Emco Enterprises Automobile Parts 5707070 A Users Manual Doppler

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Sono-Trak™ Doppler

Ultrasonic Flow Meter

EMCO PRODUCTS

April 2004 5707070-A User Manual

5707070-A iii

Sono-Trak™ Doppler Ultrasonic Flow Meter

COPYRIGHT

This manual and the information contained herein is the proprietary property of

Advanced Energy Industries, Inc.

No part of this manual may be reproduced or copied without the express written

permission of Advanced Energy Industries, Inc. Any unauthorized use of this manual

or its contents is strictly prohibited. Copyright© April 2004 Advanced Energy

Industries, Inc. All Rights Reserved.

DISCLAIMER AND LIMITATION OF LIABILITY

The information contained in this manual is subject to change by Advanced Energy

Industries, Inc. without prior notice. Advanced Energy Industries, Inc. makes no

warranty of any kind whatsoever, either expressed or implied, with respect to the

information contained herein. Advanced Energy Industries, Inc. shall not be liable in

damages, of whatever kind, as a result of the reliance on or use of the information

contained herein.

INTERPRETING THE MANUAL

The following sections explain the document type conventions and the danger,

warning, and caution boxes that provide information about the specific levels of

hazard seriousness.

TYPE CONVENTIONS

Please note the following type conventions:

• Pin and signal names appear in capitalized italics (POWER_ON).

• New terms appear in italicized text.

• Unit labels (switches, indicators, and so on) appear in boldface text (ECHO).

• Commands (162) and command names (set point) appear in boldface, lowercase

text.

CAUTION AND ATTENTION BOXES

This symbol represents important notes concerning potential harm to people, this unit,

or associated equipment. Advanced Energy® includes this symbol in Warning,

Caution, and Attention boxes to identify specific levels of hazard seriousness.

iv 5707070-A

Advanced Energy®

TRADEMARKS

is a registered trademark of Advanced Energy Industries, Inc.

Advanced Energy® is a registered trademark of Advanced Energy Industries, Inc.

AE® is a registered trademark of Advanced Energy Industries, Inc.

Sono-Trak™ is a trademark of Advanced Energy Industries, Inc.

Dow Corning® is a registered trademark of Dow Corning Corporation.

EMCO Flow Systems is a brand of Advanced Energy Industries, Inc.

Novagard® is a registered trademark of Foam Seal, Inc./ NSCG, Inc.

G661™ is a trademark of Foam Seal, Inc./ NSCG, Inc.

Swagelok® is a registered trademark of Swagelok Company

CUSTOMER FEEDBACK

Advanced Energy’s technical writing staff has carefully developed this manual using

research-based document design principles. However, improvement is ongoing, and

the writing staff welcomes and appreciates customer feedback. Please send any

comments on the content, organization, or format of this user manual to:

• tech.writing@aei.com

To order a manual, please contact Technical Support:

• support@emcoflow.com

For more EMCO Flow brand product line information, visit the EMCO website:

• www.emcoflow.com

This box identifies hazards or unsafe practices that could result in

personal injury.

This box identifies hazards or unsafe practices that could result in

product or property damage.

Attention:

This box identifies important information. It calls attention to a

procedure, practice, or condition which is important to highlight

5707070-A v

Sono-Trak™ Doppler Ultrasonic Flow Meter

Chapter 1: Introduction and Theory of Operation

Introduction ............................................................................................................... 1-1

Features of the Sono-Trak™ Doppler Ultrasonic Flow Meter ..................... 1-1

Components of the Sono-Trak™ Doppler Ultrasonic Flow Meter System .. 1-2

Electronics Enclosure and Display Panel ......................................... 1-2

Transducers and Cabling .................................................................. 1-2

Theory of Operation .................................................................................................. 1-2

Sonic Reflectors ............................................................................................ 1-3

Accuracy ....................................................................................................... 1-3

Summary ....................................................................................................... 1-3

Applications .............................................................................................................. 1-4

Chapter 2: Installation and Operation

Before Installing the Unit ......................................................................................... 2-1

Unpacking the Unit ....................................................................................... 2-1

Included Equipment .......................................................................... 2-1

Tools Required for Installation ......................................................... 2-2

Pre-installation Procedures and Checks ........................................................ 2-2

Determining if Your Process/Installation is Right for a Doppler Flow Meter ......... 2-3

Assessing Particles or Air Bubbles ............................................................... 2-4

Fluctuations in Flow Content ............................................................ 2-4

Process Changes ............................................................................... 2-4

Assessing Pipe Material and Condition ........................................................ 2-5

Assessing Flow Profile ................................................................................. 2-5

Straight Run Requirements ............................................................... 2-5

Transducer Placement ....................................................................... 2-7

Sono-Trak Transit Time Ultrasonic Flow Meters ......................................... 2-9

Installation Procedures .............................................................................................. 2-9

Mounting and Connecting the Transducers .................................................. 2-9

Mounting and Connecting Power to the Electronics Enclosure ................... 2-13

Operation .................................................................................................................. 2-15

Display Panel ................................................................................................ 2-15

LEDs ................................................................................................. 2-16

First Time Operation ..................................................................................... 2-17

If You Experience Unstable Readings .............................................. 2-20

Advanced Configuration Options ................................................................. 2-20

Before Setting Advanced Parameters ............................................... 2-22

Table of Contents

vi 5707070-A

Advanced Energy®

Setting Advanced Parameters ........................................................... 2-22

Normal Operation ......................................................................................... 2-25

Portable Battery Operation (Portable Units Only) ........................................ 2-25

Chapter 3: Troubleshooting and Customer Support

Troubleshooting the Unit .......................................................................................... 3-1

Flow Meter Troubleshooting Tables ............................................................. 3-2

Status of Unit Power ......................................................................... 3-2

Status of Echo LED: Off ................................................................... 3-3

Status of Echo LED: Flashing .......................................................... 3-5

Status of Flow Reading: High or Low .............................................. 3-6

Status of Flow Reading: Erratic ........................................................ 3-8

Additional Troubleshooting Information ...................................................... 3-9

Echo LED Light Considerations ....................................................... 3-9

Suspended Particle Test For Doppler Signals ................................... 3-10

EMCO Flow Systems Support .................................................................................. 3-11

Returning Units for Repair ....................................................................................... 3-12

Warranty ................................................................................................................... 3-12

Authorized Returns ....................................................................................... 3-13

Warranty Statement ...................................................................................... 3-13

Chapter 4: Specifications and Reference Information

Performance Specifications ...................................................................................... 4-1

Physical Specifications ............................................................................................. 4-2

Functional Specifications .......................................................................................... 4-3

Dimensional Drawings ............................................................................................. 4-6

Electronics Enclosure Dimensions ............................................................... 4-6

Clamp-On Transducer and Digitizer Dimensions ........................................ 4-8

Reference Information .............................................................................................. 4-8

Standard Pipe Data ........................................................................................ 4-9

Velocity Conversion Tables .......................................................................... 4-12

5707070-A Introduction and Theory of Operation 1-1

Chapter

Sono-Trak™ Doppler Ultrasonic Flow Meter Chapter

1

Introduction and Theory of

Operation

INTRODUCTION

The Sono-Trak™ Doppler ultrasonic flow meter provides an accurate and easy-to-use

measuring system for high-solid fluid flow through pipes 1/2 inch to 300 inches

(outside diameter). The Doppler flow meter is well suited for flow measurement

applications such as sludges, slurries, aerated liquids, sewage, dredges, pulp, plastics,

and activated sludges. The Doppler flow meter features clamp-on transducers and a

rugged NEMA 4X enclosure, and is a long-term, maintenance-free solution for your

high-solid flow measurement requirements.

Features of the Sono-Trak™ Doppler Ultrasonic Flow Meter

The Doppler flow meter features:

• AC or DC operation

• A smart LCD screen featuring high-resolution, 32 character, 2-line alphanumeric

providing rate and totalization simultaneously—in metric and English units

• Splash proof NEMA 4X case protected from water and caustic chemicals

• Easy configuration for set up and operation with on-screen prompting, quick

scrolling menus, display panel keypad, and color coded LEDs

• Clamp-on transducers

• Analog current output scaled 4 mA to 20 mA for external indication

• Separate high and low alarm outputs with LED status indication

• Extended cable distance from transducers to electronics enclosure

• High accuracy

• Wide pipe diameter range

• Maintenance-free modular construction simplifying field service

1-2 Introduction and Theory of Operation 5707070-A

Advanced Energy®

Components of the Sono-Trak™ Doppler Ultrasonic Flow

Meter System

A typical Doppler flow meter system is comprised of an electronics enclosure (with a

display panel), a digitizer, and two clamp-on transducers.

ELECTRONICS ENCLOSURE AND DISPLAY PANEL

The display panel in the electronics enclosure features an easy-to-read LCD screen, a

keypad, and LEDs to interface with the flow meter. The Doppler flow meter can be

wall mounted for permanent installation or a portable option is also available.

TRANSDUCERS AND CABLING

The Doppler flow meter is configured with clamp-on transducers. When installed, the

transducers sense fluid flow through a pipe and send this information to the system

electronics. The electronics then convert, transmit, and display the received data.

The clamp-on transducers allow you to install the Doppler flow meter without

shutting down flow and are ideal for smooth, clean pipe walls. The transducers and the

digitizer are NEMA 6-rated and fully submersible. However, for continuous

submersion, the transducers and the digitizer need to be specially encapsulated to

prevent corrosion. Contact “EMCO Flow Systems Support” on page 3-11 for

information on configuring your meter for continuous submersion.

The standard cable length between the electronics enclosure and the transducers is 25

feet. Custom cable lengths up to 5000 feet are available. See “EMCO Flow Systems

Support” on page 3-11 for contact and ordering information.

THEORY OF OPERATION

The Sono-Trak™ Doppler ultrasonic flow meter measures flow velocity by sensing

signals from reflective materials within a liquid and measuring the frequency shift due

to the motion of these reflective materials. The Doppler effect states that the received

frequency is a function of the transmitted frequency and the relative motion between

transmitter and the receiver.

The classic example of the Doppler effect is the train whistle increasing in pitch to the

listener at the station as the train approaches, then decreasing in pitch as the train

moves away from the station. To the person riding on the train, the pitch remains the

same. The increasing pitch is due to phase-front compression and the decreasing pitch

is due to phase-front expansion. The Doppler flow meter uses this effect to measure

the velocity of a liquid through a pipe wall.

5707070-A Introduction and Theory of Operation 1-3

Sono-Trak™ Doppler Ultrasonic Flow Meter

Sonic Reflectors

The Doppler flow meter requires sonic reflectors in order to operate. These reflectors

may consist of particles or air bubbles within the flow to be measured. Your readings

may vary slightly with changes in concentration or size of these reflectors as well as

the pipe condition and size.

Note: Glycerin is the only known industrial liquid today that is not sonically

conductive.

The Doppler flow meter uses two similar transducers to sense flow in a pipe. These

transducers are mounted on the outside of a pipe. This configuration presents no

obstruction to flow, and will not cause associated pressure drops.

Accuracy

The Doppler flow meter output signal is linear (as opposed to square root), which

means that accuracy is not a function of flow rate. Within certain application limits,

the meter is ideal because it is not affected by changes of pressure within the process

nor by changes of viscosity, temperature, specific gravity, sound velocity, or electrical

conductivity.

Summary

The Doppler flow meter is a non-intrusive flow meter system which operates by

sensing the frequency shifts of signals reflected from particles, air bubbles, or density

differences within a liquid, producing a linear signal proportional to the flow of the

liquid within the pipe.

