Katronic KATflow 170 Quick guide

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Clamp-On Ultrasonic Flowmeter for Hazardous Areas

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Operating Instructions
© Copyright Katronic echnologies Ltd. 2019 | Katronic® and KA flow® are registered trademarks of Katronic AG & Co. KG.
Subject to changes without prior notice. All rights reserved. | Soware version: 4.22-7565 | Issue: OI_KF170A_V30EN_1911
Katronic echnologies Ltd.
Earls Court
Warwick Street
Coventry CV 5 6E
United Kingdom
el. [phone]
Fax [phone]
E-mail [e-mail]
Web www.katronic.com

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ABLE OF CON EN S
ABLE OF CON EN S
1 SAFE Y INS RUC IONS, LEGAL REQUIREMEN S,
WARRAN Y, RE URN POLICY 5
1.1 Symbols 5
1.2 Safety instructions for the operator 5
1.3 Languages/translations 6
1.4 Warranty 6
1.5 Return policy 6
1.6 Legislative requirements 7
2 IN RODUC ION 8
2.1 Clamp-on transit-time flowmeter 8
2.2 Measuring principle 8
2.3 Approvals 9
2.3.1 Clamp-on ultrasonic sensors 9
2.3.2 Flowmeter 10
2.4 emperature limits 11
2.4.1 Clamp-on ultrasonic sensors 11
2.4.2 Flowmeter 11
2.5 Special conditions of safe use 11
2.6 EU type examination certificates 11
3 INS ALLA ION 12
3.1 Unpacking and storage 12
3.1.1 Unpacking 12
3.1.2 Storage 12
3.1.3 Identification of components 12
3.2 System configuration 13
3.3 Clamp-on sensor installation 14
3.3.1 Acoustic propagation 14
3.3.2 Straight pipe lengths 14
3.4 Installation location 15
3.5 Pipe preparation 17
3.6 Sensor mounting configurations
and separation distance 18
3.6.1 Reflection Mode 18
3.6.2 Diagonal Mode 18
3.6.3 ransducer separation distance 18
3.7 Sensor installation in hazardous areas 19
3.7.1 Acoustic coupling gel 19
3.7.2 Correct positioning of the sensors 20
3.7.3 Sensor mounting with tension straps 21
3.8 Flowmeter installation in hazardous areas 22
3.9 Flowmeter installation 22
3.9.1 Outline dimensions 22
4 ELEC RICAL INS ALLA ION 23
4.1 Electrical wiring 23
4.2 Cabling and junction box 24
4.2.1 Signal cable parameters 24
4.3 Cable glands 24
4.4 Equipotential bonding 25
4.4.1 Clamp-on ultrasonic sensors 25
4.4.2 Flowmeter 25
4.5 Process inputs/outputs 25
5 OPERA ION 26
5.1 Switching On/O 26
5.2 Keypad and display 26
5.2.1 Keypad key functions 27
5.2.2 Display icons and functions 27
5.3 Quick Setup Wizard 29
5.4 Measurement 32
5.4.1 Main process value display 32
5.4.2 hree-line display 32
5.4.3 Diagnostic display 32
5.4.4 otaliser 33
5.4.5 Dual-channel measurement screen 33
5.4.6 “Math” display 33
5.4.7 Data logger 34
6 COMMISSIONING 35
6.1 Menu structure 35
6.2 Output configuration 42
6.2.1 Serial interface 42
6.2.2 Modbus R U 42
6.2.3 HAR ® compatible output 43
6.2.4 Analogue current output 0/4 ... 20 mA 43
6.2.5 Analogue voltage output 0 ... 10 V 44
6.2.6 Analogue frequency output (passive) 44
6.2.7 Digital open-collector output 44
6.2.8 Digital relay output 45
6.3 Input configuration 45
6.3.1 Pt 100 inputs 45
6.3.2 Analogue current input 0/4 ... 20 mA 46
6.4 emperature compensation 46
6.5 Heat quantity measurement 46
6.6 Sound velocity measurement 46
6.7 Dual-channel flow calculations 46
6.8 Scope function 47
6.9 KA data+ soware 47
7 MAIN ENANCE 48
7.1 Opening/closing the Ex d compartment 48
7.2 Service/Repair 48
8 ROUBLESHOO ING 49
8.1 Measurement diiculties and error messages 49
8.2 Data download diiculties 51
Operating Instructions KA flow 170 www.katronic.com 3/66

