halstrup-walcher KAL 84 User manual

KAL 84 Instruction Manual Document 7100.003554 12/2015
Instruction Manual
KAL 84 Calibration Device
halstrup-walcher GmbH
Stegener Straße 10
D-79199 Kirchzarten
Germany
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.halstrup-walcher.com

KAL 84 Instruction Manual
KAL 84 Instruction Manual 2
Table of Contents
1Safety precautions ............................................................................................................ 4
1.1 Appropriate use ................................................................................................................ 4
1.2 Shipping, assembly, electrical connections and startup..................................................... 4
1.3 Troubleshooting, maintenance, repairs, disposal .............................................................. 4
1.4 Symbols ............................................................................................................................ 5
2Instrument description ....................................................................................................... 6
2.1 Features ........................................................................................................................... 6
2.2 User interfaces .................................................................................................................. 6
2.2.1 The 4 ½ digit LCD ............................................................................................................. 7
2.2.2 ON/OFF ............................................................................................................................ 7
2.2.3 Backlighting ...................................................................................................................... 7
2.2.4 Analog output .................................................................................................................... 7
2.2.5 Units of pressure ............................................................................................................... 7
2.2.6 Pressure ports .................................................................................................................. 7
2.2.7 Purge valves ..................................................................................................................... 7
2.2.8 Automatic zero-point calibration ........................................................................................ 7
2.2.9 Time constants ................................................................................................................. 8
2.2.10 Pressure transducer dial ................................................................................................... 8
3Start-up ............................................................................................................................. 8
4Pneumatic connections ..................................................................................................... 9
5Replacing the battery ........................................................................................................ 9
6Calibration ....................................................................................................................... 10
7Troubleshooting .............................................................................................................. 10
8Technical data ................................................................................................................. 11
8.1 Appendix A: Parts in contact with measurement medium ................................................ 12
9Dimension drawing .......................................................................................................... 13

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Purpose of instruction manual
This instruction manual describes the features of the KAL 84 calibration device and
provides guidelines for its use.
Improper use of this instrument or failure to follow these instructions may cause injury
or equipment damage. All individuals responsible for operating this instrument must
therefore be properly trained and aware of the hazards, and must carefully follow
these operating instructions and the safety precautions detailed within. Contact the
manufacturer if you do not understand any part of this instruction manual.
Handle this manual with care:
 It must be readily available throughout the lifecycle of the instrument.
 It must be provided to any individuals who assume responsibility for operating the
instrument at a later date.
 It must include any supplementary materials provided by the manufacturer.
The manufacturer reserves the right to continue developing this instrument model
without documenting such development in each individual case. The manufacturer
will be happy to determine whether this manual is up-to-date.
Conformity
This instrument corresponds to the state of the art and meets all legal requirements
set forth in EC directives as evidenced by the CE label.
© 2005
The manufacturer owns the copyright to this instruction manual. This manual contains
data, instructions and drawings pertaining to the features and usage of this
instrument; copying this manual in part or in full or distributing it to third parties is
prohibited.

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1 Safety precautions
1.1 Appropriate use
The KAL 84 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.
Use only an IEC 6F22 rechargeable battery (9 V). Do not use non-rechargeable
batteries as these can destroy the instrument.
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.
1.2 Shipping, assembly, electrical connections and startup
Do not close the pressure inputs when shipping, as changes in barometric pressure
could damage instruments with low measuring ranges.
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.
The instrument may only be operated by appropriately trained individuals who have
been authorized by the operator of the facility.
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.
Specific safety precautions are given in individual sections of this manual.
1.3 Troubleshooting, maintenance, repairs, disposal
The individual responsible for the electrical connections must be notified immediately
if the instrument is damaged or if errors occur that cannot be corrected as indicated in
section 7.
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.