• No pipe section is required to install the meter.

• The meter is not affected by changes in temperature, viscosity, specific gravity, or

the speed of sound within the liquid.

• The liquid does not have to be electronically conductive.

• A minimum particle concentration of 35 ppm @ 40 micron of suspended solids or

air bubbles is required.

• The reflector must have at least a 0.2% density difference than the liquid medium.

• For accurate volumetric measurement the pipe must be full at all times.

• The sensors, transducer crystals, are always coupled to the pipe with gel or epoxy.

• In order to obtain accurate measurements adequate upstream and downstream

pipe runs are required. Recommended straight-run requirements from any

disturbance of flow are 10 diameters upstream and 5 diameters downstream.

1-4 Introduction and Theory of Operation 5707070-A

Advanced Energy®

APPLICATIONS

Some of the materials the Sono-Trak™ Doppler ultrasonic flow meter is well-suited

for measuring include:

•Ag water

• Abrasives

• Asphalts

•Concrete

• Dredge flows

• Drilling mud

• Large contaminates

• Extremely viscous substances

•Grout

• Hazardous wastes

• Municipal sludges and wastes

• Paper pulp

• Rendering products

• Reservoirs

• Rivers and streams

• Runoffs

•Sludges

• Slurries

• Suspended solids

• Most all liquids containing suspended particles or air bubbles

5707070-A Installation and Operation 2-1

Chapter

Sono-Trak™ Doppler Ultrasonic Flow Meter Chapter

2

Installation and Operation

BEFORE INSTALLING THE UNIT

Before installing your Sono-Trak™ Doppler ultrasonic flow meter, follow the steps

listed below:

1. See “Unpacking the Unit” on page 2-1.

2. Make sure you have performed the “Pre-installation Procedures and Checks” on

page 2-2.

3. Determine if your process/installation is compatible with the requirements of

Doppler flow meter. See “Determining if Your Process/Installation is Right for a

Doppler Flow Meter” on page 2-3).

4. Proceed to “Installation Procedures” on page 2-9.

Unpacking the Unit

Unpack and inspect the unit carefully, looking for obvious physical damage. If no

damage is apparent, locate and save all documentation and then proceed with the

following procedures.

If you see signs of shipping damage, contact EMCO product support at Advanced

Energy and the carrier immediately (see “EMCO Flow Systems Support” on

page 3-11 for contact information). Save the shipping container for submitting

necessary claims to the carrier.

INCLUDED EQUIPMENT

Table 2-1 lists the standard items that ship with Sono-Trak™ Doppler ultrasonic flow

meter systems.

2-2 Installation and Operation 5707070-A

Advanced Energy®

TOOLS REQUIRED FOR INSTALLATION

• Sandpaper to clean the pipe surface to bare pipe

• Tape measure to measure pipe size

Pre-installation Procedures and Checks

Before you install your Doppler flow meter, there is a pre-install check you should

perform to ensure that this is the appropriate meter to use for your application. If you

encounter any difficulties during the pre-installation procedures, see “Determining if

Your Process/Installation is Right for a Doppler Flow Meter” on page 2-3 before

proceeding with the installation process.

To Perform the Doppler flow meter Pre-installation Check:

1. Mount the transducers side by side between 7 o’clock and 10 o’clock on the pipe

(see “Mounting and Connecting the Transducers” on page 2-9 for more

information).

2. If not already connected, connect the transducers to the electronics enclosure (see

“Mounting and Connecting the Transducers” on page 2-9).

3. Connect AC or DC power to the flow meter (see “Mounting and Connecting

Power to the Electronics Enclosure” on page 2-13).

4. Turn on the power using the switch on the display panel.

5. After the electronics enclosure powers up and the front display panel lights up,

press soft key 1 to select FPS (feet per second).

6. Estimate your expected flow rate and compare it to the reading in feet per second

on the display panel.

Table 2-1. Items shipped with the flow meter system

Fixed unit (C5F model) Portable unit (C5P model)

• Electronics enclosure

• Two transducers and a 25´ cable

(standard); custom lengths up to

5000´ are available

• Digitizer

•Tiedown kit

• Sonic coupling gel

•User manual

• Electronics enclosure

• Two transducers and a 25´ cable

(standard); custom lengths up to

5000´ are available

• Digitizer

•Tiedown kit

• Sonic coupling gel

•User manual

• 12 V 2.2 AH battery

• 110 VAC battery charger

• Tote handles and side latch

• Field transport case

5707070-A Installation and Operation 2-3

Sono-Trak™ Doppler Ultrasonic Flow Meter

4 If the reading on the display panel appears to be accurate, continue to the next

step.

4If you do not see a flow reading on the LCD screen at all, or if the flow reading

is much lower or higher than expected, try repositioning the transducers. If this

does not help, see “Determining if Your Process/Installation is Right for a

Doppler Flow Meter” on page 2-3 and consult “Troubleshooting the Unit” on

page 3-1.

7. Observe the yellow Echo LED on the display panel.

4If the Echo LED is on steady, and the flow reading appears to be accurate, your

Doppler flow meter is ready for operation. See “Normal Operation” on

page 2-25 to configure the flow meter for operation with your system.

4If the Echo LED is flashing or not illuminated, see “Determining if Your

Process/Installation is Right for a Doppler Flow Meter” on page 2-3 and

consult “Troubleshooting the Unit” on page 3-1.

DETERMINING IF YOUR PROCESS/

INSTALLATION IS RIGHT FOR A DOPPLER

FLOW METER

Accurate operation of a Doppler flow meter depends upon your application and

installation site. Doppler flow meters offer many advantages over other flow meter

models when flows are viscous, turbulence is minimal, and piping materials are

appropriate. When conditions are adverse to Sono-Trak™ Doppler ultrasonic flow

meter operation, the Sonotrak™ Transit Time flow meter may offer an excellent

alternative. Contact “EMCO Flow Systems Support” on page 3-11 for more

information about this transit time meter.

To determine which flow meter is appropriate for your process and specific

installation, consider the following:

• The presence of reflective particles in the flow

• The pipe material and condition of pipe housing the flow

• The flow profile, meaning that you are able to provide acceptable straight run

requirements to ensure more accurate readings

The following sections discuss these considerations.

2-4 Installation and Operation 5707070-A

Advanced Energy®

Assessing Particles or Air Bubbles

The ultrasonic beam from the transducer is transmitted through the pipe wall into the

liquid. The particles, air bubbles suspended in the liquid, have to be large enough to

act as reflectors to return the signal back to the transducer so that a measurement may

be taken. It is important to understand that the ultrasonic beam from the Doppler flow

meter does not penetrate air very well. A few bubbles will not affect flow meter

performance, but too many bubbles may cause the meter to malfunction. See

“Suspended Particle Test For Doppler Signals” on page 3-10 for information on how

to assess the particulate content of your flow.

Note: At a frequency of roughly 650 kHz, the minimum particle which can be sensed

is 40 microns @ 35 parts per million (ppm) and at least 0.2% density difference

from the liquid.

FLUCTUATIONS IN FLOW CONTENT

Wide fluctuations in flow suspended solids content can only be handled by an

instrument capable of monitoring such a wide fluctuation in liquid characteristics.

Extreme cases may require the use of both a transit time flow meter (such as the Sono-

Trak™ model) as well as a Doppler flow meter. For example, river water may require

a meter which is capable of measuring both clean and dirty liquids. Depending on

conditions, the river may vary considerably in suspended solid content.

PROCESS CHANGES

Changes in the process may cause the meter to cease proper operation. For example, a

Doppler meter had been operating satisfactorily for a long time in a certain

installation, and then suddenly it stopped functioning. The problem was eventually

traced to a particle filter that had recently been placed before the transducers,

effectively eliminating the reflectors from the stream.

Process changes in the other direction are also possible. The meter responds to

bubbles up to a point, but if the liquid starts to foam there may be too many air

bubbles to allow the ultrasonic beam to adequately penetrate the flow stream. This

may cause the Doppler flow meter to produce erroneous flow readings. Similarly, a

sludge may become too dense to allow proper penetration.

Attention:

The flow to be measured must always have a sufficient number of sonic

reflectors of ample size in order to provide reflection of the transmitted

sound. If the reflectors do not have sufficient density difference they

will neither rise nor fall in the solution but remain suspended. The

specific gravity will also affect the ability of a particle to reflect sound.

A good example of a reflector is a sand particle or an air bubble. A poor

example is algae or onion skins.

5707070-A Installation and Operation 2-5

Sono-Trak™ Doppler Ultrasonic Flow Meter

Assessing Pipe Material and Condition

Doppler flow meter performance is best maximized by using piping that is sonically

conductive. The Doppler flow meter assumes that the path by which the ultrasonic

beam enters the pipe and returns to the transducer is ultrasonically homogenous,

which means that you must use your flow meter with pipes with non-porous smooth

pipe walls. Concrete-lined pipes, old or crystallized cast iron pipes, hand-wrapped

fiberglass pipe, and old piping with air inclusions do not exhibit the required

homogeneity. Avoid using the Doppler flow meter for flow measurement on these

pipes unless proper operation is proven by the manufacturer through demonstration.

Contact “EMCO Flow Systems Support” on page 3-11 for more information on an

alternate meter if your application is not suitable for the Doppler flow meter.

Note: No clamp-on meter will operate properly if the liner is not solidly attached to

the pipe wall because of the probability of an air gap.

Pipe Vibration

Moderate pipe vibration does not usually adversely affect the Doppler flow meter,

since the vibration of the piping is at a significantly lower frequency than the

ultrasonic beam used to measure flow. However, in situations where the transducer

signal strength is low because of fluid, piping, or other environmental factors,

measurement accuracy may be further decreased by pipe vibration. In these situations

your display panel may register flow when there is none due to the vibration. If you

can not bracket the pipe to reduce vibration, you may be able to rectify the problem by

relocating the transducer to a pipe location with less vibration.

Assessing Flow Profile

STRAIGHT RUN REQUIREMENTS

As with other flow meters such as vortex or magnetic flow meters, the Doppler flow

meter needs a well-developed flow profile to ensure accurate flow measurement. To

assure a well-developed profile, choose a measurement point on a long run of pipe—

well away from elbows, valves, pumps, flanges, and other possible sources of

turbulence.

The ideal placement of the Doppler flow meter is with 20 diameters of straight run

upstream and 10 diameters of straight run downstream between the transducers and

any disturbance of the flow. Most typical flow meter applications use 10 diameters of

straight run upstream and 5 diameters downstream from any disturbance of the flow.

However, when the measured fluid is too clean to provide the proper number of

reflective particles, one may position the transducer near the pump or source of

turbulence in such a manner as to obtain stable readings in a continuous flow full pipe

situation. Using a transit time meter may be another viable option if the Doppler flow

2-6 Installation and Operation 5707070-A

Advanced Energy®

meter is not performing ideally. A point to remember is that turbulence is a non-linear

function of flow, so turbulence can create reflected signals. Interpret readings near

turbulent flows with caution.

Sources of turbulence are elbows, flanges, valves, orifices, wedges, pumps, pipe

openings, and pipe irregularities (rust, corrosion, and buildup). Always avoid vertical

pipe runs (especially downhill pipe runs).

Note: Accuracy is dependant on flow profile, and is related to the percentage of sound

reflectors and their size variation and distribution.

Figure 2-1 provides straight run examples.

