Dwyer Instruments UFC Series User manual

Series UFC Ultrasonic Flowmeter Kit

Installation and Operating Instructions

Bulletin F-UFC

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Table of Contents

1: General Description 1

1.1 Introduction 1

1.2 Principles of Operation 2

1.3 Supplied Hardware 3

1.4 UFC Instrument 4

1.4.1 Connections 4

1.4.2 Keypad 5

1.4.3 Power supply 6

2: Installation 7

2.1 Safety Precautions and Warnings 7

2.2 Installing the UFC Instrument 7

2.2.1 Positioning the instrument 7

2.2.2 Mounting the instrument 8

2.2.3 Connecting the instrument 9

2.3 Installing the Ultrasonic Transducers 10

2.3.1 Transducer positioning 10

2.3.2 Transducer attachment 11

2.3.3 Attaching the guide rail to the pipe 12

2.3.4 Fitting the transducers 12

2.3.5 Transducer attachment (diagonal mode) 15

3: Operating Procedures 17

3.1 Setting-up the Instrument 18

3.1.1 Using the instrument for the first time 18

3.1.2 Changing the user language 19

3.1.3 Changing the date and time 19

3.2 Using the Quick Start Menu 19

3.3 Instrument Calibration 23

3.3.1 Adjusting the zero cut-off 23

3.3.2 Adjusting the set zero flow offset 23

3.3.3 Adjusting the calibration factor 24

3.3.4 Adjusting the roughness factor 26

3.3.5 Adjusting the damping factor 26

3.4 Outputs 28

3.4.1 Current output 28

3.4.2 Pulse output 30

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3.4.3 Alarm outputs 31

3.5 How to Measure Totalized Flows (manually) 34

3.6 Display of totalizers 35

3.7 Operation with an Energy Meter 35

3.7.1 Pulse output 35

3.7.2 Configuring the UFC 35

4: Data Logging 37

4.1 How to Set Up the Basic Logging Application to Memory 37

4.2 How to Set Up Automatic (Timed) Logging Mode 39

4.3 How to Download Logged Data 40

5: Maintenance & Repair 42

5.1 Introduction 42

5.2 General care 42

5.3 Warranty / Return 42

6: Troubleshooting 43

6.1 Overview 43

6.2 General Troubleshooting Procedure 44

6.3 Warning and Status Messages 45

6.4 Diagnostics Display 47

7: Options 49

7.1 Large Pipe Diameter Transducers 49

7.2 Transducer Holder Options 49

7.3 Extended Signal Cable Options 49

8: Specification 50

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1: General Description

1.1 Introduction

This manual describes the operation of the Dwyer UFC flowmeter. The flowmeter is designed to work with clamp-

on transducers to enable the flow of a liquid within a closed pipe to be measured accurately without needing to

insert any mechanical parts through the pipe wall, or protrude into the flow system.

Using ultrasonic transit time techniques, the UFC is controlled by a micro-processor system which contains a

wide range of data that enables it to be used with pipes having an outside diameter ranging from 0.5 to 79 inches

(13 to 2000 mm) and constructed of almost any material. This can be extended to pipes of up to 197 inches (5000

mm) using the optional type D sensors. The instrument will also operate over a wide range of fluid temperatures.

UFC standard features:

•Large, easy to read graphic display with backlight.

•Simple to follow, dual function keypad.

•Simple ‘Quick Start’ set up procedure.

•Continuous signal monitoring.

•Isolated pulse output (volumetric or frequency).

•Isolated current output (4 to 20 mA, 0 to 20 mA, or 0 to 16 mA).

•2x Isolated programmable alarm outputs.

•Password-protected menu operation for secure use.

•Signal diagnostics.

•Multi-function alarm outputs.

•Operates from Mains, 24 Vac, or 24 Vdc.

•Logging of Flows and Volume total.

•Output to USB pen

Volumetric flow rates are displayed in L/h, L/min, L/sec, gal/min, gal/h, USgals/min, USgals/h, Barrel/h, Barrel/

day, m³/s, m³/min, m³/h. Linear velocity is displayed in meters or feet per second. When operating in the ‘Flow

Reading’ mode the total volumes, both positive and negative, are displayed up to a maximum 12-digit number.

The flowmeter can be used to measure clean liquids or oils that have less than 3% by volume of particulate

content. Cloudy liquids such as river water and effluent can be measured along with cleaner liquids such as

demineralized water. In addition, the UFC can function as a data logger. When operating in this mode the logged

data, which includes the flow rates and totalizers, is stored in memory and can then be transferred to a USB

memory stick.

Typical UFC applications include:

•Sea or River water.

•Potable water.

•Demineralized water.

•Treated water.

