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1. Non invasive Ultrasonic Flow Monitor KATflow 10 www katflow nt rt ru x 10 0000 7 843 206 01 48 106 0 ktf nt rt ru www katflow nt rt ru Page 2 Contents Introd ctfi B a u Principle of Operation Applications Installation Set up Procedure KATflow 10 01 only Alarm Modes Entering the Setup Mode Selecting the Alarm Mode Setting the Alarm Set Point Alarm Conditions Current Output Voltage Output Diagnostics Operation at Elevated Temperatures Cable Specification EMC Declaration Troubleshooting Technical Specification 12 14 15 15 16 16 17 17 18 19 20 21 22 Page 3 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 mo2. 091 LE 001 v8 0591 r 001 052 IZ 99 Gly 026 6 GZ OLL 2 6 Gz LZ Oly 55 z 09 OL 6 s 91 SE S92 Gee 9l Ov yes Uu Uu seuoui XW Mol j uny diedid ql edid Page 7 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 Page 8 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 se
3. 2 36 V dc 120 mA typically Operating Temperatures 40 C to 85 C Ingress Protection Rating IP67 equivalent to NEMA 6 Velocity Range Size Weight Pipe Diameter 0 3 m s to 3 5 m s Size 118 mm L x 70 mm H x 65 mm W Weight 1 5 kg 40 mm min diameter up to 400 mm max Pipe Wall Thickness up to 10 mm Hazardous Area Approvals EEx m II T6 amb 20 C to 80 C KAT flow 10 02 only Repeatability Accuracy 7 5 of reading application dependent Housing Material Type 316 stainless steel investment casting CE EMC Approval Complies with BS EN 50081 1 1992 for emissions BS EN 50082 2 1995 for immunity Bump Shock amp Vibration 7 843 206 01 48 106 0 ktf nt rt ru www katflow nt rt ru
4. KATflow 10 01 only both LED s should be illum nated for 30 secs Do not attempt to program the unit during this warm up period wait until one or both LED s go out KATflow 10 01 only after the initial start up press ing the red push button briefly 1 sec will flash the green LED and confirm that the unit is operational Page 11 Set up Procedure KATflow 10 01 only The following section describes how the KATflow 10 01 is set up It assumes the installation is complete as described in the previ ous section All the set up functions are performed using the red push but ton and the two LED s one green one red The set up consists of learning and storing the normal flow characteristics selecting the Alarm Mode and setting the Alarm Set Point The Alarm Modes are described opposite the Alarm Set Point is set as a percentage of the normal flow reading Even if you do not intend to use the relay output you still need to complete the set up procedure as several internal settings need to be configured at this stage Alarm Modes KATflow 10 01 only There are 3 Alarm Modes that can be set alarm low out of bounds alarm and alarm high Alarm Low in this mode the KATflow 10 01 will go into alarm when the flow rate falls below the alarm set point see figure 6 e g to detect pump dry running Out of Bounds Alarm in this mode the KATflow 10 01 will go into alarm when the flow rate falls outside a
5. Tflow 10 cannot detect a flow check that there is flow in the pipe and that the flow is within the rated flow rates as defined in Table 1 page 7 Check that the KAT Tow 10 is correctly aligned on the pipe and the banding is as tight as possible Check that the application criteria fits with the Application section in this booklet If the applica tion involves very pure or distilled water where the solids concentration is less than 100 parts per mil lion 100 um diameter minimum then there may not be enough particles in the flow Check that the sensor is firmly clamped to the pipe a suitable acoustic couplant i e silicon grease has been used and that the setup procedure has been Press the red button the green LED should illum nate Check that the sensor is wired correctly and the At some low flow rates the KATflow 10 will not set 10 or 2096 alarm set points as the signal resolution would be too small In these cases it will default toa 30 setting The outputs are scaled for a flow rate range of 0 3 to 3 6 m s the application flow rate range may not be the same Check that the power supply is within the range 22 to 36 V dc and is capable of supplying at least 150 mA Page 21 Technical Outputs KATflow 10 01 KATflow 10 02 Specification KATflow 10 1 volt free contact programmable 1 at 30V dc SPCO 4 20 mA auto scaled 0 10 V 0 10 V dc analogue Power Requirements 2
6. arm Set Point cannot be set it will default to the closest possible At some low flow rates the resolution of the flow measurement is insufficient to allow reliable switching if a 1096 or 20 Alarm Set Point is requested the Alarm Set point will then default to 30 e After the last button press wait 3 seconds until the green LED flashes once for each 1046 of the Alarm Set Point that has been set The calculated switching alarm set point will now be stored in the sensor memory e The red LED will now flash once Set up is now complete fatany point a mistake is made you can re enter the set up mode by pressing and holding the push button until the green LED stops flashing Alarm Conditions KATflow 10 01 only When the Alarm Set Point is crossed the sensor will flash the green LED de energise the SPCO relay the relay is energised during normal operation Current Output KAT low 10 01 only e The range of output current is 4 mA to 20 mA 4 mA corresponds to a zero flow condition and 20 mA ap Page 16 prox 3 5 m s flow velocity Voltage Output e The range of output voltage is 50 mV to 10 V The scaling of the voltage output is fixed 50 mV corresponds to a zero flow condition and 10 V approx 3 5 m s flow veloc ity Diagnostics 10 01 only There are several fault conditions that the sensor can detect such as insufficient particles in the fluid e g pure water loss of coupling between the pipe an
