KAM Simple Precision LRW User manual

KAM®LRW™
LOW RANGE WATERCUT
TEL [phone]
FAX [phone]
Email [email protected]
KAM CONTROLS, INC.
3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com
User Manual
LRWMANUAL 0918 An ISO 9001 certified company

LRWMANUAL 0918 KAM CONTROLS, INC.
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TABLE OF CONTENTS
SECTION TITLE PAGE
1Introduction 2
•Available Models and Mounting Options 2
•Theory of Operation 3
2Specifications 4
•Specifications 4
3. Installation 5
•Installation Flow Requirements 5
•Prior to Installation 5
•Flow through assembly 5
•Insertable/retractable installation 6
•Removing Fast Loop Models 8
•Wiring 9
4LRW Operation 15
•RealTerm configuration 15
•Data capture 19
•Calibrating the LRW 21
•Calibration with lab results 23
•Output process values 24
•Density input reconfiguration 24
5Maintenance 27
•Cleaning/Inspection 27
6Troubleshooting 28
APPENDIX A: Modbus Registers 32
CAUTION:
When installing the LRW®sensor in a pipeline containing petroleum products,
petrochemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ "Health, Safety and Environmental Policy Procedures" to
ensure safe installation.
KAM CONTROLS, INC. reserves the right to make changes to this document without notice.

LRWMANUAL 0918 KAM CONTROLS, INC.
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INTRODUCTION
AVAILABLE MODELS and MOUNTING OPTIONS
LRW™ flow-through
spool for 1", 2", and 3"
pipelines with included
static mixer and
manual draw-off valve
LRW™ fixed insertion for pipelines 3" and up
2", 3" or 4" flanged process connection
LRW™ insertable/retractable for pipelines 3" and up
2", 3" or 4" flanged seal housing or 2" MNPT process connection
www.KAM.com
[phone]
[e-mail]
Made in the USA
LRW Low RangeWatercut

LRWMANUAL 0918 KAM CONTROLS, INC.
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INTRODUCTION continued
The KAM LRW™ Low Range Watercut / BS&W meter uses a patented microwave resonance technology, responding
to the differing electrical properties of water and oil to determine water content for ranges 0-3%, 0-5% and 0-10%.
The technology is highly repeatable and offers industry-leading accuracy (±0.03% for a 0-3% range). Additionally,
proprietary AnyDensity™ technology allows the instrument to compensate for any change in density across the
entire API gravity range. Compensation is based on a density input from a mass flow meter or densitometer and
all compensation is automatic. This is paramount in situations where a single truck or rail unloading site could see
swings in API gravity from the 20s to the 60s.
The unit can be calibrated and verified in line.
The LRW's high-quality components are made and assembled entirely in the USA, providing reliable and consistent
performance for long-term use.
TABLE 1-1 MEASUREMENT CAPABILITIES: CALIBRATED RANGE AND ACCURACIES
THEORY OF OPERATION
Range (water in oil) 0-3% 0–5% 0-10%
Accuracy (at listed range) ±0.03% ±0.05% ±0.05% (from 0-5% water); ±0.1% from 5-10% water

