Kobold KAL-E EX Series User manual

Operating Instructions
for
Flow sensor model KAL-****Ex
with
Electronic Analyzer
Model: KAL-E**Ex

KAL-EX
Seite 2 KAL-EX K05/0322
1. Contents
1.Contents ........................................................................................................ 2
2.Note .............................................................................................................. 3
3.Instrument Inspection .................................................................................... 3
4.Regulation Use ............................................................................................. 4
5.Operating Principle ........................................................................................ 5
6.Mechanical Connection ................................................................................. 6
6.1Before installation ................................................................................ 6
6.2Installation ............................................................................................ 6
6.3Mounting position ................................................................................. 6
7.Electrical Connection .................................................................................... 7
8.Operation / Configuration / Adjustments ....................................................... 8
8.1Putting in operation .............................................................................. 8
8.2Zero-point adjustment .......................................................................... 8
8.3Expanding the trend indicator .............................................................. 8
8.4Resetting the adjustment ..................................................................... 9
8.5Switching point setting ......................................................................... 9
8.6Temperature compensation ............................................................... 10
9.Fault alarms ................................................................................................ 10
10.Maintenance ............................................................................................... 10
11.Brief operating instructions commissioning ................................................. 11
12.Technical Data ............................................................................................ 12
13.Ordering details ........................................................................................... 13
14.Dimensions ................................................................................................. 14
15.EU Declaration of conformance .................................................................. 15
16.EC-type examination certificate .................................................................. 15
17.IECEx-certificate ......................................................................................... 19
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.kobold.com

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KAL-EX K05/0322 Seite 3
2. Note
Please read these operating instructions before unpacking and putting the unit into
operation. Follow the instructions precisely as described herein.
The instruction manuals on our website www.kobold.com are always for currently
manufactured version of our products. Due to technical changes, the instruction
manuals available online may not always correspond to the product version you
have purchased. If you need an instruction manual that corresponds to the
purchased product version, you can request it from us free of charge by email
([email protected]) in PDF format, specifying the relevant invoice number and
serial number. If you wish, the operating instructions can also be sent to you by
post in paper form against an applicable postage fee.
The devices are only to be used, maintained and serviced by persons familiar with
these operating instructions and in accordance with local regulations applying to
Health & Safety and prevention of accidents.
When used in machines, the measuring unit should be used only when the
machines fulfil the EC-machine guidelines.
as per PED 2014/68/EU
for KAL-sensors with fittings model: KAL-11.. and KAL-12..
In acc. with Article 4 Paragraph (3), "Sound Engineering Practice", of the
PED 2014/68/EU no CE mark.
Diagram 8, Pipe, Group 1 dangerous fluids
3. Instrument Inspection
These devices are inspected before shipping and sent out in perfect condition.
Should damage to a device be visible, we recommend a thorough inspection of the
delivery packing. In case of damage, please inform your parcel service/ forwarding
agent immediately, since they are responsible for damages during transit.
The standard scope of supply includes the following components:
 Sensor with PVC-coated cable
 Electronic analyzer
 100  1% resistor

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4. Regulation Use
The devices in model series KAL-EX are used to monitor the flow of combustible
liquids up to explosion category IIB. They satisfy the European standards
EN 60079-0:2012 + A11:2013 and EN 60079:11:2012 for explosion protection and
are thus suitable for use in hazardous areas of Zone 0 as per DIN VDE 0165
(applies to the flow sensor only; the electronic analyzer must not be used in
hazardous areas).
Limit contacts
The devices are equipped with relays to monitor the flow speed of liquids. An
additional temperature sensor triggers a relay if the set temperature is exceeded.
Trend indicator
The actual flow value is indicated by a series of constantly illuminated LEDs on the
LED strip display. The currently set switching point is indicated on the LED strip
display by the individually blinking LED.
Sensors
These sensors are available as screw-in (insertion style) or in-line versions.
Model KAL-EX devices always consist of two components:
 KAL-...Ex sensor
 KAL-E...Ex electronic analyzer
Electronics
KAL-E3...Ex electronic analyzer
1 voltage-free changeover contact for temperature
1 voltage-free changeover contact for flow speed
The devices must only be used for liquids that will not damage the sensor housing.
When properly installed and maintained, the sensors are unaffected by dirt and
cause essentially no loss of pressure. The length of the device lead should not
exceed 100 meters.
Caution! Errors will result in zone carry-over. Danger of
explosion!
Switching ranges based on nominal pipe size (NPS).

