COMAC CAL CALOR 40 User manual

CALOR 40 Manual Page 1 (total 27) COMAC CAL s.r.o.
CALOR 40
For 0-80% ethylene-glycol mixture measurement
Installation manual and specifications

CALOR 40 Manual Page 2 (total 27) COMAC CAL s.r.o.
Contents:
Device description…………………………………………………………………….. 3
Scope of delivery ……………………………………………………………………… 4
Storage conditions …………………………………………………………………. 4
Warranty……………………………………………………………………………… 4
Installation in piping ………………………………………………………………… 5
Important information for selection of location ……………………………………… 5
In-pipe installation ……………………………………………………… 7
Wiring ……………………………………………………………………… 12
Meter wiring ……………………………………………………………. 12
Pulse outputs ………………………………………………………………………. 14
Pulse inputs ………………………………………………………………………... 15
Current output ……………………………………………………………………….. 15
Output-Failure ………………………………………………………………………… 15
Data output …………………………………………………………………………..15
Starting up ……………………………………………………………………. 17
Functional description …………………………………………………………………17
Technical data ………………………………………………………………………... 21
Operation checks ……………………………………………………………………… 21
Failures and their symptoms in the course of measurement ………………………....... 21
Evaluation unit checking …………………………………………………...... 22
Flow sensor checking ……………………………………………………………... 23
Checking the evaluation by flow simulator (optional) …………….. 24
Service ………………………………………………………………………………... 25
Replacement of the top PCB with display unit ……………………………………… 25
Power supply
replacement………………………………………………………………………. 25
Factory settings ………………………………………………………... 26
Form for returning the meter to COMAC CAL s.r.o. ………………………... 27

CALOR 40 Manual Page 3 (total 27) COMAC CAL s.r.o.
Description of the unit
The Calor 40 is a flow meter based on the measuring principle of Faraday’s electromagnetic
induction law, according to which a voltage is induced when a conductive fluid flows through
the magnetic field of the flow meter. This voltage is picked up with two electrodes that are in
direct contact with the liquid measured and it is evaluated in the electronic unit.
The inductive meter Calor 40 is suitable exclusively for measuring volumetric flow of
conductive liquids with a minimum conductivity of 2 S/cm.
The meters are designed for flow measuring where the speed of liquid is within the range
0.01 ÷ 10 m/s. The greatest accuracy of measurement is reached within the range 1 ÷ 10 m/s.
The special version of CALOR 40 provides for measurement of heat delivered by the ethylene
glycol-water mixture. For correct measurement, the correct mixture rate must be set up in the
meter. Incorrect setting or using other medium than it is presented in the chart below may
result in incorrect measurement.

CALOR 40 Manual Page 4 (total 27) COMAC CAL s.r.o.
Scope of delivery
The accessories vary according to an optional flow sensor and some above standard optional
features.
Threaded construction
The electronic evaluation unit with a wall-mounting holder (not for the compact design), a
flow sensor (in case of the compact design, the electronic unit is an integral part of the flow
sensor), a grounding cable, and installation instructions, wells with paired temperature sensors
and assembly instructions
Sandwich construction
The electronic evaluation unit with a wall-mounting holder (not for the compact design), a
flow sensor (in case of the compact design, the electronic unit is an integral part of the flow
sensor), bolts to install the sensor between flanges (see the quantity as per Torque Chart
below) with nuts and washers (it is not allowed to replace the washers delivered, especially
when these are spring washers), 2 fibre-rubber seals (part of the meter), connecting earth
cable, mounting instructions, wells with paired temperature sensors and assembly instructions
Flange construction
The electronic evaluation unit with a wall-mounting holder (not for the compact design), a
flow sensor (in case of the compact design, the electronic unit is an integral part of the flow
sensor), screws to install the sensor between flanges (two-fold quantity as per Torque Chart
below) with nuts and washers, 2 fibre-rubber seals, connecting earth cable, mounting
instructions, wells with paired temperature sensors and assembly instructions
Construction for food processing industry
The electronic evaluation unit with a wall-mounting stamping (not for the compact design), a
flow sensor (in case of the compact design, the electronic unit is an integral part of the flow
sensor), welded pipe adapter as per DIN 11851, mounting instructions, wells with paired
temperature sensors and assembly instructions
In the event of the separate construction, the induction sensor is equipped with a special cable
to connect the meter (it must not be lengthened or shortened).
Storage conditions
The transportation and storage temperature must be within the range -10 °C up to 50 °C.
Warranty
Incompetent installation or application of inductive meters (devices) may result in loss of
warranty as well as failure to comply with mounting and/or operating conditions pursuant to
this Manual.
When the meters are shipped out to the COMAC CAL plant to be checked and/or repaired,
enclose please the completed form, refer to the last page of this manual. Unfortunately, we