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SPECIFICATIONS
Media: Crude oil and refined products
Wetted parts: 316 SS, hastelloy, & PEEK (Other materials available)
Fluid temp: To 300º F (149º C)
Electronics temp: -40º F to 158º F (-40º C to +70º C)
Power requirements: 24 VDC
Power consumption: 12 watts
Available ranges: 0-3%, 0-5%, 0-10% water in oil
Accuracy: 1% of range (0-10% models have an accuracy of 0,05% for water from 0-5% and an
accuracy of 0,1% for water from 5-10%)
Repeatability: +/- 0.01%
Resolution: +/- 0.01%
Minimum water detection: 300 ppm (0-3% models)
Outputs/serial ports: 4–20 mA
Alarm relay
RS232 ASCII (calibration and diagnostics only)
RS485 Modbus
Input: 4-20 mA for density
Density Correction: AnyDensity™compensates for changes in fluid density across entire API gravity range
(requires density input)
Ingress protection: NEMA IV; IP66
Temperature Correction: Automatic
Pressure ratings: ANSI 150, 300, 600, 900
Flow conditions: Well mixed in accordance with API MPMS Chapter 8.2 mixing requirements, vertical
installation strongly recommended
Enclosure hazardous
approvals: Explosion-proof for Class I, Division 1, Groups B, C and D
Dust-ignition-proof for Class II/III, Division 1, Groups E, F and G,
hazardous (classified) locations, indoors and outdoors (Type 4X/IP66)
ATEX: II 2 G D, Ex d IIC, Ex tD A21, IP68, Ta =-40°C to +85°C
IEC EX: Ex d IIC, Ex A21 tD, IP68, Ta =-40°C to +85°C

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INSTALLATION
KAM HIGHLY RECOMMENDS VERTICAL INSTALLATIONS WHEREVER POSSIBLE FOR OPTIMAL MIXING.
PLEASE NOTE: In all KAM LRW Installations, the user should ensure that the KAM LRW is installed in a turbulent
flow with the Reynolds Number above 2000. Additionally, all KAM LRW's should be installed in accordance with API
MPMS Chapter 8, Section 2, Table 1, and in accordance with KAM mixing recommendations.
INSTALLATION FLOW REQUIREMENTS
Remove all the protective packaging materials, and ensure that the LRW®sensor was not damaged
during transit.
It is always recommended that the LRW NOT be installed in direct sunlight, and in high-ambient-temperature
installations that it be installed with recommended sunshade.
In cold weather, if LRW is exposed to an open environment, KAM CONTROLS recommends operators insulate
the LRW, and if the pipeline is heated that the heating trace be extended to include the LRW.
If the pipeline is not going to flow for extended amount of time and the pipe is not heated then LRW should be
taken out to avoid damage to the sensor probe by freezing water.
Flow through (spool) units will be shipped partionally assembled. LRW unit can be wired prior to insertion into the
spool for convenience, but this is not required.
For 2" units:
Grease around the O-ring below the small
flange.
Insert LRW body into the spool and ensure
unit is fully seated. NOTE: LCD screen face
should be alined with direction of pipe flow.
Using a 5/8" Allen wrench, install (8) hex
screws around the circumference of the
flange until tight.
Screw pitot probe into valve until tight.
PRIOR TO INSTALLATION
LRW FLOW THROUGH ASSEMBLY
For 3" and 4" flow through units:
Screw LRW body into spool using 1 3/4"
wrench flat. KAM Controls recommends
using liquid pipe sealant rather than teflon
tape.
Screw pitot probe into valvue until tight.
Pitot
probe
Hex nutsO-ring
1.
2.
3.
4.
1.
2.
FIG. 3-1 LRW FLOW THROUGH 2" AND 3" MODELS

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Prior to mounting verify that the tip of the sensor
is all the way inside the seal housing.
FIGS. 3-3, 3-4.
If sensor is not fully enclosed inside the seal
housing, pull the shaft back until the probe is
all the way in the seal housing and tighten
the Socket Cap Screws on the locking collar.
This will prevent the LRW shaft from sliding
and the probe from getting damaged during
mounting.
1.
2.
FIG. 3-3
FIG. 3-4
INSTALLATION continued
INSERTABLE/RETRACTABLE INSTALLATION
The KAM®LRW sensor should be installed
according to FIG. 3-2. A full-opening ball valve is
used to isolate the LRW sensor from the pipeline
during installation or removal. The seal housing of
the LRW sensor allows the probe to be inserted
and removed from the pipe under pressure and flow
conditions. It is the user’s responsibility to
ensure that the LRW sensor be placed at the most
representative point within the flow profile (see
location recommendations above). The LRW
sensor should be inserted so that the window of
the probe is located in the center of the diameter of
the pipeline.
Note: If line pressure exceeds 100 psi, use a KAM®
IT Insertion Tool when installing/removing
the KAM®LRW sensor.
Locking Collar
Seal Housing
Full-opening
Ball Valve
FIG. 3-2 KAM®LRW INSTALLED ON A MAIN PIPE
Socket cap screws
Loosen to retract
probe into seal housing

