Kobold KAL User manual

Operating Instruction
for
Calorimetric Flow Monitoring Device
Model: KAL

KAL
Page 2 KAL 07/04
1. Contents
1. Contents........................................................................................................2
2. Note ..............................................................................................................3
3. Instrument Inspection....................................................................................3
4. Regulated Use ..............................................................................................4
5. Operating Principle .......................................................................................5
6. Mechanical Connection.................................................................................5
7. Electrical Connection ....................................................................................6
8. Limiting Contacts ..........................................................................................6
9. Alignment / Balancing ...................................................................................7
10. Commissioning ...........................................................................................10
11. Maintenance ...............................................................................................10
12. Fault Signalling ...........................................................................................11
13. Technical Information..................................................................................11
14. Order Codes ...............................................................................................12
15. Dimensions .................................................................................................13
16. Declaration of Conformance .......................................................................14
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: [phone]
Fax: [phone]
E-Mail: i[email protected]
Internet: www.kobold.com

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KAL 07/04 Page 3
2. Note
Please read and take note of these operating instructions before unpacking and
setting the unit for operation, and follow the instructions precisely as described
herein.
The devices are only to be used, maintained and serviced by persons familiar
with these operating instructions and with the prevailing regulation applying to
procedural safety and the prevention of accidents.
By usage in machines, the measuring unit should be used only then when the
machines fulfil the EWG-machine guide lines.
PED 97/23/EG
for KAL-11.. and KAL-12..
In acc. with Article 3 Paragraph (3), "Sound Engineering Practice", of the
PED 97/23/EC no CE mark.
Table 8, Pipe, Group 1 dangerous fluids
3. Instrument Inspection
These devices are checked before dispatch and sent away in perfect condition.
Should the 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.
Scope of delivery:
•probe with 2 m PVC as standard
•Electronic setting system

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4. Regulated Use
The KAL is to be installed only in the specified applications. Every usage which
exceeds the specifications is considered to be non-specified. Any damages
resulting therefrom are not the responsibility of the manufacturer. The user
assumes all risk for such usage. The application specifications include the
installation, start-up and service requirements specified by the manufacturer.
Devices from the KAL model series are used for the monitoring of liquid flow.
Limiting relay
The devices are equipped with limiting relays for monitoring the flow speed of
liquids (KAL-E1...-E3).
Trend display
An LED bar display shows the current flow value and the set switch point via a
flashing LED (only on models KAL-E2... and KAL-E3...).
Probes
Probes are available in two options: as a screw-type or in-line version.
Model KAL devices are always made up of two structural components
•Probe
•Electronic setting system
The devices may only be used for liquids to which the probe housing materials
are resistant. With proper installation and maintenance, the probes display no
sensitivity to soiling and cause practically no pressure loss.
Materials
KAL-11... Brass material
KAL-12..., KAL-23..., KAL-53... St. steel material 1.4301
KAL-24..., KAL-54... St. steel material 1.4571
Setting ranges in relation to nominal tube diameter
ND (mm) Range (l/min) water ND (mm) Range (l/min.) water
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

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Attention! For the measuring ranges gives the flow speed was
converted to the nominal tube diameter. It should be noted in line
with this that in the tube towards the wall section the flow speed
approaches 0. Depending on nominal tube diameter, screw depth of
the probe and flow profile, occasional deviations, some of them
considerable, may result.
5. Operating Principle
The all-metal design electronic flow monitor device functions according to proven
calorimetric principles. The measuring probe is heated up a few degrees from the
inside outwards in relation to the flow medium which it is penetrating. If the
medium is flowing then the heat produced in the probe is carried away by the
medium, i.e. the probe becomes cooler. This cooling represents a measuring of
the flow speed.
The electronic setting system compares the desired flow speed with the actual
speed and activates an output relay when the desired value is not reached. By
the use of a micro-controller, simple calibrations is made possible. In this way
optimum temperature compensation can be achieved.
6. Mechanical Connection
Before installation:
•Ensure that the actual flow quantity corresponds to the setting range of the
device (i.e. to the flow speed).
•Ensure that the permitted maximum operating pressure and temperatures for
the device are not being exceeded. (See point 13 Technical Information)
Installation:
Mount the sensor in the pipe (KAL-1...)- in a sleeve welded to the pipe (KAL-2...).
Fitting position:
The function of the sensor is not dependent on
their fitting position, provided that the pipe is
completely filled with flow medium. The place
where the sensor are fitted must be free from
turbulence in the medium. (4x pipe section in
front of and behind sensor). If the medium is
likely to cause any deposits in the tube, then an
appropriate fitting position alongside is
recommended.

