halstrup-walcher KAL 100 User manual

Document 7100.004364 10/2015
Instruction Manual
KAL 100/200 Calibration Device
with Rechargeable Battery
halstrup-walcher GmbH
Stegener Straße 10
D-79199 Kirchzarten, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.halstrup-walcher.com

Instruction Manual KAL 100/200
2
Table of Contents
1Purpose of instruction manual 3
2Conformity 3
3Safety precautions 4
3.1 Appropriate use 4
3.2 Shipping, assembly, electrical connections and start-up 4
3.3 Troubleshooting, maintenance, repairs, disposal 4
3.4 Symbols 4
4Instrument description 6
4.1 Functions 6
4.2 User interfaces 7
4.2.1 Power input, primary on/off switch, micro fuse 8
4.2.2 I/O switch 9
4.2.3 Menu key 9
4.2.4 Target value key 10
4.2.5 "Test" key 11
4.2.6 Pressure key 11
4.2.7 Pressure input port 12
4.2.8 Purge feature 12
4.3 Menu items 12
4.3.1 Incrementation 12
4.3.2 P-input 12
4.3.3 Units of pressure 13
4.3.4 Unit 2 (optional) 13
4.3.5 Zeroing 13
4.3.6 Language 13
4.3.7 Rechargeable battery 14
4.3.8 Default settings 14
5Battery operation 15
5.1 Charging the rechargeable battery 15
5.2 What to do in the case of total discharge 16
6Zeroing 17
6.1 Manual zeroing 17
7Overpressure protection 17
8USB port 18
8.1 Commands for the serial interface 19
8.1.1 Operating modes 19
8.1.2 Setting parameters 20
8.1.3 Miscellaneous 20
8.1.4 Query values 21
8.2 Interface configuration 23
9PC software 24
9.1 Software downloads 24
10 Troubleshooting 25
11 Technical data 25

Instruction Manual KAL 100/200
3
1 Purpose of instruction manual
Please read this instruction manual thoroughly before operating the instrument in order to avoid
injury or equipment damage caused by improper use of this instrument or failure to follow these
instructions.
This instruction manual describes the features of the KAL 200 calibration device and provides
guidelines for its use.
Any individual charged with handling this instrument must be trained in proper instrument
operation and informed of all potential hazards. The instruction manual, and in particular the
safety precautions contained therein, must be followed carefully. Please contact the
manufacturer immediately if you do not understand any part of this instruction manual or
if you require additional information.
Handle this manual with care and ensure that it
 is readily available throughout the lifecycle of the instrument,
 is provided to any individuals who assume responsibility for operating the instrument at a
later date, and
 includes any supplementary materials provided by the manufacturer.
halstrup-walcher GmbH reserves the right to continue developing this instrument model without
documenting such development in each individual case. We will be happy to determine whether
this manual is up-to-date.
2 Conformity
This device is state of the art. It complies with the legal requirements of EC directives. This is
shown by the CE mark.
© 2010, 2014, 2015
The manufacturer owns the copyright to this instruction manual. It contains technical data,
instructions and drawings detailing the device’s features and how to use it. It must not be copied
either wholly or in part or made available to third parties.

Instruction Manual KAL 100/200
4
3 Safety precautions
3.1 Appropriate use
The KAL 200 calibration device is used for testing and calibrating pressure sensors.
Always observe the operating requirements – particularly the permissible supply voltage –
indicated on the rating plate and in the “Technical data” section of this manual.
The instrument may only be handled as indicated in this manual. Modifications to the instrument
are prohibited. The manufacturer is not liable for damages caused by improper use or failure to
follow these instructions. Violations of this type render all warranty claims null and void.
3.2 Shipping, assembly, electrical connections and start-up
Please do not close the pressure inlets during shipping! Changes in barometric pressure may
damage devices with low measuring ranges.
Assembly and the electrical connections should only be handled by professionals. Only
technical personnel who are appropriately trained and authorized by the operator of the facility
may assemble the instrument and set up its electrical connections.
Pressurized air or breath is not to be used for performance tests, as this could damage
instruments with low measurement ranges.
Measurement errors may occur if the instrument is not kept protected from sunlight.
See the individual sections of this manual for specific safety precautions.
3.3 Troubleshooting, maintenance, repairs, disposal
The individual responsible for the electrical connections must be notified if the instrument is
damaged or if errors occur that cannot be corrected as indicated in Section 10.
This individual must take the instrument out of service until the error has been corrected and
ensure that it cannot be used unintentionally.
Always unplug the power cord before opening the instrument!
This instrument requires no maintenance.
Only the manufacturer may perform repairs that require the housing to be opened.
The electronic components of the instrument contain materials that can be reused. The
instrument must therefore be sent to a recycling plant when you no longer wish to use it. The
environment codes of your particular country must be complied with.
3.4 Symbols
The symbols shown here are used throughout the following text to highlight the hazards
associated with using the KAL 200 and to point out important information for operating the
instrument.