The UFC is available in two model options. Model UFC-A is supplied with type ‘A’ transducers which are designed

to work with pipe diameters between 0.5 to 4.5 inches (13 to 115 mm). Model UFC-B is supplied with type ‘B’

transducers which are designed to work with pipe diameters between 2 to 79 inches (50 to 2000 mm). Both sets

of transducers use a common mounting system for pipe attachment, and throughout this manual any reference to

‘UFC’ applies to both ‘A’ and ‘B’ model variants unless otherwise stated.

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1: General Description

Note: In addition to the 'A' and 'B' type sensors, type 'D' sensors (option) are available for use on pipes up to 197

inches (5000 mm). These sensors have a different mounting method. See Paragraph 1.3 for further details.

1.2 Principles of Operation

Figure 1.1 Operating modes

When ultrasound is transmitted through a liquid, the speed at which the sound travels through the liquid is

accelerated slightly if it is transmitted in the same direction as the liquid flow, and decelerated slightly if

transmitted against it. The difference in time taken by the sound to travel the same distance but in opposite

directions is therefore directly proportional to the flow velocity of the liquid.

The UFC system employs two ultrasonic transducers attached to the pipe carrying the liquid and compares the

time taken to transmit an ultrasound signal in each direction. If the sound characteristics of the fluid are known,

Fluid flow

Separation

Distance

Separation

Distance

Separation

Distance

Separation

Distance

Reflex mode

Reflex mode (double bounce)

Reflex mode (triple bounce)

Diagonal mode

This is the mode most commonly used.

The two transducers (U & D) are attached

to the pipe in line with each other and the

signals passing between them are reflected

by the opposite pipe wall.

The separation distance is calculated by

the instrument in response to entered data

concerning the pipe and fluid characteristics.

In this mode the separation distance is

calculated to give a double bounce. This is

most likely to occur if the pipe diameter is

so small that the calculated reflex mode

separation distance would be impractical

for the transducers in use.

This illustration goes one step further to show

a triple bounce situation. This would normally

apply when working with very small pipes

relative to the transducer range in use.

This mode might be selected by the

instrument where relatively large pipes are

concerned. In this mode the transducers are

located on opposite sides of the pipe but the

separation distance is still critical in order

for the signals to be received correctly.

This mode can be used with the standard

‘A’ & ‘B’ transducer sets but for really large

pipe installations the optional transducer set ‘D’

might be recommended.

Upstream

transducer

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1: General Description

the instrument’s microprocessor can use the results of the transit time calculations to compute the fluid flow

velocity. Once the flow velocity is known the volumetric flow can be easily calculated for a given pipe diameter.

The system can be set up to operate in one of four modes, determined mainly by the pipe diameter and the type

of transducer set in use. The diagram in Figure 1.1 illustrates the importance of applying the correct separation

distance between the transducers to obtain the strongest, and therefore most reliable, signal.

1.3 Supplied Hardware

The supplied UFC components are shown in Figure 1.2.

Figure 1.2 Standard UFC equipment

UFC Standard equipment

•Instrument with backlit graphic display.

•Transducer cables (x2) 16.5 feet (5.0m) in length.

•Transducers ‘A-ST’ x2 (UFC-A) for use with pipes ranging 0.5 to 4.5 inches (13 to 115 mm).

•Transducers ‘B-ST’ x2 (UFC-B) for use with pipes ranging 2 to 79 Inches (50 to 2000 mm).

•Transducer holder for use with ‘A’ or ‘B’ transducers.

•Steel bands used to secure the transducer holder to the pipe.

•Acoustic couplant applicator.

•USB Memory stick.

•User documentation.

UFC Optional equipment

•Transducer set 'D' can be used for monitoring pipes of 59 inches to 197 inches (1500 to 5000 mm) outside

diameter, over a temperature range -4°F to +176°F (-20°C to +80°C). This optional kit is supplied in a

Acoustic

Steel

Transducer

Transducers

(Sensors)

UFC

Instrument

Mounting

Earthing

Transducer

Cables (x2)

User Documentation

Holder

Couplant

Applicator

(Ax2, or Bx2)*

Clamps (x2)

Bands (x2)

Cable Kit

Transducer Clamps

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1: General Description

separate case and includes the type 'D' transducers together with ratchet straps and holders for attaching

the transducers to the pipe.

1.4 UFC Instrument

The UFC is a microprocessor controlled instrument operated through a menu system using an inbuilt LCD display

and keypad. It can be used to display the instantaneous fluid flow rate or velocity, together with totalized volumes.

The instrument also provides an isolated current output, or variable pulse output, that is proportional to the

measured flow rate and can be scaled to suit a particular flow range. Two isolated alarm outputs are provided

which can be configured in a number of ways. For example, to operate when the flow rate exceeds a specified

maximum or minimum value.

