Kobold KEC-2 User manual

KEC-2 K06/0622 Page 1 of 38
Operating Instructions
for
Thermal Energy Flowmeter
for gases
Model: KEC-2

Foreword
KEC-2 K06/0622 Page 2 of 38
I. Foreword
Dear customer,
thank you very much for deciding in favour of the KEC-2. Please read this installation
and operation manual carefully before mounting and initiating the device and follow
our advice. A riskless operation and a correct functioning of the KEC-2 are only
guaranteed in case of careful observation of the described instructions and notes
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.
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

Table of Content
KEC-2 K06/0622 Page 3 of 38
II. Table of Content
I. Foreword ..........................................................................................................................2
II. Table of Content...........................................................................................................3
1Pictograms and Symbols................................................................................................5
2Signalwords according ISO 3864 and ANSI Z 535........................................................5
3Safety instructions ..........................................................................................................6
3.1 Intended Use........................................................................................................................... 7
3.2 Installation and commissioning........................................................................................... 7
4Technical data..................................................................................................................8
4.1 Signal circuits......................................................................................................................... 9
4.1.1 Modbus.............................................................................................................................. 9
4.1.2 Current output.................................................................................................................... 9
4.1.2.1 Aktive.......................................................................................................................... 9
4.1.2.2 Passive....................................................................................................................... 9
4.1.3 Pulse.................................................................................................................................. 9
4.1.4 Alarm.................................................................................................................................. 9
4.2 Measuring range flow KEC-2 .............................................................................................. 10
4.2.1 Measuring range end values “Low Speed”...................................................................... 10
4.2.1 Measuring range end values “Standard Version”............................................................ 11
4.2.1 Measuring range end values “Max Speed Version” ........................................................ 12
4.2.1 Measuring range end values “High-Speed Version”........................................................ 13
5Dimensions ....................................................................................................................14
5.1 Dimension KEC-2 Thread-version...................................................................................... 14
5.2 Dimension KEC-2 Flanged-version.................................................................................... 15
6Installation......................................................................................................................16
6.1 Pipe/tube requirements....................................................................................................... 16
6.2 Inlet / outlet runs .................................................................................................................. 16
6.2.1 Installation of KEC-2....................................................................................................... 17
6.3 Alignment Display (Housing).............................................................................................. 17
6.4Tightening torques............................................................................................................... 17
7Connection diagram......................................................................................................18
7.1 Cable glands - clamping ranges......................................................................................... 18
7.2 Connector pin assignment.................................................................................................. 19
7.3 Wire connection................................................................................................................... 20
7.3.1 General:........................................................................................................................... 20
7.3.2 Power supply ................................................................................................................... 20
7.3.3 Modbus (termination):...................................................................................................... 20
7.3.4 Pulse Output.................................................................................................................... 21
8Operation KEC-2............................................................................................................22

Table of Content
KEC-2 K06/0622 Page 4 of 38
8.1 Main menu (Home)............................................................................................................... 22
8.1.1 Intialization....................................................................................................................... 22
8.2 Main menu ............................................................................................................................ 23
8.3 Settings................................................................................................................................. 23
8.3.1 Sensor Setup................................................................................................................... 24
8.3.1.1 Input / change tube diameter.................................................................................... 24
8.3.1.2 Input / change consumption counter........................................................................ 25
8.3.1.3 Definition of the units for flow, velocity, temperature and pressure.......................... 25
8.3.1.4 Definition of the reference conditions....................................................................... 26
8.3.1.5 Setting of Zeropoint and Low-flow cut off................................................................. 28
8.3.2 Modbus Setup.................................................................................................................. 29
8.3.2.1 Modbus Settings (2001…2005)............................................................................. 30
8.3.2.2 Values Register (1001 …1500)................................................................................ 30
Remark:............................................................................................................................................. 31
8.3.3 Pulse /Alarm..................................................................................................................... 32
8.3.3.1 Pulse output.............................................................................................................. 32
8.3.4 User Setup....................................................................................................................... 33
8.3.5 Advanced......................................................................................................................... 34
8.3.6 4 -20mA ........................................................................................................................... 35
8.3.7 KEC-2 Info ....................................................................................................................... 37
8.4 MBus...................................................................................................................................... 37
8.4.1 Default Settings communication...................................................................................... 37
8.4.2 Default values transmitted............................................................................................... 37
9EU Declaration of Conformance..................................................................................38

Pictogram / Symbols
KEC-2 K06/0622 Page 5 of 38
1 Pictograms and Symbols
General Warning symbol (Danger, Warning, Caution)
General note
Installation- and Instruction manual to consider (on Nameplate)
Installation- and Instruction manual to consider
2 Signalwords according ISO 3864 and ANSI Z 535
Danger!
Imminent danger
As a consequence of incorrect handling: serious personal injury or death
Warning!
Possible hazard
As a consequence of incorrect handling: possible serious injury or death
Caution!
Imminent hazard
As a consequence of incorrect handling: possible personal injury or damage
Note!
Possible hazard
As a consequence of incorrect handling: possible personal injury or damage
Important!
Additional notes, information, tips
As a consequence of incorrect handling: Disadvantages in operation and maintenance,
no danger