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KAL-EX K05/0322 Seite 5
NPS (mm) Measuring Range
(L/min)
Wate
r
NPS (mm) Measuring Range
(L/min)
Wate
r
8 0.12 - 6.0 40 3.0 - 150
10 0.19 - 9.4 50 4.7 - 235
15 0.42 - 21.8 60 6.8 - 340
20 0.75 - 37.7 80 12.0 - 603
25 1.18 - 59.0 100 18.8 - 942
30 1.7 - 84.8 150 42.4 - 2120
Caution! In determining the specified measuring ranges the flow
speeds were based on nominal pipe sizes. However, please note
that the force exerted by the flow speed against the pipe wall is
essentially zero. Depending on the nominal pipe size, the sensor
installation depth and the flow profile, there may be some
significant deviations from the indicated flow values in the actual
installation. Any use of the flow sensor, model: KAL-EX, which
exceeds the manufacturer’s specifications, may invalidate its
warranty. Therefore, any resulting damage is not the responsibility
of the manufacturer. The user assumes all risk for such usage.
5. Operating Principle
The operation of the model KAL-EX electronic flow monitor is based on the
calorimetric principle. The sensor tip is heated to a few degrees above the
temperature of the flowing liquid. When the liquid is flowing, the heat generated in
the sensor is transferred to it, i.e. the sensor is cooled. The rate-of-cooling process
is an accurate measure of the flow speed.
The sensor signal is compared with the reference data (set threshold value) and
stored in a microcontroller. If the actual flow speed is less than the desired flow
speed, the electronic analyzer actuates an output relay. The microcontroller in the
flow monitor permits easy calibration, allowing ideal temperature compensation of
the device.

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6. Mechanical Connection
6.1 Before installation
Make sure that the actual flow speed corresponds to the switching range of the
device. Make sure that the maximum process pressures and service temperatures
specified for the device will not be exceeded. (See section 12, “Technical details”)
6.2 Installation
Mount the sensor in the piping and ensure that the tip is covered by the liquid to be
monitored. The sensor tip must extend at least 5 mm (better > 5 mm) into the pipe
(see below).
6.3 Mounting position
The sensors can be mounted in any position,
provided that the piping is completely filled
with the liquid to be monitored. The
installation position must be free of swirling
and turbulence (the recommended inlet and
outlet area: 4x the diameter of the pipe with
straight pipe sections immediately upstream
and downstream of the sensor). If it is
expected that the liquid will leave deposits in
the piping, the illustrated mounting position is
recommended (see figure at the left).
Caution: Improper installation can result in zone carry-over.
Danger of explosion!
Ablagerungen
Deposits

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KAL-EX K05/0322 Seite 7
7. Electrical Connection
Caution! Make sure that the supply voltage of your system is the same as
that specified on the device nameplate.
 Make sure that the electrical supply lines are de-energized when
connecting the device.
 Connect the sensor cable to terminals 6 and 8 of the electronic analyzer.
 Connect the supply line (power supply) to terminals 15 and 16.
Caution: The relays are shown in the rest positions. The
intrinsically safe input from electronic analyzer should only be
connected to a KAL-...Ex sensor.
AC power supply:
230 VAC, ± 10%, 50-60 Hz
24 VAC, ± 10%, 50-60 Hz
Sensor
230 V
L N
AC
Flow Temp. 24 V
AC
9 10 11 12 13 14 15 16
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
Flow Temp.

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8. Operation / Configuration / Adjustments
8.1 Putting in operation
 Install the sensor in the piping (be sure the installation position is correct.
Refer to Section 6 Mechanical Connection).
 Connect the sensor cable to the electronic analyzer.
(Refer to section 7 Electrical Connection).
 Fill the piping with liquid.
Caution! There must be no air bubbles present at the sensor tip.
The flow speed must be 0.
8.2 Zero-point adjustment
 Place the electronic analyzer in operation (switch on the supply voltage)
Rotate the flow potentiometer (1) (refer to section 11, “Brief operating
instructions”) counterclockwise as far as it will go (to the left-hand stop).
 Rotate the temperature potentiometer (2) counterclockwise as far as it will go
(to the left-hand stop).
 Briefly press the SET button for the zero-point adjustment (5)
(press it with a suitable object, such as a ball point pen)
 The flow LED (6) will blink for approximately 30 seconds.
After this time has expired, the flow LED (6) will stop blinking.
 If the system is not functioning properly, the flow LED (6) will blink
continuously. In this case, press the SET button (5) once again. The device
then switches back to measuring mode. Before continuing, inspect the
mechanical and electrical installation. Then follow the “Putting in operation”
instructions once again.
 Switch on the system and set the maximum rated flow rate.
If the whole LED strip display is not illuminated, then the display can be
expanded so that the range from 0.25 to 1.8 m/s extends across the entire
LED strip display (see section 8.3 below).
8.3 Expanding the trend indicator
 Rotate the flow potentiometer (1) (see illustration) clockwise as far as it will go
(to the right-hand stop). Then rotate the temperature potentiometer (2)
counterclockwise as far as it will go (to the left-hand stop).
 Briefly press the SET button (5).
 The flow LED (6) will blink for approximately 30 seconds. After this time has
expired, the flow LED (6) will stop blinking.

