KROHNE ALTOSONICIII User Manual

CMD

©

KROHNE 07/2005 7.30950.31.00

Variable area flowmeters
Vortex flowmeters
Flow controllers
Electromagnetic flowmeters

Ultrasonic flowmeters

Mass flowmeters
Level measuring instruments
Communications technology
Engineering systems & solutions
Switches, counters, displays and recorders
Heat metering
Pressure and temperature

Installation and
operating instructions

ALTOSONIC III

3-beam ultrasonic flowmeters
for custody transfer
of liquid hydrocarbons
UFC III F/...EEx ultrasonic flow converter
UFS III F/...EEx ultrasonic flow sensor

Subject to change without notice.

●●

Long term stability; high reliability

●●

Eliminates maintenance

●●

Non-intrusive

●●

No wear

●●

No pressure loss

●●

Bi-directional

●●

Compliant with OIML R-117, API

General advice on safety

• Do not install, operate or maintain this flowmeter without reading, understanding and following the factory-supplied
instructions, otherwise injury or damage may result.

• Read these instructions carefully before starting installation and save them for future reference.

• Observe all warnings and instructions marked on the product.

• Use only mains supply with protective earthing connected.

• Do not use the product with removed covers under wet conditions.

• Consider handling and lifting instructions to avoid damage.

• Install the product securely and stable.

• Install and connect cabling proper to exclude damage or harmful situations.

• If the product does not operate normally, refer to the service instructions or refer to qualified KROHNE service

engineers. There are no operator-serviceable parts inside the product.

The following symbols may appear in this manual or on the product.

Attention: Refer to operating and installation instructions!

Disclaimer

Product liability
and warranty

Items included with order

Danger: Risk of electric shock!

Protective Earth (PE) conductor terminal!

These terms may appear in this manual or on the instrument:

Warning statement: Identify conditions or practice that could result in injury or loss of life.
or
Caution statement: Identify conditions or practice that could result in damage to the instrument or other property.

• This document contains important information on the instrument. KROHNE attempts to be as accurate and up-to-
date as possible but assumes no responsibility for errors or omissions. Nor does KROHNE make any commitment
to update the information contained herein. This manual and all other documents are subject to change without
prior notice.

• KROHNE will not be liable for any damage of any kind by using its instrument, including, but not limited to direct,
indirect, incidental, punitive and consequential damages.

• This disclaimer does not apply in case KROHNE has acted on purpose or with gross negligence. In the event any
applicable law does not allow such limitations on implied warranties or the exclusion of limitation of certain
damages, you may, if such law applies to you, not be subject to some or all of the above disclaimer, exclusions or
limitations.

• Any instrument purchased from KROHNE is warranted in accordance with the relevant product documentation and
our Terms and Conditions of Sale.

• KROHNE reserves the right to alter the content of its documents, including this disclaimer in any way, at any time,
for any reason, without prior notification, and will not be liable in any way for possible consequences of such
changes.

• Responsibility for suitability and intended use of this ultrasonic flowmeter rests solely with the user. Improper
installation and operation of the flowmeter (syste m) may lead to loss of warranty.

• In addition, the Terms and Conditions of Sale are applicable and are the basis for the purchase contract.

• If flowmeters need to be returned to KROHNE, please note the information given on the last pages of the

installation and operating instructions. KROHNE regrets that they cannot repair or check flowmeter(s) unless
accompanied by the completed form (see last pages of the installation and operating instructions).

• ALTOSONIC III ultrasonic flowmeter, consisting of a flow sensor (UFS III) and a flow converter (UFC III) either built
together as a compact system or supplied as two separate pieces, in the size as indicated on the packaging box.

• Signal cable (only in case of a separate system).

• Special tool for opening the converter housing.

