Kobold KAL User manual

Operating Instruction

for

Calorimetric Flow Monitoring Device

Model: KAL

KAL

Page 2 KAL 07/04

1. Contents

1. Contents........................................................................................................2

2. Note ..............................................................................................................3

3. Instrument Inspection....................................................................................3

4. Regulated Use ..............................................................................................4

5. Operating Principle .......................................................................................5

6. Mechanical Connection.................................................................................5

7. Electrical Connection ....................................................................................6

8. Limiting Contacts ..........................................................................................6

9. Alignment / Balancing ...................................................................................7

10. Commissioning ...........................................................................................10

11. Maintenance ...............................................................................................10

12. Fault Signalling ...........................................................................................11

13. Technical Information..................................................................................11

14. Order Codes ...............................................................................................12

15. Dimensions .................................................................................................13

16. Declaration of Conformance .......................................................................14

Manufactured and sold by:

Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

E-Mail: i[email protected]

Internet: www.kobold.com

KAL

KAL 07/04 Page 3

2. Note

Please read and take note of these operating instructions before unpacking and

setting the unit for operation, and follow the instructions precisely as described

herein.

The devices are only to be used, maintained and serviced by persons familiar

with these operating instructions and with the prevailing regulation applying to

procedural safety and the prevention of accidents.

By usage in machines, the measuring unit should be used only then when the

machines fulfil the EWG-machine guide lines.

PED 97/23/EG

for KAL-11.. and KAL-12..

In acc. with Article 3 Paragraph (3), "Sound Engineering Practice", of the

PED 97/23/EC no CE mark.

Table 8, Pipe, Group 1 dangerous fluids

3. Instrument Inspection

These devices are checked before dispatch and sent away in perfect condition.

Should the damage to a device be visible, we recommend a thorough inspection

of the delivery packing. In case of damage, please inform your parcel service/

forwarding agent immediately, since they are responsible for damages during

transit.

Scope of delivery:

•probe with 2 m PVC as standard

•Electronic setting system

KAL

Page 4 KAL 07/04

4. Regulated Use

The KAL is to be installed only in the specified applications. Every usage which

exceeds the specifications is considered to be non-specified. Any damages

resulting therefrom are not the responsibility of the manufacturer. The user

assumes all risk for such usage. The application specifications include the

installation, start-up and service requirements specified by the manufacturer.

Devices from the KAL model series are used for the monitoring of liquid flow.

Limiting relay

The devices are equipped with limiting relays for monitoring the flow speed of

liquids (KAL-E1...-E3).

Trend display

An LED bar display shows the current flow value and the set switch point via a

flashing LED (only on models KAL-E2... and KAL-E3...).

Probes

Probes are available in two options: as a screw-type or in-line version.

Model KAL devices are always made up of two structural components

•Probe

•Electronic setting system

The devices may only be used for liquids to which the probe housing materials

are resistant. With proper installation and maintenance, the probes display no

sensitivity to soiling and cause practically no pressure loss.

Materials

KAL-11... Brass material

KAL-12..., KAL-23..., KAL-53... St. steel material 1.4301

KAL-24..., KAL-54... St. steel material 1.4571

Setting ranges in relation to nominal tube diameter

ND (mm) Range (l/min) water ND (mm) Range (l/min.) water

8 0,12 - 6,0 40 3,0 - 150

10 0,19 - 9,4 50 4,7 - 235

15 0,42 - 21,8 60 6,8 - 340

20 0,75 - 37,7 80 12,0 - 603

25 1,18 - 59,0 100 18,8 - 942

30 1,7 - 84,8 150 42,4 - 2120

KAL

KAL 07/04 Page 5

Attention! For the measuring ranges gives the flow speed was

converted to the nominal tube diameter. It should be noted in line

with this that in the tube towards the wall section the flow speed

approaches 0. Depending on nominal tube diameter, screw depth of

the probe and flow profile, occasional deviations, some of them

considerable, may result.

5. Operating Principle

The all-metal design electronic flow monitor device functions according to proven

calorimetric principles. The measuring probe is heated up a few degrees from the

inside outwards in relation to the flow medium which it is penetrating. If the

medium is flowing then the heat produced in the probe is carried away by the

medium, i.e. the probe becomes cooler. This cooling represents a measuring of

the flow speed.

The electronic setting system compares the desired flow speed with the actual

speed and activates an output relay when the desired value is not reached. By

the use of a micro-controller, simple calibrations is made possible. In this way

optimum temperature compensation can be achieved.

6. Mechanical Connection

Before installation:

•Ensure that the actual flow quantity corresponds to the setting range of the

device (i.e. to the flow speed).

•Ensure that the permitted maximum operating pressure and temperatures for

the device are not being exceeded. (See point 13 Technical Information)

Installation:

Mount the sensor in the pipe (KAL-1...)- in a sleeve welded to the pipe (KAL-2...).

