U-F-M KATflow 230 User manual

Operating Instructions
Portable
Ultrasonic Flowmeter
KATflow 230

Official Katronic distributor:
U-F-M B.V.
Argon 24
NL-4751 XC
Oud-Gastel
The Netherlands
T [phone]
E [email protected]
www.u-f-m.nl
Operating Instructions KATflow 230
Version V17EN140917
Copyright © 2014
All rights reserved.

KATflow 230 Table of Contents
KATflow 230
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
2.1 System configyration.....................................................................................8
3 Installation..........................................................................................................9
3.1 Unpacking and storage.................................................................................9
3.1.1 Unpacking..............................................................................................9
3.1.2 Storage and preservation.......................................................................9
3.1.3 Identification of components..................................................................9
3.2 Clamp-on sensor installation.........................................................................10
3.3 Installation location........................................................................................10
3.4 Pipe preparation............................................................................................13
3.5 Clamp-on sensor mounting configuration and separation distance..............13
3.6 Flowmeter installation...................................................................................14
3.6.1 Outline dimensions.................................................................................14
3.6.2 Electrical connections............................................................................15
3.7 Clamp-on sensor mounting...........................................................................15
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 fixtures and chains.............................................17
4 Operation............................................................................................................19
4.1 Switching On/Off...........................................................................................19
4.2 Battery charging............................................................................................19
4.3 Keypad and display.......................................................................................20
4.3.1 Keypad key functions.............................................................................20
4.3.2 Display functions....................................................................................22
4.4 Quick setup wizard........................................................................................23
4.5 Measurements..............................................................................................25
4.5.1 Main process value (PV) display............................................................25
3-line display...........................................................................................26
4.5.2 Diagnostic displays................................................................................26
4.5.3 Totalisers................................................................................................26
4.5.4 Dual channel measurement screen.................................................... 27
4.5.5 Math display........................................................................................ 27
4.5.6 Datalogger............................................................................................ 27
5 Commissioning..................................................................................................28
5.1 Menu structure..............................................................................................28
5.2 Diagnostics....................................................................................................33
5.3 Display settings.............................................................................................33
3

KATflow 230 Table of Contents
5.3.1 Main PV..................................................................................................33
5.4 Output configuration......................................................................................34
5.4.1 Serial interface RS 232..........................................................................34
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 configuration.........................................................................................36
5.5.1 PT100 inputs..........................................................................................36
5.6 Inputs/Outputs using serial expansion box...................................................36
5.7 Heat quantity measurement (HQM)..............................................................39
5.8 Sound velocity measurement (SVM)............................................................39
5.9 Dual-channel flow calculations (maths functions).........................................40
5.10 Wall thickness measurement......................................................................40
5.11 Scope function............................................................................................41
6 Maintenance.......................................................................................................42
7 Troubleshooting.................................................................................................43
8 Technical data....................................................................................................45
9 Specification.......................................................................................................51
10 Index..................................................................................................................54
Appendix A...........................................................................................................55
Appendix B...........................................................................................................56
4

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 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
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<BRK>
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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
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.
All products manufactured by KATRONIC are compliant with the relevant aspects
of the RoHS Directive.
6
RoHS Directive
CE marking
WEEE Directive

KATflow 230 2 Introduction
2 Introduction
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 the measure-
ment 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 sensor configuration
Clamp-on transit-
time flowmeter
Illustration 2: Transit-time measuring principle
Measuring principle

KATflow 230 2 Introduction
2.1 System configuration
A maximum of 2 sensor pairs can be installed - if two pairs are installed these can
be configured either in a 1-pipe dual-path or a 2-pipe single path configuration.
8
Illustration 4: KF230 2-pipe 1-path configuration
Illustration 3: KF230 in a 1 pipe 2 path configuration

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 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 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):
●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 probes (optional)
●Process output terminal box (optional)
9

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 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
10
Acoustic propagation
Straight pipe lengths
☞

KATflow 230 3 Installation
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
11
Table 1: Recommendations for sensor mounting location
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KATflow 230 3 Installation
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
12

KATflow 230 3 Installation
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.
13
☞
Illustration 5: Clamp-on sensor mounting configurations and sensor spacing
Diagonal Mode
Reflection Mode
Transducer separa-
tion distance

KATflow 230 3 Installation
3.6 Flowmeter installation
3.6.1 Outline dimensions
The KATflow 230 is a portable, battery operated device with the following outline di-
mensions.
14
Process I/O connector
Drawing 1: Outline dimensions KATflow 230
Flowmeter outline
dimensions
Drawing 2: Transducers
K1 type transducer
K4 type transducer

KATflow 230 3 Installation
3.6.2 Electrical connections
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 batteries must be sufficiently 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 – See Section 2.5).
15
Drawing 3: Electrical connections overview KATflow 230

KATflow 230 3 Installation
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 6: Sensor pipe mounting configurations
Illustration 7: Application of acoustic coupling gel
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KATflow 230 3 Installation
3.7.3 Correct positioning of the sensors
Mount the transducer pair so that the front edges of the sensors (opposite the cable
entry) 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. The sensor positioning screen (above, and Section 3.3)
allows fine adjustment of the sensor location.
3.7.4 Sensor mounting with fixtures and chains
●Insert the retaining clip into the groove on the top of the transducer and se-
cure it using the screw knob.
●Apply some acoustic coupling component to the contact surface of the
transducer.
17
Illustration 8: Correct positioning of the sensors
☞
Illustration 9: Sensor mounting with clips and chains

KATflow 230 3 Installation
●Place the transducer on the side of the pipe or alternatively up to 45 de-
grees from the horizontal plane through the pipe.
This is advisable to establish the best acoustic contact since on top of the
pipe air pockets could develop and deposits could accumulate at the bot-
tom of the pipe.
●Take the spring end of the chain in one hand and insert the last ball ele-
ment in the vertical slot of the retaining clip. Mount the chain around the
pipe.
●Pull the chain firmly around the pipe and fasten it in the lateral slot of the
retaining clip. There should be no air pockets between the transducer sur-
face and the pipe wall.
●Mount the second transducer the same way.
●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 10: Sensor mounting with fixtures and chains (retaining clip)
☞

KATflow 230 4 Operation
4 Operation
4.1 Switching On/Off
The flowmeter is switched on by holding the <ON> key for more than 2 seconds
continuously. Equally it can be switched off by pressing the <OFF> key for more
than 2 seconds.
4.2 Battery charging
The internal batteries can be recharged with the external battery charger supplied.
Important : Ensure that only Nickel Metal Hydride (NiMH) AA size re-
chargeable batteries are installed – attempting to recharge other battery
types is dangerous and may cause damage.
Connect the battery charger to the charging socket of the flowmeter and to the
mains supply 100 ... 240 VAC, 50/60 Hz. The battery charger mains plug is sup-
plied for specific countries as shown in the order code.
The red mark on the plug aligns with the mark on the socket. Remove plug by slid-
ing the outer casing away from the socket to release the latch.
During the charging process, the battery icon will blink. For a fully charged battery
all segments of the battery icon will be filled.
Battery charge level is also shown in the diagnostic displays.
19
Illustration 11: Battery charging
!

KATflow 230 4 Operation
4.3 Keypad and display
4.3.1 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
/
QON = Start totaliser function
Character entry:
D
E
F
3
?
Show next DISPlay
Character entry:
G
H
I
4
<
Q-= Reset negative total value
20
Illustration 12: Keypad and display overview
RS 232 Serial Interface
Display
Keypad