Katronic KATflow 230 User manual

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Advanced Clamp-On Ultrasonic Flowmeter

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Operating Instructions
© Copyright Katronic Technologies Ltd 2019 | Katronic® and KATflow® 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_KF230_V20EN_1911
Katronic Technologies Ltd
Earls Court
Warwick Street
Coventry CV 5 6ET
United Kingdom
Tel [phone]
Fax [phone]
E-mail info@katronic co uk
Web www katronic com

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TABLE OF CONTENTS
TABLE OF CONTENTS
1 SAFETY INSTRUCTIONS, LEGAL REQUIREMENTS,
WARRANTY, RETURN POLICY 5
1 1 Symbols 5
1 2 Safety instructions 5
1 3 Warranty 6
1 4 Return policy 6
1 5 Legislative requirements 6
2 INTRODUCTION 7
2 1 Clamp-on transit-time flowmeter 7
2 2 Measuring principle 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 9
3 2 System configuration 10
3 3 Clamp-on sensor installation 11
3 3 1 Acoustic propagation 11
3 3 2 Straight pipe lengths 11
3 4 Installation location 11
3 5 Pipe preparation 14
3 6 Sensor mounting configurations
and separation distance 15
3 6 1 Reflection Mode 15
3 6 2 Diagonal Mode 15
3 6 3 Transducer separation distance 15
3 7 Flowmeter installation 16
3 7 1 Outline dimensions 16
3 7 2 Electrical connections 18
3 8 Clamp-on sensor mounting 19
3 8 1 Acoustic coupling gel 19
3 8 2 Correct positioning of the sensors 20
3 8 3 Sensor mounting with fixtures
and chains 21
4 OPERATION 22
4 1 Switching On/O 22
4 2 Battery charging 22
4 3 Keypad and display 23
4 3 1 Keypad key functions 23
4 3 2 Display icons and functions 25
4 4 Quick Setup Wizard 26
4 5 Measurement 28
4 5 1 Main process value display 28
4 5 2 Three-line display 28
4 5 3 Diagnostic display 29
4 5 4 Totaliser 29
4 5 5 Dual-channel measurement screen 30
4 5 6 “Math” display 30
4 5 7 Data logger 30
5 COMMISSIONING 31
5 1 Menu structure 31
5 2 Output configuration 39
5 2 1 Serial interface 40
5 2 2 Analogue current output 0/4 20 mA 40
5 2 3 Digital relay output 40
5 2 4 Digital open-collector output 41
5 3 Input configuration 41
5 3 1 Pt 100 inputs 41
5 4 Outputs using serial expansion box
and modular cards 42
5 4 1 Modbus RTU 43
5 4 2 HART® compatible output 43
5 4 3 Analogue current output 0/4 20 mA 44
5 4 4 Analogue voltage output 0 10 V 44
5 4 5 Analogue frequency output (passive) 45
5 4 6 Digital open-collector output 45
5 4 7 Digital relay output 46
5 5 Inputs using serial expansion box
and modular cards 46
5 5 1 Pt 100 inputs 46
5 5 2 Analogue current input 0/4 20 mA 47
5 6 Temperature compensation 47
5 7 Heat quantity measurement 47
5 8 Sound velocity measurement 47
5 9 Dual-channel flow calculations 47
5 10 Wall thickness measurement 48
5 10 1 Wall Thickness Gauge Wizard 48
5 11 Scope function 48
5 12 KATdata+ soware 48
6 MAINTENANCE 49
6 1 Service/Repair 49
7 TROUBLESHOOTING 50
7 1 Measurement diiculties and error messages 50
7 2 Data download diiculties 52
8 TECHNICAL DATA 53
8 1 Sound speed of selected pipe materials 53
8 2 Technical data of selected fluids 54
8 3 Dependence between temperature
and sound speed in water 57
Operating Instructions KATflow 230 www katronic com 3/66

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TABLE OF CONTENTS
9 SPECIFICATION 60
9 1 General 60
9 2 Flowmeter 60
9 3 Quantity and units of measurement 61
9 4 Internal data logger 61
9 5 Communication 61
9 6 KATdata+ soware 61
9 7 Process inputs 62
9 8 Process outputs 62
9 9 Sensors: K1L, K1N, K1E 63
9 10 Sensors: K4L, K4N, K4E 63
10 INDEX 64
11 APPENDIX A – Certificate of Conformity 65
12 APPENDIX B – Customer Return Note (CRN) 66
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SAFETY INSTRUCTIONS, LEGAL REQUIREMENTS, WARRANTY, RETURN POLICY
1 SAFETY INSTRUCTIONS, LEGAL REQUIREMENTS, WARRANTY, RETURN POLICY
1 1 Symbols
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 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 This symbol indicates a note or detailed setup tip
Operator key Operator keys are printed in bold typeface
1 2 Safety instructions
•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 use the instrument under wet conditions with the battery cover removed or opened
•Follow the unpacking, storage and preservation instructions to avoid damage to the equipment
•Install the equipment and cabling securely and safely according to the relevant regulations
•If the product does not operate normally, please refer to the service and troubleshooting instructions, or contact
Katronic for help
Operating Instructions KATflow 230 www katronic com 5/66
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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 This 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 4 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
1 5 Legislative requirements
CE Marking
The 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 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 electromagnetic 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
WEEE Directive
The 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 The 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 for return to Katronic
RoHS Directive All products manufactured by Katronic are compliant with the relevant aspects of the
RoHS Directive
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INTRODUCTION
2 INTRODUCTION
2 1 Clamp-on transit-time flowmeter
The KATflow 230 is a portable, battery operated ultrasonic flowmeter employing clamp-on sensors for the measurement
of liquids in full, enclosed pipes Flow measurements can be undertaken without interruption of the process or interfer-
ence with the integrity of the pipeline The clamp-on sensors are attached to the outside of the pipes The KATflow 230
uses ultrasonic signals for measurement of the flow, employing the transit-time method
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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 These 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 The 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: Transit-time measuring principle
Operating Instructions KATflow 230 www katronic com 7/66