Instruction Manual KAL 100/200
5
WARNING!
This warns you of a potential hazard that could lead to bodily injury up to and
including death if the corresponding instructions are not followed.
WARNING:
This warns you of a potential hazard that could lead to significant property
damage if corresponding instructions are not followed.
INFORMATION:
This indicates that the corresponding information is important for operating the
instrument properly.

Instruction Manual KAL 100/200
6
4 Instrument description
4.1 Functions
The KAL 200 microprocess-controlled pressure calibration device can be used for the following:
 Simply generating positive and negative reference pressures
 Measuring positive and negative pressures
 Measuring differential pressure
 Identifying leaks in a test object
 Determining dynamic response behaviour of a test object
Fig. 1 Basic circuit diagram
Pressure
measurement
Controller
Pump
Pressure
actual value
Pressure
target value
actual and target values
USB
pos. pressure
Comparison of
neg. pressure
Microprocessor
PC interface
Display
+
Valves

Instruction Manual KAL 100/200
7
4.2 User interfaces
1 2 3 4 5 6 7 8 9
Fig. 2 Front
1
Secondary on/off switch
2
Menu
3
Positive pressure input/output
4
Negative pressure input/output
5
Target value
6
Pressure measurement
7
Test
8
Alphanumeric display
9
Navigation keys

Instruction Manual KAL 100/200
8
11 12 13
Fig. 3 Rear
10
USB port
11
Inlet connector for non-heating apparatus
12
Micro fuse, 315 mAT, 5 x 20 mm
13
Primary on/off switch
14
Power supply +24V/125mA, galvanic separation
15
Ground for 24V/125mA
16
Input port for current measurement 0…20 mA,
input resistance 240 Ohm
17
Ground connector for voltage and current input
port
18
Voltage input 0…10V, Ri = approx. 40kOhm
4.2.1 Power input, primary on/off switch, micro fuse
The KAL 200 calibration device is designed at the factory to
accommodate a supply voltage of 230 VAC/50-60 Hz (115 VAC/50-60
Hz is optional). Voltage fluctuations of +6% to -15% are permissible.
The supply voltage connector (11) is located on the rear of the
instrument (inlet connector for non-heating apparatus + ground wire).
The instrument’s micro fuse (12) is located above this connector. Value:
315 mAT; dimensions: 5 x 20 mm. Located above the micro fuse is the
double-pole, primary on/off switch (13), which separates the KAL 200
from the supply voltage.
WARNING! Risk of Electrical shock! Failure to unplug the power supply cord
before replacing the fuse may result in fatal injuries!
10
14
15
16
17
18
11
13
12

Instruction Manual KAL 100/200
9
4.2.2 I/O switch
Secondary on/off switch; in standby mode the power input is approx. 5 W.
Pressing the primary on/off switch, a double-pole switch located on the rear of the
instrument, separates the instrument from the power supply.
4.2.3 Menu key
Pressing the menu key allows the operator to adjust the following 8 settings:
 Target value increments: 5, 10, 20, 25, 50, 100%
 Pressure input: +P, -P, Diff (both)
 Units of pressure: kPa, hPa, Pa, mbar, Torr, mmHg, mmH2O, inH2O
 (Optional) Unit in the 2nd line (unit of pressure, V, mA)
 Zeroing: on, off
 Language: German, English, French, Italian, Spanish
 Battery data: Voltage, present current, present current source, battery charge status
 Default settings
Navigation keys
Item 1 is displayed when the menu function is first activated; users may select
other items by pressing the right/left navigation keys. The arrows on the
display indicate which navigation keys are active. Pressing any of the
operating mode keys (target value, pressure, test) exits the menu. Exiting the
menu saves user preferences, which will be automatically set the next time
the instrument is switched on.
I/O