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7. Electrical Connection
Warning! Ensure that the voltage values of your installation
correspond to the voltage values given on the device´s specification
plate.
•Make sure that the electrical power supply is off.
•Connect the sensor cable to terminals 6 & 8 on the setting system.
•Connect the power supply (voltage supply) to terminals 15 & 16.
Temperature relay only on models
KAL-E3.
The relais are illustrated in fallen state.
AC voltage supply
220 VAC, 110 VAC, 24 VAC +/- 10%, 50-60 Hz
DC voltage supply
24 VDC + 15%, - 10%
8. Limiting Contacts
Only on KAL-E1.../KAL-E2...
1x change - over relay for flow speed
Only on KAL-E3...
1x change - over relay for flow speed
1x change - over relay for temperature

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9. Alignment / Balancing
Initial operation:
9.1. Fit sensor in pipe (ensure correct fitting location, see point 6 Mechanical
Connection).
9.2. Connection sensor cables to electronic circuitry (see point 7 Electrical
Connection).
9.3. Fill pipe with flow medium.
Caution! There must be no air bubbles on the sensor. Flow speed
must be at 0.
9.4. Commission electronic circuitry (switch on supply voltage)
9.5. Only on model KAL-E-3...Set temperature potentiometer (2) to left-hand
stop.
9.6. Zero point alignment. Briefly activate the "SET"key (5) (using a suitable
object e.g. ball point pen)
9.7. "Flow" LED (6) flashes for about 30 seconds. After this time the "Flow"LED
goes off (6). The device is now operational., continue with point 9.9.
9.8. In case of malfunction the "Flow" LED flashes continuously. Press the"SET"
key once again. Device will switch back into measuring mode. Check
mechanical and electrical installation and recommence operational
procedure from point 9.4.
9.9. Switches on installation and set maximal flow.
If the flow speed is significantly less then 2 m/s, then on the trend display (3)
there will be possibly fewer then 8 LEDs on.
It is now possible to extend this display (3) to the full range (8 LEDs). This can
only be successfully achieved, however, if the flow speed is somewhere between
0,25-1,8 m/s.
•Set "Flow" potentiometer (1) (see illustration) to right-hand stop
(only on KAL-E3...; Set temperature potentiometer to left-hand stop)
•Briefly activate SET key (5)
•Flow LED (6) will flash for 30 seconds. After this time the Flow
LED will go 30 off.

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It is possible at any time to reset the electronic circuitry to the full range
•Flow potentiometer (1) at right-hand stop
•(Only on KAL E3; Temperature potentiometer (2) to left hand-
stop)
•Press the SET key (5) and hold in position until the FLOW LED
stops
The device has now been reset into basic functioning mode.
The device is now adjusted to your medium. You can now set your switch point.
(In case of malfunction see point 9.8)
9.10. Set operational flow.
Switch point setting: Model KAL-E-1...
•The further the Flow-potentiometer (1) is turned to the left, the lower the switch
point.
•The further the Flow-potentiometer (1) is turned to the right, the higher the
switch point.
Switch point setting: Model KAL-E-2.../E-3...
•Set Flow-potentiometer (1) to left-hand stop. The first LED on the luminous
display (3) will flash. Any number of LED´s on the luminous display will be
continuously illuminated.
•Turn "Flow" potentiometer (1) to the right until the desired switch point is
reached. The current switch point will be displayed by a flashing LED.
Display 3
XXXXX
Flashing flow speed
XXXXXX
LED display flashin Explanation Result
XXXXXX flow>switch point Flow relay pick-up made
Flow LED illuminated
XXXXXXflow>switch point LED Flow relay pick-up made
flashes at double
frequency
Flow LED illuminated
XXX öFlow<switch point Flow LED off
Flow relay open

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Only KAL-E-3...
with more than 10 m cable between sensor and electronic circuitry, as well as
increased accuracy when measuring temperature.
Temperature alignment
•Caution! Disconnect from power supply.
•Connect full length extention cable (>10 m) (terminals 6&8)
•Connect 100 Ohm ±1% resistor (part of delivery package) in place of
sensor at the end of the instrument leads.
•Set temperature potentiometer (2) at 80° C (right - hand stop).
•Reconnect power supply and switch device on.
•Briefly press SET key (5).
•The temperature LED will flashed and switch off again after approx. 10
seconds. In case of malfunction, see point 9.8, Initial operation. If the
temperature LED flashes more quickly, this could be caused by the fact
that the probe is connected instead of a 10 Ohm resistor.
•Remove the 100 Ohm resistor and replace the sensor.