DUALPULSE

DP490 & DP525

BI-DIRECTIONAL INSERTION FLOW TRANSDUCER
INSTRUCTION MANUAL

TRIMEC INDUSTRIES Pty.Ltd. Distributed by:

1 / 19 Northumberland Road
Caringbah NSW 2229
Sydney - AUSTRALIA
Tel : +61 2 9540 4433
Fax: +61 2 9525 9411
Email : [email protected]
Website: www.trimecind.com

TRIMEC Europe Ltd DUALPULSE

LOCK
Floor 3, 5A Boltro Road
Haywards Heath West Sussex,
UNITED KINGDOM RH16 1BP
Tel : +44 144-441-7880
Fax : +44 144-441-7668
Email : [email protected]
Website : www.trimecind.com

TRIMEC Inc.
916 Belcher Drive
Pelham, AL 35124
USA
Tel : +1 205 378 1050
Fax : +1 205 685 3001
Email : [email protected]
Website : www.trimecind.com

IMDP000-4006
 page 1

IMPORTANT INFORMATION

Thank you for purchasing a Dualpulse Flowmeter. It is important that you read this
manual to gain a full understanding of the capability and operational aspects of the CONTENTS PAGE
equipment you are about to install.
1.0 INTRODUCTION
1.1 Model number designation 2
This information is provided only to assist in the installation of the product and 1.2 Overview 3
does not diminish your obligation to read the manual. 1.3 Operating principal 3
1.4 Specifications 3
1. Select a location that meets the requirements as illustrated on the guideline
sheet (yellow pages located in the center of this manual). An ideal installation 2.0 INSTALLATION
would provide for 25 diameters of straight pipe upstream from the meter and 10 2.1 Meter location 4
diameters downstream. 2.2 Meter installation & orientation 4
2.3 Height adjustment 5
You will also need to know the pipe internal diameter (NB) and pipe wall thickness 2.4 Flow direction orientation 5
2.5 Hot tap installations 6
for calculation of the insertion depth. (refer page 5.) Non ideal installations may
require in-situ calibration (refer to the factory for details). 3.0 ELECTRICAL CONNECTIONS
3.1 Standard outputs 7
2. After screwing the Dualpulse in place ensure the flow alignment mark located 3.2 Optional Reed switch output 7
on the top positioning collar of the meter aligns with the flow in the pipe (refer 3.3 Instrument cable installation requirements 8
page 5). This ensures the paddle is correctly aligned to the flow. 3.4 Pulse output selection ( standard outputs ) 8
Note. the meter is bi-directional so a flow direction arrow is not provided. 3.5 QP Quadrature pulse output option 9
3.6 Bi-directional flow using QP option 9
3. Calculate and adjust the height of the Dualpulse (refer page 5). 3.7 Connection to family instruments 10

4. Electrical Installation depends on the model you have purchased. 4.0 K – FACTOR ( calibration factor for meter )
If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser
or rate totaliser please refer to the appropriate manual and Page 10 of this 4.1 K-factors for common pipe ID sizes <575mm 11
manual. For pulse output meters, select the appropriate output and wire to your 4.2 K-factors for large pipe ID >460mm 11
receiving device. (refer pages 7 to 9). 4.3 Calculating K-factors ( metric units – litres or M3 ) 12
4.4 Calculating K-factors ( US gallons ) 13
5. Calculate the Dualpulse K (scale) factor to suit the installation. For ideal
installations refer to page 11 or 12 or 13 of the Dualpulse Manual. For non ideal
installations the K-factor may be calculated by performing an in-situ calibration.
Enter the appropriate K-factor into your receiving instrument.
Page 2 page 3