Figure 1.3 Instrument details

1.4.1 Connections

Transducer connections

The transducers are connected to two coaxial sockets located on the bottom left-hand of the instrument. The silk-

screen above these connectors show a red and blue triangle and a direction of flow symbol. For a positive flow

reading, it is important that the upstream transducer is connected to the RED socket and the downstream

transducer to the BLUE one. It is safe to connect or disconnect these cables while the instrument is switched on.

4 to 20 mA, ‘Pulse’, and Alarm I/O connections

The 4 to 20 mA, ‘pulse’, and alarm I/O cables, enter the bottom of the instrument via two cable glands and

connected internally to a terminal block. Full details of the terminal connections are provided in Chapter 2

(Installation).

Power supply

Two cable glands located on the bottom right-hand side of the instrument are available for the power supply

cable. Two sizes of glands are provided to accept cables of different diameters.

Keypad

LCD Display

Coaxial cables to transducers

Cable glands for

Small & Large Glands

for power connection

Alarms & I/O connections

Blue = Downstream

Red = Upstream

USB Connector

(for memory key)

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1: General Description

1.4.2 Keypad

The instrument is configured and controlled via a 15-key tactile membrane keypad, as shown in Figure 1.4.

Figure 1.4 UFC Keypad

Menus and the menu selection keys

Note: As a security measure, once the instrument has been set-up for the first time, a password is required to

gain subsequent access to the operating menus (see page 22).

The UFC menus are arranged hierarchally with the MAIN MENU being at the top level. Menu navigation is

achieved by three keys located on the right hand side of the keypad which are used to scroll UP and DOWN a menu

list and SELECT a menu item. When scrolling through a menu, an arrow-shaped cursor moves up and down the

left hand side of the screen to indicate the active menu choice, which can then be selected by pressing the ENTER

(SELECT) key.

Some menus have more options than can be shown on the screen at the same time, in which case the

overflowed choices can be brought into view by continuing to scroll DOWN past the bottom visible item. Menus

generally ‘loop around’ if you scroll beyond the first or last items.

If you select Exit on any menu it usually takes you back one level in the menu hierarchy, but in some cases it

may go directly to the ‘Flow Reading’ screen.

Some screens require you to move the cursor left and right along the display as well as up and down. This is

achieved using keys 5 (scroll LEFT) and 6 (scroll RIGHT).

Dual function numerical keypad

The block of keys shown in the center of the keypad in Figure 1.4 are dual function keys. They can be used to

enter straight-forward numerical data, select the displayed flow units, or provide quick access to frequently

required control menus.

Scroll UP

ENTER (SELECT)

Scroll DOWN

Scroll LEFT Scroll RIGHT Numerical keypad

with dual function keys

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1: General Description

1.4.3 Power supply

Mains supply

As standard, the UFC instrument is designed to work with a mains supply of 86 to 236 Vac and 50/60 Hz. A mains

supply fuse is located adjacent to the mains power connection (see Figure 2.2).

24V Supply

An alternative 24 V (ac/dc) power supply module is available as a factory fitted option.

Power failure

The instrument will automatically power-up and become operational when the input power is applied. In the event

of a power failure, the instrument’s configuration parameters are stored in non-volatile memory which then allows

the instrument to return to normal operation immediately power is restored. A real time clock (RTC) records the

date and time of any power disruptions, and time-stamps any such occurrence in the output log. All data logging

ceases while power is unavailable.

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2: Installation

2.1 Safety Precautions and Warnings

2.2 Installing the UFC Instrument

2.2.1 Positioning the instrument

The UFC instrument should be installed as close as conveniently possible to the pipe-mounted ultrasonic

sensors. Standard transducer cables are 16.5 ft (5 m) in length with 33 ft (10 m) cables being optionally available.

Where, for operational reasons, it is not possible to mount the instrument this close to the sensors, bespoke

cables of up to 328 ft (1000 m) can be provided. Consult Dwyer for further information and availability.

A suitable mains supply must be available to power the instrument (an optional 24V (ac/dc) supply module is

available). The external supply must be suitably protected and connected via an identifiable isolator. A 500 mA

fuse is fitted internally in the instrument’s input supply line.

WARNING

LETHAL VOLTAGES

You may be exposed to potentially lethal (mains) voltages

when the terminal cover of this instrument is removed.

Always isolate the supply to this instrument before removing

the terminal cover.

WARNING

LETHAL VOLTAGES

This instrument must be installed by an electrically qualified

technician aware of the potential shock hazards presented

when working with mains powered equipment.

WARNING

SUPPLY EARTHING

If the equipment is powered from a 24 Vac supply then the

supply must be isolated from earth.

Caution

IP65 Enclosure Protection

Blanking plugs are fitted to the cable glands on leaving the manufacturer.

In order to preserve the enclosure’s IP65 rating, ensure that the blanking plugs

remain fitted in any unused cable gland.

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