Table 2-2. Flow meter distance from turbulence and reading accuracy

Upstream Downstream % Accuracy

20 diameters 10 diameters ±1% to 3% of full scale

10 diameters 5 diameters ±3% to 5% of full scale

5 diameters 2 diameters ±5% to 10% of full scale

5707070-A Installation and Operation 2-7

Sono-Trak™ Doppler Ultrasonic Flow Meter

Figure 2-1. Straight run examples

TRANSDUCER PLACEMENT

You should always avoid measuring liquids in vertical downward flows with any flow

meter. In the case of Doppler flow meters, vertical downward flows cause erroneous

readings by introducing air bubbles. Excessive air bubbles attenuate the measurement

signal by hampering penetration of the ultrasonic beam into the fluid. Bubbles will

tend to rise against the flow, and since the Doppler flow meter is capable of totalizing

in both directions, this will cause erroneous flow measurements as the meter factors in

the backward flow of the bubbles. Additionally, in vertical flows it may be difficult to

keep the pipe full, allowing pockets of air into the pipe. This will drastically reduce

the transducer’s ability to penetrate the flow and produce a readable signal.

D = Nominal pipe diameter

2-8 Installation and Operation 5707070-A

Advanced Energy®

When the Doppler transducers are mounted on a horizontal pipe, care should be taken

to mount them in the 7 o’clock and 10 o’clock positions (with the top of the pipe—the

side furthest from the Earth—corresponding to the 12 o’clock position). If the

transducer is mounted on the bottom of the pipe, settling particles may attenuate the

signals by introducing an additional sonic barrier. Also, air may agglomerate at the top

of the pipe. Since the ultrasonic frequencies used will not penetrate air efficiently, the

signal will be heavily attenuated so that the meter will not be able to render accurate

results.

Horizontal Pipe Mounting

The recommended placement of the Doppler transducers is a horizontal section of

piping. Figure 2-2 provides horizontal mounting examples.

Figure 2-2. Horizontal pipe mounting examples

Vertical Pipe Mounting

Measuring flow at a vertical pipe run is not recommended. If measuring flow in a

vertical run can not be avoided, we recommend you measure at a point where the

direction of flow through the pipe is upwards to help ensure the pipe will remain full

at all times (Figure 2-3). However, measuring flow even with an upward vertical pipe

run will not address all the problems associated with this configuration.

Figure 2-3. Vertical pipe mounting examples

Transducers

Transducers

5707070-A Installation and Operation 2-9

Sono-Trak™ Doppler Ultrasonic Flow Meter

Sono-Trak Transit Time Ultrasonic Flow Meters

In the event the flow to be measured does not contain the minimum required particle

size and/or parts per million count, and the transducer will not read, you may want to

consider the Sono-Trak™ Transit Time ultrasonic flow meter for your application.

Contact an EMCO sales representative with your flow meter application questions.

See “EMCO Flow Systems Support” on page 3-11 for contact information.

INSTALLATION PROCEDURES

After you have performed the pre-install check and determined that the Doppler flow

meter will work for your application, follow these steps to install your meter.

To Install the Sono-Trak™ Doppler Ultrasonic Flow Meter:

1. Mount and connect the transducers (see page 2-9)

2. Mount and connect power to the electronics enclosure (see page 2-13)

3. Turn on power to the electronics enclosure using the switch on the display panel

and follow display panel for meter set up (see “Operation” on page 2-15 for more

information on configuring your meter for operation)

Mounting and Connecting the Transducers

The clamp-on transducers are NEMA 6-rated and fully submersible. However, if your

system requires that the transducers and the digitizer be continuously submerged, they

need to be specially encapsulated to prevent corrosion. Contact “EMCO Flow

Systems Support” on page 3-11 for information on configuring your flow meter

components for continuous submersion.

To Mount the Clamp-On Transducers to the Pipe:

1. Ensure the pipe surface is clean. Use sandpaper to remove all paint and scale from

the pipe surface if necessary.

2. Apply sonic gel to the transducer lenses. For best results in most weather

conditions and heat, use Dow Corning® High Vacuum Grease or the supplied

Novagard® grease G661™.

Attention:

Always apply sonic gel to the transducer lenses before placing on the

pipe. The sonic gel must be used to transmit the energy from the

transducer crystals through the pipe wall and into the flow to be

measured.

2-10 Installation and Operation 5707070-A

Advanced Energy®

3. Place the transducers side by side between 7 o’clock and 10 o’clock on the pipe

as shown in Figure 2-4. Place the transducers flush to the pipe, facing the same

direction. See Figure 2-5 for an example.

Note: Be careful with transducer placement. Air bubbles near the top of the pipe

or sediment on the bottom of the pipe can hinder successful flow readings.

Place the transducers as shown in Figure 2-4.

Figure 2-4. Clamp-on transducer placement

4. Use the supplied chain and bungee cord to strap the transducers in place, securing

them tightly to the pipe. Figure 2-5 provides an example of two properly mounted

clamp-on transducers.

Transducers

Cross-section of pipe

with mounted

transducers

Electronics enclosure

12 o’clock position

6 o’clock position

5707070-A Installation and Operation 2-11

Sono-Trak™ Doppler Ultrasonic Flow Meter

Figure 2-5. Clamp-on transducers secured with a bungee and chain

To Connect the Transducers to the Electronics Enclosure:

1. Ensure AC or battery (DC) input power is turned off.

2. Connect the transducer cable to the electronics enclosure by routing the cable

through the appropriate opening (see “Bottom view of the electronics enclosure”

on page 4-7 for location of cable access openings). Use a cable gland and a cable

backing nut to securely fasten the trasnducer cable to the electronics enclosure.

3. Connect the transducer wires to the processor board as shown in Figure 2-6 on

page 2-12 for correct placement. The transducer 4-wire connection is as follows:

4White = Digital signal output (0 V to 12 V pulse train)

4Green = Echo good logic signal (when used)

4Red = 12 VDC to 15 VDC at 100 mA nominal power in

4Black = Ground / Common

Note: Do not connect bare shield wire to black (common / ground)

Transducers

2-12 Installation and Operation 5707070-A

Advanced Energy®

Figure 2-6. Main electronics board connections

Transducer

wires

5707070-A Installation and Operation 2-13

Sono-Trak™ Doppler Ultrasonic Flow Meter

4. Continue with “Mounting and Connecting Power to the Electronics Enclosure” on

page 2-13.

Mounting and Connecting Power to the Electronics Enclosure

The fixed Doppler flow meter model electronics enclosure is wall mounted for

permanent installation. The portable meter model does not need to be mounted.

To Mount the Fixed Electronics Enclosure:

1. Locate and install the four mounting feet supplied with your system to the base of

the electronics enclosure.

Figure 2-7. Wall mounting feet of the electronics enclosure

2. Using the reinforced holes in the mounting feet, securely mount the electronics

enclosure to the wall.

To Connect Input Power to the Electronics Enclosure:

Note: You can either use AC power or DC/ battery power to operate your Doppler

flow meter.

1. If you are using AC power:

4If not already connected, supply input power to the electronics enclosure by

routing the power cable through the appropriate opening (see “Bottom view of

the electronics enclosure” on page 4-7).

4If needed, connect the AC power cable wires to the AC Pwr Input (117/220

VAC) section of the processor board using Figure 2-6 and Figure 2-8 as a

guide, making sure to properly connect ground.

4Use a cable gland and a cable backing nut to securely fasten the input power

cable to the electronics enclosure.

4Verify that the A/C Select switch is set for the proper voltage (115 VAC or 230

VAC)

4 Move the AC/ Battery (DC) switch to the AC side. See Figure 2-8 for switch

locations.

2-14 Installation and Operation 5707070-A

Advanced Energy®

4Plug AC power into the appropriate outlet.

Figure 2-8. Another view of processor board connections

2. If you are using DC/ battery power:

4If not already connected, supply input power to the electronics enclosure by

routing the power cable through the appropriate opening (see “Bottom view of

the electronics enclosure” on page 4-7).

4If needed, connect the DC power cable wires to the Internal Battery section

of the processor board using Figure 2-6 and Figure 2-8 as a guide.

4Use a cable gland and a cable backing nut to securely fasten the input power

cable to the electronics enclosure.

5707070-A Installation and Operation 2-15

Sono-Trak™ Doppler Ultrasonic Flow Meter

4Move the AC/ Battery switch to the Battery (DC) side. See Figure 2-8 for the

switch location.

4Plug the battery in to the power cable. For information on charging your

battery, see “Portable Battery Operation (Portable Units Only)” on page 2-25.

3. Continue on to “First Time Operation” on page 2-17.

OPERATION

The following sections describe the display panel in the electronics enclosure, first

time operation, and normal operation of your Doppler flow meter.

Display Panel

The display panel in the Doppler flow meter electronics enclosure provides an

interface for monitoring and controlling the flow meter. The high resolution 2-line

(16-digits per line) display shows operating information and configuration menu

prompts. You may use the keypad to make selections when prompted by the

configuration menu prompts.

2-16 Installation and Operation 5707070-A

Advanced Energy®

Figure 2-9. Display panel

LEDS

If your Doppler flow meter is working properly with your system, when you power up

the flow meter you should see the green Power LED and the yellow Echo LED

illuminate. If this is not the case, consult the table below and see “Troubleshooting the

Unit” on page 3-1.

5707070-A Installation and Operation 2-17

Sono-Trak™ Doppler Ultrasonic Flow Meter

First Time Operation

Once you have successfully completed installation of the Doppler flow meter, you are

ready to configure your unit for operation using the front panel in the electronics

enclosure.

Table 2-3. LED conditions and indications

LED Condition Indication

Power

(Green)

Off Power is not available to the unit.

If you have tried to power up your

unit and this light is off, see

“Troubleshooting the Unit” on

page 3-1.

Illuminated steady Power is available to unit.

Proceed with normal operation.

Echo

(Yellow)

Off No echo signal.

Consult “Troubleshooting the Unit”

on page 3-1.

Flashing Echo signal is weak.

Consult “Troubleshooting the Unit”

on page 3-1.

Illuminated steady Echo signal is good.

Proceed with normal operation.

Alarm

High or Low

(Red)

Off No alarm conditions exist.

Proceed with normal operation.

Illuminated steady An alarm condition exists.

Your system is running at high or low

flow. Adjust your flow levels or

consult “Troubleshooting the Unit”

on page 3-1.

2-18 Installation and Operation 5707070-A

Advanced Energy®

To Operate Your Doppler Flow Meter for the First Time:

1. Complete all the steps in “Before Installing the Unit” on page 2-1.

2. Complete all the steps in “Installation Procedures” on page 2-9.

3. Turn on power and observe the display panel LCD. The display will show the

model name and number of the unit.

4. Following the prompts presented by the display panel LCD, and making your

entries using the keypad, configure your unit for operation.

4The LCD screen displays SELECT RATE. Select the unit of measure for rate

display:

If you select FPS, the flow meter will automatically begin measuring flow in feet

per second. If you select keys 2 through 7, the LCD screen will ask that you enter

your pipe ID in inches. See “Standard Pipe Data” on page 4-9 to estimate your

pipe ID.

After you enter your pipe ID, the LCD screen will then display SELECT

TOTALIZER. Select the unit of measure for totalizer display:

Attention:

If your display flashes LOW BAT at any time during setup or

programming, consult “Status of Unit Power” on page 3-2 for

troubleshooting information.