CALOR 40 Manual Page 5 (total 27) COMAC CAL s.r.o.
will not be able to process correctly and promptly your requirement for modification and/or
repair of your meter.
In-pipe installation
Relevant information for selection of location
!!! In the event of the separate construction, the cable must not be lengthened or shortened !!!
Outdoor conditions
It is necessary to prevent the flow sensor from being directly exposed to weather conditions
and prevent the liquid to be measured from freezing over inside the flow sensor, which might
damage the measuring tube.
In the case that the Electronic Evaluation Unit is located outdoors, the manufacturer
recommends a protective case, and if appropriate, a roof to avoid direct sunshine so that the
evaluation electronics cannot warm up excessively.
Sources of disturbance
These are the sources disturbing the steady flow of a liquid:
·Pumps and bends or elbows located closely in series in various planes. These
elements should be at a distance of at least 20d (“d” stands for inside diameter of the
sensor in mm) before the flow sensor.
·Sudden variations in the pipe section unless constructed as a cone with angle
16° (where is the angle between the bevelled walls of the pipe adapter).
·Incorrectly centred seal, the seal with a mall internal diameter, or the seal made of
Soft elastic materials which penetrate into internal section of the pipe after the
flanges have been tightened.
·Anything that interferes with the flow of liquid, e.g. the thermometer well.
·Branches, T-pieces, bends, elbows, slide valves, taps, and throttles. Shut-off valves,
control valves, butterfly valves, and check valves. Pipe outlets from tanks, heat
exchangers, and filters.
No strong electromagnetic field must take effect close to the inductive flow sensor (pick-up).
Vibrations
We recommend you to support the connecting pipes at both sides of the meter to partially
eliminate vibrations. The level and range of vibrations must be below 2.2g within frequency
range of 20 ÷ 50 Hz according to IEC 068-2-34 standard.
Proper location
The flow sensor must not be at the top of the pipeline where air intake occurs or in the
declining and also in horizontal pipeline with open end where air may penetrate.
Sedimentation of impurities may occur during a long-run measurement of very low flow rates
Q < 0.1 m/s. The site where the flow sensor is installed there must be a sufficient pressure so
that vapour or gas bubbles cannot be discharged from the liquid. The tiny bubbles occurring
in liquids all the time can accumulate at any of the electrodes and they can cause incorrect
function of the meter. The gas bubbles are discharged from liquids also during a sudden drop