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The electronic components of the instrument contain environmentally hazardous
materials and materials that can be reused. For this reason the instrument must be
recycled in accordance with the environmental guidelines of the jurisdiction in
question once it has been taken permanently out of service.
1.4 Symbols
The symbols given below are used throughout this manual to indicate instances when
improper operation could result in the following hazards:
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

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2 Instrument description
2.1 Features
The KAL 84 is a portable device for calibrating pressure gauges. Typical applications
include calibrations of medical devices such as blood pressure meters, ventilators
and infusion pumps. The halstrup-walcher KAL 84 pressure calibration device is also
used in the manufacture of pressure sensors and pressure switches. Its sturdy
construction and rechargeable battery also make this instrument ideal for use in
assembling pressure transducers, as it allows the transducers to be calibrated on site.
Use of the KAL 84 for quality assurance purposes, e.g., as a transfer standard for test
equipment monitoring, is also becoming increasingly important.
The KAL 84 pressure calibrator consists of a pressure sensor, a liquid crystal display
and a transducer used to generate the desired pressure.
2.2 User interfaces
1 2 3 4 5 6 7 8 9 10
Fig. 1
1
4 ½ digit, backlit LCD
2
ON/OFF
3
Backlighting for display
4
Analog output
5
Pressure units (kPa/mmHg)
6
Pressure ports
7
Purge valves
8
Automatic zero-point calibration
9
Time constants: 0.02 s / 0.1 s / 1 s
10
Pressure transducer dial

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2.2.1 The 4 ½ digit LCD with “Low battery”- function
The 4 ½ digit LCD displays the pressure measured by the internal reference sensor. If
a test object has been connected to the instrument, the actual value displayed will
agree with that of the test object after the settling time of the instrument.
In case of “Low-battery” showed on the display, recharge or replace the battery. The
displayed values do not agree with the system-pressure in that case.
2.2.2 ON/OFF
Pressing this key once turns the instrument on. Pressing this key a second time turns
the instrument off.
2.2.3 Backlighting
Pressing this key once turns the backlighting on. Pressing this key a second time
turns the backlighting off.
2.2.4 Analog output
The analog output—connected via common banana plugs (d = 4mm) with at least 2
k of resistance—generates an output voltage proportional to the pressure.
2.2.5 Units of pressure
This feature allows the operator to toggle between 2 units of pressure, e.g., Pa and
mmHg. A red LED indicates the units used.
2.2.6 Pressure ports
These ports are for connecting the test object to the KAL 84 (inner diameter of tubing
= 5 mm)
2.2.7 Purge valves
Purge valves are used to vent any overpressure that results when the test object is
connected to the system. Turn the purge valves to the left to open. The purge valves
should also be opened if the transducer dial has been turned as far as it will go in only
one direction and then returned to its starting position when the test object has been
connected.
The purge valves should always be closed when taking measurements!
2.2.8 Automatic zero-point calibration
Press the “>0<” key to calibrate the zero point (typically performed before each
measurement). The purge valves must be opened before calibrating the zero
point.
The final place on the display reading may be off by a few digits after
calibrating the zero point. This is within the acceptable range of tolerance.
The display is not lit while the zero point is being calibrated and may need
to be switched on again afterwards.

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2.2.9 Time constants
Pressing this key toggles between three different time constants (response times) for
the KAL 84 pressure sensor. A red LED indicates the time constant selected. The
default time constant (20 ms) is used if no LED appears.
2.2.10 Pressure transducer dial
Turning the dial generates pressure—left for negative pressure, right for positive
pressure. The pressure transducer must be brought to its middle position before
generating negative pressure. This is done by turning the dial to the right several
times with the pressure ports open.
Never force the dial!
3 Start-up
Before plugging in the power adapter, make sure the correct supply voltage is
available. The rechargeable battery (included) will charge up when the instrument is
run from the power adapter, even if the KAL 84 is not turned on. Because the battery
may or may not be fully charged upon delivery, we recommend charging the battery
before start-up. The KAL 84 will only run on battery power if the power adapter is
unplugged.
If the battery has reached the end of its lifecycle and is no longer usable, it
must be replaced with a 9 V, IEC 6F22 rechargeable battery.
The power adapter should never be connected if non-rechargeable batteries
have been installed, as this could destroy the instrument.
Only use the included power adapter! For replacement please contact the
manufacturer.
Pressing the “0/1” switch places the instrument in operating mode. Please remember
that it takes roughly 30 minutes for the pressure sensor to warm up. During this
period, the zero point can fluctuate, particularly if the instrument is subject to changes
in temperature. The automatic zero-point calibration feature should be activated
numerous times during this period.