ALTOSONIC III 2

Installation and operating instructions

Documentation supplied

• Handbook; manual and installation and operation instructions

• Approval documents and certificates

• Report of factory settings of the flow converter

• Certificate of flowmeter calibration data

This instrument is developed and manufactured by:
KROHNE Altometer
Kerkeplaat 12
3313 LC Dordrecht
The Netherlands

For information, maintenance or service, please contact your nearest local KROHNE representative.
See www.krohne.com.

WARNING!

No changes may be made to the devices. Unauthorized changes might affect the explosion safety of the devices.
Be sure to follow these instructions!

IMPORTANT!

• The prescriptions and regulations as well as the electrical data described in the EC type examination certificate
must be obeyed.

• Beside the instructions for electrical installations in non-hazardous locations according to the applicable national
standard (equivalent of HD 384 or IEC 364, e.g. VDE 0100), especially the regulations in EN 60079-14 "Electrical
installations in hazardous locations" or equivalent national standard (e.g. DIN VDE 0165 Part 1) must be strictly
followed.

• Installation, establishment, utilization and maintenance are only allowed to be executed by personnel with an
education in explosion safety!

WARNING!
When removing the front or rear cover of the converter any sealing will be broken.

3 ALTOSONIC III

Table of contents

1. Introduction.....................................................................................................................................................5

1.1 Cautions................................................................................................................................................................................................................ 5

1.2 Unpacking and inspection.................................................................................................................................................................................. 5

1.3 System description.............................................................................................................................................................................................. 5

1.4 Approvals.............................................................................................................................................................................................................. 5

2. Mechanical Installation...................................................................................................................................6

2.1 Handling the flowmeter....................................................................................................................................................................................... 6

2.2 Installation location and position....................................................................................................................................................................... 6

2.3 Accessibility and environmental precautions .................................................................................................................................................. 8

2.4 Special installation requirements....................................................................................................................................................................... 8

2.5 Pipe flanges.......................................................................................................................................................................................................... 9

2.6 Pipes with cathodic protection........................................................................................................................................................................... 9

3. Connecting the signal converter..................................................................................................................10

3.1 Safety instructions............................................................................................................................................................................................. 10

3.2 Installation in hazardous areas ........................................................................................................................................................................ 10

3.3 Converter terminal box...................................................................................................................................................................................... 10

3.4 Power supply connection .................................................................................................................................................................................10

3.5 Connection of sensor cables............................................................................................................................................................................ 11

3.6 Electrical connection of the signal inputs and outputs................................................................................................................................. 12

3.7 Connection diagram examples......................................................................................................................................................................... 12

3.8 Start-up ............................................................................................................................................................................................................... 14

3.9 Operating the signal converter......................................................................................................................................................................... 14

3.10 Menu structure and function of operating keys ............................................................................................................................................. 15

3.11 Description of functions.................................................................................................................................................................................... 20

4. Functional checks and service....................................................................................................................26

4.1 Functional checks.............................................................................................................................................................................................. 26

4.2 Device information............................................................................................................................................................................................. 26

4.3 Measuring zero flow value................................................................................................................................................................................ 26

5. Installation in hazardous areas, zone 1 and zone 2 ...................................................................................27

5.1 Approvals............................................................................................................................................................................................................ 27

5.2 Compact flowmeter............................................................................................................................................................................................ 27

5.3 Flow sensor........................................................................................................................................................................................................ 27

5.4 Flow converter.................................................................................................................................................................................................... 28

5.5 Technical data.................................................................................................................................................................................................... 29

6. Electrical installation....................................................................................................................................30

6.1 General................................................................................................................................................................................................................ 30

6.2 Connecting cables............................................................................................................................................................................................. 30

6.3 Connection diagrams........................................................................................................................................................................................ 30

7. Service and maintenance.............................................................................................................................33

7.1 Introduction........................................................................................................................................................................................................ 33

7.2 Replacement of electronics unit or power fuse(s) ......................................................................................................................................... 33

7.3 Replacement of electronics unit....................................................................................................................................................................... 34

7.4 Replacement of mains fuse .............................................................................................................................................................................. 34

7.5 Returning the flowmeter to KROHNE for service or repair............................................................................................................................ 35

ALTOSONIC III 4

Installation and operating instructions

1. Introduction

1.1 Cautions

For flowmeters supplied with a voltage over 50 V AC:

• Refer all maintenance or service to trained KROHNE service engineers.