CALOR 40 Manual Page 6 (total 27) COMAC CAL s.r.o.
of pressure. Therefore, the control butterfly valves and similar components should be inserted
behind the flow sensor. For the same reason, the flow sensor should not be installed at the
suction side of the pump. To prevent the bubbles from accumulating in the flow sensor while
the flow is slow, it is useful for the pipeline either to be slightly ascending or the sensor is put
into the vertical part of the pipeline.
If the meter is populated with measuring electrodes only (2 or 3 electrodes located beyond
the upper profile of the tube), it is necessary for proper function of the meter, to fill up the
flow sensor with the fluid to be measured so that erroneous measurement of quantity of liquid
passing through the meter can be avoided when the pipe is empty. It is necessary to select the
location of the meter in such a way that the flow sensor aeration is avoided.
In the case of an open system, the flow sensor is placed in the bottom position of the U-
profile, ensuring that the fluid will not flow out of the sensor.
Examples of installation
The trouble free and accurate operation of the meter depends on correct location in the
system, especially when the internal PTFE or rubber lining is used where there is a risk of
damage as a result of negative pressure. The most frequent methods of positioning are
illustrated in the following figures:
Recommended positions for installation Down pipe
Horizontally positioned pipe Long pipe
(bubbles are accumulated in the
pipe; erroneous measurement)
Install a purge valve
behind the sensor 
Place the sensor into a
slightly ascending pipe
Pipe is
empty;
erroneous
measuring
Correct
positioning
Always install the control and shut-
off components behind the sensor

CALOR 40 Manual Page 7 (total 27) COMAC CAL s.r.o.
Free inlet or outlet Pumps
The flow of liquid in the flow sensor
The flow of liquid in the flow sensor should be steady and with no whirls. For this reason,
straight pipe sections of the same diameter as that of the sensor (permitted deviation +5%)
are usually inserted before and behind the flow sensor. The minimum length of the sections is
3d before the flow sensor and 2d behind the flow sensor.
It is not necessary to adhere to the minimum length of the straight section when conical
junctions with angles 1,216(1 –angle of the cone before the flow meter, 2–angle of
the cone after the flow meter) are used if their minimum internal diameter is identical to the
internal diameter of the flow sensor (with permissible deviation +5%).
No sources disturbing the steady flow must be found in the specified straight sections. They
must be positioned in the pipe behind the flow sensor or at the longest possible distance
before it.
The sources of disturbance may substantially decrease the measuring range and accuracy of
the flow meters.
Recommendation
When the flow is whirled up, increase the stabilizing sections of the pipe or install the flow
conditioner.
When mixtures are blended, it is necessary to install the flow meter either before the blending
spot or at a sufficient distance behind it (30xd min.) otherwise it may result in unstable
readouts.
The grounding rings are necessary when plastic or metal pipes with the internal non-
conductive layer are used.
Compact construction of the meter:
When the compact heat meter or flow meter is used, it is necessary to respect the maximum
temperature of liquid up to 90 °C. If this temperature is exceeded, correct operation of the
Electronic Evaluation Unit is not secured, eventually there is a risk of its destruction.
Do not pick up the meter during installation by means of the Evaluation Unit housing.
If the pipe is exposed to excessive vibrations (e.g. from pumps), the use of compact meters is
not recommended.
The designer, or in some case, the user himself are responsible for suitability and adequacy of
application of compact inductive meters.
Actual in-pipe installation
The flow meter is installed and put in operation only by the organization with authorization to
conduct such activity and whose staff has passed the appropriate training course in installation
Install in the U-pipe
The flow meter must not be installed
in the suction side of the pump