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ABLE OF CON EN S
9 ECHNICAL DA A 52
9.1 Sound speed of selected pipe materials 52
9.2 echnical data of selected fluids 53
9.3 Dependence between temperature
and sound speed in water 56
10 SPECIFICA ION 59
10.1 General 59
10.2 Flowmeter 59
10.3 Quantity and units of measurement 60
10.4 Internal data logger 60
10.5 Communication 60
10.6 KA data+ soware 60
10.7 Process inputs 61
10.8 Process outputs 61
10.9 Clamp-on sensors: K1Ex, K4Ex 62
11 INDEX 63
12 APPENDIX A – Certificate of Conformity 64
13 APPENDIX B – Customer Return Note (CRN) 66
4/66 www.katronic.com Operating Instructions KA flow 170

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SAFE Y INS RUC IONS, LEGAL REQUIREMEN S, WARRAN Y, RE URN POLICY
1 SAFE Y INS RUC IONS, LEGAL REQUIREMEN S, WARRAN Y, RE URN POLICY
1.1 Symbols
Danger
his 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.
Ex-hazard his warning refers to an immediate danger when using the equipment in a hazardous
area.
Attention
his symbol indicates important instructions which should be respected in order to
avoid damaging or destroying the equipment. Follow the precautions given in these in-
structions 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 his symbol indicates a note or detailed setup tip.
Operator key Operator keys are printed in bold typeface.
1.2 Safety instructions for the operator
hese safety instructions are applicable for sensor type K1Ex/K4Ex and KA flow 170 flowmeter installations in
hazardous areas.
•Do not install, operate or maintain this flowmeter without reading, understanding and following these operating in-
structions, otherwise injury or damage may result.
•Study these operating instructions carefully before the installation of the equipment and keep them for future refer-
ence.
•Observe all warnings, notes and instructions as marked on the packaging, on the equipment, and detailed in the oper-
ating instructions.
•Do not change or alter the sensors or the transmitter. Unauthorised changes may aect the explosion safety of the
equipment.
Operating Instructions KA flow 170 www.katronic.com 5/66
ESC

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SAFE Y INS RUC IONS, LEGAL REQUIREMEN S, WARRAN Y, RE URN POLICY
•he special conditions of use as described in the EU type examination certificate must be followed. In addition, all
given electrical specifications must be met.
•he electrical installation must be in accordance with applicable national standards (equivalent to IEC 364) in addition
to the requirements for installation in hazardous areas according to EN/IEC 60079-14 “Electrical installations in hazard-
ous locations” or equivalent national standards.
•Installation, operation, service and maintenance of the equipment must only be performed by authorised and trained
personnel with the necessary knowledge and qualifications in explosion safety.
•If the product does not operate normally, please refer to the service and troubleshooting instructions, or contact
Katronic for help.
1.3 Languages/translations
hese safety instructions are compiled in English. If English is not your native language and you have diiculties under -
standing the content of these instructions, please contact Katronic and/or your authorised local distributor for a transla-
tion of this text.
1.4 Warranty
•Any product purchased from Katronic is warranted in accordance with the relevant product documentation and as
specified in the sales contract provided. his is subject to the condition that 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 immedi-
ately revoke any warranty given or implied.
•Responsibility for suitability and intended use of this ultrasonic flowmeter rests solely with the user. Improper installa-
tion and operation of the flowmeter may lead to a loss of warranty.
•Please note that there are no operator-serviceable parts inside the equipment. Any unauthorised interference with the
product will invalidate the warranty.
1.5 Return policy
If the flowmeter has been diagnosed to have a problem, it can be returned to Katronic for repair using the Customer Re-
turn Note (CRN) attached to the Appendix of this manual. Katronic regret that for health and safety reasons we cannot ac-
cept the return of the equipment unless accompanied by the completed CRN.
6/66 www.katronic.com Operating Instructions KA flow 170