Instruction Manual KAL 100/200
10
4.2.4 Target value key
The target value function and integrated hose pump allow the user to enter a
predefined pressure. The target value is set using the navigation keys. The purge
valve is activated or deactivated by repeated pressing of the target value key.
Press the right/left navigation keys to position the blinking cursor over the digit to be changed.
Select the desired value by pressing the up/down keys. To change the sign of the target value,
position the cursor over the +/- sign and press the up/down keys to change. Move the cursor to
the right positions over the percentage symbol, to change the percentage by the increments
previously specified in the menu.
The target pressure to be set is the product of the target value and the percentage value.
Example: Increment set from the menu: 25 %; target value 1000 Pa
0 % => 0 Pa; 25 % => 250 Pa; 50 % => 500 Pa; 75 % => 750 Pa; 100 % => 1000 Pa
The actual pressure is shown in the lower portion of the display. It takes about 1s to adjust
settings when small volumes are connected. An additional pump is advisable if connecting
larger volumes, as it would otherwise take too long to adjust the settings. The maximum target
value may not exceed 120% of the measurement range.
If no tubing is connected to the pressure input valve and the target value has been set to 0 or
0%, the KAL 200 will constantly seek to correct for pressure differences (such as those caused
by temperature drift). To minimize this, the control unit (motor) shuts down after roughly 5 min.
The display reads "inactive".
Press any key (other than the I/0 switch) to return the instrument to the "active" state.
S +100.00 Pa 100 %
A + 99.98 Pa +OK
----standby---
I 0.61 Pa +P

Instruction Manual KAL 100/200
11
4.2.5 "Test" key
The test feature blocks both pressure ports. This allows the operator to measure
a drop in pressure on the test object itself (leakage test).
Elapsed time and departure from the starting pressure (in %) are shown in the
top line of the display. Pressing the test key starts the measurement again. The
target value feature allows the user to restore the previous target pressure.
Only one pressure port may be connected if using the KAL 200 to generate
positive or negative overpressure. The hose pump draws in air through the
other pressure port.
4.2.6 Pressure key
This allows the user to measure both positive and negative pressures up to a
nominal pressure of +20%. In other words, a KAL 200 with a measurement range
of 1000 Pa can measure up to ±1200 Pa. The pressure measurement capsule is
protected if this value is exceeded. Differential pressures can be measured by
using both pressure ports. Navigation keys do not have any function in this case.
The purge valve is activated or deactivated by repeated pressing of the target
value key.
The P-input must be set properly in order to ensure that pressure measurements
are as accurate as possible. The KAL 200 should also be operated at room
temperature (22°C).
Test
Test 2s -0.02 %
A + 99.98 Pa +OK

Instruction Manual KAL 100/200
12
4.2.7 Pressure input port
For technical reasons, the sensitivity of the pressure sensor
varies according to the pressure chamber used. Selecting the
pressure input allows the user to compensate for these
differences. The selected setting is displayed along with the
"+P", "-P" or "dP" symbols.
4.2.8 Purge feature
If the instrument is in target value or pressure mode, the purge feature can be activated or
deactivated by pressing the appropriate key again. This connects the two ports of the
instrument with each other internally in order to release any overpressure. This feature is also
useful if sensitive sensors are to be connected. The use of short lengths of tubing can result in
high pressures, which may damage or even destroy the sensor. No pressure can build if the
purge feature is activated as the air can escape through the free port. When the purge feature is
activated, the two pressure ports of the KAL200/100 are displayed in the lower line on the right.
4.3 Menu items
4.3.1 Incrementation
This feature allows the user to modify the percentage of the target value in the following
increments: 5 %, 10 %, 20 %, 25 %, 50 % and 100 %.
4.3.2 P-input
This allows the user to select the pressure input as: +P, -P or DIFF.