• Mains power shall be disconnected from the product before performing any maintenance.

• This product is prepared for and can only function with the rated AC mains or DC supply voltage as indicated on

the type plate.

For 100 – 240 V AC supplied flowmeters:

• This product is a Class 1 device (earthed) and requires a correct connection to protective earth. The protective
earth conductor of the main power shall be properly connected to the marked protective earth terminal to ensure
safety from electric shock for the operator and its environment.

1.2 Unpacking and
inspection

• The product has been thoroughly inspected and tested before shipment and is ready for operation.

• After carefully unpacking, inspect for shipping damage before attempting to operate. If any indication of mechanical

damage is found, immediately contact the responsible transport service and your local KROHNE representative.

• A simple operating check of the electronics after unpacking and before permanent installation is advisable to
ascertain whether it has suffered damage during shipment.

• Confirm for the correct mains voltage printed on the type plate. If it differs from the ordered product please contact
your local KROHNE representative.

• After connecting to the mains, check if there is any indication on the display and if the backlight of the display is
lighted. If not, contact your local KROHNE representative.

1.3 System description

The ALTOSONIC III ultrasonic flowmeter is a precision instrument designed for linear, bi-directional flow measurement
of liquids. Flow measurement values can be outputted via the standard analog and-or pulse/frequency outputs. Via a
user friendly operator interface (HMI) the flow can be read. Next to actual volumetric flow measurement the converter
can be configured to perform measurement and output of the liquid sonic velocity and acoustic signal attenuation.

1.4 Approvals

CE Approvals

EMC, Electromagnetic Compatibility Directive
EMC directive 89/336/EEC.

Low Voltage Directive

73/23/EEC and is designed in accordance with EN IEC 61010-1 first and second edition.

Pressure Equipment Directive 97/23/EC / Module H

The KROHNE organization complies with the requirements of Module H of the Pressure Equipment Directive 97/23/EC
(full quality assurance).

ATEX directive ATEX Directive 94/9/EC

Both the flow sensor and the flow converter are in compliance with the European Directive 94/9 EG (i.e. ATEX 100A).

5 ALTOSONIC III

2. Mechanical
Installation

2.1 Handling the

flowmeter

Important: Do not lift the flowmeter by the signal converter housing or the
terminal box. Check the weight of the flowmeter as indicated on the type
plate before handling the unit. When handling the flowmeter avoid hard
blows, jolts or impacts.

2.2 Installation location

and position

Do not place the flowmeter on the signal converter housing.

As the ALTOSONIC III is used in hydrocarbon pipelines, be aware of
potentially explosive atmospheres. Local standards and regulations must be
respected.

The flow sensor must be completely filled at all times for proper flow
measurement. Non-wetted sensors show loss of signal. There is no damage
when this occurs.
The sensor must be installed in a horizontal or vertical position. A correct
position of the unit guarantees a completely filled flow sensor and accurate
flow measurement.

Inlet and outlet sections

For functioning within stated accuracy the flow sensor has to be installed with specified inlet flow conditioner and outlet
sections. The flow conditioner is delivered as a part of the flowmeter as the flow sensor and flow conditioner are calibrated
together for optimal performance.

Inlet configurations (upstream): Straight inlet section, length 10 D with ISO tube bundle flow conditioner.
Outlet configuration (downstream): Straight outlet section, length 5 D.

D = nominal diameter of the flow sensor.
It is advised to keep length of 5 D straight pipe section upstream between flow conditioner and upstream disturbances.

ALTOSONIC III 6

Bush guides

Every ALTOSONIC III is calibrated in combination with a dedicated inlet flow
conditioner. To minimize the installation effects on the performance of the
ALTOSONIC III a provision is made to assure that the flow conditioner
versus the ALTOSONIC III have the same position at operation as during the
initial calibration.