1.2 Overview
1.0 INTRODUCTION Trimec Dualpulse insertion flow transducers provide a cost effective and simple means of
measuring the flow of a wide range of low viscosity liquids. Installation is quick and
1.1 Model number designation inexpensive for pipe diameters ranging from 40mm to 900mm (1.5-36") and up to 2500mm
DP490 1.5 to 36" pipes ( 40 - 900mm ) 1.5" threaded process connections (100") nominal bore for the Hot tap capable model DP525.
DP525 2 to 100" pipes ( 50 to 2500 mm ) "hot-tap" version, 2" threaded process connections
Body material Dualpulse has a linear measuring range of 0.3~10.0 metres/sec. (1~33 ft/sec.). Minimum
S 316 Stainless Steel detectable flow velocity is 0.15 m/sec. (0.5 ft/sec.). When used in conjunction with the RT12
Rotor material flow rate totaliser NLC feature the linear flow range is extended down to 0.15 m/sec. (0.5
2 PEEK (Polyetheretherketone) with a graphite-PTFE impregnated PEEK bearing
ft/sec.) with an improved linearity.
9 Special
The Dualpulse is constructed from 316 L (1.4404) stainless steel enabling use in many
O-ring materials
applications for metering water and low viscosity chemicals.
1 Viton
9 Special
Two independent pulse outputs are standard & can directly input to a wide range of
Maximum temperature ancillary instruments, PLC’s and computers. Both pulse outputs have a high level of
5 100ºC (212ºF) standard, ( 85ºC [185ºF] for non magnetic output type 4 ) immunity to electrical interference. Options include a reed switch.
2 125ºC (260ºF) - available with electrical connections 5 & 6 only
3 150ºC (300ºF) - NPN output only ( with electrical connection 5 only ) 1.3 Operating principle
6 200ºC (390ºF) - with output type 6 HT coil, electrical connection 5 only Flow passes through a pipe causing the rotor to spin. Magnets installed in the rotor pass by
Process connections pulse sensors within the transducer body & inturn this produces frequency outputs
- 1 BSPT male thread - 1½" ( DP490 ) 2" ( DP525 ) proportional to flow rate.
- 2 NPT male thread - 1½" ( DP490 ) 2" ( DP525 )
- 3 2" BSPT male thread on the DP490
- 4 2" NPT male thread on the DP490
1.4 Specifications ( subject to change without notice )
Output type
1 NPN open collector & voltage pulse ( standard )
Model No. DP490 DP525
2 NPN open collector(s) only ( for temp code 3 or QP option ) Suits pipe sizes 40mm - 900mm 50mm - 2500mm
( 1.5 – 36 inches ) ( 2 – 100 inches )
3 Reed switch ( typically for use in hazardous areas )
Flow range 0.25 - 6300 litres/sec. 0.4 - 49000 litres/sec.
4 Non magnetic NPN output ( for liquids with ferrous impurities )
( 4-99600 USGPM ) ( 6-780000 USGPM )
6 High temp. 200ºC (390ºF) coil output
Process connections 1.5" or 2” NPT or BSPT 2" NPT or BSPT
Electrical connections Velocity range 0.3 - 10 metres/sec. ( 1 - 33 feet/sec.)
1 3 metres cable ( 10ft ) - standard Linearity typically ± 1.5%
2 10 metres cable ( 33ft ) Repeatability typically ± 0.5%
3 20 metres cable ( 66ft ) Pressure (max) 80 Bar ( 1200PSI )
4 50 metres cable ( 164ft ) Temperature range -40°C to 100°C (-40°F to 212°F ) – refer options
5 Terminal box on stem kit Body material 316L stainless steel (1.4404)
6 Stem kit ( included with integral options B2, B3, R2, R3 & EO ) Rotor materials PEEK rotor with graphite-PTFE impregnated PEEK bearing
Integral options O-Ring material VITON - options available
QP Quadrature pulse output (a) Voltage output (to 125°C) 1.5volt x 10µ sec pulse width, self-generated (2 wire)
with scaleable pulse output B2 BT11 dual totaliser (b) Square wave ( Hall Effect ) 5-24vdc, 3wire NPN open collector (20mA max. current sink)
IECEX & ATEX approved B3 I.S. intrinsically safe BT11 (c) Reed Switch (to 100°C) 30vdc max. x 20mA max. (output freq. is 1/3 std. K-factor)
pulse, alarms & 4~20mA outputs R2 RT12 rate totaliser Output freq. @ max. velocity ( a & b ) outputs 220~240 Hz ( c ) output 73~80 Hz
IECEX & ATEX approved R3 I.S. intrinsically safe RT12 Output options Ultra high temp. coil 204°C (400°F) or non magnetic
E0 Ecobatch dc powered batch controller Transmission distance 1000 metres ( 3300 feet ) maximum
Model number example SB Specific build requirement Wiring (standard) 5 core, screened cable, length 3 metres ( 10 feet )
Protection class IP68 submersible ( Nema 6X )
DP490 S 2 1 5 - 1 1 6 R2
Conduit entry (terminal box) 3/8" NPT or PG9
Shipping Weight 1.2 kg ( 2.7 lbs.) 1.5 kg ( 3.3 lbs.)
page 4 page 5