Note: If you are switching from battery (DC) power to AC power and the

A/C Select switch selection does not match your incoming power level,

you may see a LOW BAT warning in the front panel display. Adjust the

A/C Select switch to the correct incoming power level (115 VAC or

230 VAC), and this warning should disappear.

Table 2-4. Rate selection

Key Selection Definition

1FPS Feet per second

2GPM Gallons per minute

3CFS Cubic feet per second

4MGD Million gallons per day

5MPS Meters per second

6LPS Liters per second

7CMS Cubic meters per second

8< = > Use this key to move between rate screens

5707070-A Installation and Operation 2-19

Sono-Trak™ Doppler Ultrasonic Flow Meter

Your Doppler flow meter is now configured to measure flow per the parameters you

have set. After you set the flow reading parameters you need for your system, you can

secure these settings so they are saved in the event of power loss to the electronics

enclosure.

Note: To clear the rate and totalizer parameters you have set, simply switch the power

off using the on/ off switch on the display panel. Until settings are saved using

the security switch, turning off power clears all previously set parameters.

When you turn on power again, the LCD screen will prompt you to restart

programming.

To Save Your Programmed Flow Reading Settings Using the Security Switch:

1. Complete setting the flow reading parameters (see “First Time Operation” on

page 2-17 to set parameters).

2. Unscrew the face of the display panel to expose the processor board by turning

both white plastic screws on the right side of the face of the display panel

counterclockwise at the same time.

3. The security switch (called “S1” on the electronics board) is located in the upper

left corner of the processor board, See Figure 2-8 to find the location of this

switch. While programming, the switch was on the “B” side (Program/ run mode).

4. To save your new settings, move the security switch on the processor board to the

“A” side (Secure/ run mode). This switch ensures your settings will be saved in

the event of power loss.

5. Be sure to close and resecure the face of the display panel when you are finished.

Carefully rethread the screws clockwise simultaneously.

Note: If you need to change your programming, reopen the electronics enclosure and

unscrew the display panel to expose the processor board. Slide the security

switch to the “B” side (Program/ run mode). Once your new selections are

Table 2-5. Totalizer selection

Key Selection Definition

1GAL Gallons

2CU FT Cubic feet

3AC FT Acre feet

4MG Millions of gallons

5LTRS Liters

6CM Cubic meters

8< = > Use this key to move between totalizer

selection screens

2-20 Installation and Operation 5707070-A

Advanced Energy®

complete, you can then return the switch to the “A” side to preserve your new

settings. Again, be sure to close and carefully resecure the face of the display

panel when you are finished.

If you wish to further customize your flow meter system for operation in your process,

continue on to “Advanced Configuration Options” on page 2-20.

IF YOU EXPERIENCE UNSTABLE READINGS

A steady display and solid illuminated Echo lamp indicates a good signal. An erratic

display and/or a flashing Echo lamp indicates a poor signal. Reposition the transducer

heads until readings are steady and the Echo lamp is illuminated solid or select

another position to mount the sensors. Possible reasons for poor signals are:

• Partially full pipe

• Extreme aeration

• Insufficient suspended particles (minimum particle size and concentration are 40

microns at 35 ppm and greater than 0.2% density difference)

Any fluids with particle size/concentration less than the requirement listed above

should be measured with a transit time flow meter and not a Doppler flow meter.

• Extreme turbulence

• Interference from electric motors or motor controllers

If your meter readings do not stabilize, see “Troubleshooting the Unit” on page 3-1

and “Echo LED Light Considerations” on page 3-9 for further assistance.

Advanced Configuration Options

The display panel keypad has a secondary menu for advanced configuration options

(the keypad toggle menu). You may want to use this menu to set Analog output or to

select alarm setpoints. To access the secondary menu, you must press and hold the

keypad key for one second, and then when the display changes release the key. To

exit, press and hold the key again for one second and then release.

•Figure 2-10 on page 2-21 provides a visual representation of the toggle menu.

•Table 2-6 lists the advanced configuration options accessible from the display

panel keypad.

5707070-A Installation and Operation 2-21

Sono-Trak™ Doppler Ultrasonic Flow Meter

Figure 2-10. Display unit keypad

Table 2-6. Keyboard toggle menu Note 1

Key Selection Functional Specifications

1 FPS Feet per second/ clear pwr

2 Bar graph Analog bar graph of flow rate

3 K FAC Select K factor while running

4 MA Set up 4-20 mA analog output

6 LFC Set low flow cut off (maximum = 2.5 fps)

7 MPS Meters per second/ clear pwr

9 UT Set update time (0 to 99 seconds)

HI/LO ALARM Set up HI/LO limit alarms

TOT RESET Reset totalizer while running

Note 1 Press and hold key for one second to access/exit function

FPS/PWR clear

4-20 mA

MPS/PWR clear

High / Low alarm

Bar graph

K factor reset (1 to 256)

Low flow cutoff

Set update time

Totalizer reset

(maximum = 2.5 fps)

(0 to 99 seconds)

2-22 Installation and Operation 5707070-A

Advanced Energy®

BEFORE SETTING ADVANCED PARAMETERS

The default setting for secondary keyboard functions is feet per second (fps), or

meters per second (mps) if the flow meter is configured for metric units. Once the

flow meter is operational and you wish to activate the analog bar graph, 4-20 mA

output, high or low alarm, or low flow cut-off options, you must first determine the

velocity (fps or mps).

To determine the velocity unit of measure, push and hold the FPS/1 or MPS/7 key on

the front panel of the electronics enclosure until the LCD screen changes and then

release the key. The fps (or mps) value will display in the rate column of the display.

With this information you may then push and hold the FPS/1 or MPS/7 key again and

return the display to the normal volumetric indication.

Sample Parameter Setting

You have a velocity of 5 fps and you would like the 4-20 mA output to be 12 mA or

50% of scale. Push and hold the MA/4 key until the screen changes and then release

the key. Enter a scale value of 10 fps via the keypad. The screen will automatically

return the display to volumetric indication. The 4-20 mA output will read 12 mA at the

terminal strip located on the right side of the main electronics circuit board.

Note: Never adjust any of the potentiometers on the main processor board. These

settings are to be performed by authorized personnel only.

SETTING ADVANCED PARAMETERS

This section explains how to set advanced parameters using the toggle keyboard on

the front panel of the unit.

Bar Graph

To Set the Analog Bar Graph of Flow Rate:

1. Press the FPS/1 or MPS/7 key to obtain the current feet per second or meters per

second reading. Press the key again to return to the flow reading parameters

previously shown.

2. Press the Graph/2 key. Enter the desired full-scale flow rate in feet per second or

meters per second.

3. To return to the rate and totalizer flow reading, press the Graph/2 key again.

4. To return to the graph, press the Graph/2 key again.

K Factor (Correction Factor)

The default K Factor on the Doppler flow meter is set at 90 hZ/ fps for version V 5.6.

For nearly all applications, this default K Factor setting should be adequate. There are

only a few circumstances that might merit adjusting the default K Factor setting on

your Doppler flow meter.

5707070-A Installation and Operation 2-23

Sono-Trak™ Doppler Ultrasonic Flow Meter

If the flow rate readings are not as expected, these are factors that may be

contributing:

1. The meter is measuring flow with a high level of turbulence, which may be caused

by too short of a straight run for proper transducer placement.

2. The liquid being measured has high viscosity, is too thick, or contains sound

absorbing materials (for example, drilling mud).

If either of these conditions exist, and your flow readings appear inaccurate, then you

may need to adjust the K Factor (correction factor) to get the desired flow rate.

Note: The K Factor is linear. Increase the K Factor to lower the flow rate or decrease

the K Factor to increase the flow rate by the percentage that the flow is off.

Again, for most applications, the default K Factor setting ensures the most accurate

reading by your Doppler flow meter. Consult “Troubleshooting the Unit” on page 3-1

to troubleshoot inaccurate flow readings before making this adjustment.

To Set the K Factor:

1. Press the K FAC/3 key.

2. Enter Hz/ FPS. If you want to keep the default setting, enter 090.

3. After setting the K Factor, the LCD screen will return to the rate and totalizer flow

reading.

Analog Output

To Set the Analog Output:

1. Press the FPS/1 or MPS/7 key to obtain the current velocity reading in feet per

second or meters per second. Press the key again to return to the flow reading

parameters previously shown.

2. Press the MA/4 key. Using the current FPS/1 or MPS/7 reading as a guide, enter

the full scale feet per second or meters per second reading to set the output in mA.

3. After the output level has been set, the LCD screen will return to the rate and

totalizer flow reading.

Low Flow Cutoff

To Set the Low Flow Cutoff:

1. Press the FPS/1 or MPS/7 key to obtain the current reading in feet per second or

meters per second. Press the key again to return to the flow reading parameters

previously shown.

2. Press the LFC/6 key. Enter the cutoff in feet per second or meters per second. If

you enter a parameter that is too high, the LCD screen will display the maximum

allowable cutoff setting and then will return to the prompt for cutoff in feet per

second.

2-24 Installation and Operation 5707070-A

Advanced Energy®

3. After the low flow cutoff is set, the LCD screen will return to the rate and totalizer

flow reading.

Meters per Second/ Power Clear

To Read Meters Per Second:

1. Press the MPS/7 key. The LCD will show the flow reading in meters per second

on the upper line of the LCD screen, replacing the rate parameter previously on

the screen. The totalizer reading remains the same parameter.

2. To return to the previous flow rate reading, press the MPS/7 key again.

Update Time

To Set Update Time:

1. Press the UT/9 key.

2. Enter the update time in seconds. You may enter any number from 0-99.

3. After the update time is set, the LCD screen will return to the rate and totalizer

flow reading.

Hi/Low Alarms

To Set the High/ Low Alarms:

1. Press the FPS/1 or MPS/7 key to obtain the current feet per second reading or

meters per second reading. Press the key again to return to the flow reading

parameters previously shown.

2. Press the HI/LO ALARM key. Enter the high limit alarm in feet per second or

meters per second.

3. Now enter the low limit alarm in feet per second or meters per second.

4. After the high and low alarm parameters are set, the LCD screen will return to the

rate and totalizer flow reading.

Totalizer Reset

To Reset the Totalizer While the Unit is Running:

1. Press the TOT RESET key. The totalizer reading will return to zero.

2. The meter will begin taking totalizer readings from zero. The rate reading remains

unchanged.

5707070-A Installation and Operation 2-25

Sono-Trak™ Doppler Ultrasonic Flow Meter

Normal Operation

Once you have set up the Doppler flow meter for operation in your system, you may

virtually forget about it. The system is maintenance free, and does not require

calibration, since the readings do not drift over time. In the event of a power

interruption, your settings will be saved for up to 10 days in volatile memory powered

by a slow-discharge capacitor. the capacitor will recharge when power is restored.

Portable Battery Operation (Portable Units Only)

The LCD screen will flash LOW BAT every second when there is approximately one

half hour of safe operation remaining. Never totally discharge the gel cell battery. The

charger provided with the flow meter will recharge the battery fully in approximately

8 hours. You may leave the batteries in the charger overnight, since prolonged

charging periods will not damage the battery. The POWER switch on the flow meter

front panel must be in the OFF position in order for the internal battery to charge. If

the internal battery has been deep discharged, it will be necessary to charge the battery

for a minimum of 30 minutes before the front panel POWER switch is turned ON.

2-26 Installation and Operation 5707070-A

Advanced Energy®

5707070-A Troubleshooting and Customer Support 3-1

Chapter

Sono-Trak™ Doppler Ultrasonic Flow Meter Chapter

3

Troubleshooting and Customer

Support

The following sections provide useful information for troubleshooting your Sono-

Trak™ Doppler ultrasonic flow meter and process as related to your flow meter.