Installation and operating instructions

During the mechanical installation of the ALTOSONIC III and the flow
conditioner it is absolutely required that both parts are aligned with high
accuracy.

“Bush Guides” are permanently welded in one of the top bolt holes of the
inlet flange of the ALTOSONIC III and the outlet flange of the flow
conditioner. The position of these “Bush Guides” is marked on the flange
with “BG”. This provision is integrated to assure the position and to align the
ALTOSONIC III in combination with the flow conditioner as accurate as
possible. If the ALTOSONIC III is used bi-directionally the outlet flange is
provided with a ”Bush Guide” as well.

Seen upstream, only the right top hole is fitted with a bush guide. When the
flowmeter is bidirectional, both flanges of the flowmeter are fitted with a bush
guide, which are placed collinear.

Mark the location of the bush guide in both flanges

Flow direction

Please note to the forward direction of the flow sensor indicated by the
direction arrow on the body. If the flow has this direction the output indication
will be positive.

Bolts and nuts

Use the specified bolts and nuts and gaskets, according to the ordered
flange type and pressure rating and mount according the general or local
requirement.

Vibration

Do not expose the sensor unit to intensive vibrations. Support of the flow
sensor is only allowed at the in- and outlet sections near the flowmeter.

7 ALTOSONIC III

2.3 Accessibility and

environmental
precautions

2.4 Special installation

requirements

Gas inclusion

To avoid measuring errors due to gas inclusion, adequate measures have to
be taken. Gas inclusion should be limited to the lowest possible value and
shall be < 1 vol. % according to OIML R117 for accurate measuring.

Particle inclusion

To avoid measuring errors due to particle inclusion, adequate measures
have to be taken. Particle inclusion should be limited to the lowest possible
value and shall be < 5 % for accurate measurement.

Cavitation

In order to prevent cavitation in the following formula should be applied to
calculate the minimum required back pressure:

Pb ≥ 2.65 10E-5 ρL* vL
Pb Back pressure [bar]

ρL Liquid density [kg/m3]
vL Liquid velocity [m/s]
Pv Vapour pressure [bar] (at operational temperature)

If required the position of the signal converter can be modified by turning the
display through 90° or 180°.

In case of direct sunlight, we recommend installation of a sunshield to
prolong the life of the meter. No direct damage will occur without a sunshield.
Do not expose the signal converter to excessive vibration. For this, support
the pipeline on either side of the flowmeter.

Ambient temperature: -40°C to +70°C/ -40°F to +158°F
Product temperature: -25°C to +180°C/ -13°F to +356°F
Storage temperature: -40°C to +80°C/ -40°F to +176°F

Keep a minimum distance between pipe centerline and adjacen t wall of at
least 0.5 m (1.6 ft).

To avoid measuring errors and malfunctioning of the flowmeter due to gas or
air inclusions or an empty pipe, please observe the following precautions:
Since gas will collect at the highest point of a pipe, installation of the
flowmeter at that location should be avoided at all times. Also installation in a
down going pipe should be avoided since a completely filled pipe may no t be
guaranteed due to cascading affects. Additionally flow profile distortion is
possible.

2

+ 1.25 Pv

Long horizontal pipes

Install in slightly ascending pipe section. If not possible, ensure adequate
velocity to prevent air, gas or vapor from collecting in upper part of flow tube
As a partially filled meter will report higher than actual flow rates, or not
measure (as transducer pairs become non-wetted).

Mixing different fluid products

Install the flowmeter upstream of mixing point or at minimum distance of 30
D (D = flowmeter diameter) downstream of the mixing point, otherwise the
flow measurement may be unstable.

ALTOSONIC III 8

2.5 Pipe flanges

Installation and operating instructions

Refer to dimensional drawings for flange spacing and in addition allow for
thickness of gaskets. Install flowmeter in line with pipe axis. Pipe flange
faces must be parallel to each other, max.
Permissible deviation: Lmax - Lmin ≤ 0.5 mm (0.02").

