Katronic Technologies KATflow 150 User manual

Operating Instructions
Ultrasonic Flowmeter
KATflow 150

Katronic Technologies Ltd.
23 Cross Street
Leamington Spa
Warwickshire CV32 4PX
United Kingdom
Tel. [phone]
Fax [phone]
Internet www.katronic.co.uk
E-mail [email protected]o.uk
Operating Instructions KATflow 150
Version V11E0310
Copyright © 2010
All rights reserved.

KATflow 150 Table of Contents
KATflow 150
Operating Instructions
Table of Contents
Page
1 Safety instructions, legal requirements, warranty, return policy..................5
1.1 Symbols used in these operating instructions...............................................5
1.2 Safety instructions.........................................................................................5
1.3 Warranty........................................................................................................6
1.4 Return policy.................................................................................................6
1.5 Legislative requirements...............................................................................6
2 Introduction........................................................................................................7
3 Installation..........................................................................................................8
3.1 Unpacking and storage.................................................................................8
3.1.1 Unpacking..............................................................................................8
3.1.2 Storage ..................................................................................................8
3.1.3 Identification of components..................................................................8
3.2 Clamp-on sensor installation.........................................................................9
3.3 Installation location........................................................................................9
3.4 Pipe preparation............................................................................................12
3.5 Clamp-on sensor mounting configurations and sensor spacing...................12
3.6 Flowmeter installation...................................................................................13
3.6.1 Wall mounting........................................................................................13
3.6.2 Electrical connections............................................................................15
3.7 Clamp-on sensor mounting...........................................................................16
3.7.1 Sensor pipe mounting configurations.....................................................16
3.7.2 Acoustic coupling gel.............................................................................16
3.7.3 Correct positioning of the sensors.........................................................17
3.7.4 Sensor mounting with tension straps.....................................................17
4 Operation............................................................................................................19
4.1 Switching On/Off...........................................................................................19
4.2 Keypad and display.......................................................................................19
4.2.1 Keypad key functions.............................................................................19
4.2.2 Display functions....................................................................................21
4.3 Quick setup wizard........................................................................................22
4.4 Measurements..............................................................................................24
4.4.1 Main process value (PV) display............................................................24
3-line display format...............................................................................25
4.4.2 Diagnostic displays................................................................................25
4.4.3 Totalisers................................................................................................25
4.4.4 Datalogger..............................................................................................25
5 Commissioning..................................................................................................26
5.1 Menu structure..............................................................................................26
5.2 Diagnostics....................................................................................................31
5.3 Display settings.............................................................................................31
5.4 Output configurations....................................................................................31
5.4.1 Serial interface RS 232..........................................................................31
5.4.2 Serial interface RS 485..........................................................................31
3

KATflow 150 Table of Contents
5.4.3 Analogue current output 0/4 ... 20 mA...................................................32
5.4.4 Digital Open-Collector output.................................................................32
5.4.5 Digital relay output.................................................................................32
5.5 Input configurations.......................................................................................33
5.5.1 PT100 inputs..........................................................................................33
5.5.2 Analogue current input 0/4 ... 20 mA......................................................33
5.6 Heat quantity measurement (HQM)..............................................................33
5.7 Sound velocity measurement (SVM)............................................................34
5.8 Dual-channel flow calculations (maths functions).........................................34
6 Maintenance.......................................................................................................34
7 Troubleshooting.................................................................................................35
8 Technical data....................................................................................................37
9 Specification.......................................................................................................43
10 Index..................................................................................................................46
Appendix A...........................................................................................................47
Appendix B...........................................................................................................48
4

KATflow 150 1 Safety instructions, legal requirements, warranty, return policy
1 Safety instructions, legal requirements, war-
ranty, return policy
1.1 Symbols used in these operating instructions
Danger
This symbol represents an immediate hazardous situation which could result in
serious injury, death or damage to the equipment. Where this symbol is shown,
do not use the equipment further unless you have fully understood the nature of the
hazard and have taken the required precautions.
Attention
This symbol indicates important instructions which should be respected in order to
avoid damaging or destroying the equipment. Follow the the precautions given in
these instructions to avoid the hazard. Call our service team if necessary.
Call service
Where this symbol is shown call our service team for advice if necessary.
Note
This symbol indicates a note or detailed set-up tip.
Information point.
Operator keys are printed in bold typeface and placed in pointed brackets.
1.2 Safety instructions
● Do not install, operate or maintain this flowmeter without reading, under-
standing and following these operating instructions, otherwise injury or
damage may result.
● Study these operating instructions carefully before the installation of the
equipment and keep them for future reference.
● Observe all warnings, notes and instructions as marked on the packaging,
on the equipment, and detailed in the operating instructions.
● Do not use the instrument under wet conditions with the battery cover re-
moved or opened.
● Follow the unpacking, storage and preservation instructions to avoid dam-
age to the equipment.
● Install the equipment and cabling securely and safely according to the rel-
evant regulations.
● If the product does not operate normally, please refer to the service and
troubleshooting instructions, or contact KATRONIC for help.
5
!
<BRK>
!
☞
•