Product warranty, return policy, and customer support information appears near the

end of this chapter.

TROUBLESHOOTING THE UNIT

If you suspect your Doppler flow meter is malfunctioning, please perform the

following checks before calling EMCO Flow Systems Support:

1. Make sure that the unit is properly connected to input power. See “Mounting and

Connecting Power to the Electronics Enclosure” on page 2-13. Also, see “Status

of Unit Power” on page 3-2.

2. Make sure that the transducers are properly connected to the electronics enclosure

and that they are properly mounted. See “Mounting and Connecting the

Transducers” on page 2-9.

3. Ensure input power is on and power is within specifications. See “Functional

Specifications” on page 4-3 for power requirements.

4. Is the Echo LED light flashing or off? See “Status of Echo LED: Flashing” on

page 3-5 or “Status of Echo LED: Off” on page 3-3 for troubleshooting

information.

5. Does your Doppler flow meter flow rate reading appear too low, too high, or

erratic, but your Echo light is on? See “Status of Flow Reading: High or Low” on

page 3-6 or “Status of Flow Reading: Erratic” on page 3-8 for troubleshooting

information. Also, consult “Echo LED Light Considerations” on page 3-9 for

more information about the Echo light.

6. Have you performed the above checks and you still have no flow reading?

4If you have performed all the above checks and followed troubleshooting

procedures in the “Flow Meter Troubleshooting Tables” on page 3-2 and your

unit is still malfunctioning, contact “EMCO Flow Systems Support” on

page 3-11.

3-2 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

Flow Meter Troubleshooting Tables

Follow these tables in sequential order for the best use. Answer the heading question

in bold at the beginning of each section before continuing on to the next section.

STATUS OF UNIT POWER

Is the unit receiving power? (Is the green Power light on?)

4Yes. If the unit is receiving power, continue on to “Status of Echo LED: Off”

on page 3-3.

4No. If the unit is not receiving power, troubleshoot using Table 3-1 below.

Table 3-1. Status of unit power troubleshooting checklist

Question/ Possible Cause Corrective Action

Is AC or BATTERY (DC)

power properly connected to the

processor board?

Ensure that input power is properly connected.

See “To Connect Input Power to the Electronics

Enclosure:” on page 2-13.

Is the battery charged if you are

using BATTERY (DC) power,

or is the AC power cord plugged

in if you are using AC power?

If you are using DC battery power, make sure your battery

is charged and that the power cables are securely

connected.

If you are using AC power, make sure your AC power is

plugged in.

See “To Connect Input Power to the Electronics

Enclosure:” on page 2-13 and “Portable Battery Operation

(Portable Units Only)” on page 2-25 for more information.

Is the power switch on the

display panel on?

Ensure the power switch on the front display panel is in the

On position.

See “Display panel” on page 2-16 for the location of this

switch.

Is the A/C Select voltage selector

set correctly?

Make sure that the A/C Select switch is in the proper

location for your system input power (115 VAC or

230 VAC).

See “To Connect Input Power to the Electronics

Enclosure:” on page 2-13 and Figure 2-8 on page 2-14 for

the location of the switch.

5707070-A Troubleshooting and Customer Support 3-3

Sono-Trak™ Doppler Ultrasonic Flow Meter

STATUS OF ECHO LED: OFF

Is the Echo LED on steady?

4Yes. If the Echo LED is on steady or is flashing, continue on to “Status of Echo

LED: Flashing” on page 3-5.

4No. If the Echo LED is off, troubleshoot using Table 3-2 below.

Note: See “Additional Troubleshooting Information” on page 3-9 for additional

information about the Echo LED indicator.

Is the AC/ BATTERY power

switch set correctly?

Make sure the AC/ BATTERY switch is in the proper

position for your system input power:

•AC = AC input power

•BATTERY = DC input (battery) power

See “To Connect Input Power to the Electronics

Enclosure:” on page 2-13 and Figure 2-8 on page 2-14 for

the location of the switch.

Is there a LOW BAT flashing in

the display?

If you are switching from BATTERY (DC) power to AC

power and the A/C Select switch selection does not match

your incoming power, you may see a LOW BAT warning

in the front panel display. Adjust the A/C Select switch to

the correct incoming power level (115 VAC or 230 VAC)

and this warning should disappear.

If you are using the battery (DC power) to power the unit,

your battery may be low. See “Portable Battery Operation

(Portable Units Only)” on page 2-25.

Is there is a blown input power

fuse?

Check to see if all fuses on the processor board are good.

See Figure 2-8 on page 2-14 for fuse block location on the

processor board.

Table 3-1. Status of unit power troubleshooting checklist

Question/ Possible Cause Corrective Action

3-4 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

Table 3-2. Status of Echo light troubleshooting checklist: Echo off

Question/ Possible Cause Corrective Action

Are the transducers properly

connected to the processor

board?

Make sure the transducer wires are connected correctly to

the processor board.

See “To Connect the Transducers to the Electronics

Enclosure:” on page 2-11.

Are the transducers mounted

properly on the pipe?

Make sure that the transducers have been mounted on a

clean, smooth pipe using the required coupling grease.

Ensure that the transducers are securely mounted flush with

the pipe, side by side.

See “To Mount the Clamp-On Transducers to the Pipe:” on

page 2-9.

Is there fluid in the pipe? Is the

pipe full?

Verify that the pipe is full of fluid and that the fluid is

flowing above the minimum velocity specifications.

See “Functional Specifications” on page 4-3 for flow

velocity specifications.

Have the transducers been

placed in the recommended

location on the pipe?

Make sure that the transducers have been mounted in an

acceptable location:

4Consider straight run requirements (see “Straight

Run Requirements” on page 2-5 for more

information

4Make sure the transducers are mounted flush with the

pipe, facing the same direction

See “To Mount the Clamp-On Transducers to the Pipe:” on

page 2-9 for more details.

5707070-A Troubleshooting and Customer Support 3-5

Sono-Trak™ Doppler Ultrasonic Flow Meter

STATUS OF ECHO LED: FLASHING

Is the Echo LED flashing?

4No. If the Echo LED light is on steady, continue on to “Status of Flow

Reading: High or Low” on page 3-6.

4Yes. If the Echo LED light is flashing, troubleshoot using Table 3-3 below.

Note: Review the three questions in Table 3-3. If you can answer yes to all three, and

you have determined that you do not have a power issue, you may have an

application that would be better suited for a transit time meter. See

“Determining if Your Process/Installation is Right for a Doppler Flow Meter”

on page 2-3 and “Additional Troubleshooting Information” on page 3-9.

Has the pipe been cleaned

down to bare metal before

transducer placement? Is this an

old pipe?

Make sure the pipe was cleaned with sandpaper prior to

transducer placement. Also, check to make sure the type of

pipe in your application is suitable for use with a Doppler

flow meter.

See “Assessing Pipe Material and Condition” on page 2-5.

Is the measured fluid too clean,

or is the particle content

fluctuating below readable

specifications?

Verify that suspended solid content of fluid is at least 40

microns @ 35 ppm with at least a 0.2% density difference

from the liquid.

See “Suspended Particle Test For Doppler Signals” on

page 3-10 to check your fluid for particle content, and also

consult “Determining if Your Process/Installation is Right

for a Doppler Flow Meter” on page 2-3.

Note: Use a transit time meter if the fluid does not meet the

suspended solid specifications of a Doppler flow

meter. Contact “EMCO Flow Systems Support” on

page 3-11 for more information.

Table 3-2. Status of Echo light troubleshooting checklist: Echo off

Question/ Possible Cause Corrective Action

3-6 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

STATUS OF FLOW READING: HIGH OR LOW

Is the flow reading showing a rate that is lower or higher than expected?

4No. If the flow reading is erratic rather than low or high, or you are

experiencing another issue, continue on to “Status of Flow Reading: Erratic”

on page 3-8.

4Yes. If the flow reading appears too low or too high, troubleshoot using Table

3-4 below.

Table 3-3. Status of Echo light troubleshooting checklist: Echo flashing

Question/ Possible Cause Corrective Action

Have the transducers been

placed in the recommended

location on the pipe?

Make sure that the transducers have been mounted in an

acceptable location:

4Try moving the transducers. Consider straight run

requirements when deciding where they need to be

mounted (see “Straight Run Requirements” on

page 2-5 for more information)

4Make sure the transducers are mounted side by side,

flush with the pipe

4Make sure the exterior of the pipe was cleaned prior

to mounting the transducers

See “To Mount the Clamp-On Transducers to the Pipe:” on

page 2-9 for more details.

Have you performed the

suspended particle test to see if

the liquid in the flow is

compatible with Doppler

operation?

See “Suspended Particle Test For Doppler Signals” on

page 3-10.

Have you consulted the Echo

light consideration section?

See “Echo LED Light Considerations” on page 3-9 for

information on whether the Doppler is the right meter for

your application. A transit time meter may work better for

your application if the Echo light continues flashing.

5707070-A Troubleshooting and Customer Support 3-7

Sono-Trak™ Doppler Ultrasonic Flow Meter

Table 3-4. Status of flow reading troubleshooting checklist: High or low

Question/ Possible Cause Corrective Action

Has the meter been properly

programmed?

Using the display panel keypad and the LCD screen,

verify that the rate selection and totalizer selection are set

correctly.

See “To Operate Your Doppler Flow Meter for the First

Time:” on page 2-18.

Has the meter been set up with

sufficient straight run piping?

Make sure that the transducers are properly placed for

use with your Doppler flow meter.

See “Straight Run Requirements” on page 2-5 for more

information on correct transducer placement in your

system.

Are the transducers mounted

properly on the pipe?

Make sure that the transducers have been mounted on a

clean, smooth pipe using the required coupling grease.

Ensure that the transducers are securely mounted side by

side.

See “To Mount the Clamp-On Transducers to the Pipe:”

on page 2-9.

Has the pipe been cleaned down to

bare metal before transducer

placement? Is this an old pipe?

Make sure the pipe was cleaned with sandpaper prior to

transducer placement. Also, check to make sure the type

of pipe in your application is suitable for use with a

Doppler flow meter.

See “Assessing Pipe Material and Condition” on

page 2-5.

Does your Doppler show a flow

reading that varies from the

reading on your alternative

measurement device?

Verify that pumps are operating and that valve settings

are correct. Compare the velocity reading with an

alternative type of flow meter.

4If the flow reading on your Doppler is similar to

the reading on your alternative meter, the Doppler

is probably reading correctly.

4If the flow reading on your Doppler varies from

the reading on the alternative meter, you may

need to adjust the K Factor accordingly to correct

the flow reading.

See “K Factor (Correction Factor)” on page 2-22 for

information on adjusting your K Factor.

3-8 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

STATUS OF FLOW READING: ERRATIC

Is the flow reading showing an erratic rate?

4Yes. If the flow reading appears erratic, troubleshoot using Table 3-5 below.

4No. If you have followed all the troubleshooting steps and procedures and your

Doppler is still not working correctly, contact “EMCO Flow Systems Support”

on page 3-11 for information on how to proceed.

Table 3-5. Status of flow reading troubleshooting checklist: Erratic

Question/ Possible Cause Corrective Action

Have the transducers been placed in

the recommended location on the

pipe?