2.6 Pipes with cathodic

protection

Pipes with electric corrosion protection
are generally insulated inside and
outside so that the fluid has no
conductive connection to ground. The
flowmeter must be insulated from the
pipe. Note the following when installing
the flowmeter:

The pipe flanges must be connected to
each other using a copper cable (L), but
must not be connected to the flowmeter.
The bolts for the flange connections and
the gaskets must be insulated. Use
sleeves and washers that are made of
insulating material (these must be
provided by customer).

Follow grounding instructions.
Use ≥ 4 mm² (≥ AWG 11 cable).
Note: No earthing cables are supplied by KROHNE.

1. Flange of flow sensor

2. Pipe flange

3. Gasket

4. Bolt

5. Nut

6. Washer

7. Insulating sleeve

9 ALTOSONIC III

3. Connecting
the signal
converter

3.1 Safety

instructions

3.2 Installation in

hazardous
areas

3.3 Converter

terminal box

3.4 Power supply

connection

This product is designed for use in accordance with EN IEC 61010-1 for Installation Category 2 and Pollution Degree 2.
Hazardous voltages are present within this product during normal operation.
The product is designed for Protection Class I and should never be operated without protective earthing.
The product shall also never be operated with covers removed unless equivalent protection of the operator and its environment
from accidental contact with hazardous internal voltages is provided. Always follow basic and local safety precautions when
using this product to reduce risk of injury from electrical shock, spread of fire or other dangerous situations.

All ultrasonic flowmeters of the ALTOSONIC III series must always be incorporated within the equipotential bonding system of
the hazardous area. For this purpose it is provided with an external PE-terminal. The external PE-terminal is located on the
connecting flange at the bottom of the flow converter housing and on top of the support of the flow sensor, just below the junction
box.
A separate bonding conductor must be at least 4 mm
Clause 413 of HD 384.4.41 or IEC 364-4-41. Make sure that the core of the bonding wire is properly mounted under the U-clamp
of the PE-terminal and that the screw is tightly fixed.

• The converter terminal box is accessible after removing the rear (blind) cover of the electronics section using the special
wrench supplied with the flowmeter.

• Do not damage the screw thread and the gasket, never allow dirt to accumulate, and make sure that the screw thread is well
greased, using Teflon grease at all times. A damaged gasket must be replaced immediately!

• Do not cross or loop the cables in the terminal box of the signal converter. Use separate cable entries for power supply and
signal cables.

Environmental conditions

The ALTOSONIC III is designed to operate safely under the following conditions:

• Suitable for indoor and outdoor use, the instrument is usable up to protection category IP 67 (IEC 60529).

• Use up to an altitude of 2000 m above sees.

• Suitable for an operation ambient temperature range: - 40°C to +70°C / - 40°F to +158°F.

• Suitable for an storage temperature range: -40°C to + 80°C / -40°F to + 176°F.

• Suitable for use in atmospheres with a relative humidity up to 80%.

• Mains supply voltage fluctuations up to -15 and +10% of the specified voltage range.

• Over voltages up to category II on the main supply voltage (IEC 60364-4-443).

• Connected to protective earth conductor (Protection Class I).

• Rated pollution degree 2.

• This instrument is intended for permanent connection to the mains. It is required (for example for service) to mount an

external switch or circuit breaker near the product for disconnection from the mains. It must be easily reachable by the
operator and marked as the disconnecting device for this product. The switch or circuit breaker has to be suitable for the
application and shall also be in accordance with to local (safety) requirements and of the building installation (IEC 60947-1/-

3).

• The protective conductor clamp terminal size M5, press-fitted in the terminal compartment (near the main connection
terminals), shall always to be connected to the protective earth conductor of the mains supply. Conductors up to 4 mm² (11
AWG) be connected to this terminal. The diameter of the conductors of the mains supply, including the protective earth
conductor shall be in accordance with the general and local requirements.

