Kobold KAL-K User manual

KOBOLD KAL-K (KAL-4000 Series)
Thermal Flow Switch
User Instructions
KOBOLD Instruments Inc. 1801 Parkway View Drive Pittsburgh PA 15205
Phone [phone] • Fax [phone]
KAL-K_manual_8-29-06

KAL-K
FM Rev. 8/29/06
Table of Contents
1.0 General............................................................................................. 1
2.0 Specifications................................................................................... 1
3.0 Mechanical Installation...................................................................... 4
4.0 Electrical Connections...................................................................... 5
5.0 Operation.......................................................................................... 7
5.1 Calibration............................................................................. 7
5.2 Flow Setpoint Adjustment...................................................... 8
5.3 Setting the KAL-K Output Transistor Type............................ 9
5.4 KAL-K Diagnostics and Troubleshooting.............................. 9
5.5 Applications........................................................................... 10
6.0 Maintenance..................................................................................... 11
7.0 Arrival of Damaged Equipment........................................................ 11
8.0 Need Help With Your KAL-K............................................................ 11
List of Diagrams
Diagram 2.1 Dimensions................................................................ 3
Diagram 3.1 Mechanical Installation............................................... 4
Diagram 4.1 Interior Controls Layout for 24 VDC Versions............ 5
Diagram 4.2 Interior Controls Layout for 110 VAC Versions........... 5
Diagram 4.3 KAL-K Wiring 24 VDC Versions................................. 6
Diagram 4.4 KAK-K Wiring 110 VAC Versions............................... 6
Diagram 4.5 Quick Disconnect (option M-12) Wiring 7
List of Tables
Table 2.1 Switching Ranges Vs. Pipe Diameter.......................... 2

KAL-K
FM Rev. 8/29/06
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
1.0 General
The KOBOLD KAL-K (a.k.a. KAL-4000 Series) flow switch is intended for use in
monitoring and control applications involving moderate flowrates of non-viscous or dirty
liquids. The KAL-K flow switch uses the proven thermal dispersion principle and operates
as follows:
1. The probe is heated internally to a few degrees above the temperature of the
medium into which it extends.
2. As the medium flows past the probe it removes heat from the probe tip. The
rate at which heat is removed is proportional to the flowrate.
3. The measured flowrate is compared to the setpoint value selected by the user.
If the setpoint is reached, the electronic circuitry activates a transistor switch
and bi-colored alarm LED. The electronic circuitry also controls an LED trend
indicator which can be used to indicate relative system flow.
The microprocessor-controlled design permits simple calibration and setup. The compact
probe design permits monitoring of flowrate with minimal head loss.
2.0 Specifications
Measuring Range: 0.05 - 2 meters/sec.
Available Fitting Sizes: 1/2” NPT
1-1/2” Tri-Clamp®
3/4” NPT
Maximum Pressure: 1450 PSIG for threaded units,
Tri-Clamp® versions to clamp rating
Maximum Temperature:
Ambient: 0 to 140°F
Medium: 32° to 250°F
Clean in Place (CIP): 280°F (non-operating)
Supply Power:
Standard: 24 VDC ± 10%, 300 mA Max.
Optional: 110 VAC Nominal
Wetted Parts:
KAL-4215: 304 Stainless Steel
KAL-4315: 316 Stainless Steel
KAL-4320: 316 Stainless Steel
KAL-4340-S 316 Stainless Steel

KAL-K 2
FM Rev. 8/29/06
Housing: Reinforced Polyamide (NEMA 4)
Switching Characteristics:
Switchpoint Adjustment: By internal potentiometer
Switch Type:
Standard: NPN or PNP transistor (selectable)
Max. 24 VDC, 400mA
Suffix P03R: SPST relay, 5 A @ 250 VAC Max.
Calibration Data: Stored in non-volatile memory, data
retained for at least 10 years in the event
of power failure
Table 2.1 Switching Ranges Vs. Pipe Diameter
Note: The flow ranges specified in the table above have been calculated for each pipe diameter
based on the known velocity range of the KAL-K. It must be noted that flow in pipes is
non-uniform across the pipe cross section, and approaches zero at the pipe wall. This
means that, in practice, the depth of installation of the probe, the internal pipe diameter,
and the flow profile of the liquid in the pipe can interact to produce significant deviations
from the flow ranges in the above table.
Nominal I.D
Inches
Range
GPM Water
Nominal I.D
Inches
Range
GPM Water
1/2 0.3-5.0 4 12-220
3/4 0.5-8.9 6 28-500
1 0.8-14 8 50-900
1-1/4 1.1-20 10 78-1400
1-1/2 2.0-35 12 110-2000
2 3.1-55 16 200-3600
3 7.9-140 20 310-5600