Make sure that the transducers have been mounted in

an acceptable location:

4Consider straight run requirements (see

“Straight Run Requirements” on page 2-5 for

more information

4Make sure the transducers are mounted side by

side

See “To Mount the Clamp-On Transducers to the

Pipe:” on page 2-9 for more details.

Has the pipe been cleaned down to

bare metal before transducer

placement? Is this an old pipe?

Make sure the pipe was cleaned with sandpaper prior

to transducer placement. Also, check to make sure the

type of pipe in your application is suitable for use with

a Doppler flow meter.

See “Assessing Pipe Material and Condition” on

page 2-5.

Is the unit near an electric motor or

motor controller?

Move the transducers away from interference and see

if the flow readings become more stable.

Is your update time allowing for

erratic flow readings?

Change your flow meter update time and see if the

flow readings become more stable.

See “To Set Update Time:” on page 2-24.

Can you adjust Analog damping to

provide a more accurate reading?

See “Main electronics board connections” on

page 2-12 and “Another view of processor board

connections” on page 2-14 to find the Analog damping

on the Doppler flow meter processor board and adjust

it to eliminate erratic flow readings.

5707070-A Troubleshooting and Customer Support 3-9

Sono-Trak™ Doppler Ultrasonic Flow Meter

Additional Troubleshooting Information

ECHO LED LIGHT CONSIDERATIONS

Sono-Trak™ Doppler ultrasonic flow meters require suspended solids or air bubbles

to operate. The strict requirement is that sonic discontinuities exist. If the speed of

sound in the solids and liquids are identical, then there are no sonic discontinuities

(which act as ultrasonic reflectors), and most Doppler flow meters will not function.

Some bacterial slurries and chemical slurries may have suspended solids but cannot be

measured with a Doppler flow meter for this reason.

The behavior of the Echo light on the display panel of your Doppler flow meter

electronics enclosure may provide indication as to whether the Doppler flow meter is

the correct one for your application. If after troubleshooting your unit, the Echo light

does not remain on steady while you are operating your unit, you may need to

consider changing the meter to a transit time meter.

See “Determining if Your Process/Installation is Right for a Doppler Flow Meter” on

page 2-3 and “Troubleshooting the Unit” on page 3-1 if you are having trouble

maintaining a steady Echo light during operation of your flow meter.

Table 3-6. Echo light scenarios

Echo light

condition

Flow rate

reading

Applicable Meter Solution

Illuminated

steady

Yes Doppler flow meter If the Echo light is on and the

flow reading appears correct,

the Doppler is the best meter

for your application.

Flashing Yes Doppler flow meter

or

Transit time meter

There may be an inadequate

level of reflective materials in

the flow to ensure correct flow

readings. Move the transducers

until you get a steady light, or

replace your Doppler meter

with a transit time meter.

Off Yes Transit time meter There may be an inadequate

level of reflective materials in

the flow to ensure correct flow

readings. Replace your Doppler

meter with a transit time meter.

Off No flow Contact Factory Clamp on transducers may not

be able to provide accurate

flow readings in your

application.

3-10 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

SUSPENDED PARTICLE TEST FOR DOPPLER SIGNALS

Particles in a liquid may be either in suspension or dissolved. Dissolved particles will

not reflect Doppler signals because there is no physical dimension nor density

difference to return the sound to the receiver.

Suspended particles generally will return the Doppler signal if there are enough

present and their size is sufficient to meet the requirements of the transmitted

frequency. Materials such as wood pulp, algae, moss, onion skins, fine sand, or other

materials that do not meet the 35 ppm/ 40 micron/ 0.2% density difference minimum

requirements will not reflect sounds. Instead, the signal simply passes through this

material as if it were water. Usually these materials have a specific gravity of 0.999 or

1.001. This is almost exactly the same as water itself and therefore will neither rise nor

fall in the solution. These materials will move about almost anywhere in the solution

controlled only by the motion of the liquid itself.

A simple test requires a clear glass container and a sample of the liquid you wish to

measure with the Doppler sensors. Stir the liquid and watch it for about 3 to 5 minutes.

If the visible particles in suspension neither rise nor fall, they are most likely the same

specific gravity as water and may not reflect Doppler signals. If these particles are the

same specific gravity as water, but do have a membrane or shell around them that is at

least 0.2% density difference than the water molecules, than the signals should be

strong enough for the Doppler to report correct flow readings.

If the particles rise or fall in the solution, they should provide adequate sonic

reflection as long as they meet the specified quantity, size, and density requirements

for the Doppler (see “Specifications and Reference Information” on page 4-1 for more

information).

5707070-A Troubleshooting and Customer Support 3-11

Sono-Trak™ Doppler Ultrasonic Flow Meter

Figure 3-1. Suspended particle test

EMCO FLOW SYSTEMS SUPPORT

For product support or more information on EMCO Industrial Flow Products, contact:

EMCO Sales

Advanced Energy

1625 Sharp Point Drive

Fort Collins, CO 80525 USA

Phone: 800-356-9362 or

970-407-6949

Fax: 970-407-5179

Email: support@emcoflow.com

www.emcoflow.com

The complete EMCO product line for liquid, gas, and steam applications includes

industrial inline vortex, industrial insertion vortex and turbine, commercial vortex,

electromagnetic, and clamp-on ultrasonic flow products. For more information, refer

to the EMCO website (http://www.emcoflow.com/).

Rising particles

Floating particles

Falling particles

3-12 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

RETURNING UNITS FOR REPAIR

Before returning any product for repair and/or adjustment, first follow all

troubleshooting procedures. If, after following these procedures, you still have a

problem, or if the procedure instructs you to, contact EMCO Flow Systems and

discuss the problem with a representative. (See also “Authorized Returns” on

page 3-13).

If you return a unit without first getting authorization from EMCO Flow

Systems Support and that unit is found to be functional, you will be charged a

retest and calibration fee, plus shipping charges.

To ensure years of dependable service, Advanced Energy® products are thoroughly

tested and designed to be among the most reliable and highest quality systems

available worldwide.

WARRANTY

Advanced Energy® (AE) products are warranted to be free from failures due to defects

in material and workmanship for 12 months after they are shipped from the factory

(please see warranty statement below, for details).

In order to claim shipping or handling damage, you must inspect the delivered goods

and report such damage to AE within 30 days of your receipt of the goods. Please note

that failing to report any damage within this period is the same as acknowledging that

the goods were received undamaged.

For a warranty claim to be valid, it must:

• Be made within the applicable warranty period

• Include the product serial number and a full description of the circumstances

giving rise to the claim

• Have been assigned a return material authorization number (see below) by EMCO

Flow Systems Support at Advanced Energy

All warranty work will be performed at an authorized AE service center (see list of

contacts at the beginning of this chapter). You are responsible for obtaining

authorization (see details below) to return any defective units, prepaying the freight

All returns to EMCO Flow Systems Support at Advanced Energy must be

free of harmful, corrosive, radioactive, or toxic materials, and have purge

documentation when appropriate.

5707070-A Troubleshooting and Customer Support 3-13

Sono-Trak™ Doppler Ultrasonic Flow Meter

costs, and ensuring that the units are returned to an authorized AE service center. AE

will return the repaired unit (freight prepaid) to you by second-day air shipment (or

ground carrier for local returns); repair parts and labor will be provided free of charge.

Whoever ships the unit (either you or AE) is responsible for properly packaging and

adequately insuring the unit.

Authorized Returns

Before returning any product for repair and/or adjustment, call EMCO Flow Systems

Support and discuss the problem with them. Be prepared to provide the model number

and serial number of the unit as well as the reason for the proposed return. This

consultation call will allow EMCO Flow System Support to determine if the unit must

actually be returned for the problem to be corrected. Such technical consultation is

always available at no charge.

Units that are returned without authorization from EMCO Flow Systems Support and

that are found to be functional will not be covered under the warranty (see warranty

statement, below). That is, you will have to pay a retest and calibration fee, and all

shipping charges.

Warranty Statement

The seller makes no express or implied warranty that the goods are

merchantable or fit for any particular purpose except as specifically stated in

printed AE specifications. The sole responsibility of the Seller shall be that it will

manufacture the goods in accordance with its published specifications and that

the goods will be free from defects in material and workmanship. The seller's

liability for breach of an expressed warranty shall exist only if the goods are

installed, started in operation, and tested in conformity with the seller's

published instructions. The seller expressly excludes any warranty whatsoever

concerning goods that have been subject to misuse, negligence, or accident, or

that have been altered or repaired by anyone other than the seller or the seller's

duly authorized agent. This warranty is expressly made in lieu of any and all

other warranties, express or implied, unless otherwise agreed to in writing. The

warranty period is 12 months after the date the goods are shipped from AE. In

all cases, the seller has sole responsibility for determining the cause and nature of

the failure, and the seller's determination with regard thereto shall be final.

3-14 Troubleshooting and Customer Support 5707070-A

Advanced Energy®

5707070-A Specifications and Reference Information 4-1

Chapter

Sono-Trak™ Doppler Ultrasonic Flow Meter Chapter

4

Specifications and Reference

Information

The following sections provide specification and accessory information for the Sono-

Trak™ Doppler ultrasonic flow meter, as well as useful pipe and conversion

information.

PERFORMANCE SPECIFICATIONS

Table 4-1. Performance specifications

Description Specification

Fluid conditions

Measured fluid Homogenous liquids with Newtonian flow profiles (sludges,

slurries, sewage, wastewater, and other fluids containing

suspended particles)

State of flow Axis-symmetric flow in pipe filled with fluid

Fluid type Liquids containing suspended particles of at least 35 ppm at

40 microns at 0.2% density of undissolved solids or air bubbles

Measurable fluid

temperature range

-40 ºF to 300 ºF (-40 ºC to 149 ºC)

Velocity range 0.1 fps to 50 fps (0.04 mps to 15.25 mps)

Flow sensitivity 0.01 fps (0.04 mps)

Piping conditions

Pipe diameter range Velocity indication: 0.5" to 300" (13 mm to 7620 mm) diameter

Volumetric indication: 0.5" to 100" (13 mm to 2540 mm)

diameter

Pipe Including but not limited to: carbon steel, stainless steel, ductile

iron, cast iron, FRP, PVC, fiberglass, teflon, and most concrete

lined or coated pipes

Pipe lining Including but not limited to: tar, epoxy, mortar, rubber, teflon,

PVC, and glass

4-2 Specifications and Reference Information 5707070-A

Advanced Energy®

PHYSICAL SPECIFICATIONS

Measurement Accuracy

Accuracy Typically ± 1% to 3% of full scale

See Table 2-2 on page 2-6 for straight run requirements and

specific accuracies.

Note: Accuracy is a function of flow profile.

Linearity ± 0.5% of full scale

Repeatability ± 0.1% of full scale

Response time 1 second or less

Table 4-1. Performance specifications (Continued)

Description Specification

Table 4-2. Physical specifications

Description Specification

Electronics Enclosure

Dimensions 9.21" (H) x 7.21" (W) x 5.09" (D)

285 mm (H) x 183 mm (W) x 129 mm (D)

Note: See Figure 4-1 on page 4-6 for dimensional

illustrations.

