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Kapat KARAT-520, Operation Manual

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Instantaneous flow rate represents a current flow rate value of work-
ing fluid. 
The present parameter is displayed on LCD with 5 significant digits. 
Examples of instantaneous flow rate are given on figure 1.11.

Figure 1.11 – 

Displaying of instantaneous flow rate value

3

Instantaneous flow rate is

m /h

 0,0000 

 

Set

h

3

m

3

m /h

3

Instantaneous flow rate is

m /h

10,000 

3

Instantaneous flow rate is

m /h

 100,00 

СМАФ.407251.002 РЭ     

. August 2012

Edition 3.0

 

 КАRАТ-520

Ultrasonic flowmeters

19

1. 
Description 
and operation

2. 
Intended use

3. 
Maintenance

4.
Verification

5. 
Repair

6. 
Transportation 
and warehousing

7. 
Utilization

Set

h

3

m

3

m /h

Set

h

3

m

3

m /h

Summary of Contents for KARAT-520

Page 1: ...OPERATIONS MANUAL Ultrasonic flowmeters KARAT 520 ...

Page 2: ...Ultrasonic flowmeters KARAT 520 ...

Page 3: ...included in State Register ofmea suring instruments under register number 44424 12 PatternApproval CertificateofMeasuringInstrumentsRU C 29 005 A 47132 The present operations manual applies to all design versions of Ka rat 520 ultrasonic flowmeters and is intended for study of flowmeters operation and structure Manual also contains information required for proper installation operation and verific...

Page 4: ...king 28 1 5 2 Sealing 28 1 6 Packing and scope of delivery 29 1 7 Warranty 29 2 INTENDED USE 30 2 1 Operating limitations 30 2 2 Recommendations for choosing a flowmeter 30 2 3 Preparation for use 31 2 3 1 General requirements 31 2 3 2 Preparation for installation 32 2 3 3 Instructions for flowmeters installation 32 2 3 4 Installation work 35 2 3 5 Electric installation work 38 2 4 Flowmeters use ...

Page 5: ...ystem SSM State System for Ensuring Uniform Measurement LCD liquid crystal display SAE set of attachment elements PET piezoelectric transducer FC flow conditioner PSO power supply organization Qmax maximum limit of flow measurement Qmin minimum limit of flow measurement Qnom rated flow Qt transition flow rate СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 5 1 Descriptio...

Page 6: ...er power supply type output signals type or types combination construction of mo unting elements microprocessor measuring and calculating КАRАТ 520 ХХ Х АR Flowmeter description Dimension type of the flowmeter ND 20 25 32 40 50 65 80 Design variant of the flowmeter 0 1 2 3 4 Additional functions the flowmeter has flow archives in the absence of symbol there are no archives in the flowmeter the flo...

Page 7: ...d output KARAT 520 20 25 32 40 flowmeters are thread nipple moun ted it means that they are installed on the pipelines by means of con nectors nipples and coupling nuts KARAT 520 50 65 80 flowmeters are flange mounted they are installed on the pipelines by means of flanges KARAT 520 appearance is presented on the figures 1 1 and 1 2 СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic f...

Page 8: ...800 40 0 80 0 10 0 Table 1 3 Overall dimensions and weights Dimension type of a flowmeter Overall dimensions mm not more than Weight kg not more than Length Width Height КАRАТ 520 20 190 100 150 1 5 КАRАТ 520 25 260 100 150 2 0 КАRАТ 520 32 260 100 150 2 2 КАRАТ 520 40 300 160 200 5 2 КАRАТ 520 50 300 180 200 7 3 КАRАТ 520 65 300 200 220 9 4 КАRАТ 520 80 300 220 220 12 1 Table 1 4 Limits of permis...

Page 9: ... ХХ 1 KARAT 520 ХХ 2 design versions with digital output RS 485 M Bus have the output signal parameters which meet the requirements mentioned in standards for the present interfaces 1 3 3 Power supply characteristics In accordance with design version table 1 1 flowmeters can be sup plied both from internal and external power sources according to de sign version Flowmeters of design version it 1 2 ...

Page 10: ...ed in GOST R 51318 22 Electromag netic compatibility of technical equipment Information technology equipment Man made radio disturbance Limits and methods of mea surement with parameters specified in 5 clause of GOST R 51649 Heat meters for water heat supply systems General specifica tions and GOST R EN 1434 4 Heat meters Part 4 Tests for design approval 1 3 6 Failure properties Mean time between ...