Fitting position:

The function of the sensor is not dependent on

their fitting position, provided that the pipe is

completely filled with flow medium. The place

where the sensor are fitted must be free from

turbulence in the medium. (4x pipe section in

front of and behind sensor). If the medium is

likely to cause any deposits in the tube, then an

appropriate fitting position alongside is

recommended.

KAL

Page 6 KAL 07/04

7. Electrical Connection

Warning! Ensure that the voltage values of your installation

correspond to the voltage values given on the device´s specification

plate.

•Make sure that the electrical power supply is off.

•Connect the sensor cable to terminals 6 & 8 on the setting system.

•Connect the power supply (voltage supply) to terminals 15 & 16.

Temperature relay only on models

KAL-E3.

The relais are illustrated in fallen state.

AC voltage supply

220 VAC, 110 VAC, 24 VAC +/- 10%, 50-60 Hz

DC voltage supply

24 VDC + 15%, - 10%

8. Limiting Contacts

Only on KAL-E1.../KAL-E2...

1x change - over relay for flow speed

Only on KAL-E3...

1x change - over relay for flow speed

1x change - over relay for temperature

KAL

KAL 07/04 Page 7

9. Alignment / Balancing

Initial operation:

9.1. Fit sensor in pipe (ensure correct fitting location, see point 6 Mechanical

Connection).

9.2. Connection sensor cables to electronic circuitry (see point 7 Electrical

Connection).

9.3. Fill pipe with flow medium.

Caution! There must be no air bubbles on the sensor. Flow speed

must be at 0.

9.4. Commission electronic circuitry (switch on supply voltage)

9.5. Only on model KAL-E-3...Set temperature potentiometer (2) to left-hand

stop.

9.6. Zero point alignment. Briefly activate the "SET"key (5) (using a suitable

object e.g. ball point pen)

9.7. "Flow" LED (6) flashes for about 30 seconds. After this time the "Flow"LED

goes off (6). The device is now operational., continue with point 9.9.

9.8. In case of malfunction the "Flow" LED flashes continuously. Press the"SET"

key once again. Device will switch back into measuring mode. Check

mechanical and electrical installation and recommence operational

procedure from point 9.4.

9.9. Switches on installation and set maximal flow.

If the flow speed is significantly less then 2 m/s, then on the trend display (3)

there will be possibly fewer then 8 LEDs on.

It is now possible to extend this display (3) to the full range (8 LEDs). This can

only be successfully achieved, however, if the flow speed is somewhere between

0,25-1,8 m/s.

•Set "Flow" potentiometer (1) (see illustration) to right-hand stop

(only on KAL-E3...; Set temperature potentiometer to left-hand stop)

•Briefly activate SET key (5)

•Flow LED (6) will flash for 30 seconds. After this time the Flow

LED will go 30 off.

KAL

Page 8 KAL 07/04

It is possible at any time to reset the electronic circuitry to the full range

•Flow potentiometer (1) at right-hand stop

•(Only on KAL E3; Temperature potentiometer (2) to left hand-

stop)

•Press the SET key (5) and hold in position until the FLOW LED

stops

The device has now been reset into basic functioning mode.

The device is now adjusted to your medium. You can now set your switch point.

(In case of malfunction see point 9.8)

9.10. Set operational flow.

Switch point setting: Model KAL-E-1...

•The further the Flow-potentiometer (1) is turned to the left, the lower the switch

point.

•The further the Flow-potentiometer (1) is turned to the right, the higher the

switch point.

Switch point setting: Model KAL-E-2.../E-3...

•Set Flow-potentiometer (1) to left-hand stop. The first LED on the luminous

display (3) will flash. Any number of LED´s on the luminous display will be

continuously illuminated.

•Turn "Flow" potentiometer (1) to the right until the desired switch point is

reached. The current switch point will be displayed by a flashing LED.

Display 3

XXXXX

Flashing flow speed

XXXXXX

LED display flashin Explanation Result

XXXXXX flow>switch point Flow relay pick-up made

Flow LED illuminated

XXXXXXflow>switch point LED Flow relay pick-up made

flashes at double

frequency

Flow LED illuminated

XXX öFlow<switch point Flow LED off

Flow relay open

KAL

KAL 07/04 Page 9

KAL

Page 10 KAL 07/04

Only KAL-E-3...

with more than 10 m cable between sensor and electronic circuitry, as well as

increased accuracy when measuring temperature.

Temperature alignment

•Caution! Disconnect from power supply.

•Connect full length extention cable (>10 m) (terminals 6&8)

•Connect 100 Ohm ±1% resistor (part of delivery package) in place of

sensor at the end of the instrument leads.

•Set temperature potentiometer (2) at 80° C (right - hand stop).

•Reconnect power supply and switch device on.

•Briefly press SET key (5).

•The temperature LED will flashed and switch off again after approx. 10

seconds. In case of malfunction, see point 9.8, Initial operation. If the

temperature LED flashes more quickly, this could be caused by the fact

that the probe is connected instead of a 10 Ohm resistor.

•Remove the 100 Ohm resistor and replace the sensor.

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