halstrup-walcher KAL 100 User manual

Instruction Manual
Calibration Device KAL 100/200 Series 3

7100.006934_Instruction_manual_KAL100/200_A_EN 2 13.09.2022
halstrup-walcher GmbH
Stegener Straße 10
D-79199 Kirchzarten, Germany
Tel. [phone]
[e-mail]
www.halstrup-walcher.com
© 2022, Me
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 them. It must not be
copied either wholly or in part or made available to third parties.
The instruction manual is part of the product. Please read this manual carefully, follow our
instructions, and pay special attention to the safety information provided. This instruction manual
should be available at all times. Please contact the manufacturer if you do not understand any
part of the instructions.
The manufacturer reserves the right to continue developing this device model without
documenting such development in each individual case. The manufacturer will be happy to
determine whether this manual is up-to-date.

7100.006934_Instruction_manual_KAL100/200_A_EN 3 13.09.2022
Table of Contents

7100.006934_Instruction_manual_KAL100/200_A_EN 4 13.09.2022

Purpose of instruction manual
7100.006934_Instruction_manual_KAL100/200_A_EN 5 13.09.2022
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 100 and 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
Conformity
This device is state of the art. It complies with the legal requirements of EC directives.
This is shown by the CE mark.

Safety precautions
7100.006934_Instruction_manual_KAL100/200_A_EN 6 13.09.2022
1 Safety precautions
1.1 Symbols
The symbols shown here are used throughout the following text to highlight the hazards
associated with using the KAL 100 and KAL 200 and to point out important information for
operating the instrument.
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.
WARNING! ELECTRICITY HAZARD!
1.2 Appropriate use
The KAL 100 and KAL 200 calibration device is used for testing and calibrating pressure sensors.
The instrument is designed for indoor use. To avoid damage, never expose the instrument to
liquids or humidity. Avoid strong sunlight, heavy dirt and strong vibrations.
Dust and dirt deposits inside can damage the Instrument. Under appropriate environmental
conditions (dust, smoke) the device should be serviced regularly by qualified personnel to prevent
damage due to overheating and other malfunctions.
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.

Safety precautions
7100.006934_Instruction_manual_KAL100/200_A_EN 7 13.09.2022
1.3 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.
1.4 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.
WARNING! ELECTRICITY HAZARD!
Electric shock due to high voltages inside the instrument.
Inside the instrument there are parts that are under high electrical voltage.
Never remove covers. There are no user-serviceable parts inside the unit. Do not use the
instrument if any covers are missing or damaged.
This instrument requires no maintenance.
Only the manufacturer may perform repairs that require the housing to be opened.
The electronic components of the instrument and the optionally included rechargeable battery
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.
WARNING!
Risk of injury due to improper handling of lithium-ion batteries
Lithium-ion batteries can cause serious injury in case of short circuit, overheating or mechanical
damage.

Instrument description
7100.006934_Instruction_manual_KAL100/200_A_EN 8 13.09.2022
2 Instrument description
2.1 Functions
The KAL 100 / 200 microprocessor-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

Calibration cycle
7100.006934_Instruction_manual_KAL100/200_A_EN 9 13.09.2022
3 Calibration cycle
3.1 Calibration data
The date of the last calibration is shown on the display for a short moment after each switch-on.
3.2 Recalibration
Depending on the application, it is recommended to have a recalibration performed after 12 or 24
months. For this purpose, please send the device back to the manufacturer.
Please use our online contact form at
https://www.halstrup-walcher.de/en/contact/

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 10 13.09.2022
4 Control elements of the device
4.1 Control elements on the front panel
Fig. 2: Controls on the 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
Table 1: Controls on the front
1
2
3
4
5
6
7
8
9

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 11 13.09.2022
4.1.1 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.
4.1.2 Menu key
Pressing the menu key allows the operator to adjust the following 7 settings:
1. Target value increments: 5, 10, 20, 25, 50, 100%
2. Pressure input: +P, -P, Diff (both)
3. Units of pressure: kPa, hPa, Pa, mbar, Torr, mmHg, mmH2O, inH2O
4. (Optional) Unit in the 2nd line (unit of pressure, V, mA)
5. Zeroing: on, off
6. Language: German, English, French, Italian, Spanish
7. 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.
4.1.3 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 (see chapter 4.1.7).
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.