KATflow 150 1 Safety instructions, legal requirements, warranty, return policy
1.3 Warranty
● Any product purchased from KATRONIC is warranted in accordance with
the relevant product documentation and as specified in the sales contract
provided it has been used for the purpose for which it has been designed
and operated as outlined in these operating instructions. Misuse of the
equipment will immediately revoke any warranty given or implied.
● Responsibility for suitability and intended use of this ultrasonic flowmeter
rests solely with the user. Improper installation and operation of the flow-
meter may lead to a loss of warranty.
● Please note that there are no operator-serviceable parts inside the equip-
ment. Any unauthorised interference with the product will invalidate the
warranty.
1.4 Return policy
If the flowmeter has been diagnosed to be faulty, it can be returned to KATRONIC
for repair using the Customer Returns Note (CRN) attached to the Appendix of this
manual. KATRONIC regret that for Health & Safety reasons we cannot accept the
return of the equipment unless accompanied by the completed CRN.
1.5 Legislative requirements
The flowmeter is designed to meet the safety requirements in accordance with
sound engineering practice. It has been tested and has left the factory in a condi-
tion in which it is safe to operate. The equipment is in conformity with the statutory
requirements of the EC directive and complies with applicable regulations and
standards for electrical safety EN 61010 and electro-magnetic compatibility EN
61326. A CE Declaration of Conformity has been issued in that respect, a copy of
which can be found in the Appendix of these operating instructions.
The Waste Electrical and Electronic Equipment Directive (WEEE Directive) aims to
minimise the impact of electrical and electronic goods on the environment by in-
creasing re-use and recycling and by reducing the amount of WEEE going to land-
fill. It seeks to achieve this by making producers responsible for financing the col-
lection, treatment, and recovery of waste electrical equipment, and by obliging dis-
tributors to allow consumers to return their waste equipment free of charge.
KATRONIC offers its customers the possibility of returning unused and obsolete
equipment for correct disposal and recycling. The Dustbin Symbol indicates that
when the last user wishes to discard this product, it must be sent to appropriate fa-
cilities for recovery and recycling. By not discarding this product along with other
household-type waste, the volume of waste sent to incinerators or landfills will be
reduced and natural resources will be conserved. Please use the Customer Return
Note (CRN) in the Appendix for return to KATRONIC.
The European Union’s RoHS (“Restriction of the use of certain Hazardous Sub-
stances”) Directive (2002/95/EC) came into effect on July 1, 2006. All of the instru-
mentation manufactured by KATRONIC falls under Category 9, Measurement and
Control Equipment. Currently this category is exempt from RoHS compliance until
at least 2010, when it and other exemptions will be reviewed. Regardless of this, all
products manufactured by KATRONIC are compliant with the RoHS Directive.
6
RoHS Directive
CE marking
WEEE Directive

KATflow 150 2Introduction
2 Introduction
The KATflow 150 is an ultrasonic flowmeter employing clamp-on sensors for the
measurement of liquids in full, enclosed pipes. Flow measurements can be under-
taken without interruption of the process or interference with the integrity of the
pipeline. The clamp-on sensors are attached to the outside of the pipes. The KAT-
flow 150 uses ultrasonic signals for measurement of the flow, employing the transit-
time method.
Ultrasonic signals are emitted by a transducer installed on a pipe and received by a
second transducer. These signals are emitted alternately in the direction of flow and
against it. Because the medium is flowing, the transit time of the sound signals
propagating in the direction of flow is shorter than the transit time of the signal
propagating against the direction of flow. The transit-time difference ∆T is meas-
ured and allows the determination of the average flow velocity along the path of
acoustic propagation. A profile correction is then performed to obtain the average
flow velocity over the cross-sectional area of the pipe, which is proportional to the
volumetric flow rate.
7
Illustration 1: Clamp-on ultrasonic flowmeter configuration
Measuring principle
Illustration 2: Transit-time measuring principle
Clamp-on transit-
time flowmeter