2.0 INSTALLATION 2.3 Height adjustment calculation

Calculate the adjustment height A for DP490 (or AA for the DP525) as follows:
2.1 Meter location
Choose an appropriate section of horizontal or vertical pipe as per the guidelines below. A ( for DP490 ) = 175mm ( 6.9") - ( B + C + D )
With vertical pipe installations the media should be pumped up through the pipe past the AA ( for DP525 ) = 420mm (16.5") - ( B + C + D )
flow sensor so that any entrained air will pass freely.
Where :
The DP flow sensor requires a fully developed turbulent flow profile to ensure maximum B = Distance between the top of the pipe & the top of the hex adaptor.
measurement accuracy and repeatability. This can be achieved by installing the DP in a C = Pipe wall thickness
straight run of pipe. We recommend at least 10 but ideally 25 straight pipe diameters D = Insertion depth ( pipe ID ÷ 8 )
upstream & at least 5 but ideally 10 pipe diameters downstream of the Dualpulse. Major
obstructions such as pumps, valves or strainers will require longer straight runs before and ALIGNMENT SLOT TO
after the Dualpulse. PARRALLEL PIPE

Major obstructions such as LOCK

pumps,valves,reducers or strainers
to be kept well outside the straight
3
Examples of insertion depth D :
run pipe sections
For 40mm pipe ID ( D= 5.0 mm ) 1 A (AA)
For 50mm pipe ID ( D= 6.25 mm )
10 pipe dia. minimum 5 pipe dia. min. For 100mm pipe ID ( D= 12.5 mm )
25 pipe dia. prefered 10 pipe dia. prefered For 400mm pipe ID ( D= 50.0 mm )
C
2 B
FLOW D

2.2 Meter installation & orientation

Cut a 40mm diameter hole (1.6") on either the 2, 10 or 12 o’clock positions of the pipe. If
there is any likelihood of air entrainment in a horizontal pipe do not locate the flow C
transducer in the 12 o’clock position.

12 o’clock 2 o’clock

Turn the height adjustment nuts (1) as required so that the distance between the top of the
Other positions hex adaptor (2) and the top of the positioning collar (3) equals your calculated distance A
around the pipe are (for DP490) or AA for model DP525. Retighten the height adjustment nuts (1).
acceptable
2.4 Flow direction orientation
The unit is bi-directional however the paddle must be aligned with the direction of flow.

Using a 2mm hex key (Allen key), unlock the locking screw located on the positioning collar
(3) then insert the hex key (as a lever) in the body rotating hole located above the collar,
Install a female threaded weld on fitting (threadolet) or service saddle. turn the body until the alignment slot is parallel with the direction of pipe. Retighten the
Wrap the threads of the Dualpulse with Teflon tape or sealing compound & screw the unit locking screw.
into the installed fitting.
 page 6 page 7
3.0 ELECTRICAL CONNECTIONS
2.5 Hot tap installation ( see page 9 for QP outputs )
( model DP525 ) IMPORTANT
Before removing the 3.1 Standard outputs
DP525 from the
installation first Conductor color coding also applies to the Non-magnetic
sensor and high temperature output options
withdraw the
Clean & lubricate screw transducer body to
threads before the maximum
withdrawing the
distance allowed by Pull up resistor
transducer body in order
to avoid nut seizure the three height required, they are
generally incorporated
adjusting threaded in most receiving
rods. This will enable Positioning
instruments
the isolating valve collar
Height
to be fully closed adjustment DUALPULSE
LOCK
without damaging the nuts SQUARE WAVE
PULSE OUTPUT
paddle.
Black ( -0v ground )

Red ( VDC supply )

Body
White ( + Sig. output )

If necessary extend valve

port using a 2” nipple &
socket combination to
ensure the paddle is clear Hex adaptor
of the ball valve. A1 A2
1.5” or 2” BSPT
or NPT Screen
B1 B2
Rotor b1
VOLTAGE PULSE
CAUTION : Hot tap installation OUTPUT
Terminal box option
should only be performed by terminal connections Yellow ( + )
qualified personal. Installation 2" ball or gate
procedures should be in accordance isolation valve. Green ( - )
with the safety rules, regulations and (Allow min. 40mm I.D. to
requirements applying to the territory clear metering head)
in which the flow transducer is being
installed.
3.2 Optional Reed switch output