Instruction Manual KAL 100/200
13
4.3.3 Units of pressure
This feature allows the operator to select the units used for displaying pressures. Certain
measurement ranges cannot be displayed meaningfully in some units, in which case the units in
question are not available. The following units may be selected:
 hPa
 mbar
 Torr
 mmHg
 mmH2O
 inH2O
 kPa
 Pa
4.3.4 Unit 2 (optional)
As an option, the KAL200 can now be fitted with an input port for voltage measurements and an
input port for current measurements. If this option is active, it can be used to display the
measurement, which is presented in the second line. For example, if the user selects V as the
unit, the voltage measured at the voltage input port will be displayed in the second line. This
also applies for the pressure and target value features. The KAL200 is therefore capable of
measuring the voltage and output current of a sensor. These values can also be readout using
the interface and, if necessary, processed directly in a form. The corresponding ports are
located on the rear of the instrument.
4.3.5 Zeroing
By default the instrument resets the zero point approximately 6 minutes after it is initially
switched on and then automatically every 30 minutes or after a major temperature change.
Zeroing always results in changes in volume and thus to pressure. This can disrupt certain
measurement sequences. Zeroing is automatically suppressed when the instrument is in test
mode. The instrument can also be zeroed by pressing and holding (approx. 0.5 s) any of the
operating mode keys (target value, pressure, test).
4.3.6 Language
This feature allows the operator to select the language used. The languages available are
German, English, French, Italian and Spanish.

Instruction Manual KAL 100/200
14
4.3.7 Rechargeable battery
With this menu item, the user can display the voltage, present current, battery charge status and
present current source for the instrument. Use the UP and DOWN keys to select the parameters
to be displayed.
4.3.8 Default settings
Press the UP or DOWN navigation keys to restore the default settings. Default settings are as
follows:
 Incrementation = 25%
 P-input = +P
 Units = hPa
 Zeroing = ON

Instruction Manual KAL 100/200
15
5 Battery operation
The device contains a rechargeable lithium ion battery, which allows the device to operate even
when not connected to a mains electricity supply. The operating time provided by the battery
depends on the mode of operation. When measuring pressure, a fully charged battery is
capable of powering the device for between 20 and 30 hours. The operating time is less in
target value mode as additional electricity is required to drive the device. However, even in this
mode, an operating time of 8…10 hours should pose no problem.
If you do not intend to use the device for a longer period of time, you should
fully charge the rechargeable battery beforehand in order to avoid total
discharge.
5.1 Charging the rechargeable battery
In order to maximise the operating life of the rechargeable battery, it is important to ensure that
it always has a sufficient residual charge. As the device continues to consume power when
switched off, albeit at a very low level, this is particularly important if it is to be left switched off
for a longer period of time. Consequently, there is a risk of the battery discharging completely
over an extended period.
While operating in normal mode, the battery is charged using a low current in order to prevent
additional heat being generated by the device itself. The charging time here is approx. 12 hours.
When the device is switched off (key on the front panel), it checks the status of the battery and
activates the charging mode if it is less than 80% charged. The display shows the following
message:
The device switches itself off when the battery is fully charged. If you wish to use the device
before charging has been completed, you can start the normal operating mode again at any
time by pressing the on/off switch on the front panel. Switching off the mains power supply
interrupts the charging process.
The charge level is displayed in 25%-steps. The 0% and the 25% Steps might be seen only
after a long period of not using the KAL. In the normal use the KAL would switch itself off at a
charge level of about 40%, which is aprox. at 13,5V. This early cutoff is done to avoid a deep
discharge during a longer period of storage.
Accu: Charging
Charging: xx.x%

