Katronic Technologies KATflow 230 User manual

Operating Instructions
Portable
Ultrasonic Flowmeter
KA Tflow 230

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 230
Version V09E1108
Copyright © 2008
All rights reserved.

KATflow 230 Table of Content
KATflow 230
Operating Instructions
Table of Content Page
1 Safety instructions, legal requirements, warranty, return policy..................7
1.1 Symbols used in these operating instructions...............................................7
1.2 Safety instructions.........................................................................................7
1.3 Warranty........................................................................................................8
1.4 Return policy.................................................................................................8
1.5 Legislative requirements...............................................................................8
2 Introduction........................................................................................................9
3 Installation..........................................................................................................10
3.1 Unpacking and storage.................................................................................10
3.1.1 Unpacking..............................................................................................10
3.1.2 Storage and preservation.......................................................................10
3.1.3 Identification of components..................................................................10
3.2 Clamp-on sensor installation.........................................................................11
3.3 Installation location........................................................................................11
3.4 Pipe preparation............................................................................................13
3.5 Clamp-on sensor mounting configurations and separation distance............14
3.6 Flowmeter installation...................................................................................15
3.6.1 Outline dimensions.................................................................................15
3.6.2 Electrical interconnections.....................................................................17
3.7 Clamp-on sensor mounting...........................................................................17
3.7.1 Sensor pipe mounting configurations.....................................................17
3.7.2 Acoustic coupling gel.............................................................................18
3.7.3 Correct positioning of the sensors.........................................................19
3.7.4 Sensor mounting with fixtures and chains.............................................19
4 Operation............................................................................................................21
4.1 Switching On/Off...........................................................................................21
4.2 Battery charging............................................................................................21
4.3 Keypad and display.......................................................................................22
4.3.1 Keypad key functions.............................................................................22
4.3.2 Display functions....................................................................................24
4.4 Quick setup wizard........................................................................................25
4.5 Measurements..............................................................................................27
4.5.1 Main process value (PV) display............................................................27
4.5.2 3-line display..........................................................................................27
4.5.3 Diagnostic displays................................................................................27
4.5.4 Totalisers................................................................................................28
5 Commissioning..................................................................................................29
5.1 Menu structure..............................................................................................29
5.2 Diagnostics....................................................................................................34
5.3 Display settings.............................................................................................34
5.3.1 Main PV..................................................................................................34
5.3.2 Line 1......................................................................................................34
5.4 Output configurations....................................................................................34
5.4.1 Serial interface RS 232..........................................................................35
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KATflow 230 Table of Content
5.4.2 Analogue current output 0/4 ... 20 mA...................................................35
5.4.3 Digital Open-Collector output.................................................................35
5.4.4 Digital relay output.................................................................................35
5.5 Input configurations.......................................................................................36
5.5.1 PT100 inputs..........................................................................................36
5.6 Heat quantity measurement (HQM)..............................................................36
5.7 Sound velocity measurement (SVM)............................................................36
5.8 Dual-channel flow calculations (maths functions).........................................36
5.9 KATdata+ software.......................................................................................36
5.10 Wall thickness measurement (WTM).........................................................36
6 Maintenance.......................................................................................................36
7 Troubleshooting.................................................................................................37
8 Technical data....................................................................................................39
9 Specification.......................................................................................................45
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KATflow 230 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 a
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 damage or destroy 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 advise if necessary.
Note
This symbol indicates a note or detailed set-up tip.
This symbol represents enumeration.
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 save them for future reference.
●Observe all warnings, notes and instructions as marked on the packaging,
on the equipment and those detailed in the operating instructions.
●Do not use the instrument with removed or opened battery cover under wet
conditions.
●Consider the unpacking, storage and preservation instructions to avoid
damage to the equipment.
●Install the equipment and cabling securely and safely according to the re-
spective regulations in place.
●If the product does not operate normally, please refer to the service and
trouble shooting instructions or contact KATRONIC for help.
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KATflow 230 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
for 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 we cannot accept the return of the equipment un-
less accompanied by the completed CRN for Health & Safety reasons.
1.5 Legislative requirements
The flowmeter is designed to meet the safety requirements in accordance with
sound engineering practise. It has been tested and left the factory in a condition in
which it is safe to operate. The equipment is in conformity with the statutory re-
quirements of the EC directive and comply with applicable regulations and stand-
ards for electrical safety EN 61010 and electro-magnetic compatibility EN 61326. A
CE Declaration of Conformity is 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 reducing the amount of WEEE going to landfill. It
seeks to achieve this by making producers responsible for financing the collection,
treatment, and recovery of waste electrical equipment, and by obliging distributors
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 the return to KATRONIC.
The European Union’s RoHS (“Restriction of the use of certain Hazardous Sub-
stances”) Directive (2002/95/EC) goes 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.
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CE marking
WEEE Directive
RoHS Directive