CALOR 40 Manual Page 8 (total 27) COMAC CAL s.r.o.
of these meters and flow meters in terms of this manual at the manufacturer. The
manufacturer will issue certificates, confirming that the workers have passed this training
course.
The inductive flow sensor is installed in arbitrary position in vertical piping. In the case of
horizontal piping, it is necessary to make sure that the sensor is installed with its measuring
electrodes in horizontal position. If the version with grounding electrode, or empty pipe test is
in question, then the installation is always carried out with a cable grommet for the sensor, or
with the evaluating unit in the upright position (in case of compact version). Then the
grounding electrode is in the bottom position and the sensing electrode in the top position of
the flow sensor.
The assembly is carried out by fixing between the counter-flanges (sandwich) that are welded
to the modulating piping (5d before and 3d behind in the flow direction) whereas the fluid
must flow through the flow sensor in the direction that is indicated with an arrow on it.
When counter flanges are being welded on the pipe, it is essential to maintain their alignment
so as to ensure uniformity of seating faces of the flanges on the face areas of the sensor
(however, this must not be reached by uneven tightening of the connecting bolts because there
is a risk of leakage resulting from temperature strain in the future and, in some case, the
measuring tube might crack when being tightened unevenly). The difference in LMAX and
LMIN distances of the both sealing faces on the flanges before the flow sensor is installed,
must not be longer than 0.5 mm.
In the same way, the mating positions of holes for connecting bolts in counter-flanges should
be ensured as well as ample room behind the flanges for the connecting bolts and nuts in order
to ensure proper installation of the sensor in the pipe and the attachment by connecting bolts.
The manufacturer recommends using a fitting adapter for welding. It is absolutely
inadmissible to use the flow meter as a fitting adapter due to possible thermal destruction. The
welding current must not flow through the flow sensor during electric welding. The
installation of the flow sensor itself is carried out after all welding, painting, building, and
similar jobs are finished.
If the flow sensor has a fibre-rubber sealing, it is inevitable to lubricate it using graphite
grease or oil with graphite.

CALOR 40 Manual Page 9 (total 27) COMAC CAL s.r.o.
When a threaded connection is used, it is essential to check the thread on the sensor, while it
is being tightened, to prevent it from moving round a slight amount.
Avoid during the installation:
-Dropping the meter on the floor and causing injury especially to the ceramic
measuring tube.
-Contamination of electrodes (do not touch the electrodes as contamination occurs).
-Using any additional seal so as to prevent it from extending to the flow profile of the
sensor between its flanges and the pipe, otherwise the error in flow measurement
may be increased.
Tightening torque values
It is absolutely essential to tighten the connecting bolts and nuts evenly and subsequently on
opposite sides and in the order illustrated in the figure with the maximum torque indicated in
the table below.
Measuring tube
Corundum/
PVDF
Corundum/
PVDF
Corundum/
PVDF
Corundum
Rubber/
PTFE
Rubber/
PTFE
Rubber/
PTFE
DN (mm)
6 ÷ 20
25
32 ÷ 50
65 ÷ 80
100
150
200
No. of bolts
4
4
4
8
8
8
12
Mk (Nm)
20
25
50
60
75
80
90
When the thermoplastic tube in flange construction is used, the same torque figures apply as
those for the corundum tube.
If you do not find your inside diameter or construction in the Torque table, it is a special or
non-standard construction. In this case contact the manufacturer for detailed information
please.

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Tightening is necessary to be done three times; for the first time to 50% of max. torque as per
the table above. For the second time, to 80% and for the third time, to 100% of the max.
torque.
It is recommended to check the tightening of the bolts approx. 24 hours after the meter has
been installed.
When the flow sensors over 200 mm are installed, it is essential to observe, apart from the
above mentioned rules, also simultaneous tightening of the parallel screws on both counter
flanges to prevent the electrodes or the measuring tube from possible injury (symmetrical
stretching of the lining).
Grounding
Each of the flow meters must be perfectly and effectively grounded. The grounding line must
not transfer interference voltage, therefore, this line must not be used simultaneously for
grounding other electric meters.
The flow sensor is equipped with a stainless grounding screw with washer and nut for the
grounding cable being delivered with mounting accessories. This must be conductively
connected with the counter flanges. If it is not ensured that the counter flanges are in direct
contact with the measured liquid and they are conductive, it is essential to apply grounding
rings, see hereinafter.
1 –opposite flange
2 –seal
3 –sensor
4 –grounding connector
Grounding rings
Only if they are ordered. They are applied for plastic or metal pipes with the inside layer for
the measuring tube elevated or put out onto the faces of the flow sensor. The conductive rings
made of stainless steel provide conductive connection with the measured fluid.
The flow sensor is furnished with a stainless grounding screw for the grounding cable being
delivered with mounting accessories. This must be conductively connected with the
grounding rings.
1 –opposite flange
2 –seal
3 –grounding ring
4 –sensor
5 –grounding connector