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INSTALLATION continued
Measure the calculated MID from the top of the Locking Collar and place a mark with a permanent marker or
tape on the Shaft. FIG. 3-6.
Bolt or screw the LRW sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded LRW).
Open full opening valve.
Loosen Socket Cap Screws on the locking collar.
Push LRW sensor in until the mark is at the top edge of the locking collar. Ensure that LRW flow indicator is
aligned with pipeline flow direction. FIG. 3-7.
5.
MID
6.
7.
8.
FIG. 3-6
9.
Calculate the minimum insertion distance for the LRW.
Minimum insertion distance (MID) =
D1 +
Pipe Wall Thickness (WT) +
Gasket Thickness +
3"
Example for D1=16", WT =1/4",
Gasket Thickness=1/8"
MID = 16 + 1/4 + 1/8 + 3
MID = 19 3/8"
4.
Measure the distance (D1) from the outside diameter of main pipe to the end of the
connection where the LRW sensor is going to be installed. FIG. 3-5.
D1
D1
3.
FIG. 3-5
FIG. 3-7
Mark
Hex Nuts
Socket
cap screws

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REMOVING THE LRW®SENSOR FROM FLOW THROUGH SPOOLS WITH FIXED INSERTION
To remove the LRW®sensor, first shut off power to the
instrument. Discontinue flow in loop from the main line and
drain fluid from loop. The probe can removed from the hous-
ing by removing the 5/8" hex screws on collar (2" models) or
unscrewed from spool body (3" and 4" models). FIG. 3-8. The
probe can then be lifted from the cell for testing/inspection/
calibration purposes.
Removal should be conducted in accordance with all regional
and Class requirements.
FIG. 3-8
INSTALLATION continued
REMOVING THE LRW SENSOR
To remove the LRW sensor, first shut off power to the instrument. Loosen the Socket Cap Screws on the Lock Down
Collar. Slide the LRW sensor upward until the probe rests inside the seal housing. There is a mechanical stop when
the unit is fully retracted. Retighten the Socket Cap Screws. Next, close the Full-opening Ball Valve tightly. Drain oil
from valve if possible. The LRW sensor may now be unbolted from the system.
Note: If line pressure exceeds 100 psi, use a KAM® IT Insertion Tool when installing/removing the KAM®LRW sensor.
Removal should be conducted in accordance with all regional and Class requirements.
Re-tighten the Socket Cap Screws.
Tighten the hex nuts holding down the Locking Collar one half turn. (FIG. 3-7) These should never be
over-tightened. Their major function is to apply light pressure on the chevron packing to ensure a seal between
the seal housing body and the insertion shaft.
10.
11.
Hex screws
2" LRW flow through model
3" and 4" LRW flow through models

LRWMANUAL 0918 KAM CONTROLS, INC.
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INSTALLATION continued
WIRING
DENSITY IN4-20+
4-20- GND
GND GND GND
485+
232-TXD
232-RXD
485-
DOUT1 GND GND CHS POWER- POWER+
FIG. 3-9 WIRING DIAGRAM
4-20 mA current loop output
LCD connector
Density input
(4-20 mA)
Digital relay output
open drain (max 50 W)
Power input (12-24 V)
Chassis connection
RS232
serial connections
MODBUS/RS485 serial connections
optional ground
CAUTION: Do not connect power to 4-20 mA output. This will damage the board and void product warranty.