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4 Pneumatic connections
Connect the device to be calibrated to the KAL 84 using a Y connector as shown
below:
If the volume of the test object is high enough that the pressure bellows cannot
generate enough pressure, use an additional manual pump (included with the
calibrator upon request) and hook it up to the instrument with a Y connector.
Exercise caution when using the manual pump. A manual pump can quickly
generate high levels of pressure, which can destroy the instrument. Caution
is particularly advised when using instruments with low measurement
ranges.
5 Replacing the battery
The LCD will read “Low Battery” if available power falls below that required to operate
the instrument. When this happens, either replace the battery or recharge it using the
charger included with the calibrator. To replace the battery, open the cover of the
battery compartment located on the rear of the instrument.
Do not put defective batteries in the garbage. They must be taken to the
waste collection site specified by local authorities.

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6 Calibration
Please keep in mind that part I of DIN 16 005 requires reference instruments to be at
least four times as precise as the device being calibrated.
Equipment used to test halstrup-walcher pressure calibration devices are monitored
continuously and our instruments are themselves calibrated using reference
pressures based on national standards.
In order to maintain this high level of quality over a long period of time, we
recommend sending your pressure calibration device to the manufacturer for
recalibration at least once a year. A halstrup-walcher certificate of linearity or a
calibration certificate from a testing facility accredited by Germany's National
Accreditation Body (DAkkS) is available upon request.
Please note when the next calibration is due (indicated on the rear of the
instrument).
7 Troubleshooting
Problem
Cause
Corrective Action
KAL 84 will not switch on
power adapter is not plugged in
(to electrical outlet)
power adapter is not plugged in
(to the KAL 84)
incorrect supply voltage
dead battery
 plug the adapter into the
outlet
 connect the adapter to the
KAL 84
 provide correct supply voltage
 recharge or replace battery
Set pressure does not
remain constant
purge valve is open
leak in tubing
low battery
 close purge valve
 inspect tubing
 recharge or replace battery
Table 2

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8 Technical data
Measurement Data
measurement ranges
from 0 - 100 Pa to 0 - 100 kPa, or
±100 Pa to ±100 kPa (others available upon request)
overpressure range
99 %
overload capacity
10x for measurement ranges ≤ 20 kPa
2x for measurement ranges > 20 kPa
maximum system pressure
100 kPa
hysteresis
<0.1 % of the starting range
warm-up time
approx. 30 min.
temperature-dependent drift in zero
point
0.4 %/10 K (at +10° C…+50° C)
offset by running zero-point calibration
temperature-dependent drift in
measurement range
0.4 %/10 K (at +10° C…+50° C)
calibration temperature: 22° C
deviation from characteristic curve
(starting point setting)
0,2 % ± 1 Digit for 1kPa≤ measurement range ≤ 50kPa
or
0.5 % ± 1 Digit
Ambient conditions
medium
air, all non-aggressive gases
operating temperature
10 °C to +40 °C
storage temperature
-10 °C to +70 °C
relative humidity
0…80 %
EMC standards
EN 50081 part 1 and EN 50082 part 1
conformity
declaration of conformity available upon request
Electrical data
power consumption
max. 0.2 W
supply voltage
9 V rechargeable battery
with 230 VAC 50…60 Hz / 9 VDC adapter
others available upon request
setting time
20 ms, 100 ms, 1 s; set from keys on front panel
load resistance RL
RL ≥2 kΩ
display
4 ½ digit, LCD with backlighting that can be toggled on and
off, character height = 10 mm
Physical data
pressure connections
Ø 6.5 mm for NW6 tubing
(interior tubing diameter = 5 mm)
dimensions (w x h x d)
290 x 100 x 214 mm
weight
3 kg
operating position
horizontal

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8.1 Appendix A: Parts in contact with measurement medium
 beryllium bronze CuBe2  Araldite CY236 / HY988
 Mu metal (nickel alloy)  Loctite 242e
 Brass CuZn39Pb3  Carbonyl iron
 Aluminum AlCuMgPb / AlMg3  KEL (FPM: fluorinated rubber)
 Silicon (tubing) optional: Viton  Vepuran Vu 4457/51
 Crastin (PTBP)  UHU-Plus endfest 300 binder

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9 Dimension drawing
7100 003554_KAL84.doc 14.12.2015 Me