Katronic KATflow 10 Series User manual

M-10-0000-E
Non-invasive Ultrasonic Flow Monitor
KATflow 10
user manual
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K A T f l o w 10 s e r i e s

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K A T f l o w 10 s e r i e s
Introduction.................................................... 4
Principle of Operation.................................... 5
Applications.............................................…... 6
Installation.................................................…. 8
Set up Procedure (KATflow 10-01 only) ..... 12
Alarm Modes................................. 12
Entering the Setup Mode.............. 14
Selecting the Alarm Mode............ 15
Setting the Alarm Set Point.......... 15
Alarm Conditions.......…………….. 16
Current Output............................... 16
Voltage Output............................... 17
Diagnostics.................................... 17
Operation at Elevated Temperatures..........…. 18
Cable Specification......................................… 19
EMC Declaration........................................…. 20
Troubleshooting..........................................…. 21
Technical Specification...............................…. 22
Contents

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K A T f l o w 10 s e r i e s
Introduction
The KATflow 10 series is a range of non-invasive flow monitors
and switches designed for use on most industrial liquid flow
applications. The latest, proven ultrasonic techniques are
employed to provide repeatable and reliable switching points.
The KATflow 10 series can be installed and set up in minutes
without disturbing the process it is monitoring.
The microprocessor control allows the set up procedure to be
completed in a few seconds as well as providing fault diagnosis
and alarm indication.
There are two models in the range, the KATflow 10-01 is the
standard version for use in non-hazardous industrial
applications and the KATflow 10-02 is a hazardous area version
(EEx m) for use in Zone 1 & Zone 2 hazardous areas.
The KATflow 10-01 provides a 4 to 20 mA output, a 0 to 10 V
analogue voltage output and a programmable volt free relay
contact as standard.
The KATflow 10-02 provides a 0 to 10 V analogue voltage
output as standard.
Note:
The KATflow 10-01 must be powered by a fused power supply,
the recommended dc fuse rating is 250 mA.
The KATflow 10-02 must be powered by a fused power supply,
the recommended dc fuse rating is also 250 mA. In addition the
dc fuse must have a rated breaking capacity of 4000 A.

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K A T f l o w 10 s e r i e s
Principle of Operation
The KATflow 10 series uses a proven ultrasonic technique. An
ultrasonic signal is transmitted into the fluid and is reflected
back off any solid particles or air bubbles in the fluid. If the parti-
cles are moving the signal will be reflected back at a slightly dif-
ferent frequency than the transmitted signal. The difference in
the frequencies between the received and transmitted signals, or
frequency shift, relates directly to the speed that the solid parti-
cles are travelling at in the pipe. The KATflow 10 series converts
this frequency shift into an analogue voltage which is propor-
tional to the flow rate. This analogue voltage is then scaled to 0
to 10 V and buffered to provide the analogue output voltage.
KATflow 10-01 only -The 4 to 20 mA output is scaled directly
from the analogue voltage output (4 mA = 50 mV & 20 mA = 10
V). The relay switching point is determined from the analogue
voltage signal.

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K A T f l o w 10 s e r i e s
Applications
For the best results the KATflow 10 series can be applied
where:
•there is a full pipe flow.
•the pipe material is steel, iron, plastic or glass but not con-
crete, rubber or flexible plastic pipes.
•the pipe diameter is greater than 40 mm, and less than 400
mm.
•the pipe wall thickness is less than 10 mm.
•the flow velocity is between 0.3 m/s and 3.5 m/s. See the ta-
ble opposite for minimum and maximum flow rates.
•the ambient temperature is between-40 oC and +85 oC.
•if the intended application is in a designated hazardous area
(zone 1 or 2) then the KATflow 10-02 must be used.
•The solids concentration in the fluid is greater than 100 parts
per million. (e.g. not pure or distilled water). The solids parti-
cles must be greater than 100 µm in diameter.

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K A T f l o w 10 s e r i e s
Pipe ID
mm Pipe ID
inches Min. Flow
ltr/min Max. Flow
ltr/min Min Flow
m3/hr Max. Flow
m3/hr Min. Flow
Imp. Gall/
min
Max. Flow
Imp. Gall/
min
40 1.6 22.5 265 1.35 16 5.9 70 50 235 410 2.1 25 9.2 110 75 379 920 4.75 56 21 250
100 4140 1650 8.4 100 37 440 150 6315 3700 19 220 84 970 200 8560 6600 33.5 400 147 1760 250 10 880 10250 53 620 233 2730 300 12 1275 14750 76 880 335 3870 400 16 2850 26000 170 1600 750 7050
Table 1. Minimum and Maximum Flow Rates

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K A T f l o w 10 s e r i e s
Installation
•Before installation ensure that the application and in-
tended mounting position are compatible with the re-
quirements in the previous section and that the power
supply is capable of supplying the rated voltage and
current (22 to 36 V dc @ 150 mA) and is fused cor-
rectly (250 mA).
•NB:The KATflow 10-02 power supply must have a dc
fuse with a rated breaking capacity of 4000 A.
•The unit should be installed on a straight section of
pipe at least 4 pipe diameters from any restrictions to
flow or sources of fluid turbulence, e.g. pumps etc.
•The point at which the sensor attaches should be
cleaned down to bare metal / plastic etc.
•On horizontal pipes it is preferable to mount the sensor
between the 1 o’clock and the 5 o’clock position on
the pipe to ensure that the ultrasound is easily trans-
mitted into the fluid and not into an air pocket (top of
pipe) or through a layer of sediment (bottom of pipe),
see figure 1.
Figure 1. Correct Positioning on horizontal pipes

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K A T f l o w 10 s e r i e s
Figure 2. Correct alignment on pipe
•The sensor is strapped to the pipe using suitable metal
banding (11 mm wide maximum). Prior to mounting the
sensor on the pipe ensure that the length of banding
will go around the pipe and then thread one end
through the slot in the base of the sensor.
•Before clamping the sensor, smear some silicon grease
(Dow Corning DC4 or similar) along the bottom of the
sensor, where it touches the pipe. This is to provide a
good acoustic path for the ultrasonic signal between
the sensor and the pipe.
•Thread one end of the banding through the grub screw
attachment and fit the grub screw. Tighten the banding
as tight as possible whilst checking that the sensor is
aligned along the pipe axis, see figure 2.
•Note: Do not install a KATflow 10 within 3 m of an-
other KATflow 10 on the same section of pipe.
•KATflow 10-01 only -Undo the four captive screws
and remove the sensor lid.
•KATflow 10-01 only -Feed a multi-core cable, (see ca-

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K A T f l o w 10 s e r i e s
ble specification page 19) with the end already pre-
pared, see figure 3, through the cable gland and wire
the sensor as shown in figure 4.
•KATflow 10-01 only –Tighten the cable gland.
Before applying power to the sensor check that the power supply is
rated at 22 to 36 V dc, 150 mA and is suitably fused (dc side) with a
250 mA fuse. In addition, on KATflow 10-02 applications, the dc
fuse must have a rated breaking capacity of 4000 A.
Figure 4. KATflow 10-01 wiring details
Figure 3. Cable End Preparation