LRWMANUAL 0918 KAM CONTROLS, INC.
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INSTALLATION continued
POWER (–) GND
POWER (+) 24-30 VDC
DENSITY IN From mass flow or densitometer.
GND
4-20 mA (–) Current output, source powered. Set to requisite percent water at factory.
4-20 mA (+)
DIG OUT (–) Alarm or relay (digital contact closure / max 50 W)
DIG OUT (+)
RS232 Console port – communication interface for calibration, connection to PLC
RS485 Modbus interface
All wiring and maintenance on the KAM LRW must be done in accordance with regional and classification
requirements. It is the user's responsibility to understand these requirements.
It is also recommended that the LRW be wired with flexible wiring/conduit with additional slack/length in the
wire to accommodate insertion, removal, and testing.
To avoid repeatedly opening electronics enclosure during diagnostics, it is recommended operators permanently
wire an RS232 connection to the instrument with corresponding 9-pin connection at junction box for PC
connection.
Operators should take all possible precautions to avoid any moisture from entering the electronics enclosure.
The enclosure should not be left open in inclement weather or for long periods of time, especially during
operation, as condensation will accumulate. All conduits should be sealed and secured in accordance with re-
gional and classification requirements, and unused 3/4" NPT openings should be sealed with provided plug. Do
not power wash the unit.
If necessary, disconnect LCD connector in order to access wiring terminals. The LRW supplies power for the
loop. Make sure the device that receives data from the LRW does not have a power source of its own switched
on. Also, the LOOP+ and LOOP- are isolated inputs from the chassis/earth. Do not connect either to a common
ground. Use an isolator if necessary.
INPUTS/OUTPUTS/SERIAL

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INSTALLATION continued
TYPICAL POWER AND LOOP WIRING CONFIGURATIONS
POWER (+)
POWER (-)
4-20 (+)
4-20 (-)
POWER SUPPLY
24VDC
ISOLATED
RECEIVER
INPUT
(+)
(-)
(+)
(-)
(+)
(-)
RECEIVER
INPUT
(+)
POWER SUPPLY
24VDC
POWER (+)
POWER (-)
4-20 (+)
4-20 (-) (-)
WRONG
WIRING
THE 4-20 mA (-) and
power supply (-) can
not be the same or
connected togeather.
24VDC
POWER SUPPLY
(+)
(-)
(-)
(+)
POWER (+)
POWER (-)
4-20 (+)
4-20 (-)
WRONG
WIRING
LRW PROVIDES POWER FOR THE 4-20mA
loop adding external power can damage
4-20mA output
RECEIVER
INPUT
LRW
LRW
LRW
TYPICAL
WIRING
WRONG:
The 4-30 mA (-) and power supply (-)
cannot be the same or connected
together.
CORRECT
WRONG:
LRW provides power for the 4-20 mA
loop. Adding external power can damage
the 4-20 mA outpout.
FIG. 3-10

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RECEIVER
INPUT
POWER SUPPLY
24VDC
(+)
(-)
(+)
POWER (+)
POWER (-)
4-20 (+)
4-20 (-)
(-)
4-20 mA ISOLATOR
INPUT
OUTPUT
(-)
(+)
WITH ISOLATOR
LRW
INSTALLATION continued
TYPICAL POWER AND LOOP WIRING CONFIGURATIONS
FIG. 3-11 Power and loop with isolator

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INSTALLATION continued
DENSITY INPUT WIRING
DENSITY WIRING
Density meter provides power for the 4-20mA output
DENSITY IN (+)
GND
LRW
(-) OUTPUT
DESITY METER
(+)
DESITY METER
OUTPUT
(+)
(-)
LRW
DENSITY IN (+)
GND
2ND
RECEIVER
POWER SUPPLY
(+)
(+)
(+)
(-)
(-)
(-)
OUTPUT 1
OUTPUT 2
POWER
IN
4-20mA
Input
4-20mA Signal Splitter
FIG. 3-12 Density meter provides power for 4-20 mA output