Weight 12 lb (5.45 kg)

Materials Flame retardant, fiberglass reinforced polyester with lockable

latch, gray in color

Environmental rating NEMA 4X (IP65)

Ambient temperature

range

-13 ºF to 132 ºF (-25 ºC to 55 ºC)

Ambient humidity Less than 100% RH

Transducers

Dimensions • Transducer heads: 4.85"(L) x 1.33"(W) x 1.35"(D)

(123 mm x 33.8 mm x 34.3 mm)

• Digitizer: 4.45"(L) x 2.50" (W) x 1.10" (D)

(113 mm x 63.5 mm x 28 mm)

Note: See Figure 4-3 on page 4-8 for the dimensional

illustration

Weight 2.30 lb (1 kg)

5707070-A Specifications and Reference Information 4-3

Sono-Trak™ Doppler Ultrasonic Flow Meter

FUNCTIONAL SPECIFICATIONS

Housing material Cast aluminum

Mounting Mounted to the outside of pipe by means of stainless straps,

nylon belts, or bungee and steel chain

Crystal wedge material Epoxy resin (all transducer models)

Environmental rating NEMA 6 (IP67)

Ambient temperature

range

-20 ºF to 200 ºF (-29 ºC to 93 ºC)

Ambient humidity Less than 100% RH

Transducer cable

Standard cable 25´ (7.6 m) 2 twisted pairs, 24 AWG, belfoil shield

Note: Custom cable lengths are available

Maximum cable length 5000´ (1524 m)

Table 4-2. Physical specifications (Continued)

Description Specification

Table 4-3. Functional specifications

Description Specification

Power

Fixed units 110 VAC or 220 VAC at 50/60 Hz (AC line voltage selectable

via internal selector switch; see Figure 2-8 on page 2-14 for

switch location)

12 VDC (DC operation enabled by internal selector switch; see

Figure 2-8 on page 2-14 for switch location)

Portable units Internal gel-cell, 8-hour continuous operation built-in battery

Recharge time is 12 hours using the external power adaptor/

charger or DC auto cigarette lighter

Power adaptor/charger Standard adaptor: 115 VAC, 50/60 Hz (± 10%) input delivering

12 VDC, 500 mA output

Optional adaptor: 230 VAC, 50/60 Hz (± 10%) input delivering

12 VDC, 500 mA output

Power consumption 10 W typical

Analog output signal 4 mA to 20 mA DC, 700 Ω maximum load resistance, internally

fused, active output

4-4 Specifications and Reference Information 5707070-A

Advanced Energy®

Alarm output When on AC power:

15.0 VDC = Active alarm

• High alarm: switched +15.0 VDC, 500 mA

• Low alarm: switched +15.0 VDC, 500 mA

When on battery power:

12.0 VDC = Active alarm

• High alarm: switched + 12.0 VDC, 500 mA

• Low alarm: switched + 12.0 VDC, 500 mA

Power failure backup An internal super-capacitor allows the electronics assembly to

retain all parameter information and current totalizer value for

up to 10 days

Standard interface

LCD display 2-line, 16 characters per line, high resolution

LED indicators • Yellow: Echo signal received

• Red: High alarm or low alarm activated

• Green: Power available

Keypad 12 keys, tactile feedback

Note: Keypad lockout available through internal switch; see “To

Save Your Programmed Flow Reading Settings Using the

Security Switch:” on page 2-19 and Figure 2-8 on

page 2-14 for the switch location

Display panel Rate selection, totalizer selection, K factor selection, analog

output set, low flow cutoff set, update time (damping) set, high/

low alarm set, fps or mps selection, totalizer reset

Output setting function 4-20 mA output scaling (set in velocity from keypad)

Alarm setting function High and low alarm set points (entered in velocity from keypad)

Rate indication 4-digit LCD, velocity or volume (user selectable)

English units: feet per second (fps), gallons per minute (gpm),

cubic feet per second, and million gallons per day

Metric units: meters per second (mps), liters per second (lps),

and cubic meters per second

Note: Gallons refers to U.S. gallons.

Table 4-3. Functional specifications (Continued)

Description Specification

5707070-A Specifications and Reference Information 4-5

Sono-Trak™ Doppler Ultrasonic Flow Meter

Totalizer indication 11-digit LCD

English units: gallons, cubic feet, acre feet, and millions of

gallons

Metric units: liters and cubic meters

Note: Gallons refers to U.S. gallons.

Update time

(damping)

0 s to 99 s, entered from keypad

Low flow cutoff 0 fps to 2.5 fps (0 mps to 0.76 mps), entered from keypad

K factor A value of 1 to 256, entered from the keypad depending upon

sensor type. The default is 90 Hz (correction factor) for version

V5.6.

Totalizer reset Totalizer can be manually reset to zero from the keypad

Table 4-3. Functional specifications (Continued)

Description Specification

4-6 Specifications and Reference Information 5707070-A

Advanced Energy®

DIMENSIONAL DRAWINGS

Electronics Enclosure Dimensions

Figure 4-1. Front view of the electronics enclosure (the display panel)

5707070-A Specifications and Reference Information 4-7

Sono-Trak™ Doppler Ultrasonic Flow Meter

Figure 4-2. Bottom view of the electronics enclosure

Power cable

access

Alarms

(4 to 20 mA)

access (fixed

unit options

only)

Transducer

cable

access

4-8 Specifications and Reference Information 5707070-A

Advanced Energy®

Clamp-On Transducer and Digitizer Dimensions

Figure 4-3. Dimensions of clamp-on transducer

REFERENCE INFORMATION

This section provides reference information for setting up the Doppler flow meter in

your system.

•“Standard Pipe Data” on page 4-9 contains three tables to assist in pipe

measurement:

4 “Steel, stainless steel, and PVC” on page 4-9

4“Cast iron pipe (standard classes)” on page 4-10

4“Ductile iron pipe standard classes (inside diameters)” on page 4-11

•“Velocity Conversion Tables” on page 4-12 contains three tables to assist in

converting the default flow readings of meters per second or feet per second:

4“Velocity conversion table (MPS to LPM and LPS)” on page 4-12

4“Velocity conversion table (MPS to LPS and M3/Hr)” on page 4-12

4“Velocity conversion table (FPS to GPM)” on page 4-13

Transducer

heads

Digitizer Digitizer,

end view

Transducer head,

end view

Cable from

transducers to

digitizer,

maximum

cable length =

12 ft (3.66 m)

Cable to

electronics

enclosure,

maximum

cable length =

5000 ft

(1524 m)

5707070-A Specifications and Reference Information 4-9

Sono-Trak™ Doppler Ultrasonic Flow Meter

Standard Pipe Data

Table 4-4. Steel, stainless steel, and PVC

Size

Inches

Standard Schedules Inside Diameters

510

LTWALL

20 30 STD 40 60 STG 80 100 120 140 180 O.D.

1 1.185 1.097 1.049 1.049 0.957 0.957 0.815 1.315

1.25 1.53 1.442 1.380 1.380 1.278 1.278 1.160 1.660

1.5 1.77 1.682 1.610 1.610 1.500 1.500 1.338 1.900

2 2.245 2.157 2.067 2.067 1.939 1.939 1.687 2.375

2.5 2.709 2.635 2.469 2.469 2.323 2.323 2.125 2.875

3 3.334 3.260 3.068 3.068 2.900 2.900 2.624 3.500

3.5 3.834 3.760 3.548 3.548 3.364 3.364 4.000

4 4.334 4.260 4.026 4.026 3.826 3.826 3.624 3.438 4.500

5 5.345 5.295 5.047 5.047 4.813 4.813 4.563 4.313 5.563

6 6.407 6.357 6.065 6.065 5.761 5.761 5.501 5.187 6.625

8 8.407 8.329 8.125 8.071 7.981 7.981 7.813 7.625 7.625 7.437 7.187 7.001 6.813 8.625

10 10.482 10.42 10.25 10.13 10.02 10.02 9.750 9.750 9.562 9.312 9.062 8.750 8.500 10.75

12 12.42 12.39 12.25 12.09 12.00 11.938 11.626 11.75 11.37 11.06 10.75 10.50 10.12 12.75

14 13.50 13.37 13.25 13.25 13.124 12.814 13.00 12.50 12.31 11.81 11.50 11.18 14.00

16 15.50 15.37 15.25 15.25 15.000 14.688 15.00 14.31 13.93 13.56 13.12 12.81 16.00

18 17.50 17.37 17.12 17.25 16.876 16.564 17.00 16.12 15.68 15.25 14.87 14.43 18.00

20 19.50 19.25 19.25 19.25 18.814 18.376 19.00 17.93 17.43 17.00 16.50 16.06 20.00

24 23.50 23.25 23.25 23.25 22.626 22.126 23.00 21.56 20.93 20.93 19.87 19.31 24.00

30 29.37 29.00 29.00 29.25 29.250 29.00 30.00

36 35.37 35.00 35.00 35.25 35.25 35.00 36.00

42 41.25 41.25 41.00 42.00

48 47.25 47.25 47.00 48.00

4-10 Specifications and Reference Information 5707070-A

Sono-Trak™ Doppler Ultrasonic Flow Meter

Table 4-5. Cast iron pipe (standard classes)

Nominal

Pipe Size

Inches

Class A Class B Class C Class D Class E Class F Class G Class H

O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D.

3 3.80 3.02 3.96 3.12 3.96 3.06 3.96 3.00

4 4.80 3.96 5.00 4.10 5.00 4.04 5.00 3.96

6 6.90 6.02 7.10 6.14 7.10 6.08 7.10 6.00 7.22 6.06 7.22 6.00 7.38 6.08 7.38 6.00

8 9.05 8.13 9.05 8.03 9.30 8.18 9.30 8.10 9.42 8.10 9.42 8.10 9.60 8.10 9.60 8.00

10 11.10 10.10 11.10 9.96 11.40 10.16 11.40 10.04 11.60 10.12 11.60 10.00 11.84 10.12 11.84 10.00

12 13.20 12.12 13.20 11.96 13.50 12.14 13.50 12.00 13.78 12.14 13.78 12.00 14.08 12.14 14.08 12.00

14 15.30 14.16 15.30 13.98 15.65 14.17 15.65 14.01 15.98 14.18 15.98 14.00 16.32 14.18 16.32 14.00

16 17.40 16.20 17.40 16.00 17.80 16.20 17.80 16.02 18.16 16.20 18.16 16.00 18.54 16.18 18.54 16.00

18 19.50 18.22 19.50 18.00 19.92 18.18 19.92 18.00 20.34 18.20 20.34 18.00 20.78 18.22 20.78 18.00

20 21.60 20.26 21.60 20.00 22.06 20.22 22.06 20.00 22.54 20.24 22.54 20.00 23.02 20.24 23.02 20.00

24 25.80 24.28 25.80 24.02 26.32 24.22 26.32 24.00 26.90 24.28 26.90 24.00 27.76 24.26 27.76 24.00

30 31.74 29.98 32.00 29.94 32.40 30.00 32.74 30.00 33.10 30.00 33.46 30.00

36 37.96 35.98 38.30 36.00 38.70 35.98 39.16 36.00 39.60 36.00 40.04 36.00

42 44.20 42.00 44.50 41.94 45.10 42.02 45.58 42.02

48 50.50 47.98 50.80 47.96 51.40 47.98 51.98 48.00

54 56.66 53.96 57.10 54.00 57.80 54.00 58.40 53.94

60 62.80 60.02 63.40 60.06 64.20 60.20 64.82 60.06

72 75.34 72.10 76.00 72.10 76.88 72.10

84

5707070-A Specifications and Reference Information 4-11

Sono-Trak™ Doppler Ultrasonic Flow Meter

Table 4-6. Ductile iron pipe standard classes (inside diameters)