Page 11: ...ension types differ in FTstructure Diversity in FT structure is caused by fluid dynamic properties in pipe lines of different diameters FTare marked in accordance with 1 6 1 clause of the present OM Figure 1 4 KARAT 520 flowmeters 1 electronic module 2 marking 3 pulse output wire 4 interface module wire 5 flow tube 1 5 3 4 Thread mounted Flange mounted 2 1 5 3 4 2 СМАФ 407251 002 РЭ August 2012 Ed...

Page 12: ...onnected to FT by a metal plate is made of shock resistant plastic EM body bottom part is made of plastic with low thermal conductivity There is an air gap be tween bottom part of EM body and a metal plate therefore heat trans fer from a plate to flowmeter body is reduced Datacables 3and4calloutsonfigure1 4 aremadewithisolationofsili cone material it ensures high temperature strength In accordance...

Page 13: ...nual Figure 1 5 FT description of KARAT 520 20 25 32 flowmeters 1 built in straight piping 2 ND 2 PET transducer 3 plastic tube 4 tube flaring in the low end of tube 2 3 4 1 2 2 3 1 2 4 СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 13 1 Description and operation 2 Intended use 3 Maintenance 4 Verification 5 Repair 6 Transportation and warehousing 7 Utilization ...

Page 14: ...puts Devices marked with R symbol have normalized metrological characteristic in case of reverse flow Galvanic separation optocoupler allows to separate external com munication line from internal circuit of a flowmeter СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 14 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru Set h 3 m h Ultrasonic flowmeter КАRАТ 520 20 0 3 Q m h 3 ...

Page 15: ...settings viewing 10 socket for interface or analog modules connection 11 technological module 12 socket for internal power source connection 13 place for magnet application 14 flowmeter nameplate Figure 1 7 end Electronic module appearance without top cover СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 15 1 Description and operation 2 Intended use 3 Maintenance 4 Verif...

Page 16: ...on LCD is dis abled Information changes every 3 4 seconds subsequently dis playing the following parameters 3 n instantaneous flow rate of working fluid m h 3 n cumulative volume in forward direction m 3 n cumulative volume in reverse direction m n operating time starting from the time of meter installation h Microprocessor integrated in EM calculates the time difference and then flow rate and vol...

Page 17: ...s than 3 seconds to selected place on a flowmeter nameplate 13 clause figure 1 7 under which magnetically operated sealed switch is located n By means of long pressing not less than 3 seconds of settings dis play button 9 clause figure 1 7 in case of uncovered EM of flowmeter Figure 1 9 Parameters indicated on LCD during standard displayed mode is indicated only in case of nonzero value Operating ...

Page 18: ...rs are indicated on LCD every 3 4 seconds Standard display mode is switched automati cally after 5 cycles of measured parameters display figure 1 10 3 4 sec 3 4 sec 3 4 sec СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 18 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 ...

Page 19: ...1 Displaying of instantaneous flow rate value 3 Instantaneous flow rate is m h 0 0000 Set h 3 m 3 m h 3 Instantaneous flow rate is m h 10 000 3 Instantaneous flow rate is m h 100 00 СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 19 1 Description and operation 2 Intended use 3 Maintenance 4 Verification 5 Repair 6 Transportation and warehousing 7 Utilization Set h 3 m 3 ...

Page 20: ... after decimal point If the value exceeds 3 10 000 m cumulative volume value is indicated accurate to 2 digits after decimal point and so on figure 1 12 Figure 1 12 Standard mode of data display on LCD Cumulative volume value is displayed accurate to 4 digits after decimal point Cumulative volume value is displayed accurate to 3 digits after decimal point Cumulative volume value is displayed accur...

Page 21: ... the absence of high order digits display Screen appearance during extended display precision mode is given on figure 1 13 Indicator is signaling about switching of extended display precision mode Indicator is signaling about the absence of high order digits display Figure 1 13 Extended precision mode of forward volume display on LCD 70234 1263 3 70234 1263 м Standard display mode Extended display...

Page 22: ...f 2 methods n by means of quick magnet application about 1 second to the se lected place on a flowmeter nameplate 13 clause figure 1 7 n by means of short pressing about 1 second of settings display but ton 9 clause figure 1 7 in case of uncovered EM of flowmeter Service parameters are indicated on LCD one time with 3 4 seconds time span sequentially displaying the data presented above figure 1 16...

Page 23: ...se Checksum of calibration constants 3 4 seс 3 4 seс 3 4 seс СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 23 1 Description and operation 2 Intended use 3 Maintenance 4 Verification 5 Repair 6 Transportation and warehousing 7 Utilization Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h Set h 3 m 3 m h ...