KATflow 150 3Installation
3 Installation
3.1 Unpacking and storage
3.1.1 Unpacking
Care should be taken when opening the box containing the flowmeter, any mark-
ings or warnings shown on the packaging should be observed prior to opening. The
following steps should then be taken:
● Unpack the flowmeter in a dry area.
● The flowmeter should be handled with care and not left in an area where it
could be subject to physical shocks.
● If using a knife to remove packaging care should be taken not to damage
the flowmeter or cables.
● The flowmeter package and contents should be checked against the deliv-
ery note supplied and any missing items reported immediately.
● The flowmeter package and contents should be checked for signs of dam-
age during transport and any problems reported immediately.
● The vendor accepts no responsibility for damage or injury caused during
the unpacking of the instrumentation supplied.
● Excess packing materials should be either recycled or disposed of in a suit-
able way.
3.1.2 Storage
If storage is necessary, the flowmeter and sensors should be stored:
● in a secure location,
● away from water and harsh environmental conditions,
● in such a way as to avoid damage,
● small items should be kept together in the bags provided to avoid loss.
3.1.3 Identification of components
The following items are typically supplied (please refer to your delivery note for a
detailed description):
● KATflow 150 ultrasonic flowmeter
● Clamp-on sensors (one pair for single channel operation, two pairs for dual
channel operation)
● Sensor connection cable(s) if not direct sensor connection
● Sensor mounting accessories
● Coupling component
● Operating instructions
● Project and/or hazardous area documentation (optional)
● Calibration certificate(s) (optional)
● Temperature measurement probes (optional)
8

KATflow 150 3Installation
3.2 Clamp-on sensor installation
The correct selection of the sensor location is crucial for achieving reliable meas-
urements and high accuracy. Measurement must take place on a pipe in which
sound can propagate (see Acoustic propagation) and in which a rotationally sym-
metrical flow profile is fully developed (see Straight pipe lengths).
The correct positioning of the transducers is an essential condition for error-free
measurements. It ensures that the sound signal will be received under optimal con-
ditions and evaluated correctly. Because of the variety of applications and the differ-
ent factors influencing the measurement, there can be no standard solution for the
positioning of the transducers.
The correct position of the transducers will be influenced by the following factors:
● diameter, material, lining, wall thickness and general condition of the pipe,
● the medium flowing in the pipe,
● the presence of gas bubbles and solid particles in the medium.
Check that the temperature at the selected location is within the operating temper-
ature range of the transducers (see Specification).
After the sensor location has been selected, make sure that that supplied cable is
long enough to reach the flow transmitter mounting location. Ensure that the tem-
perature at the selected location is within the ambient operating temperature range
of the flow transmitter (see Specification).
Acoustic propagation is achieved when the flowmeter is able to receive sufficient
signal from the transmitted ultrasonic pulses. The signals are attenuated in the
pipe material, the medium and at each of the interfaces and reflections. External
and internal pipe corrosion, solid particles and gas content in the medium contribute
heavily to signal attenuation.
Sufficient straight lengths of pipe on the inlet and outlet of the measuring location
ensure an axi-symmetrical flow profile in the pipe, which is required for good meas-
urement accuracy. If insufficient straight lengths of pipe are available for your ap-
plication measurements are still obtainable, but the certainty of the measurement
can be reduced.
3.3 Installation location
Select an installation location following the recommendations in Table 1 and try to
avoid measuring
● in the vicinity of deformations and defects of the pipe,
● near welding seams,
● where deposits could be building up in the pipe.
For a horizontal pipe:
Select a location where the transducers can be mounted on the side of the pipe, so that the sound waves emitted by
the transducers propagate horizontally in the pipe. In this way, the solid particles deposited on the bottom of the pipe
and the gas pockets developing at the top will not influence the propagation of the signal.
Correct Incorrect
9
Acoustic propagation
Straight pipe lengths
☞