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INSTALLATION continued
DENSITY INPUT WIRING
2ND
RECEIVER
(-)
DENSITY IN (+)
GND
LRW
(+)
(-)
(+)
POWER
IN
OUTPUT 2
POWER SUPPLY
(-)
(+)
LRW
DENSITY IN (+)
GND
4-20mA Signal Splitter
4-20mA
Input
(-)
(-)
(+)
OUTPUT 1
DENSITY WIRING
Where density meter 4-20mA output requires external power.
DESITY METER
OUTPUT
(+)
DESITY METER
OUTPUT
POWER SUPPLY
POWER SUPPLY
FIG. 3-13 Density meter 4-20 mA output requires external power

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KAM LRW OPERATION
CONFIGURATION
1.
2.
3.
4.
FIG. 4-1
RealTerm software is used for testing and calibration of the LRW. RealTerm is available as a free download.
To download RealTerm, go to http://sourceforge.net/projects/RealTerm/ and click on download button.
Follow on screen instructions to install RealTerm.
If you haven't already done so, connect the RS232 cable to the LRW board as shown on page 9, FIG. 3-9 of
this manual.
Connect the other end of RS232 cable to the serial port of your computer. An RS232 cable for connecting
your PC to the LRW has been supplied with the LRW as well as a USB adaptor in case your computer does
not have an RS232 serial port.
Open RealTerm software. A window will open as shown in FIG. 4-1.
The window will automatically default to the "Display" tab. Click on the up arrow beneath the "Cols" window
until the number reaches 120. Do not attempt to type the number in as this will result in an error message. If
you receive the error message you must close RealTerm and reopen.
Display
tab
Click until value reaches "120"

LRWMANUAL 0918 KAM CONTROLS, INC.
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KAM LRW OPERATION continued
5.
6.
Click on the "Port" tab (FIG. 4-2) and then configure setting to match below.
Baud: 115200
Parity: None
Data Bits: 8
Stop Bits: 1
Hardware Flow Control: 1
Port: Select port number assigned to your serial port or USB port connected to converter
Click on the "Change" button to save these settings.
FIG. 4-2
Port tab
Port
number
Change to
save

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KAM LRW OPERATION continued
If not already turned on, turn on power to LRW™. The initial greeting message will appear if the unit
is newly powered up. FIG. 4-3
7.
Click on the "Send" tab and select first four boxes under "EOL" (FIG. 4-4)
8.
FIG. 4-3
FIG. 4-4
Send tab
EOL: Click first four boxes

LRWMANUAL 0918 KAM CONTROLS, INC.
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KAM LRW OPERATION continued
9. LRW output will start automatically in CSV (comma separated values) format. FIG. 4-5
Data can be exported using the capture function. See next page (19) for instructions.
FIG. 4-5
Column 1: percent water
Column 2: minimum voltage (V)
Column 3: maximum voltage (V)
Column 4: minimum frequency (Hz)
Column 5: frequency offset (Hz)
Column 6: electronics temperature (˚C)
Column 7: fluid temperature at probe (˚C)
Column 8: density in volts
Column 9: density in API gravity
Column 10: density in g/cm3
Column 11: density correction
frequency (Hz)

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KAM LRW OPERATION continued
DATA CAPTURE IN REALTERM
Click on the "Capture" tab. FIG 4-6
Uncheck the "Direct Capture" option
Click on the button marked with the ellipses: "..."
A new window will open. If a folder is not already selected, choose a folder and click open. Name the data file
and save to selected folder. FIG 4-7. Click on "Open".
Press the "Start: Overwrite" button. The screen will clear and start continuously capturing all data. Fig. 4-6.
FIG. 4-6
1.
2.
3.
4.
5.
Capture
tab
Direct captureEllipses button
(pauses data capture)
Start: Overwrite
(overwrites existing
data)
Start: Append
(resumes data
capture)
FIG. 4-7
Click here