Instruction Manual KAL 100/200
16
After switching on the KAL, the charge level must be evaluated and sent to the Display unit.
Due to this the displayed charge level may be delayed or might show wrong values( 0.0%) for
some seconds.
The device cannot charge if it is not connected to the mains power supply or if the master switch
on the back of the device is not switched on. In this case, the following message will be
displayed for a few seconds as soon as the residual charge of the battery falls below 40%:
If the main power supply is not connected or switched off the device will switch off itself after a
few seconds. If this happens, the device should be connected to the mains power supply to
charge the rechargeable battery. This is particularly important if the device will not be used for a
longer period of time.
If, after switching on the power supply, the device reports with the normal operating mode
(display: KAL200 Rev. X.X), it can be put into the rapid charge mode described above by
pressing the on/off switch on the front panel.
Due to the 25% steps of the charge level, the level might show 100.0% for some time. At a real
charge level of aprox. 90% the display will switch the 90% Display, but the battery will continue
to charge. When the battery is fully charged (device has switched itself off), you can separate
the device from the mains power supply again. The charged battery has enough power to work
for 1 to 2 days with the KAL or some month of not using the KAL200.
5.2 What to do in the case of total discharge
The integrated rechargeable battery has its own protective switch. This completely switches off
the output voltage of the battery if it falls below a specified value. If this happens, the display of
the KAL200/100 may not show the battery symbol. Whenever it is switched on, the KAL100/200
will attempt to reactivate the rechargeable battery. It is therefore advisable in these
circumstances to switch the device on and off until the rechargeable battery symbol is visible
once again.
However, the most effective method is to avoid leaving the device with an empty battery
for an extended period and always to charge the battery before any longer periods during
which it will not be in use.
Charge < 40%
connect mains

Instruction Manual KAL 100/200
17
Zeroadjust
6 Zeroing
External influences such as temperature, position or ambient pressure can shift the instrument’s
zero point, i.e. the value displayed when the pressure ports are open. Zeroing is the process by
which the instrument automatically registers this shift and figures it into the currently displayed
pressure value. The instrument always zeroes itself after it is switched on. If automatic zeroing
has been activated, it will zero itself again after 6 min. and then every 30 min.
Zeroing switches the internal valves, which necessarily involves a loss in pressure. If this
interferes with instrument operation, the automatic zeroing feature can be switched off.
Automatic zeroing is always suppressed when the instrument is in test mode.
Display when zeroing:
6.1 Manual zeroing
Pressing and holding the ‘pressure’, ‘target value’ or ‘test’ keys will cause the instrument to zero
itself regardless of the menu setting.
7 Overpressure protection
The KAL 200 has an internal overpressure safeguard that protects the precision pressure
measurement capsule from damage. Nevertheless, great caution should be taken when
connecting the instrument to an unknown pressure source.

Instruction Manual KAL 100/200
18
8 USB port
The KAL 200 has a USB port, which is detected by a PC as a serial interface. This port allows
the instrument to exchange information and commands with a PC. This feature allows the
operator to save settings and to transfer results to a PC.
The interface (USB serial port (COMx)) has the following settings:
 9600 baud
 8 data bits
 no parity
 one stop bit
The following table provides an overview of commands and the corresponding data.

Instruction Manual KAL 100/200
19
8.1 Commands for the serial interface
8.1.1 Operating modes
Command
Meaning
Echo
MT
Mode – test
MT
MZ
Mode – zeroing
MZ
MS
Mode – target value
MS
MP
Mode – pressure measurement
MP
MK1
Keyboard on
MK1
MK0
Keyboard off
MK0
MB
Block ports. Instrument is inactive.
Cancel using commands MS or MP
MB
ME
Cancel purge in pressure or target
value mode using MM
MM
Measure in pressure or target value
mode
MI0
Positive P-input
MI0
MI1
Negative P-input
MI1
MI2
Differential pressure measurement
MI2

Instruction Manual KAL 100/200
20
8.1.2 Setting parameters
Command
Meaning
Format
Description
>PSxxx.xxxxx
Target value in
hPa
Floating
>PDx
Incrementation
1 digit, 8 bit 0..5
0: 5%
2: 20%
4: 50%
1: 10%
3: 25%
5: 100%
>PEx
Units
1 digit, 8 bit 0..9
0: kPa
2: hPa
4: psi
6: mmHg
8: inHg
1: Pa
3: mbar
5: Torr
7: mmH2O
9: inH2O
>PLx
Language
1 digit, 8 bit 0..4
0: German
2: French
4: Spanish
1:English
3: Italian
>PPxxx
Percentage value
1 digit, 8 bit 0 … 100
8.1.3 Miscellaneous
Command
Meaning
Echo
STOS
Save setting parameters
OK
RCLS
Load setting parameters
OK
RCLP
Load device parameters
OK
RV
Retrieve device revision
Kal200 Rev. X.X