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INSTALLATION
3 INSTALLATION
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 The following steps should then be taken:
•Unpack the flowmeter in a dry area
•The 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
•The flowmeter package and contents should be checked against the delivery note supplied and any missing items re-
ported immediately
•The flowmeter package and contents should be checked for signs of damage during transport and any problems re-
ported immediately
•The 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
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INSTALLATION
3 1 3 Identification of components
The following items are typically supplied (please refer to your delivery note for a detailed description):
•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),
•Temperature measurement probe(s) (optional),
•Wall thickness measurement probe (optional),
•Process output terminal box (optional)
Operating Instructions KATflow 230 www katronic com 9/66

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INSTALLATION
3 2 System configuration
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 3) or a two-pipe single-path (see Picture 4) configuration
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Picture 3: KATflow 230 in a 1-pipe 2-path configuration
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Picture 4: KATflow 230 in a 2-pipe 1-path configuration
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INSTALLATION
3 3 Clamp-on sensor installation
The 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)
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 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
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 temperature range of the transducers
(see Chapter 9)
3 3 1 Acoustic propagation
Acoustic propagation is achieved when the flowmeter is able to receive suicient 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
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
3 4 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
Operating Instructions KATflow 230 www katronic com 11/66

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INSTALLATION
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
Table 1: Recommendations for sensor mounting location
Look for a sensor installation location with suicient straight pipe to obtain accurate measurements Please refer
to Table 2 as a guideline for recommended distances from disturbance sources
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INSTALLATION
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: T-section
Inlet
L ≥ 50D
Outlet
L ≥ 10D
Disturbance source: diuser
Inlet
L ≥ 30D
Outlet
L ≥ 5D
Operating Instructions KATflow 230 www katronic com 13/66

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INSTALLATION
Disturbance source: reducer
Inlet
L ≥ 10D
Outlet
L ≥ 5D
Disturbance source: valve
Inlet
L ≥ 40D
Outlet
L ≥ 10D
Disturbance source: pump
Inlet
L ≥ 50D
Table 2: 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
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INSTALLATION
3 6 Sensor mounting configurations and separation distance
3 6 1 Reflection Mode
The most common clamp-on sensor mounting configuration is the Reflection Mode, sometimes known as V-Mode (see
Picture 5, sketch 1) Here, the ultrasonic signal passes twice through the medium (two 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
Picture 5: Clamp-on sensor mounting configurations and sensor spacing
3 6 2 Diagonal Mode
An alternative mounting configuration (see Picture 5, sketch 3) is the Diagonal Mode (Z-Mode) The signals travel only once
through the pipe This 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 5, sketch 2)
3 6 3 Transducer separation distance
The transducer separation distance A is measured from the inside edges of the sensor heads as shown (see Picture 5) 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 5, 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
Operating Instructions KATflow 230 www katronic com 15/66

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INSTALLATION
3 7 Flowmeter installation
3 7 1 Outline dimensions
The KATflow 230 is a portable, battery operated device with the following outline dimensions (Picture 6)
Picture 6: Outline dimensions KATflow 230
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INSTALLATION
Picture 7: K1 and K4 type transducers
Operating Instructions KATflow 230 www katronic com 17/66

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INSTALLATION
3 7 2 Electrical connections
Battery charger Flow channel 1 Flow channel 2
TOP CONNECTIONS
Temperature sensor
Pt 100 channel 1 Expansion box
Input/Output
Temperature sensor
Pt 100 channel 2
Breakout box
for system I/O
Serial interface
RS 232
BOTTOM CONNECTIONS
Picture 8: Electrical connection diagram KATflow 230
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INSTALLATION
3 8 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 batteries must be suiciently charged,
•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) The sensor spacing is calculated by the
flowmeter from the pipe parameters entered (see Section 3 6)
3 8 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 9: Application of acoustic coupling gel
Operating Instructions KATflow 230 www katronic com 19/66

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INSTALLATION
3 8 2 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 dierent
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 con-
junction with the indicated measured value, will help to determine the direction of flow (see Section 3 4)
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 The sensor positioning screen (see Section 4 4) allows fine adjust-
ment of the sensor location
Picture 10: Correct positioning of the sensors
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