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SAFE Y INS RUC IONS, LEGAL REQUIREMEN S, WARRAN Y, RE URN POLICY
1.6 Legislative requirements
CE Marking
he flowmeter is designed to meet the safety requirements in accordance with sound
engineering practice. It has been tested and has le the factory in a condition in which it
is safe to operate. he equipment is in conformity with the statutory requirements of the
EC directive and complies with applicable regulations and standards for hazardous area
equipment (2014/34/EU), and for electrical safety (EN 61010) and electromagnetic com-
patibility (EN 61326). A CE Declaration of Conformity has been issued in that respect, a
copy of which can be found in Appendix of these operating instructions.
WEEE Directive
he Waste Electrical and Electronic Equipment Directive (WEEE Directive 2012/19/EU)
aims to minimise the impact of electrical and electronic goods on the environment by
increasing re-use and recycling and by reducing the amount of WEEE going to landfill. It
seeks to achieve this by making producers responsible for financing the collection, treat-
ment, and recovery of waste electrical equipment, and by obliging distributors to allow
consumers to return their waste equipment free of charge. Katronic oers its customers
the possibility of returning unused and obsolete equipment for correct disposal and re-
cycling. he dustbin symbol indicates that when the last user wishes to discard this
product, it must be sent to appropriate facilities for recovery and recycling. By not dis-
carding 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 13 for return to Katronic.
RoHS Directive All products manufactured by Katronic are compliant with the relevant aspects of the
RoHS Directive.
Operating Instructions KA flow 170 www.katronic.com 7/66

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IN RODUC ION
2 IN RODUC ION
2.1 Clamp-on transit-time flowmeter
he KA flow 170 is a fixed installation ultrasonic flowmeter designed for use in hazardous areas employing clamp-on
sensors for the measurement of liquids in full, enclosed pipes. Flow measurements can be undertaken without interrup-
tion of the process or interference with the integrity of the pipeline. he clamp-on sensors are attached to the outside of
the pipes. he KA flow 170 uses ultrasonic signals for measurement of the flow, utilising the transit-time method. he
sensors of type K1Ex and K4Ex are equally suitable for use in hazardous areas. he KA flow 170 flowmeter can only be
used with A EX or IECEx certified sensors.
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Picture 1: Clamp-on ultrasonic flowmeter configuration
2.2 Measuring principle
Ultrasonic signals are emitted by a transducer installed on a pipe and received by a second transducer. hese signals are
emitted alternately in the direction of flow and against it. Because the medium is flowing, the transit time of the sound sig -
nals propagating in the direction of flow is shorter than the transit time of the signal propagating against the direction of
flow. he transit-time dierence ∆t is measured 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.
Picture 2: ransit-time measuring principle
8/66 www.katronic.com Operating Instructions KA flow 170

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IN RODUC ION
2.3 Approvals
2.3.1 Clamp-on ultrasonic sensors
he clamp-on ultrasonic sensors are manufactured according to European Directive 2014/34/EU. his equipment has
been approved for installation and use in hazardous classified areas of Zone 1 and 2 by the certification agency RaC
(A EX notified body identification 0891). he protection method for the sensors is “encapsulation” as per EN/IEC 60079-18.
he K1Ex, K4Ex transducers meet the requirements of the following standards:
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EN 60079-0:2014
IEC 60079-0:2011
Electrical equipment for use in explosive atmosphere – General requirements
EN 60079-18:2015
IEC 60079-18:2014
Electrical equipment for use in explosive atmosphere – Encapsulation “maD, mbD”
EN 60079-31:2014
IEC 60079-31:2013
Electrical equipment for use in the presence of combustible dust – Protection by enclos-
ures “tD”
Certificate number of the K1Ex and K4Ex sensors: RAC 09 A EX 21226 X
Picture 3: Rating plate sensors K1Ex and K4Ex
Operating Instructions KA flow 170 www.katronic.com 9/66

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IN RODUC ION
2.3.2 Flowmeter
he KA flow 170 flowmeter is available in epoxy-coated aluminium or in stainless steel. Both versions are certified for use
in hazardous area Zone 1 or 2. K1Ex and K4Ex sensors are connected to the KA flow 170 either directly or through an
Ex e certified junction box with cables provided by Katronic. he protection method for the KA flow 170 is “explosion-
proof” Ex d and “increased safety” Ex e as per the following standards:
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EN 60079-0:2014
IEC 60079-0:2011
Electrical equipment for use in explosive atmosphere – General requirements
EN 60079-1:2015
IEC 60079-1:2014
Electrical equipment for use in explosive atmosphere – Flameproof “d”
EN 60079-7:2016
IEC 60079-7:2015
Electrical equipment for use in explosive atmosphere – Increased safety “e”
EN 60079-31:2014
IEC 60079-31:2013
Electrical equipment for use in the presence of combustible dust – Protection by enclos-
ures “tD”
Certificate of the KA flow 170 flowmeter: IBExU17A EX1001X (A EX)
IECEx IBE 17.0001X (IECEx)
Certification coding: II 2G Ex db eb IIC 6 Gb
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Picture 4: Rating plate KA flow 170
10/66 www.katronic.com Operating Instructions KA flow 170

