer is capable of accurately measuring flow in both directions without
modification. Meters fitted with the QP output option (quadrature pulse output) may be
interfaced with the Pulse Discriminator Module (PD1). The PD1 accepts the Quadrature
pulse inputs & from these will discriminate between forward & reverse flow. Two individual
& proportional pulse outputs can then be sent to appropriate totalising registers or an add
and subtract flow rate totaliser.
It is important to note that the Quadrature Pulse option has the same pulse resolution
(pulses/unit volume) as a standard Dualpulse for both forward & reverse outputs.
Screen
Red
Black
White
(5-24vdc supply )
signal output
( -0v ground )
Flow meter w ith QP outputs
PD1 Pulse Discriminator
5~24Vdc maxi mum
supply
(forward flow)
Output Signal 1
Ground
(reverse flow)
Output Signal 2
Reverse flow Sig.
Forw ard flow Sig.
-0V
+8~24Vdc
1
2
5
4
Output signals
Sig.1
Sig.2
-0V
+Vdc
7
Reg
Reg
X
X
Vdc
+
+
-0V
9
6
10
Screen
Red ~ Vdc
b2
Black ~ -0V
White ~ output 1
Blue ~ output 2
Yellow ( + )
Green ( - )
Optional reed switch
Screen
Yellow
Green

10 Electrical connections
3.7 Voltage Pulse Connection to family instruments
Calibration 11
4.0 K – FACTORS ( calib ration factors for meter )
The K-factor (pulses / litre, gallon etc.) will vary in relation to the bore size of the pipe in
which the Dualpulse is installed.
The K-factors and formula shown are a result of factory testing using smooth bore piping
under ideal conditions. Variations to the given K-factors may occur when using rough bore
piping or inadequate flow conditioning on either side of the flow transducer (refer clause
2.1). In these instances on site calibration may be used to determine the K-factor.
4.1 Flow transducer K- factors for common pipe sizes
For other pipe sizes below 610mm (24") not listed above, use the graphs and apply the
formula on the following pages ( 12 & 13 ).
4.2 K-factors for large pipes 460mm ID (18") and above use:
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
pulse output.
1 2 3
All DIP switches to
be in the OFF
position
ON
Flow instruments or a
terminal box can be
directly mounted to the
Dualpulse using ST4 (f or
DP490) or ST5 (DP52 5)
mounting stem kits
Note: For other output styles see
receiving instrument manual
y ellow
green
Screen
6
5
4
3
2
1
7
-0V (ground)
8
9
10
11
12
13
14
All f low DIP
switches in the
OFF position
3
2
1
O
N
RATE TOTALISER
& ECOB ATCH
INSTRUMENTS
The Dualpulse cable should
not be run with other high
energy cables ( clause 3.3 ).
y ellow
green
Screen
+Vdc
+∏
-gnd
4
5
6
BATTER Y
TOTALISER
gnd
+
-
1
2
3
RATE TOTALISER
RESET
>
PROGRAM
ENTER
gal
RUN ACCUM. TOTAL STOP BA T LOW
RATE
TOTAL
ACCUM
TOTAL
^
DUALPULSE
LOCK
DUALPULSE
LOCK
Pulse s per litre = 28647 ÷ pipe ID² (mm)
Pulse s per M³ = 28647000 ÷ pipe ID² (mm)
Pulse s per US gallon = 168.14 ÷ pipe ID² (inches)
Pulse s per Imp. gallon = 201.94 ÷ pipe ID² (inches)
Pipe detail
NB ID (#40)
inches mm p / litre p / m3 p / USgal p / litre p / m3 p / USgal
1.5" 40.9 18.678 18678 70.695 21.524 21524 81.468
2" 52.6 11.238 11238 42.534 12.818 12818 48.517
2.5" 62.7 7.880 7880 29.824 8.899 8899 33.682
3" 78.0 5.062 5062 19.161 5.676 5676 21.485
3.5" 90.2 3.768 3768 14.263 4.200 4200 15.896
4" 102 2.912 2912 11.021 3.233 3233 12.237
5" 128 1.839 1839 6.959 2.025 2025 7.665
6" 154 1.268 1268 4.798 1.402 1402 5.307
8" 203 0.719 719.0 2.721 0.787 787.2 2.980
10" 255 0.450 450.3 1.705 0.496 495.9 1.877
12" 303 0.316 316.0 1.196 0.347 347.4 1.315
14" 333 0.261 260.5 0.986 0.286 285.7 1.081
16" 381 0.198 198.0 0.750 0.217 217.0 0.821
18" 429 0.156 155.8 0.590 0.171 170.6 0.646
20" 478 0.125 125.4 0.475 0.138 137.8 0.521
24" 575 0.087 86.64 0.328 0.095 95.39 0.361
K-factors ( standard K-factors for voltage & square wave outputs )
Schedule 40 pipe - (#40)
Schedule 80 pipe - (#80)

12 Calibration
4.3 Calculating K-factors ( litres or m³ )
Calculate K-factor ( pulses / litre ) using the above graph and the metric constant of 1273.2
as follows :
Pulses / litre = 1273.2 x (A) from graph
pipe ID² (mm)
Example ‘a’ :
K-factor for 100mm pipe: 1) from graph 100mm ID (A) = 24.0
2) pulses/litre. = 1273.2 x 24.0
10000 = 3.056 p/litre
K-factor for m³ : multiply by 1000 eg. K = 3056 p/m³
K-factor for megalitres : multiply by 1000000 eg. K = 3056000 p/megalitre
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
pulse output.
Calibration 13
4.4 Calculating K-factors ( US gallons )
Calculate K-factor ( pulses / gallon ) using the above graph and the volumetric
constant of 24.51 as follows :
Pulses / US gal. = 24.51 x (A) from graph
pipe ID² (inches)
Example ‘b’ :
K-factor for 10" pipe: 1) from graph 10" ID (A) = 7.01
2) pulses/gal. = 24.51 x 7.01
100 = 1.718 p/gal
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.
22
22.5
23
23.5
24
24.5
25
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
460
(A)
pipe ID
(mm)
Pipe ID 450mm & above (A) = 22.5
See
example a
6.8
6.9
7.0
7.1
7.2
7.3
7.4
7.5
7.6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
(A)
pipe ID
(inches)
Pipe ID 19.5 ” & above (A) = 6.86