KAM Simple Precision CHA User manual

API COMPLIANT
TEL [phone]
FAX [phone]
Email [email protected]
KAM CONTROLS, INC.
3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com
User Manual
KAM® CHA™
COLORIMETER/HAZE ANALYZER PTB 04 ATEX 1027
Ex II 2 G Ex db IIB T6 Gb
CHAMANUAL-0917

1
CHAMANUAL 0917 KAM CONTROLS, INC.
TABLE OF CONTENTS
SECTION TITLE PAGE
1Introduction 2
• Available models and mounting options 2
• Theory of operation 2
• Features 3
• Applications 3
2Specifications 4
• Specifications 4
• Dimensional drawings 5
3Installation 7
• "Do's" and "don't"s 7
• Main line 8
• Removal 11
• Power wiring 12
• Communications wiring 13
4Operations and maintenance 15
• Calibration 15
• Color scale ranges 15
• Hyperterminal (RS485) 15
• Cleaning and inspection 16
• Readings verification 16
5 MODBUS Configuration 17
CAUTION:
When installing the CHA™ sensor in a pipeline containing petroleum products,
petro-chemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ “Health, Safety and Environmental Policy Procedures” to
ensure safe installation.
KAM CONTROLS, INC. reserves the right to make changes to this document without notice.

2
CHAMANUAL 0917 KAM CONTROLS, INC.
INTRODUCTION
AVAILABLE MODELS and MOUNTING OPTIONS
THEORY OF OPERATION
Color variations in refined products indicate impurities and/or the presence of water. Refined products are often prone
to haze or diffused water contamination due to cooling towers which use water and in turn can saturate the product.
This can be a significant liability as color differentiation can be easily detected by the end user. The KAM®CHA™
Colorimeter/Haze Analyzer is the ideal quantitative solution for monitoring both the color of refined products, including
dyed product, and the presence of haze (trace/dissolved water) in pipelines following the refining process. The KAM®
CHA™ detects interface color variations within 1%, and unlike most colorimeters can detect the entire range of
visible color as defined by CIE 1931 (International Commission on Illumination). The simplicity of design and quality
of engineering employed in the Colorimeter/Haze Analyzer mean there are no moving parts. Using long-lasting LED
light sources ensures long-term, stable performance with limited maintenance and power requirements. In addition,
locating the electronics within an explosion-proof enclosure directly on the atmospheric end of the optical probe
creates a complete and compact unit with maximum installation flexibility. The KAM®CHA™ easily installs where
other colorimeters, weighed down by large electronics/computer units, cannot.
The five LED sources (Red, Blue, Green, Yellow, and IR) send light via fiber optics to the sensor end inserted into the
pipeline or analyzer loop. These beams of light pass through a 25mm window of pipeline fluids and then are reflected
back through fiber optics to the electronics enclosure for a total path of 50mm. KAM uses four LED's for color
determination to increase the accuracy over three-color (RGB) models. The fifth (IR) LED provides haze detection.
FIG. 1-1 FIG. 1-2 FIG. 1-3
Rectractable CHA™ on a
main pipe, with 2", 3", or 4"
flanged Seal Housing
Rectractable CHA™
on a main pipe, with
2" MNPT Seal Housing
CHA™ FT Flow Through
with 1" or 2" spool
(Custom flow through models avail.)
Full-opening
ball valve
Full-opening
ball valve