3 KAL-K
FM Rev. 8/29/06
Diagram 2.1 Dimensions
KAL-4215, 4315, 4320
KAL-4340S

KAL-K 4
FM Rev. 8/29/06
3.0 Mechanical Installation
To install the KAL-K flow switch into your piping system, proceed as follows:
3.0.1 The KAL-K flow switch can be mounted in virtually any orientation
as long as the piping is completely filled with fluid. It is recom-
mended that the unit be installed in the upper hemisphere of the
pipe when being used in horizontal piping runs. This ensures that
sediments do not deposit on the probe. It is also recommended that
the unit not be installed in the top of the pipe on horizontal runs. This
ensures that air pockets which collect in the top of the pipe do not
cause false switching
Diagram 3.1 Mechanical Installation
3.0.2 For optimal measuring accuracy, allow for a minimum of 5 pipe
diameters of straight-run piping both upstream and downstream of
the flow switch. This ensures that flow profile at the sensing probe is
uniform and fully developed.
3.0.3 Prior to installation, ensure that the desired flow alarm setpoint is
within the switching range of the KAL-K. Additionally, ensure that the
maximum system temperature and pressure are within the limits
specified per Section 2.0, Specifications.
3.0.4 It is recommended that a suitable thread sealant, such as PTFE
tape, be applied to the probe threads to ensure a leaktight seal.
3.0.5 Using an appropriate sized wrench, carefully thread the sensor
probe into the piping system. The probe must be installed such that,
at a minimum, the probe tip extends beyond the inner diameter of
the piping and into the fluid stream.
Bubbles can insulate the
probe from the process liquid
Correct
Sediments cannot
on the probecollect
Incorrect

5 KAL-K
FM Rev. 8/29/06
4.0 Electrical Connections
Diagram 4.1 shows the layout of electrical connections, as well as other controls for the
24 VDC KAL-K. Diagram 4.2 shows the layout for 110 VAC versions.
Diagram 4.1 Interior Controls Layout for 24VDC Versions
1
2
3
Trend Indicator
(8 LED’s)
Bi-colored LED
Green = Switch Activated
Red = Switch not Activated
Calibrating
Switch SW 1
Terminal Strip
3=+24 VDC
2=DC Ground
1=Output
Setpoint
Potentiometer P1
Output Selector
Switch SW2
PNP/NPN
Diagram 4.2 Interior Controls Layout for 110 VAC Versions
setpoint potentiometer P1
calibrating switch SW1
bi-colored LED
trend indicator LED’s
access
access

KAL-K 6
FM Rev. 8/29/06
Diagram 4.3 KAL-K Wiring 24 VDC Versions
NPN Configuration PNP Configuration
3
2
1
3=24 VDC
2=GND
1=Output
PNP NPN
SW 1
KAL-K
L
O
A
D
+
-
24 VDC
300 mA
+-
-DC Ground switched to pin 1 when switch
is activated. High impedance at pin 1 when
switch is not activated.
3
2
1
3=24 VDC
2=GND
1=Output
PNP NPN
SW 1
KAL-K
L
D
24 VDC
300 mA
+-
A
O
+
-
+24 VDC is switched to pin 1 when switch
is activated. High impedance at pin 1 when
switch is not activated.
Diagram 4.3 shows typical electrical wiring for the KAL-K 24 VDC versions configured as
either a NPN or PNP transistor switch. Instructions for selecting between the PNP or
NPN output is provided in section 5.3, Setting the KAL-K Output Type. The KAL-K
requires a 24 VDC, 300 mA power supply regulated to within ±10%. If the same power
supply will be used to provide current to devices being switched by the KAL-K (e.g.
relays), sufficient additional current must be available to power these devices. Diagram
4.4 shows the wiring for the 110 VAC versions of the KAL-K (suffix P03R).
Diagram 4.4 KAL-K Wiring 110 VAC Versions
1
2
3
4
110 VAC Power
Switch: 250 VAC @5 Amp
Green/Yel = Ground