7. d the sensor or transducer failure In any one of these fault conditions KATflow 10 01 will de energise the relay clamp the voltage output to approx 50 mV 100 mV illuminate the red LED In the event of a power failure or circuit failure the sensor out puts will all failsafe i e the voltage output will drop to 0 V at all other times the output will have a small offset of approx 50 mV the current output will drop to 0 mA the relay contacts will de energise the LED s will not be illuminated Page 17 Operation at Elevated Temperatures If the KAT low 10 series is to be operated in ambient tempera tures in excess of 55 C the maximum allowable power supply voltage will need to be de rated according to the graph below KATflow 10 MAXIMUM INPUT VOLTAGE DE RATING GRAPH amp 40 8 c gt 20 amp 10 3 40 20 0 2 4 6 8 Temperature Figure 9 Supply Voltage Ambient Temperature de rating graph Page 18 Cable Specification The cable used should be a shielded multi core with 4 to 9 cores dependent upon the outputs used The screen must be solidly connected to the housing using the top hat in the cable gland as shown in figure 2 KATflow 10 series requires minimum power supply parameters of 18 V dc 150 mA at the sensor In order to determine a suitable cable specification you need to calculate the voltage drop along the cable and subtract that from the power supp
8. ime out after 10 seconds Page 14 Selecting the Alarm Mode KATflow 10 01 only e Select 1 of the 3 Alarm Modes see previous pages for an explanation by pressing the button 1 2 or 3 times Each button press will cause the green LED to extinguish for 0 5 seconds as confirmation Alarm Low Mode is entered by pressing the set up but ton once Out of Bounds Alarm Mode is entered by pressing the set up button twice Alarm High Mode is entered by pressing the set up button three times Once the required mode has been entered the red LED will flash for a couple of seconds then the green LED will flash 1 2 or 3 times to confirm which alarm mode has been set Wait until both LED s are extinguished before setting the Alarm Set Point Setting the Alarm Set Point KATflow 10 01 only The Alarm Set Point is set by pressing the button once for 10 twice for 20 three times for 30 etc up to a maxi mum of 10 times for 100 The green LED will flash each time you press it as confirmation Example a 30 alarm set point is selected In alarm low mode a 30 set point will trigger an alarm if the flow goes below 70 of normal flow In out of bounds alarm mode a 30 set point will trigger an alarm if the flow exceeds 130 of normal flow or falls below Page 15 Z0 of normal flow In alarm high mode a 30 set point will trigger an alarm if the flow exceeds 130 of normal flow Ifthe requested Al
9. ly output voltage such that Viensor Vpsu Varop gt 18 V Cable resistance ohm metre x Cable length metres x 0 15 The cable gland fitted will accept cables with an outside diameter of between 6 88 mm and 8 8 mm Suitable cable conductor sizes are 4 core 16 0 2 mm conductors 6 core 16 0 2 mm conductors 8 core 16 0 2 mm or 7 0 2 mm conductors 12 core 7 0 2 mm conductors A cable gland to suit larger cables is available upon request Page 19 EMC Declaration The product described in this manual has been tested and complies with the following European standards EN50081 1 1992 Generic Emission Standard Residential Commercial and Light Industry EN50082 2 1995 Generic Immunity Standard Industrial Environ ment Note The product is susceptible to fields greaterthan4 V mat 750 kHz in the band 1 48 to 1 52 MHz A full declaration of conformity is available upon request This declaration assumes that the product has been installed cor rectly as described in this manual Page 20 Troubleshooting The red LED is illuminated after the setup procedure has completed There is no change in the KATflow 10 output for a given change in flow The LED s are not illum nated The alarm set point cannot be set to a 1096 or 2096 band level at certain flow rates The output does not reach 10 V or 20 mA even at maximum flow The mA output is less than 4 mA The KA
10. n upper and lower alarm set point see figure 7 e g to detect when a flow rate goes Page 12 m m c s o iL Figure 6 Alarm Low operating mode outside the normal flow range Alarm High in this mode the KATflow 10 01 will go into alarm G lt when the flow rate rises above the alarm set point see figure 8 Y For example to detect when a flow exceeds a safe limit Figure 7 Out of bounds alarm mode Once the KATflow 10 01 has been installed on the pipe and all the necessary electrical connections made Installation page 8 the unit has been powered up and the warm up period has Page 13 un a L Figure 8 Alarm High operating mode finished the set up procedure can commence if the lid has not been removed you will need to remove it now Before proceedin g with the set up decide which Alarm Mode and Alarm Set Point are required e Setup the normal flow condition in the pipe and allow time for the flow to stabilise before starting the set up proce dure Entering Setup Mode KATflow 10 01 only Press and hold the red push button the green LED will flash The KATflow 10 01 will now record and store a value for normal flow this value will be scaled to 10096 When the green LED stops flashing approximately 3 sec onds and stays illuminated you can release the button You are now ready to set the Alarm Mode The sensor will remain in this mode until the button is pressed or t
11. nitoring 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 amp Zone 2 hazardous areas The KATflow 10 01 provides 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 Page 4 Principle of Operation The KAT flow 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
12. nsor 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 KA T low 10 within 3 m of an other KAT low 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 Page 9 Earthing from cable gland fired between che outer shest ene the sorgen Cable Gland 110 mm Orly tive cores shawi Cone ca not manaia y Figure 3 Cable End Preparation 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 Figure 4 KATflow 10 01 wiring details Page 10 IV Ask Whi Sina Fati math Figure 5 KATflow 10 02 wiring details Apply power to the sensor
13. 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 amp 20 mA 10 V The relay switching point is determined from the analogue voltage signal Page 5 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 C and 85 C if the intended application is in a designated hazardous area zone 1 or 2 then the KAT low 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 um in diameter Page 6 SILY MOL pue T 0904 09 0091 041 00092 0582 91 00 0 85 Gee 088 9 05 71 9 21 zL 00 0 2 552 09 gs 09201 088 0L 052 0941 rL 007 Gee 0099 095 8 002 0 6 v8 ozz 6l 00 5 918 9
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