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KAL-EX K05/0322 Seite 9
8.4 Resetting the adjustment
You can reset the electronic analyzer so that it once again uses its full range
(0 - 2.0 m/s)
 Rotate the flow potentiometer (1) clockwise as far as it will go (to the right-hand
stop).
 Rotate the temperature potentiometer (2) counterclockwise as far as it will go
(to the left-hand stop).
 Press and hold the SET button (5) until the flow LED stops flashing
 The device is now reset to its initial state (0 - 2 m/s).
8.5 Switching point setting
After the device is adjusted to the specific liquid being measured (see above), you
can then set the switching point.
 Adjust the flow rate.
 Rotate the flow potentiometer (1) counterclockwise as far as it will go (to the
left-hand stop). The first LED in the LED strip display (3) starts to blink.
 Any number of LEDs in the LED strip display (3) is illuminated constantly.
 Rotate the flow potentiometer (1) clockwise to the desired switching point.
The switching point selected is indicated by the blinking LED.
Display 3
X X X X X
X X X X X X
X X X X X X
X X X X X X
X X X
explanation output
flow > setpoint Flow relays
activated
Flow LED li
g
hts
flow = setpoint Flow relays
activated
Flow LED lights
flow < setpoint Flow relays
deactivated
Flow LED off
blinks Flow speed
LED indicator blinks

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8.6 Temperature compensation
If the length of the cable connecting the sensor and the electronic analyzer is greater than 10
meters or if increased accuracy in temperature measurement is desired, we recommend that
device be compensated as described below.
Caution! Be sure to switch off the power supply
 Connect the entire length of the cable to be used to terminals 6 and 8.
Instead of the sensor, connect a 100 ohm ±1% resistor (included in the delivery).
 Set the temperature potentiometer (2) to 80° C (rotate to right-hand stop) Switch on the
power source and place the electronic analyzer in operation.
 Briefly press the SET button (5).
The temperature LED and the flow LED will start to blink. After 10 seconds, they will go
out.
 If the system is not functioning properly, the flow LED (6) will blink continuously. In this
case, press the SET button (5) once again. The device then switches back to measuring
mode. Before continuing, inspect the mechanical and electrical installation. Then follow the
“Temperature compensation” instructions once again.
 If the temperature LED blinks faster, then the error could be caused because the sensor is
still connected instead of the 100 ohm resistor.
 Finally, remove the 100 ohm resistor and reconnect the sensor.
9. Fault alarms
In alarm mode the current relay stops functioning.
This occurs under the following conditions:
 Actual value < Setpoint value
 Short circuit (at sensor)
 Line break
 Power failure
10. Maintenance
This device is maintenance-free. Once a month, the sensor tip should be checked for the
presence of mineral deposits (lime, etc.) and cleaned if necessary.

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11. Brief operating instructions commissioning
(1) Potentiometer
Adjusting the flow switching point
Zero-point adjustment
- Turn to the left-hand stop
- Expand measuring range
- Turn to the ri
g
ht-hand stop
(2) Potentiometer for setting
the temperature switching
point
(SET button 5)
(for adjustment, expanding measuring
range)
(6) Flow LED illuminates
when flow is greater than
the set switching point
(4) Temp. LED illuminates
when operating
temperature
is lower than the set
temperature limit.
(3) LED trend indicator for
flow speed and switching
point
(switching point blinks)