3
CHAMANUAL 0917 KAM CONTROLS, INC.
INTRODUCTION CONTINUED
FEATURES
• 5-LED design offers greater accuracy over other, 3-LED models
• Uses LEDs for long-term performance with minimal power and maintenance requirements
• Inserts in directly in pipeline under process conditions
• Outputs for industry scales ASTM D1500, Platinum-Colbalt, Saybolt plus Haze
• All requisite electronics housed on atmospheric end of probe; requires no additional controller
APPLICATIONS
• Multi-product pipeline interface detection
•Transmix/regrade reduction
• Haze monitoring/quality control at refineries and pipeline terminals
• Haze monitoring/quality control for incoming diesel fuel in power and marine applications
• Haze/quality control for aviation fuels at pipeline, tank farm, fuel trucks and carts
The disparity in light output versus light reflected back is then converted into an electronic or optical signature
which is amplified and sent to the computer. The computer in turn utilizes a mathematical formula to determine the
exact color and haze (turbidity) of the fluid in the pipeline. Final color measurement from the KAM®CHA™ can be
expressed as haze plus three color (X, Y, Z, CIE 1931) or in several other industry-standard color scales including,
Saybolt, Platinum and Cobalt, and ASTM 1500 (see Specifications, Section 2).
The computer automatically adjusts for electronic noise and any LED fluctuations. Because the absorption rates of
the different colored fluids vary resulting in different signal strengths, the computer also automatically adjusts the
amplification or gain accordingly.
Measurement is fully automatic without the need for operator intervention or supervision. The output signal can be
sent to the SCADA, PLC’s, or to a Central Control Room for logging or display on chart recorders or monitors.
The KAM®CHA™ probe can be installed in an analyzer loop or in the main line, and because it’s easily mounted
through a full-opening ball valve, you can insert or retract the probe without having to ever drain the pipe.

4
CHAMANUAL 0917 KAM CONTROLS, INC.
SPECIFICATIONS
Media: Refined products
Material: Wetted parts–316 stainless steel, sapphire
Power: 12–24 VDC 5 Watts max
Outputs: 4-20 mA (2) reflect values for Haze plus designated color scale (see Color Range P15)
Communication
Interface: RS-485 MODBUS (X,Y, Z values plus all color scales, and individual LED readings)
Fluid temperature: -40º to 200º F (-40º to 93º C)
Electronics temp.: -22º to 185º F (-30º to 85º C)
Pressure ratings: ANSI 150, 300, 600
Hazardous area: PTB04 ATEX 1027
(Ex II 2 G Ex db IIB T6 Gb)
NEMA4 (IP66 equivalent)
Accuracy: Haze ± 5%, Color ± 1%
Repeatability: Haze ± 1%, Color ± 1%
Reproducibility: Haze ± 1%, Color ± 1%
Haze Range: 0-100%
Color Range: Complete range of: ASTM D 1500; ASTM D 156 (Saybolt);
ASTM D 1209 (APHA Platinum-Cobalt)
Mounting: 1" or 2" flanged flow through spool (custom sizes available)
2" MNPT Seal Housing
2", 3", or 4" Flanged Seal Housing
Sensor Dimensions: 3.5" x 1.25"Ø (89 mm x 32 mm)
EX enclosure: 4.6" x 7.1" x 4.4" (117 mm x 180 mm x 112 mm)
Shaft length: 12" to 60" – Off-the-shelf lengths are 12", 24", 36", 48", and 60"
(305 mm, 610 mm, 762 mm, 914 mm, 1219 mm, 1524 mm)
Pipe size: 1" to 48" (25 mm to 1219 mm)
Weight: from 20 lbs. (9 kg)

5
CHAMANUAL 0917 KAM CONTROLS, INC.
SPECIFICATIONS CONTINUED
DIMENSIONAL DRAWINGS
150 300 600 900
"
2
3
4
INCHES
8.40
8.60
8.60
INCHES
8.50
8.75
8.90
INCHES
8.90
9.15
9.40
INCHES
9.40
9.40
9.65
MM
213
218
218
MM
216
222
226
MM
226
232
240
MM
240
240
245
TABLE 2-2 FLANGE SIZE AND CLASS (SL)
TABLE 2-3 DIMENSIONS
A
B
C
D
E
F
INCHES
1.25
3.5
7. 1
4.6
.47
1
MM
32
90
180
117
12
25
Shaft Lengths are available in .5" (12.7
mm) increments.
Standard sizes are 24", 30", 36", 48",
and 60". (609.6 mm, 762 mm, 914.4
mm, 1219 mm, 1524 mm)
D
FIG. 2-1 CHA™ SENSOR
Sensor Profile
ASeal Housing
¾" FNPT
B
Shaft Length ± .5"
C
EF
SL

6
CHAMANUAL 0917 KAM CONTROLS, INC.
SPECIFICATIONS CONTINUED
INCHES
11. 8
11
7.25
4.7
FIG. 2-4 FLOWTHROUGH CHA™
A
B
C
D
MM
299
279
184
119
TABLE 2-5 DIMENSIONS
C
D
A
B
ANSI FLANGES