2" Nipple HAZARDOUS AREAS

The REED SWITCH output is classed as a

2" Weld-O-let “simple apparatus“ as defined in the
( threadolet ) CENELEC standard EN50020 &
recognized IEC & ATEX directive. It can REED SWITCH
be connected to an approved I.S. OUTPUT
secondary instrument with both being DUALPULSE
LOCK
located in the hazardous area.
Hot tap clearance hole in The Reed Switch may also be connected Screen
pipe wall to be a minimum through an approved I.S. barrier.
FLOW of 40mm diameter (1.6"). rd
Note: The Reed switch produces 1/3 Yellow
the normal pulse output value
To -0V
( eg. 1/3 the standard K-factor ) Green
page 8 Page 9
3.5 Quadrature outputs
3.3 Instrument cable installation requirements DP series flowmeters supplied with the QP option produce two NPN open collector pulse
Use twisted multi-core low capacitance shielded instrument cable (22 AWG ~ 7x 0.3 outputs from two Hall Effect sensors. The outputs are “ phase offset ” in their timing so that
stranded) for electrical connection between the flow meter and the remote instrumentation. external electronics are able to differentiate. These outputs may be used to assure output
The screen should be earthed at the readout instrument end only to protect the transmitted signal integrity or to measure bi-directional flow.
signal from mutual inductive interference.

The cable should not be run in a common conduit or parallel with power and high inductive
load carrying cables as power surges may induce erroneous noise transients onto the Screen
transmitted pulse signal. Run the cable in separate conduit or with other low energy
instrument cables . Red ~ Vdc
White ~ output 1
Blue ~ output 2
3.4 Pulse output selection ( standard outputs )
The standard flowmeter has two independent pulse output signals that are linearly Black ~ -0V
proportional to volumetric flow rate. Pulse transmission can be up to 1000 metres (3300 ft ).
An optional I.S. Reed Switch output is available (see page 7).

Voltage pulse (pulse wire) output 3.6 Bi-directional flow

A self generating pulse output which produces a strong 1.5 volt voltage spike of The DP flow transducer is capable of accurately measuring flow in both directions without
approximately 10 micro/second duration with no dependence on rotor speed. modification. Meters fitted with the QP output option (quadrature pulse output) may be
interfaced with the Pulse Discriminator Module (PD1). The PD1 accepts the Quadrature
pulse inputs & from these will discriminate between forward & reverse flow. Two individual
& proportional pulse outputs can then be sent to appropriate totalising registers or an RT12
Screen
add and subtract flow rate totaliser.

Yellow ( + ) It is important to note that the Quadrature Pulse option has the same pulse resolution
(pulses/unit volume) as a standard Dualpulse for both forward & reverse outputs.
Green (-)

Flowmeter with QP outputs

5~24Vdc maximum
Vdc
PD1 Pulse Discriminator
Square Wave Pulse (Hall sensor) ( also applies to non-magnetic & QP Hall outputs ) Reg
An NPN open collector transistor pulse output produced by a solid state Hall Effect device. Output Signal 1
+
10 +Vdc +8~24Vdc 5
X (forward flow)
This three wire device requires 5~24vdc and produces an NPN square wave output (20mA 9 Sig.1 Forward flow Sig. 4
max. sink), pulse width is 2~75 mSec. The Hall output requires a pull up resistor, these are Output signals
generally incorporated in most receiving instruments. For (QP) Quadrature pulse output
refer details page 9. Reg
Output Signal 2
7 Sig.2 Reverse flow Sig. 2
+
X (reverse flow) 6 -0V -0V 1

Screen Ground
-0V
(5-24vdc supply )
Red
signal output
White
( -0v ground )
Black
page 10 page 11

3.7 Voltage Pulse Connection to family instruments 4.0 K – FACTORS ( calibration factors for meter )

The K-factor (pulses / litre, gallon etc.) will vary in relation to the bore size of the pipe in
Note: For other output styles see which the Dualpulse is installed.
receiving instrument manual
The K-factors and formula shown are a result of factory testing using smooth bore piping
RATE TOTALISER
under ideal conditions. Variations to the given K-factors may occur when using rough bore
gal piping or inadequate flow conditioning on either side of the flow transducer (refer clause
RUN ACCUM. TOTAL STOP BAT LOW
1 RT & EB SERIES
14 2.1). In these instances on site calibration may be used to determine the K-factor.
INSTRUMENTS
RESET PROGRAM ACCUM 2 13
> ENTER TOTAL
^ yellow
3 All flow DIP
4.1 Flow transducer K- factors for common pipe sizes
3 O 12
RATE