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12. Technical Data
ATEX-Approval: DMT 99 ATEX E096
Marking: II 1G Ex ia IIB T4 Ga (sensor)
II (1)G [Ex ia Ga] IIB (electronic)
IECEx-Approval: IECEx BVS 15.0027
Marking: Ex ia IIB T4 Ga (sensor)
[Ex ia Ga] IIB (electronic)
Sensor KAL-... Ex
Housing: Stainless steel 1.4301 or 1.4571
Cable gland: MS nickel-plated: conduit thread 7
Cable: 2 m PVC cable, 2 x 0.56 mm
2
max. line length 100 m
Switching ranges: 4 cm/s to 200 cm/s
Liquid temperature: -20 to +80 °C
Max. pressure: 100 bar, except KAL-1132/KAL-1140: 25 bar
Protection type (DIN 40050): IP 68
Electronic analyzer KAL-E3..-Ex
Power consumption: max. 3.6 W
Switching capacity: max. 250 V
AC
/ 2 A, 125 V
AC
/ 3 A,
30 V
DC
/ 3 A
Switching points compensation: at potentiometer
Switching function: relay is operated with flow,
(terminal 9+10 closed, LED illuminated)
relay is operated when temperature is
exceeded, LED illuminated,
(terminal 12+13 closed)
Output: 2 relays, each with 1 changeover contact
Output state indicator: LED indication
Time delay before availability: max. 12 s.
Temperature range: -20 °C to +55 °C
Top-hat rail mounting: DIN EN 50022 and DIN 46277
Protection type housing: IP 40
Protection type terminals: IP 20
Material: Polycarbonate
Sensor output: Intrinsically safe
Cable break or short circuit: Detected as loss of flow, flow LED blinks
Power failure: Calibration data remain stored over 10 years, without
battery
Trend indication: Accuracy of approx. 10%
Reproducibility: Approx. 2%
Response time: Typically 5 sec., max 12 sec.
Accuracy temperature limit value: ± 2 °C
Floating voltage: U
0
16 V
DC
Short-circuit current: I
0
 1.1 A

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KAL-EX K05/0322 Seite 13
13. Ordering details
A KAL-Ex measuring system always consists of a sensor and an electronic analyzer.
Senor order details (example: KAL-1308 Ex)
Connection
Order numbers
Electrical connection/
version
Sensor with insertionfitting Sensor with inline fitting
1.4301 1.4571 Fitting brass / Sensor 1.4301 Fitting 1.4301/ Sensor 1.4301
G 1/4 KAL-1308 KAL-1408 KAL-1108 KAL-1208 00=2 m PVC cable
HT=2 m Silicone cable
YP=PVC cable/
special length
YS=Silicone cable/
special length
YY=Special cable/
special length
Ex=Ex-Sensor,
PVC cable
ATEX/IECEx
(specify cable length)
G 3/8 - - KAL-1110 KAL-1210
G 1/2 KAL-1315 KAL-1415 KAL-1115 KAL-1215
G 3/4 KAL-1320 KAL-1420 KAL-1120 KAL-1220
G 1 - - KAL-1125 KAL-1225
G 11/4 - - KAL-1132 KAL-1232
G 11/2 - - KAL-1140 KAL-1240
M 12 x 1 KAL-0312 - - -
1/4 NPT KAL-5308 KAL-5408 KAL-5108 KAL-5208
3/8 NPT - - KAL-5110 KAL-5210
1/2 NPT KAL-5315 KAL-5415 KAL-5115 KAL-5215
3/4 NPT KAL-5320 KAL-5420 KAL-5120 KAL-5220
Electronics order details (example: KAL-E30Ex)
Field of
application Flow trend indication Temperature
monitoring Supply voltage
24 VDC 24 VAC 110 VAC 230 VAC
Flow - -
KAL-E13 KAL-E12 KAL-E11 KAL-E10
KAL-EH13 KAL-EH12 KAL-EH11 KAL-EH10
Flow 8-LEDs -
KAL-E23 KAL-E22 KAL-E21 KAL-E20
KAL-EH23 KAL-EH22 KAL-EH21 KAL-EH20
Flow/
Temperaturw 8-LEDs -20...+80°C KAL-E33 KAL-E32 KAL-E31 KAL-E30
0...+120°C KAL-EH33 KAL-EH32 KAL-EH31 KAL-EH30
Flow/
Temperature 8-LEDs -20...+80°C – KAL-E32Ex – KAL-E30Ex