Size

Inches

Outside

Diameter

Class

50

Class

51

Class

52

Class

53

Class

54

Class

55

Class

56

Cement Lining Note 1

Standard

Thickness

Double

Thickness

3 3.96 3.46 3.40 3.34 3.28 3.22 3.16

4 4.80 4.28 4.22 4.16 4.10 4.04 3.98

6 6.90 6.40 6.34 6.28 6.22 6.16 6.10 6.04 0.125 0.250

8 9.05 8.51 8.45 8.39 8.33 8.27 8.21 8.15

10 11.10 10.52 10.46 10.40 10.34 10.28 10.22 10.16

12 13.20 12.58 12.52 12.46 12.40 12.34 12.28 12.22

14 15.30 14.64 14.58 14.52 14.46 14.40 14.34 14.28

16 17.40 16.72 16.66 16.60 16.54 16.48 16.42 16.36

18 19.50 18.80 18.74 18.68 18.62 18.56 18.50 18.44 0.1875 0.375

20 21.60 20.88 20.82 20.76 20.70 20.64 20.58 20.52

24 25.80 25.04 24.98 24.92 24.86 24.80 24.74 24.68

30 32.00 31.22 31.14 31.06 30.98 30.90 30.82 30.74

36 38.30 37.44 37.34 37.06 37.14 37.04 36.94 36.84

42 44.50 43.56 43.44 43.32 43.20 43.08 42.96 42.84 0.250 0.500

48 50.80 49.78 49.64 49.50 49.36 49.22 49.08 48.94

54 57.10 55.96 55.80 55.64 55.48 55.32 55.16 55.00

Note 1 Reduce I.D. by dimension shown; these figures also apply to C.I. pipe

4-12 Specifications and Reference Information 5707070-A

Sono-Trak™ Doppler Ultrasonic Flow Meter

Velocity Conversion Tables

Table 4-7. Velocity conversion table (MPS to LPM and LPS)

Nominal pipe

size (mm)

MPS

0.3

MPS

0.6

MPS

1.0

MPS

1.5

MPS

2.0

MPS

2.5

MPS

3.0

MPS

5.0

MPS

7.0

(10 mm wall) LPM LPM LPM LPM LPM LPM LPS LPS LPS

50 35 71 118 177 236 294 5.9 10 14

75 80 159 265 398 530 663 13.3 22 31

100 141 283 471 707 942 1178 23.6 39 55

150 318 636 1060 1590 2120 2651 53 88 124

200 565 1130 1885 2827 3770 4712 94 157 220

250 884 1768 2945 4418 5890 7363 147 245 344

300 1272 2544 4241 6361 8482 10602 212 353 495

400 2262 4524 7539 11309 15078 18848 377 628 880

Table 4-8. Velocity conversion table (MPS to LPS and M3/Hr)

Nominal pipe

size (mm)

MPS

0.3

MPS

0.6

MPS

1.0

MPS

1.5

MPS

2.0

MPS

2.5

MPS

3.0

MPS

5.0

MPS

7.0

(15 mm wall) LPS LPS LPS LPS LPS LPS M3/Hr M3/Hr M3/Hr

500 59 88 196 295 392 491 35.3 58.9 82.5

600 85 170 283 424 566 707 51 85 119

750 133 266 442 663 884 1104 79.5 132.5 186

1000 236 472 785 1178 1570 1963 141.4 236 330

1200 339 678 1131 1696 2262 2827 204 339 475

1500 530 1060 1767 2651 3534 4418 318 530

5707070-A Specifications and Reference Information 4-13

Sono-Trak™ Doppler Ultrasonic Flow Meter

Table 4-9. Velocity conversion table (FPS to GPM)

Nominal pipe

size (inches)

Velocity in Feet Per Second (fps)

Schedule 40 1/2 fps 1 fps 2 fps 3 fps 4 fps 5 fps 6 fps 8 fps 10 fps 15 fps 20 fps

GPM GPM GPM GPM GPM GPM GPM GPM GPM GPM GPM

1 1.32.75.48 11 13 1622274054

1.5 3.26.51319 25 32 38516495127

2 5.2 10.5 21 31 42 52 63 84 105 157 209

2.5 7.5 15 30 45 60 75 90 119 149 224 299

3 11.5 23 46 69 92 115 138 184 231 346 461

4 20 40 80 119 159 199 238 318 397 596 794

5 31 62 125 187 250 312 374 499 624 936 1248

6 45 90 180 270 360 451 541 721 901 1352 1802

8 78 156 312 468 624 780 936 1248 1561 2341 3121

10 123 246 492 738 984 1230 1476 1968 2460 3690 4920

12 175 349 698 1047 1397 1746 2095 2793 3492 5237 6983

14 211 422 844 1266 1688 2110 2532 3376 4220 6330 8440

16 276 551 1103 1654 2205 2756 3308 4410 5513 8269 11025

18 349 698 1396 2093 2791 3489 4187 5582 6978 10466 13955

20 434 867 1734 2602 3469 4336 5203 6938 8672 13008 17344

24 627 1254 2508 3763 5017 6271 7525 10034 12542 18814 25085

30 1048 2096 4192 6288 8385 10481 12577 16769 20961 31442 41923

36 1522 3044 6089 9133 12177 15221 18266 24354 30443 45664 60886

42 2084 4169 8338 12506 16675 20844 25013 33351 41688 62532 83377

48 2735 5470 10940 16409 21879 27349 32819 43758 54698 82047 109396

54 3441 6882 13764 20646 27528 34410 41292 55056 68821 103231 137641

60 4192 8395 16769 25154 33538 41923 50307 67076 83845 125768 167690

4-14 Specifications and Reference Information 5707070-A

Sono-Trak™ Doppler Ultrasonic Flow Meter

5707070-A Specifications and Reference Information 4-15

Sono-Trak™ Doppler Ultrasonic Flow Meter

4-16 Specifications and Reference Information 5707070-A

Advanced Energy®

5707070-A i

Sono-Trak™ Doppler Ultrasonic Flow Meter

Numerics

4-20 mA output, specifications 4-3

A

AC power

requirements 4-3

troubleshooting 3-2

accuracy 4-2

adaptor, battery 4-3

alarm output, specifications 4-4

analog output

setting parameters 2-23

signals 4-3

assessing flow profile 2-5

B

battery

operation 2-25

power adaptor/charger 4-3

before installing the unit 2-1

C

cables, transducers 1-2, 4-3

cast iron pipe data 4-10

charger, battery 4-3

checklist for troubleshooting 3-1

clamp-on transducers, dimensions 4-8

connecting

AC input power 2-13

DC input power 2-14

electronics board 2-12

input power 2-13

conversion tables, velocity 4-12

correction factor 2-22

crystal wedge material 4-3

customer support, EMCO 3-11

D

DC power

requirements 4-3

troubleshooting 3-2

dimensions 4-8

electronics enclosure 4-2

electronics enclosure, illustration 4-6

transducers 4-2

Doppler flow meter, features 1-1

ductile iron pipe data 4-11

E

ECHO LED

flashing 3-5

off 3-3

unstable readings 2-20

electronics enclosure 4-2

ambient temperature range 4-2

board connections 2-12

dimensions 4-2

overview 1-2

weight 4-2

email, customer support 3-11

EMCO customer support 3-11

F

features 1-1

first time operation 2-17

flow requirements

assessing profile 2-5

flow sensitivity, specification 4-1

fluid conditions, specifications 4-1

front panel 2-17

functional specifications 4-3

H

hi/ low alarms, setting 2-24

high flow rate reading, troubleshooting 3-6

horizontal pipe mounting 2-8, 2-9

I

illustrations

clamp-on transducer dimensions 4-8

electrical connections 2-12

electronics enclosure 4-6

electronics enclosure mounting 2-13

indications

rate 4-4

totalizer 4-5

input power requirements 4-3

inside diameters, pipes 4-9

Index

ii 5707070-A

Advanced Energy®

installation

horizontal pipe mounting 2-8

pre-installation procedures 2-2

procedures 2-9

straight run requirements 2-5

tools required 2-2

vertical pipe mounting 2-8

introduction 1-1

K

K factor, setting 2-22

keypad

lockout switch 4-4

L

LCD display

rate selection 2-18

totalizer selection 2-19

LEDs

ALARM 2-16

ECHO 2-20

indications 2-16

POWER 2-16

specifications 4-4

lockout switch, keypad 4-4

low flow cutoff

setting 2-23

specifications 4-5

low flow rate reading, troubleshooting 3-6

M

main components 1-2

measurement accuracy 4-2

meters per second, reading 2-24

mounting

horizontal pipe 2-8

vertical pipe 2-8

N

normal operation 2-25

O

operating temperature range

electronics enclosure 4-2

transducers 4-3

operation

first time 2-17

normal 2-25

portable battery 2-25

output signals

alarms 4-4

analog output 4-3

P

performance specifications 4-1

physical specifications 4-2

pipe conditions, specifications 4-1

pipe data 4-9

cast iron pipe 4-10

ductile iron pipe 4-11

PVC 4-9

stainless steel 4-9

steel 4-9

pipe material

assessing condition 2-5

portable battery operation 2-25

power adaptor 4-3

power failure, backup 4-4

power requirements

AC 4-3

DC 4-3

procedures

connecting power to electronics enclosure

2-13

connecting transducers to electronics

enclosure 2-11

first time operation 2-18

mounting the electronics enclosure 2-13

mounting transducers 2-6

mounting transducers to the pipe 2-9

process

determining application requirements 2-3

product introduction 1-1

PVC pipe data 4-9

R

rate indications, units of measure 4-4

rate selection 2-18

reference

pipe data 4-9

velocity conversion tables 4-12

reflectors

air bubbles and particles 1-3

sonic 1-3

repeatability 4-2

returning units for repair 3-12

S

sales, EMCO contact information 3-11

sensitivity, flow 4-1

5707070-A iii

Sono-Trak™ Doppler Ultrasonic Flow Meter

setting parameters

advanced 2-22

analog output 2-23

hi/ low alarms 2-24

K factor 2-22

low flow cutoff 2-23

read meters per second 2-24

sample setting 2-22

totalizer reset 2-24

update time 2-24

sonic reflectors 1-3

specifications

flow sensitivity 4-1

fluid conditions 4-1

functional 4-3

input power requirements 4-3

performance 4-1

physical 4-2

pipe conditions 4-1

velocity of fluid 4-1

stainless steel pipe data 4-9

standard pipe data 4-9

steel pipe data 4-9

straight run

examples 2-7

requirements 2-5

support, EMCO customer support 3-11

system

components 1-2

overview 1-1

T

theory of operation 1-2

tools for installation 2-2

totalizer

indication, units of measure 4-5

reset, setting 2-24

selection 2-19

transducers

cable length 4-3

cabling 1-2

connecting to electronics enclosure 2-11

dimensions 4-2

housing material 4-2

mounting 2-9

placement guidelines 2-7

positioning guidelines 2-6

unstable readings 2-20

weight 4-2

troubleshooting

additional information 3-9

checklist 3-1

ECHO light flashing 3-5

erratic flow rate 3-8

flow rate high or low 3-6

no ECHO light 3-3

no power to unit 3-2

troubleshooting table 3-2

unstable readings 2-20

U

unpacking the system 2-1

update time, setting 2-24

V

velocity conversion tables 4-12

velocity, measurable fluid 4-1

vertical pipe mounting 2-8

voltage selector switch 2-13

W

warranty

authorized returns 3-13

filing a claim 3-12

returning units 3-13

statement 3-13

web site, EMCO 3-11

wedge material, crystal 4-3

iv 5707070-A

Advanced Energy®