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IN RODUC ION
2.4 emperature limits
2.4.1 Clamp-on ultrasonic sensors
he K1Ex and K4Ex clamp-on ultrasonic sensors can be used for the following process temperatures depending on the
temperature class specified for the application (see able 1):
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6 -50 ... +75 °C
5 -50 ... +90 °C
4 -50 ... +115 °C
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he ambient temperature is the limiting factor but cannot exceed +115 °C therefore the
maximum temperature designation is 80 °C - 120 °C.
able 1: emperature class K1Ex and K4Ex sensors
2.4.2 Flowmeter
For KA flow 170 flowmeters located in Zone 1 or 2 hazardous areas the ambient temperature range is -20 ... +60 °C. he
unit is manufactured to a degree of protection of IP 66 (see Picture 4).
2.5 Special conditions of safe use
•he transducers must only be used in conjunction with a flowmeter unit (e. g. KA flow 170) which conforms to
the signal parameters and thermal protection conditions as outlines in the special conditions of safe use.
•he transducers must be securely fixed to the pipe to protect the PEEK surface of the sensors from mechan -
ical impact and electrostatic charging.
•Where the connecting cable may be subject to mechanical damage then the user shall provide additional
mechanical protection.
•Clause 10, EN 60079-18: he pulsed supply to the transducers must not exceed 330 V at a maximum frequency
of 4 MHz (met by KA flow 170 electronics).
2.6 EU type examination certificates
See A EX documentation pack.
Operating Instructions KA flow 170 www.katronic.com 11/66

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INS ALLA ION
3 INS ALLA ION
3.1 Unpacking and storage
3.1.1 Unpacking
Care should be taken when opening the box containing the flowmeter, any markings or warnings shown on the packaging
should be observed prior to opening. he following steps should then be taken:
•Unpack the flowmeter in a dry area.
•he flowmeter should be handled with care and not le 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.
•he flowmeter package and contents should be checked against the delivery note supplied and any missing items re-
ported immediately.
•he flowmeter package and contents should be checked for signs of damage during transport and any problems re -
ported immediately.
•he vendor accepts no responsibility for damage or injury caused during the unpacking of the instrumentation sup-
plied.
•Excess packing materials should be either recycled or disposed of in a suitable 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 and small plastic boxes provided to avoid loss.
3.1.3 Identification of components
he following items are typically supplied (please refer to your delivery note for a detailed description):
•KA flow 170 ultrasonic flowmeter,
•Clamp-on sensors (one pair for single-channel operation, two pairs for dual-channel operation),
•Ex e junction box if not direct sensor connection (one junction box for single-channel operation, two junction boxes for
dual-channel operation),
•Sensor connection cable(s) if not direct sensor connection,
•Sensor mounting accessories,
•Coupling component,
•Operating instructions,
•Project and hazardous area documentation,
•Calibration certificate(s) (optional).
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INS ALLA ION
3.2 System configuration
he KA flow 170 flowmeter and K1Ex and/or K4Ex sensors can be installed in Zone 1 or 2 hazardous areas with or
without a certified optional junction box depending on the required cable distances.
A maximum of two sensor pairs can be installed - if two pairs are installed these can be configured either in a one-pipe
dual-path (see Picture 5) or a two-pipe single-path (see Picture 6) configuration.
Picture 5: KA flow 170 with direct sensor connection in a 1-pipe 2-path configuration
Picture 6: KA flow 170 in a 2-pipe 1-path configuration using optional junction boxes
Operating Instructions KA flow 170 www.katronic.com 13/66