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14. Dimensions
Note: “SW” indicates the wrench size in mm across flats
A B C D A B C D E
M 12x1 SW 19 23 43 G 1/4 SW 27 10 50 81
G 1/4 SW 19 26 43 G 1/2 SW 27 10 50 81
G 1/2 SW 27 43 58 G 3/4 SW 32 15 52 82.5
G 3/4 SW 32 43 58 G 1 SW 39 15 56 85
1/4 NPT SW 19 26 43 G 1 1/4 SW 46 15 50 90
1/2 NPT SW 27 43 58 G 1 1/2 SW 55 15 50 92.5
3/4 NPT SW 32 43 58

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KAL-EX K05/0322 Seite 15
15. EU Declaration of conformance
EU-KONFORMITÄTSERKLÄRUNG zur Bestätigung
der Übereinstimmung einer Baugruppe mit der
Richtlinie 2014/34/EU
EU DECLARATION OF CONFORMITY to
confirm the conformance of a device with the
Directive 2014/34/EU
Der Hersteller The manufacturer
Kobold Messring GmbH, Nordring 22-24, DE 65719 Hofheim
erklärt hiermit in alleiniger Verantwortung, dass die
nachfolgende Maschine oder Baugruppe hereby declares under sole responsibility, that the machinery or subassembly equipment described
below
Bezeichnung Description
Flow sensor type KAL-**** Ex with Flow monitor type KAL-E**-Ex
Kennzeichnung / Marking: II 1G Ex ia IIB T4 Ga and/or II (1)G [Ex ia Ga] IIB
Fertigungs-Nummer lt. Lieferpapieren und Typenschild Serial number see shipping documents and type label
mit den Bestimmungen folgender harmonisierter
Normen der Europäischen Union, in der zum
Unterschriftsdatum gültigen Fassung, überein- stimmt:
• EN 60079-0:2012 + A11:2013
Explosionsgefährdete Bereiche - Teil 0:
Betriebsmittel - Allgemeine Anforderungen
• EN 60079-11:2012 Explosionsgefährdete Bereiche
– Teil 11: Geräteschutz durch Eigensicherheit "i"
conforms with the provisions of the following
harmonized standards in the version of the
European Union, valid at signature date:
• EN 60079-0:2012 + A11:2013 Explosive
atmospheres – Part 0: General Requirements
• EN 60079-11:2012 Explosive atmospheres –
Part 11: Equipment protection by intrinsic
safety “i”
Ebenfalls mit folgenden Europäischen und nationalen
Normen und technischen Vorschriften in der zum
Unterschriftsdatum gültigen Fassung übereinstimmt:
• Technische Regeln für Gefahrstoffe (TRGS) 727,
Vermeidung von Zündgefahren infolge
elektrostatischer Aufladungen
Also conforms with the following European and
national standards and technical provisions in the
version, valid at signature date:
• Technical rules for hazardous substances
(TRGS) 727, Avoidance of ignition hazards as
consequence of electro- static charging
Die vorgenannte Baugruppe stimmt mit dem Modell
überein, das die EG- Baumusterprüfbescheinigung mit
der Nummer DMT 99 ATEX E 096 der notifizierten
Stelle 0158 DEKRA EXAM, Bochum, Deutschland
erhalten hat.
Die vorgenannte Baugruppe stimmt ebenfalls mit
folgenden EU-Richtlinien und EU-Normen überein:
 2011/65/EU RoHS (Kategorie 9)
 EN 50581:2012 Technische Dokumentation zur
Bewertung von Elektro- und Elektronikgeräten im
Hinblick auf die Beschränkung gefährlicher Stoffe
The equipment complies with the model, which
has obtained an “EC” type certificate, number
DMT 99 ATEX E 096, issued by the notified body
0158 DEKRA EXAM, Bochum, Germany.
The equipment complies also with the following
EU directives and EU norms:
 2011/65/EU RoHS (category 9)
 EN 50581:2012 Technical documentation for
the assessment of electrical and electronic
products with respect to the restriction of
hazardous substances

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Seite 16 KAL-EX K05/0322
Ausgefertigt in Hofheim am 11. April 2018 done at Hofheim on April, 11th, 2018
Name des Unterzeichners / Name of signatory Name des Unterzeichners / Name of signatory
H. Peters, Geschäftsführer / CEO Manfred Wenzel, Prokurist / authorized signatory
Unterzeichnet für und im Namen der / Signed for and on behalf of Kobold GmbH

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16. EC-type examination certificate

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page 18 KAL-EX K05/0322

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17. IECEx-certificate

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