KATflow 230 2 Introduction
2 Introduction
The KATflow 230 is a portable, battery operated ultrasonic flowmeter utilising
clamp-on sensors for the measurement of liquids in full closed pipes. Flow meas-
urements can be undertaken without interrupting of the process or interfering with
the integrity of the pipeline. The clamp-on sensors are simply attached to the out-
side of pipes. The KATflow 230 uses ultrasonic signals for the measurement of the
flow, employing the so-called transit-time method.
Ultrasonic signals are emitted by a first transducer installed on one side of a pipe,
reflected on the opposite side and received by a second transducer. These signals
are emitted alternatively in the direction of flow and against it. Because the medium
in which the signals propagate 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.
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Illustration 1: Clamp-on ultrasonic flowmeter configuration
Clamp-on transit-
time flowmeter
Measuring principle
Illustration 2: Transit-time measuring principle

KATflow 230 3 Installation
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 parcel should be observed prior to opening. The fol-
lowing 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 for completeness
against the delivery note supplied and any missing items reported immedi-
ately.
●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 re-cycled or disposed of in a
suitable way.
3.1.2 Storage and preservation
If storage or preservation is necessary, the flowmeter and sensors should be
stored:
●in a secure location,
●away from water and harsh environmental conditions,
●in a way as to avoid damage,
●small items should be kept together in the bags and small plastic boxes
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 of your scope of supply):
●KATflow 230 portable flowmeter
●Clamp-on sensors (usually one or two pairs depending on pipe sizes to be
measured)
●Sensor extension cable(s) (optional)
●Sensor mounting accessories
●Coupling component
●Measuring tape
●Operating instructions
●Calibration certificate(s) (optional)
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KATflow 230 3 Installation
3.2 Clamp-on sensor installation
The correct selection of the sensor location is crucial for achieving reliable meas-
urements and a 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 guarantees that the sound signal will be received under optimal
conditions and evaluated correctly. Because of the variety of applications and the
different 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,
●and 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 technical specification in the Appendix).
Acoustic propagation is given when the flowmeter is able to receive sufficient signal
from the transmitted ultrasonic pulses. The signals are attenuated in the pipe ma-
terial, the medium and at each of the interfaces and reflections. External and in-
ternal pipe corrosion, solid particles and gas content in the medium do heavily con-
tribute to signal attenuation.
Sufficient straight lengths of pipe on the inlet and outlet of the measuring location
guarantee an axi-symmetrical flow profile in the pipe for good measurement accur-
acy. If no sufficient straight lengths of pipe are available for your application, meas-
urements are still obtainable but the uncertainty of the measurement can be com-
promised.
3.3 Installation location
Select an installation location as per 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. Thus, 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
For a free inlet or outlet pipe section:
Select the measuring point at a location where the pipe cannot run empty.
Correct Disadvantageous
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Acoustic propagation
Straight pipe lengths
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KATflow 230 3 Installation
Correct Disadvantageous
For a vertical pipe:
Select the measuring point at a location where the liquid flows upward to insure 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
to 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
Disturbance source: 2 x 90°-elbows in different pla nes
Inlet Outlet
L ≥40 D L ≥5 D
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Table 1: Recommendations for sensor mounting location
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