Page 24: ...lse outputs Connection diagram of KARAT 520 ХХ 0 R is presented on 1 17 figure КАRАТ 520 ХХ 0 R Pulse output OUT1 Pulse output OUT2 Red Black Blue White КАRАТ 520 ХХ 0 Pulse output OUT1 Red Black Blue White Microprocessor Microprocessor СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 24 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 25: ...t V1 V2 OUT 2 Red Black Blue White KARAT 520 ХХ 1 А and KARAT 520 ХХ 2 А flowmeters accumu late and store values of measured parameters in logger which has the following structure n Hour logger 1080 records n Daily logger 62 records n Monthly logger 60 records n Annual logger 5 records n Events log 50 records Red Black Blue White СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flow...

Page 26: ...transfer rate is set during device setting it can be within the range of 600 bit sec up to 9600 bit sec KARAT 520 ХХ 1 А R connection diagram is given on figure 1 19 КАRАТ 520 ХХ 1 А OUT 1 OUT 2 Output U U A B КАRАТ 520 ХХ 1 АR To 12 36 V power source To RS 485 circuit To RS 485 circuit Pulse output OUT1 Pulse output OUT2 Red Black Blue White OUT 1 OUT 2 Output U U A B To 12 36 V power source To R...

Page 27: ...KARAT 520 ХХ 3 KARAT 520 ХХ 3 Р output circuit diagram OUT 1 OUT 2 Output U U КАRАТ 520 ХХ 3 R To 12 36 V power source Current output 1 Current output 2 Pulse output OUT1 Pulse output OUT1 OUT 1 OUT 2 Output U U Iout1 КАRАТ 520 ХХ 3 To 12 36 V power source Current output 1 Pulse output OUT11 Iout1 Iout2 Iout2 Red Black Blue White Module of 4 20mA current output Module of 4 20 mA current output Cir...

Page 28: ...ithrequirementsofMR50 2 107 09 metrologicalregulations 1 5 2 Sealing Flowmeters are sealed in order to prevent unauthorized tampering in operation of configured verified devices placed in operation Flowmeters structure provides for 2 sealing levels 1 level QCD quality control department seal 6 callout figure 1 7 placed after manufacturing and seal stamped with verification mark 7 callout figure 1 ...

Page 29: ... tainer wooden or cardboard box in accordance with GOST 5959 Uncollapsable wooden sheet material boxes for weights to 200 kg mass General specifications or GOST 2991 Wooden uncollapsible cases for weights up to 500 kg General specifications 1 7 Warranty During transportation storing mounting and operation of flowmeters consumer should follow the instructions of corresponding sections of the presen...

Page 30: ...optimal dimension type of a flowmeter is the main con dition of its reliable operation durability and acquisition of consistent measurement results The main selection criteria are the following n technical specification compliance to design parameters of engi neering system flow range pressure drop in pipelines where a flowmeter is installed n nominal pipeline diameter should correspond to flowmet...

Page 31: ...t measuring sections of pipeline adjoin ing with flowmeter with no local hydraulic resistances Straight sec tions can be formed by n pipelines of engineering system in case of fulfilment of 2 3 3 clause conditions of the present manual n by means of mounting cutting in of purpose made straight sec tions on the pipeline 2 3 4 4 clause of the present manual Straight pipe length is given in ND units ...

Page 32: ...ith required access to the present type of works Inlet and outlet pipes with diameter bigger or smaller than flowmeter diameter should be cut in the pipeline only by means of concentric reducers confusor diffuser or diffuser con fusor in accordance with GOST17378 Seamless welded steel pipe 2 line components for Pn 10 MPa 100 kgf cm Reducers Design and dimensions Reducers are mounted on the pipelin...

Page 33: ... working fluid n Air pocket air bubbles and blocks is not allowed in measured flow during flowmeter operation In certain cases when other mounting variants are not possible it is allowed to install the flowmeter on downstream pipelines subject to conditions mentioned above Figure 2 2 Recommended flowmeter mounting in the pipeline Recommended mounting Admissible installation СМАФ 407251 002 РЭ Augu...

Page 34: ...e within the range of 0 45 figure 2 3 The present mounting method allows to considerably reduce EM heat ing by hot convection current Flowmeters should be installed on pipelines unexposed to vibration In case of pipeline vibration with frequency and amplitude values ex ceeding permissible values it is required to install additional pipe sup ports Table 2 2 Permissible variation of flowmeters diame...