7
CHAMANUAL 0917 KAM CONTROLS, INC.
Remove all the protective packaging materials , and ensure that the CHA™ sensor was not damaged
during transit.
PRIORTO INSTALLATION
INSTALLATION
Do not install the CHA in direct sunlight
Ensure there is no entrained air in the line or excessive levels
of organic compounds such as rouge.
CHA should be installed after a minimum of 4 pipe diameters
of straight run to reduce flow turbulence. Fig. 3-1
The CHA should be installed on a vertical line. If the unit
must be intalled on a horizontal line, it should be at 3 or 9
o'clock position. Fig. 3-2
The KAM CHA probe must be oriented so that the flow
indicator is parallel to the flow direction of the pipe to
enable flow through the measurement window. Fig. 3-3
Flow
indicator
INSTALLATION DOs and DONTs
MINIMUM 4 PIPE
DIAMETERS BEFORE
METER
MINIMUM 4 PIPE
DIAMETERS BEFORE
METER
FIG. 3-1 VERTICAL INSTALLATION
FIG. 3-2 HORIZONTAL INSTALLATION FIG. 3-3
3 O'clock
9 O'clock
NOTE: Installation at the 12 O'clock or 6 O'clock position
could result in the accumulation of fluid contaminents
(dirt, etc.) on the lenses, causing measurement malfunc-
tion.

8
CHAMANUAL 0917 KAM CONTROLS, INC.
MAIN LINE INSTALLATION
1.
2.
FIG. 3-5
FIG. 3-6
CAUTION: For probe installations and removal when
line pressure is above 100 psi, a KAM®IT Insertion Tool
must be used.
Without the IT, pressure above 100 psi could cause the
probe to forcibly move outward from the pipeline,
risking bodily injury and/or damage to the probe
The KAM®CHA™ sensor should be installed
according to FIG. 3-4, ideally at the 3 or 9 o'clock
position within the pipeline. Installing the
instrument horizontally prevents the long-term buildup
of any sediment on the sapphire windows. A full-open-
ing ball valve is used to isolate the CHA™ sensor from
the pipeline during installation or removal. The Seal
Housing of the CHA™ sensor allows the probe to be
inserted and removed from the pipe under
pressure and flow conditions. The CHA™ sensor
should be inserted so that the window of the probe
is fully located within the pipeline. See page 9 of this
manual to determine the proper insertion depth.
FIG. 3-4 KAM®CHA™ INSTALLED ON A MAIN PIPE
Locking Collar
Seal Housing
Full-opening
Ball Valve
Socket Cap Screw
Prior to mounting verify that the tip of the sensor
is fully inside the Seal Housing. FIG. 3-5, 3-6
If sensor is not fully enclosed inside the Seal
Housing, loosen the Socket Cap Screws and pull
the shaft back until the probe is all the way in
the Seal Housing and re-tighten the Socket Cap
Screws on the Locking Collar. This will prevent
the CHA™ shaft from ejecting and the probe
from getting damaged during mounting.
INSTALLATION CONTINUED

9
CHAMANUAL 0917 KAM CONTROLS, INC.
INSTALLATION CONTINUED
To ensure proper installation depth, measure the distance (D1) from the outside diameter of main pipe to the end
of the connection where the CHA™ sensor is going to be installed. FIG. 3-7
3.
You must now calculate the minimum insertion distance for the CHA (minimum depth to ensure probe is fully
in flow)
Minimum Insertion Distance (MID) = D1 + Pipeline Wall Thickness + 2"
Example for D1=16", pipe WT =1/4", Seal Thickness=1/8":
MID = 16 + 1/4 + 1/8 + 2
MID = 18 3/8"
4.
Measure the calculated MID from the top of the
seal clamp and place a mark with a permanent
marker or tape on the Shaft. FIG. 3-8
5.
MID
6. Bolt or screw the CHA™ sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded CHA™).
Open full-opening valve.
7.
Loosen Socket Cap Screws on the Locking Collar.
REMINDER: Line pressure must be below 100 psi for CHA installation and removal or a KAM®IT Insertion
Tool must be in place.
8.
FIG. 3-8
D1
D1
FIG. 3-7