KATflow 150 3Installation
For a free inlet or outlet pipe section:
Select the measuring point at a location where the pipe cannot run empty.
Correct Disadvantageous
Correct Disadvantageous
For a vertical pipe:
Select the measuring point at a location where the liquid flows upward to ensure that the pipe is completely filled.
Correct Incorrect
Look for a sensor installation location with sufficient straight pipe to obtain accurate
measurements. Please refer to Table 2 as a guideline for recommended distances
from disturbance sources.
Disturbance source: 90°-elbow
Inlet Outlet
L ≥10 D L ≥5 D
Disturbance source: 2 x 90°-elbows in one plane
Inlet Outlet
L ≥25 D L ≥5 D
10
Table 1: Recommendations for sensor mounting location
☞

KATflow 150 3Installation
Disturbance source: 2 x 90°-elbows in different planes
Inlet Outlet
L ≥40 D L ≥5 D
Disturbance source: T-section
Inlet Outlet
L ≥50 D L ≥10 D
Disturbance source: diffuser
Inlet Outlet
L ≥30 D L ≥5 D
Disturbance source: reducer
Inlet Outlet
L ≥10 D L ≥5 D
Disturbance source: valve
Inlet Outlet
L ≥40 D L ≥10 D
Disturbance source: pump
Inlet
L ≥50 D
Table 2: Recommended distances from disturbance sources
11

KATflow 150 3Installation
3.4 Pipe preparation
● Clean dirt and dust from around the area of the pipework where the
sensors are to be placed.
● Remove loose paint and rust with a wire brush or file.
Firmly bonded paint does not necessarily need to be removed provided the flow-
meter diagnostics indicate sufficient signal strength.
3.5 Clamp-on sensor mounting configurations and separation
distance
The most common clamp-on sensor mounting configuration is the Reflection Mode,
sometimes known as V-Mode (see Illustration 3, sketch (1). Here, the ultrasonic
signal passes twice through the medium (2 signal passes). The Reflection Mode is
the most convenient mounting method as the transducer separation distance can
be measured easily and the sensors can be accurately aligned. This method
should be used whenever possible.
An alternative mounting configuration (Illustration 3, sketch (3)) is the Diagonal
mode (Z-Mode). The signals travel only once through the pipe. This method is of-
ten used for larger pipes where greater signal attenuation might occur.
Further variation of the Reflection and the Diagonal Modes are possible by altering
the number of passes through the pipe. Any even number of passes will require
mounting the sensors on the same side of the pipe, while with an odd number of
passes, the sensors must be mounted on opposite sides of the pipe. Commonly,
for very small pipes, sensor mounting configurations such as 4 passes (W-mode)
or 3 passes (N-mode) are used (Illustration 3, sketch (2)).
The transducer separation distance A is measured from the inside edges of the
sensor heads as shown in illustration 3. It is automatically calculated by the flow-
meter based on the parameter entries for pipe outside diameter, wall thickness, lin-
ing material and thickness, medium, process temperature, the sensor type and the
selected number of signal passes.
A negative separation distance A < 0 can occur for mounting configurations on
small pipes where diagonal mode operation has been selected (see Illustration 3,
sketch (3). Negative separation distances may be suggested for reflection mode in-
stallations, but are not possible. In these cases, use diagonal mode or a larger
number of passes.
12
Illustration 3: Clamp-on sensor mounting configurations and sensor spacing
Sensor spacing
☞
☞
Diagonal Mode
Reflection Mode
Transducer separa-
tion distance

KATflow 150 3Installation
3.6 Flowmeter installation
3.6.1 Wall mounting
The KATflow 150 is a wall mounted device and can be installed using suitable
screws and wall plugs according to the following drawings.
13
Drawing 1: Outline dimensions KATflow 150 ultrasonic flowmeter
Flowmeter outline di-
mensions
258.5
243.5
1
2
0
C
R
S
9
0
C
R
S
7
5.5DIA
146.5
2
3
6
.
7
2
7
81
M20 GLAND
2
6
3
.
7

KATflow 150 3Installation
Make sure that the ambient temperature is within the -10 ... 60 °C operating tem-
perature range specified for the flowmeter unit.
14
Drilling aid for wall
mounting
Drawing 2: Drilling aid for wall mounting
!
243.5
120
CRS
90
CRS

KATflow 150 3Installation
3.6.2 Electrical connections
Please note that in order to supply the unit with MAINS POWER, the equipment
must be protected by suitably sized switches and circuit breakers.
100 ... 240 V AC, 50/60 Hz 10 W
9 ... 36 V DC 10 W
15
Drawing 3: Electrical connection diagram for the KATflow 150 flowmeter
!
Electrical wiring
!