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 12 13.09.2022
Example: increment: 25 %; target value 1.000 Pa
0 % 0 Pa; 25 % 250 Pa; 50 % 500 Pa; 75 % 750 Pa; 100 % 1.000 Pa
Install the device with the pressure connections facing downwards so that any condensation that
may occur in the hoses does not run into the sensor.
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.
The "+OK" appears on the display when the adjusted setpoint is reached. The deviation between
setpoint and actual value must be <0.05% of the device measuring range for this purpose.
4.1.4 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.
Information: Only one pressure port may be connected if using the KAL 100 / 200 to
generate positive or negative overpressure. The hose pump draws in air through the other
pressure port.
S +100.00 Pa 100 %
I + 99.98 Pa +OK
Test 2s -0.02 %
I + 99.98 Pa +OK

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 13 13.09.2022
4.1.5 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 100 / 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 (see chapter 4.1.7)
Information: In order to achieve the highest possible accuracy in pressure
measurements, it is necessary to set the correct pressure input port (see 4.1.6). In
addition, the KAL 100 / 200 should be operated at a room temperature of 22°C and should
be switched on for at least 30 minutes.
4.1.6 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.
4.1.7 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 KAL 100 / 200 are displayed in the lower
line on the right.

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 14 13.09.2022
4.2 Rear panel
Fig. 3 Rear panel
10
USB-Port *
11
Inlet connector for non-heating apparatus
12
Micro fuse, 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
Input port for voltage measurement 0…10V, Ri = approx. 40kOhm *
Table 2: Rear panel
*KAL 100 only optional
10
11
15
12
14
13
17
16
18

Control elements of the device
7100.006934_Instruction_manual_KAL100/200_A_EN 15 13.09.2022
4.2.1 Power input, primary on/off switch, micro fuse
The KAL 100/200 calibration instrument is factory-equipped with an all-
voltage power supply for voltages from 85 to 264 VAC and mains
frequencies from 47 to 63Hz (tolerance is already included).
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 see electrical data).
Located above the micro fuse is the double-pole, primary on/off switch (13),
which separates the KAL 100 / 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!
11
12
13

Menu items
7100.006934_Instruction_manual_KAL100/200_A_EN 16 13.09.2022
5 Menu items
5.1 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 %.
5.2 P-input
This allows the user to select the pressure input as: +P, -P or DIFF.
5.3 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
5.4 Unit 2 (KAL 200 as standard, KAL 100 optional)
The KAL 100 / 200 has one input for voltage measurement and one input for current
measurement. This allows the settings of the measured variable displayed in the second line to be
displayed and adjusted. 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 KAL 100 / 200 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.
5.5 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).
5.6 Language
Here you can select the language used in the display. You can choose between the following
languages:
•German
•English
•French
•Italian
•Spanish

Menu items
7100.006934_Instruction_manual_KAL100/200_A_EN 17 13.09.2022
5.7 Restore default settings
Press the UP or DOWN navigation keys to restore the default settings. Default settings are as
follows:
Incrementation
25 %
P-input
+P
Unit
hPa
Zeroing
ON
Table 3:factory default settings

Battery operation (optional)
7100.006934_Instruction_manual_KAL100/200_A_EN 18 13.09.2022
6 Battery operation (optional)
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.
Infomation: In battery mode, the device switches off automatically after 30 minutes
without pressing a key.
Information: 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. A
reload after 3 to 4 Months is highly recommended. The storage temperature is 0° to 40°C.
6.1 Charging the 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), the quick-charging mode is activated
automatically.
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.
There are different 4 symbols for the charging status:
0 to
15 %:
(flashing)
16 to
40%:
41 to
90%:
91 to
100%:
After switching on the KAL 100 / 200, 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 for some
seconds.
Accu: Charging
Charging:

Battery operation (optional)
7100.006934_Instruction_manual_KAL100/200_A_EN 19 13.09.2022
In order to prevent damage to the battery due to deep discharge, the device switches itself off
automatically at a residual charge of approx. 5%. This is indicated by the message "Battery low"
on the display shortly before switching off.
If the device is not connected to the mains power when it is switched off or the mains switch on
the rear is not switched on, charging is not possible.
If this happens, the device should be connected to the mains power supply to charge the 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 quick-charge mode described above by
pressing the on/off switch on the front panel.
Due to the four steps of the charge level, the level “91 to 100%” is shown for some time, but the
battery will continue to charge. When the charging is completed the device switches itself off.
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 100 / 200 or some month of not using the device.
6.2 Behavior with deeply discharged battery
The integrated 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 KAL 100 / 200 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.
Information: 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.

Zeroing
7100.006934_Instruction_manual_KAL100/200_A_EN 20 13.09.2022
7 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 minutes.
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:
7.1 Manual Zeroing
Pressing and holding the ‘pressure’, ‘target value’ or ‘test’ keys will cause the instrument to zero
itself regardless of the menu setting.
8 Overpressure protection
The KAL 100 / 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.
Zeroadjust