Page 35: ...ling gaskets in accordance with GOST 15180 Flexible flat gaskets Main parameters and dimensions L total length of cut section for straight pipe mounting mounting dimension Lmount depends on nominal diameter its val ues are given in table 2 3 mount mounting L 2 3 4 2 Use of MI Welding and mounting works for straight pipes installation are requ ired to be performed with the use of MI Overall dimensi...

Page 36: ...straight sections for the latter case it is recommended to use pipes in accordance with GOST 8732 GOST 8734 GOST 3262 Water supply and gas supply steel pipes Ready mounted straight section is a metal pipe with the length of not less than 3 5 or 10 ND There is a mounting element nipple or flange on the one end of the straight section and the other end is prepared for welding Assembling of welding j...

Page 37: ...uded in SAE 2 providing diameter clearance less than 0 1 mm n Flanges welding to system pipeline in accordance with require ments to flange installation accuracy given on figure 2 6 n Flowmeter installation after welding and mounting works completion Mounting in pipeline with straight pipes insert n Straight section preparation in accordance with figure 2 6 and table 2 1 n Welding of confusor and ...

Page 38: ...strapped down bolts should be tightened on flange joint by turns by diametri cally opposite pairs It is required to ensure that there is no misalignment of sealing gas kets of flowmeter FTduring installation Displacement of sealing gaskets inside the flowmeter FT is not al lowed 2 3 5 Electric installation work Electrical circuits should be connected after welding and mounting works completion in ...

Page 39: ...rnal devices values It is required to record commissioning date in flowmeter certificate and attest it with signature of person responsible for flowmeter main tenance 2 4 2 Exploitation Flowmeters put in commissioning do not require special technical ser vice In case of partial filling of pipeline or presence of air bubbles and solid particles in working fluid in concentration exceeding values giv...

Page 40: ...СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 40 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 41: ... fluid pressure in system pipeline Cavitation con ditions when air bubbles and cavities filled with gas steam or their mixture can occur should be avoided Inobservance of operational conditions may cause performance degradation of the flowmeter Visual inspection interval depends on operational conditions and is defined by company maintaining the measuring unit in coordination with operating organi...

Page 42: ...СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 42 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 43: ...with VM 22 221 2012 SSM State System for Ensuring Uniform Measurement KARAT 520 ultrasonic flowmeters Verification method Calibration period is 4 years СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 43 1 Description and operation 2 Intended use 3 Maintenance 4 Verification 5 Repair 6 Transportation and warehousing 7 Utilization ...

Page 44: ...СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 44 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 45: ...pair n Reclamation report with failures description Example of reclama tion report is given inAppendix B of flowmeter certificate n KARAT 520 Certificate SMAF 407251 002 PS СМАФ 407251 002 РЭ August 2012 Edition 3 0 КАRАТ 520 Ultrasonic flowmeters 45 1 Description and operation 2 Intended use 3 Maintenance 4 Verification 5 Repair 6 Transportation and warehousing 7 Utilization ...

Page 46: ...СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 46 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 47: ...ns as to environment cli matic aspects influence with minus 25 C lower temperature value Flowmeters should be arranged and fixed in transport means in steady position in order to exclude impacts between devices and transport wall Flowmeters should be stored in transport containers or manufacturer packing in warehouses with no dust vapors of acid alkali and ag gressive gases in accordance with 3 st...

Page 48: ...СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 48 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 49: ...T bodies ABS PESU PBT PC Plastic recycling Packing Cardboard Wastepaper recycling 7 UTILIZATION Flowmeters contain no precious metals and materials which require special utilization methods and pose direct threat to life and health of people Operating organization implements measures for overaged flow meters utilization Flowmeter is utilized in accordance with table 7 1 СМАФ 407251 002 РЭ August 2...

Page 50: ...40 flowmeters APPENDIX B Pattern Approval Certificate of MI of KARAT ultra sonic flowmeters in Russian Federation Figure A 2 Installation diagram of KARAT 520 50 65 80 flowmeters СМАФ 407251 002 РЭ Operations manual Edition 3 0 August 2012 50 КАRАТ 520 Ultrasonic flowmeters КАRАТ RPA www karat npo ru ...

Page 51: ......

Page 52: ...TY STOCK RESERVE HEAD OFFICE TECHNICAL SUPPORT Yasnaya st 22 B Yekaterinburg 620102 Russia Tel fax 7 343 22 22 306 7 343 22 22 307 e mail ekb karat npo ru Yasnaya st 22 B Yekaterinburg 620102 Russia Tel fax 343 375 89 88 icq 600 995 810 e mail tech karat npo ru ...

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