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INS ALLA ION
3.3 Clamp-on sensor installation
he correct selection of the sensor location is crucial for achieving reliable measurements and high accuracy. Measure-
ment must take place on a pipe in which sound can propagate (see Section 3.3.1 Acoustic propagation) and in which a ro-
tationally symmetrical flow profile is fully developed (see Section 3.3.2 Straight pipe lengths).
he correct positioning of the transducers is an essential condition for error-free measurements. It ensures that the sound
signal will be received under optimal conditions and evaluated correctly. Because of the variety of applications and the
dierent factors influencing the measurement, there can be no standard solution for the positioning of the transducers.
he 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.
Aer the sensor location has been selected, make sure that the supplied cable is long enough to reach the flowmeter
mounting location.
Check that the temperature at the selected location is within the operating temperature range of the transducers
(see Chapter 10).
3.3.1 Acoustic propagation
Acoustic propagation is achieved when the flowmeter is able to receive suicient signal from the transmitted ultrasonic
pulses. he 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.
3.3.2 Straight pipe lengths
Suicient 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 measurement accuracy. If insuicient straight lengths of pipe are available for your
application measurements are still obtainable, but the certainty of the measurement can be reduced.
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3.4 Installation location
Select an installation location following the recommendations in able 2 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.
For a free inlet or outlet pipe section:
Select the measuring point at a location where the pipe cannot run empty.
For a vertical pipe:
Select the measuring point at a location where the liquid flows upward to ensure that the pipe is completely filled.
able 2: Recommendations for sensor mounting location
Look for a sensor installation location with suicient straight pipe to obtain accurate measurements. Please refer
to able 3 as a guideline for recommended distances from disturbance sources.
Operating Instructions KA flow 170 www.katronic.com 15/66

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INS ALLA ION
Disturbance source: 90°-elbow
Inlet
L ≥ 10D
Outlet
L ≥ 5D
Disturbance source: 2 x 90°-elbow in one plane
Inlet
L ≥ 25D
Outlet
L ≥ 5D
Disturbance source: 2 x 90°-elbow in dierent planes
Inlet
L ≥ 40D
Outlet
L ≥ 5D
Disturbance source: -section
Inlet
L ≥ 50D
Outlet
L ≥ 10D
Disturbance source: diuser
Inlet
L ≥ 30D
Outlet
L ≥ 5D
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INS ALLA ION
Disturbance source: reducer
Inlet
L ≥ 10D
Outlet
L ≥ 5D
Disturbance source: valve
Inlet
L ≥ 40D
Outlet
L ≥ 10D
Disturbance source: pump
Inlet
L ≥ 50D
able 3: Recommended distances from disturbance sources
3.5 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 flowmeter diagnostics indicate
suicient signal strength.
Operating Instructions KA flow 170 www.katronic.com 17/66

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INS ALLA ION
3.6 Sensor mounting configurations and separation distance
3.6.1 Reflection Mode
he most common clamp-on sensor mounting configuration is the Reflection Mode, sometimes known as V-Mode (see
Picture 7, sketch 1). Here, the ultrasonic signal passes twice through the medium (two signal passes). he Reflection Mode
is the most convenient mounting method as the transducer separation distance can be measured easily and the sensors
can be accurately aligned. his method should be used whenever possible.
Picture 7: Clamp-on sensor mounting configurations and sensor spacing
3.6.2 Diagonal Mode
An alternative mounting configuration (see Picture 7, sketch 3) is the Diagonal Mode (Z-Mode). he signals travel only once
through the pipe. his method is oen 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 four passes (W-Mode) or three passes (N-Mode) are used (see Picture 7, sketch 2).
3.6.3 ransducer separation distance
he transducer separation distance A is measured from the inside edges of the sensor heads as shown (see Picture 7). It 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.
A negative separation distance A < 0 can occur for mounting configurations on small pipes where Diagonal Mode
operation has been selected (see Picture 7, sketch 3). Negative separation distances may be suggested for Reflec-
tion Mode installations, but are not possible. In these cases, use Diagonal Mode or a larger number of passes.
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3.7 Sensor installation in hazardous areas
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 transmitter.
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). he sensor spacing is calculated by the
flowmeter from the pipe parameters entered (see Section 3.6).
he transducers must be securely fixed to the pipe to protect the PEEK surface of the sensors from mechanical
impact and electrostatic charging.
3.7.1 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.
Picture 8: Application of acoustic coupling gel
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3.7.2 Correct positioning of the sensors
Always mount the transducer pair so that the free front edges of the sensors face each other. here is a dierent
engraving on the top of each transducer. he transducers are mounted correctly if the engravings on the two
transducers form an arrow. he transducer cables should point in opposite directions. Later, the arrow, in con-
junction with the indicated measured value, will help to determine the direction of flow (see Section 3.4).
he 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. he sensor positioning screen (see Section 5.3) allows fine adjust-
ment of the sensor location.
Picture 9: Correct positioning of the sensors
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