Kobold DF-**01 series User manual

DF-SEN_manual_12/13
KOBOLD Model DF Flow Sensor
User Instructions
Kobold Instruments Inc. • 1801 Parkway View Drive • Pittsburgh PA 15205
Phone [phone] • Fax [phone] • www.kobold.com

Table of Contents
1.0 General. . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 1
2.0 Specifications. . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 2
3.0 Installation Instructions. . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 5
4.0 Operation. . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 6
5.0 Arrival of Damaged Equipment. . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 7
6.0 Maintenance.. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 7
7.0 Need Help with your DF Flow Sensor?. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 7
List of Diagrams
Diagram 2.4: Sensor Dimensions.. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 4
Diagram 3.1: Wiring . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 5
List of Tables
Table 2.1: Material Combinations and Maximum Limits. . . . . . . . . . . . . . . . . . . 2
Table 2.2: Electrical Data . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 3
Table 2.3: Flow Ranges and Fitting Sizes. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 3

DF-SEN
FM Rev. 12/13
KOBOLD Model DF Flow Sensor
User Instructions
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
1.0 General
The KOBOLD DF flow sensor is intended for use in applications where flow
measurement is desired and the flow rate data needs to be transmitted as a pulse rate
output. The DF sensor contains a flow transducer which transmits a 0-100 Hz (nominal)
signal. This output frequency is linearly proportional to the flow measured by the
instrument and is transmitted by a bipolar transistor operating in an open collector
configuration.
The DF uses a paddle wheel to determine flow. The principle of operation is quite
simple; the paddle wheel rotation speed is calibrated for the maximum flow rate. This
rotation-flow relationship is linear in theory. In practice, theory is nearly borne out,
leading to a very precise measuring device. Any non-linearity is within the stated
measurement error of the device.
The paddle wheel approach to flow measurement has the advantage that the instrument
may be installed in both vertical and horizontal orientations (the axle, however, must
remain in a horizontal plane). Further, this measurement technique is relatively
insensitive to dirt in the medium (large quantities of ferritic contaminants, however, must
be avoided).

DF-SEN 2
FM Rev. 12/13
2.0 Specifications
Table 2.1: Material Composition & Operational Limits
* Fittings not Rotatable Abbreviations: PP - Polypropylene
2SS on Model DF-XX01 NP - Nickel Plated
Material
Combination I II/IIB * III IV * VI * VII *
Fittings NPT NPT NPT NPT or
FLANGE NPT NPT or FLANGE
Housing Trogamid® Polysul-
fone/PP NP-Brass SS NP-Brass SS
Window Trogamid® Polysul-
fone/PP Polysulfone Polysulfone NP-Brass SS
Fittings NP-Brass SS/PP NP-Brass SS NP-Brass SS
Locking Pins Brass Brass Brass - - -
O-Rings Buna-N FKM Buna-N FKM Buna-N FKM
Paddle Wheel POM PTFE POM PTFE POM PTFE
Axle SS SS/
Ceramic SS SS SS SS
Axle Bearing PTFE PTFE PTFE PTFE PTFE PTFE
Orifice PTFE 2PTFE 2PTFE 2PTFE 2PTFE 2PTFE 2
STANDARD VERSION HIGH PRESSURE
VERSION
Maximum
Pressure 145 PSIG 145/85
PSIG 230 PSIG 230 PSIG 1450 PSIG
1450 PSIG
or
580 PSIG
with flange
Maximum Media
Temperature 145°F 180°F 180°F 180°F 180°F 180°F

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FM Rev. 12/13
Table 2.2: Electrical Data
Power Supply: +5 to +24 VDC
Open Collector Output: +5 to +24 VDC
@ 10 mA max.
Operating Temperature Range: -10° F to 180° F
(+145°F for DF-01..)
Environmental Protection: NEMA 4
Table 2.3: Flow Ranges & Fitting Sizes

DF-SEN 4
FM Rev. 12/13
Diagram 2.4; Sensor Dimensions

5DF-SEN
FM Rev. 12/13
3.0 Installation Instructions
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
To install, proceed as follows:
1. Make sure that the actual flow rate in your system lies within the flow range of
the instrument. The flow range can be read off the identification tag. Flow rates
in excess of 120% of the range maximum will, in continuous use, lead to
bearing and/or paddle wheel damage.
2. Ensure that the power supply voltage is in accordance with that specified on
the identification tag. Electrical connections are made with a 3-pin terminal
block as specified by the wiring diagram (Diagram 3.1).
3. If the sensor is to be used to provide a voltage pulse output, a sourcing output
pull-up resistor MUST be connected between the supply voltage terminal and
the open collector output terminal (pins 1 and 3). This resistor should be sized
such that the collector to emitter current is nominally limited to 5 mA or less
during the transistor “on” state. Under no circumstances should the collector
to emitter current be allowed to exceed 10 mA.
Diagram 3.1; Wiring
R pull-up = ______________ Ohms
V supply
0.005

DF-SEN 6
FM Rev. 12/13
If you have an OEM version (supplied without terminal box), a connector with three wires
will be visible. Depending on the color combination of wires your sensor has, attach
these as follows:
Blue - (-) Ground Blue - (+) VDC
Yellow - Open Collector or Yellow - Open Collector
Red - (+) VDC Green - (-) Ground
You are now ready to mechanically connect the unit.
1. The flow direction is indicated by an arrow on the housing. Install the
instrument with the arrows aligned with the flow direction in your pipes. To
achieve the operational design accuracy, output consistency over the entire
measuring range and longest service life, orient the unit so that the axle
always remains in a horizontal plane.
2. Connect with appropriately sized fittings. Take care not to place stresses on
the housing - use a wrench to hold the instrument fittings static while you
tighten the fittings on your pipe. As with any flowmeter, this device must not be
used as a structural member of the piping system to avoid damage.
3. Should there be small amounts of ferrite contaminants in the medium, we
recommend the installation of our magnetic filter (type MFR or equivalent).
4. Medium should always be introduced to the system slowly to avoid pressure
surges which could damage the instrument.
4.0 Operation
The device is delivered with a calibration diagram describing its frequency versus flow
rate behavior. You must use this to calculate rate of flow in your system. Modification of
the sensor (by physically modifying or replacing sensor components) requires
recalibration of the unit.
4.1 - Turning the Unit On
The sensor is operational as soon as it is wired into a power supply.
4.2 - Flow Measurement
A frequency counting device must be used to read the sensor output and convert that
measurement to rate of flow (output frequency is directly proportional to flow rate). The
nature of this relationship is described by the sensor’s “k-factor” which is the number of
pulses the sensor generates per gallon of water flow through the sensor. The device’s
nominal k-factor can be easily calculated with the use of the provided output frequency
(in Hz) and knowing the maximum flow rate of the particular sensor.