• It is not allowed to use the protective conductor terminal for any other connection than the protective earth conductor.

• IP 67 is only warranted when using suitable cabling with the cable glands and covers mounted as specified.

2

(11 AWG) or 2,5 mm2 (14 AWG) in case it is mechanical protected, see

ALTOSONIC III 10

Installation and operating instructions

100-240 V AC supply:
The mains voltage
power supply terminal
has two connections

L Live power supply

N

Neutral power supply

Mains voltage AC supply: 100…240 V AC +10%/-15%,
48 - 63 Hz, 11 W

PE: Protective ground connection
FE: Functional ground connection

Protective conductor clamp terminal. Conductors up to 4
mm² (11 AWG) need to be connected to this terminal.

24 V AC/DC supply:
The low voltage
AC/DC power supply
terminal has two
connections

L

L

Live power supply

Neutral power supply
FE: Functional ground connection

SELV AC/DC supply:
24 V AC +10%/-15%, 48 - 63 Hz, 8 W of
24 V DC +33%/-25%, 8 W

3.5 Connection of
sensor cables

The sensors of the separate flowmeter must be connected using the factory supplied MR06 cable between the flow sensor
terminal box and the converter housing terminal box. For compact flowmeters these are connected at the factory.
Both the flow sensor terminals and the converter sensor terminals should be connected between the appropriate numbers
indicated on the sensor cable and in the terminal boxes

Cable diameter: 11 mm (0,433 inch), minimum bending radius: 8 x cable diameter.

3.2 3.1

2.2 2.1

1.2 1.1

11 ALTOSONIC III

3.6 Electrical
connection of
the signal
inputs and
outputs

The terminal to connect the electrical signal inputs
and outputs consist of 6 connections. For wiring of
the signal inputs and outputs it is advised to use
unshielded twisted pairs.

Terminal Function Specification

⊥
P1 Pulse output 1, passive open collector output. Pulse

P2 Pulse output 2, passive open collector output. 90° or

S Status output. Function can be set via menu option

I/C Current output (I), 0(4) to 20 mA

Common ground -

output to flow computer for volume counting.
Function can be set via menu option.

180° phase shifted from P1. For pulse fidelity checking
P1 and P2 should be connected to 2 separate inputs of
a flow computer.
Function can be set via menu option.

3.5.0.

Passive open collector current sink output. Digital input
(C)
Function can be set via menu option 3.4.0. and 3.6.0.

: 150 mA

I

max

: 32V DC, 24V AC

U

max

Max frequency: 1,5 kHz

: 150 mA

I

max

U

: 32V DC, 24V AC

max

Max frequency: 1,5 kHz

I

: 150 mA

max

U

: 32V DC, 24V AC

max

Current output (I): I ≤ 22 mA,

≤ 680 Ohm. U

R

load

Digital input (C): low = 0-5 V DC, high = 15-32 V DC.
Will be switched off when current output activated.

max

The electrical input and output signals can be connected in passive mode. Please observe instrument polarity:
current (I) is always flowing towards P1, P2, S, I/C, terminals (current sink).

3.7 Connection
diagram
examples

Pulse output, P1,
P2

For supply:
U ≤ 32V DC, ≤
24V AC

= 15V DC.

Status output, S

For supply:
U ≤ 32V DC, ≤
24V AC

ALTOSONIC III 12

Installation and operating instructions

Current output /
control input, I/C

For supply:
U = 15…24V
DC, ≥ 22mA

For supply:
15 – 30V DC, I ≥
1,5 mA

Connection to
Omni 3000/6000
flow computer

Single flow pulse
connection
Omni 6000,
Omni 3000
A/B type combo
module
Channel 3 or 4
on A type
Channel 3 only
on B type

13 ALTOSONIC III

Dual pulse

connection
for pulse fidelity
checking
Omni 6000,
Omni 3000
E type combo
module