4 N
2 switches in the Pipe detail K-factors ( standard K-factors for voltage & square wave outputs )
TOTAL 1 OFF position 11
green NB ID (#40) Schedule 40 pipe - (#40) Schedule 80 pipe - (#80)
5 -0V (ground) 10
inches mm p / litre p / m3 p / USgal p / litre p / m3 p / USgal
6 9
1.5" 40.9 18.678 18678 70.695 21.524 21524 81.468
7 8
Screen 2" 52.6 11.238 11238 42.534 12.818 12818 48.517
2.5" 62.7 7.880 7880 29.824 8.899 8899 33.682
3" 78.0 5.062 5062 19.161 5.676 5676 21.485
3.5" 90.2 3.768 3768 14.263 4.200 4200 15.896
BT11 TOTALISER 4" 102 2.912 2912 11.021 3.233 3233 12.237
5" 128 1.839 1839 6.959 2.025 2025 7.665
ON DIP switch 1 in 6" 154 1.268 1268 4.798 1.402 1402 5.307
the ON position
1 2 3 ( 2 Khz max.) 8" 203 0.719 719.0 2.721 0.787 787.2 2.980
10" 255 0.450 450.3 1.705 0.496 495.9 1.877
1 2 3
+ - gnd +Vdc +∏ -gnd 12" 303 0.316 316.0 1.196 0.347 347.4 1.315
DUALPULSE 1 2 3 4 5 6 14" 333 0.261 260.5 0.986 0.286 285.7 1.081
LOCK

16" 381 0.198 198.0 0.750 0.217 217.0 0.821

yellow
18" 429 0.156 155.8 0.590 0.171 170.6 0.646
green
20" 478 0.125 125.4 0.475 0.138 137.8 0.521
24" 575 0.087 86.64 0.328 0.095 95.39 0.361
Screen For other pipe sizes below 610mm (24") not listed above, use the graphs and apply the
formula on the following pages ( 12 & 13 ).

The Dualpulse cable should

not be run with other high 4.2 K-factors for large pipes 460mm ID (18") and above use:
energy cables ( clause 3.3 ).
Pulses per litre = 28647 ÷ pipe ID² (mm)
Pulses per M³ = 28647000 ÷ pipe ID² (mm)
Pulses per US gallon = 168.14 ÷ pipe ID² (inches)
Pulses per Imp. gallon = 201.94 ÷ pipe ID² (inches)

Flow instruments or a
terminal box can be NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
directly mounted to the DUALPULSE pulse output.
LOCK
Dualpulse using ST4 (for
DP490) or ST5 (DP525)
mounting stem kits
page 12 page 13

4.3 Calculating K-factors ( litres or m³ ) 4.4 Calculating K-factors ( US gallons )

7.6
25

7.5

24.5
7.4

24 7.3

Pipe ID 450mm & above (A) = 22.5 7.2

(A) 23.5
(A)
7.1 Pipe ID 19.5 ” & above (A) = 6.86
23
See 7.0
example a
22.5
6.9

22 6.8
40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
pipe ID (mm) pipe ID (inches)

Calculate K-factor ( pulses / gallon ) using the above graph and the volumetric
Calculate K-factor ( pulses / litre ) using the above graph and the metric constant of 1273.2 constant of 24.51 as follows :
as follows :

Pulses / litre = 1273.2 x (A) from graph Pulses / US gal. = 24.51 x (A) from graph
pipe ID² (mm) pipe ID² (inches)

Example ‘a’ : Example ‘b’ :

K-factor for 100mm pipe: 1) from graph 100mm ID (A) = 24.0 K-factor for 10" pipe: 1) from graph 10" ID (A) = 7.01
2) pulses/litre. = 1273.2 x 24.0 2) pulses/gal. = 24.51 x 7.01
10000 = 3.056 p/litre
100 = 1.718 p/gal

K-factor for m³ : multiply by 1000 eg. K = 3056 p/m³

K-factor for megalitres : multiply by 1000000 eg. K = 3056000 p/megalitre

NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
pulse output.