KATflow 150 3Installation
3.7 Clamp-on sensor mounting
Before the sensors can be mounted
● the installation location should have been determined,
● a sensor mounting method should be chosen,
● the flowmeter must be mechanically and electrically installed,
● the sensors must be connected to the flowmeter.
Depending on which sensor mounting method is being used, the clamp on sensors
are either mounted on the same side of the pipe (Reflection Mode) or on opposite
sides of the pipe (Diagonal Mode). The sensor spacing is calculated by the flow-
meter from the pipe parameters entered.
3.7.1 Sensor pipe mounting configurations
3.7.2 Acoustic coupling gel
In order to obtain acoustical contact between the pipe and the sensors, apply a
bead of acoustic coupling gel lengthwise down the centre of the contact area of the
sensors.
16
Illustration 4: Sensor pipe mounting configurations
Illustration 5: Application of acoustic coupling gel
☞
Sensor mounting

KATflow 150 3Installation
3.7.3 Correct positioning of the sensors
Always mount the transducer pair so that the free front edges of the sensors face
each other.
There is a different engraving on the top of each transducer. The transducers are
mounted correctly if the engravings on the two transducers form an arrow. The
transducer cables should point in opposite directions.
Later, the arrow, in conjunction with the indicated measured value, will help to de-
termine the direction of flow.
The sensor separation distance is automatically calculated by the flowmeter based
on the parameter entries for pipe outside diameter, wall thickness, lining material
and thickness, medium, process temperature, the sensor type and the selected
number of signal passes.
3.7.4 Sensor mounting with tension straps
● Cut the tension straps to the appropriate length.
● Pull at least 2 cm of the tension strap through the slot in the clamp and
bend the strap back to secure the clamp to the tension strap.
● Guide the other end of the tension strap through the groove on top of the
sensor.
● Place the sensor onto the prepared pipe section.
● Hold the clamp on the transducer with one hand and guide the tension
strap around the pipe.
17
Illustration 7: Metallic mounting straps
Illustration 6: Correct positioning of the sensors
Correct sensor
position
☞

KATflow 150 3Installation
● Pull the tension strap and guide the free end through the clamp so that the
clamp hooks engage. Slightly tighten the screw on the clamp.
● Mount the second sensor in the same way.
● Press the sensors firmly to the pipe. There should be no air pockets
between the transducer surface and the pipe wall.
● Using a measuring tape, adjust the sensor separation distance as sugges-
ted by the flowmeter. When the sensor positioning screen (Section 3.3) is
displayed, the middle bar allows fine adjustment of the sensor location.
18
Illustration 8: Sensor mounting with tension straps and clamps

KATflow 150 4Operation
4 Operation
4.1 Switching On/Off
The flowmeter is switched on by connecting the power supply to the instrument.
Disconnecting the external supply switches off the flowmeter.
4.2 Keypad and display
4.2.1 Keypad key functions
Key Main function Secondary function
Character entry:
1 (1 short key stroke)
, (2 short key strokes)
. (3 short key strokes)
_ (4 short key strokes)
Show NEXT available item
Character entry:
A
B
C
2
/
Q
ON
= Start totaliser function
Character entry:
D
E
F
3
?
Show next DISPlay
19
Illustration 9: Keypad and display overview
Display
Keypad
RS 232 Serial Interface
Switching On/Off
Keypad

KATflow 150 4Operation
Character entry:
G
H
I
4
<
Q
-
= Show negative total value
Character entry:
J
K
L
5
>
Character entry:
M
N
O
6
$
Q
+
= Show positive total value
Character entry:
P
Q
R
S
7
Toggle MUltipleXer (where multi-
channel functions are provided)
Character entry:
T
U
V
8
*
Q
OFF
= Stop totaliser function
Character entry:
W
X
Y
Z
9
DIRECT access to trend plot
Move menu/list selection item
UP
Character backspace clear
Character entry:
. (decimal point)
Switch LCD backlight on/off
Character entry:
0
Space character
+
=
#
Move menu/list selection item
DOWN
Character entry : - (minus sign)
ESCape menu item Abort entry without saving
20
Table 3: Menu structure