Safety instructions
KEC-2 K06/0622 Page 6 of 38
3 Safety instructions
Please check whether this manual corresponds with the device type.
Please attend to all notes indicated in this instruction manual. It contains essential
information,
which
has to be followed during installation, operation and maintenance. Therefore this
instruction manual has to be read categorically by the technician as
well as by the responsible
user/qualified personnel before installation, initiation and maintenance
Regional and national regulations respectively, have to be observed in addition to this instruction
manual if necessary.
This instruction manual has to be available at any time at the operation site of the DS 500.
Ensure that the KEC-2 operates within the permissible and listed limits on the nameplate.
Otherwise there is a risk to human and material, and it may occur functional and operational
disturbances
In case of any obscurities or questions with regard to this manual or the instrument please contact
Kobold GmbH..
Warning!
Risk of injury in case of inadequate qualification!
Improper handling can result in significant personal injury and damage.
All activities described in this operating instructions
manual must be carried out only by qualified
personnel qualifications described below.
Professionals (Technical staff)
The technical staff is based on his education/training, his knowledge of measurement and control
technology as well of the local regulations, standards and guidelines in the position to do the work as
described and to identify the possible hazards.
Special working conditions require further appropriate knowledge, e.g. of aggressive media.
Caution!
Malfunction of KEC-2
Faulty installation and insufficient maintenance may lead to malfunctions of the KEC-2, which may
affect the display and open to misinterpretation.
Danger!
Inadmissible operating parameters!
By exceeding or falling short of limits there is a risk for people and material, in addition there may
occur further functional and operational disturbances.
Measures:
•Make sure that the KEC-2 operates only within the permissible and listed limits on the nameplate
•Ensure the operation within the performance data of KEC-2 in connection with the application
•Do not exceed the admissible storage and transportation temperature.
Additional safety information:
• When installing and operating the relevant national regulations and safety rules must also be
observed.

Safety instructions
KEC-2 K06/0622 Page 7 of 38
3.1 Intended Use
The instrument described in this manual is exclusively to use for measuring the thermal mass flow of
gases. At the same time, the gas temperature is measured too.
The KEC-2 can be configured for measuring a predetermined range of pure gases or of
gas mixtures.
Consumption measurement of gases such as air, oxygen, nitrogen, carbon dioxide, argon, etc.
Improper or incorrect use the operational reliability will be canceled. The manufacturer is not liable for
any damage resulting by improper or incorrect use.
3.2 Installation and commissioning
•Installation, electrical installation, commissioning, operation and maintenance of the device
must only be carried by qualified personnel, which were authorized by the plant operator.
The personnel must read the operating instructions and understand and follow their
instructions.
•If carrying out welding work on the pipeline the grounding of the welding unit is not allowed to
be done over the KEC-2 itself.
•The installer has to ensure that the KEC-2 is connected according to the electrical
connection diagrams properly. The sensor must be grounded, unless special protective
measures have been taken (e.g. galvanically isolated power supply)
•The existing/ applicable national regulations governing opening and repair of the device have
to be applied.
•The device fulfills the general safety requirements in accordance with EN 61010-1,
the EMC requirements of IEC / EN 61326 and NAMUR recommendation NE 43.

Technical data
KEC-2 K06/0622 Page 8 of 38
4 Technical data
Measures:mass flow, consumption
flow speed, temperature
Measuring principle: thermal mass flow sensor
Medium temperature range: -40 ... 180 °C Probe
Operating temperature range: -20 ... 70 °C
Operating pressure: 50 bar
Power supply: 18 … 36 VDC
Power consumption: max. 5 W
Output: Modbus RTU (acc. EIA/TIA-485 Standard)
2 x 4...20 mA active (optional passive) RL < 500Ohm
galvanically isolated pulse (Pulse weight freely selectable,
Alarm max. 48 Vdc 0.5 A,
optional: HART, ProfibusDP, Profi Net,
Accuracy: ± 1.5 % m.v. ± 0.3 % f.s.
Standard version*
(m.v. of meas. value)
(f.s. of full scale)
Accuracy: ± 1.0 % m.v. ± 0.3 % f.s.
Precision version*
(m.v. of meas. value)
(f.s. of full scale)
Repeatability : 0,25% m.v in case of correct mounting(mounting aid,
position,inlet section
Accuracy indications: referred to ambient temperature 22 °C +/-2 °C, system
pressure 6 bar
Response time: t90 < 3 s
Display: 2“ TFT Color Display (320 x 240)
Material: Housing aluminum die cast,
probe stainless steel1,4571
Protection class IP67
* Reference conditions for Temperature and pressure can be freely set, standard conditions are 0 ° and 1013
mbar.

Technical data
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4.1 Signal circuits
4.1.1 Modbus
•According Standard EIA/TIA-485
4.1.2 Current output
4.1.2.1 Aktive
•Galvanically isolated
•4 … 20 mA
•RL< 500 Ohm
4.1.2.2 Passive
•Galvanically isolated
•4 … 20 mA
•RL< 500 Ohm
•Vin 12-36 Vdc
4.1.3 Pulse
•Galvanically isolated (dry contact)
•Passive: 48 Vdc , 500 mA
•Max. pulse output freq. 50 Hz
4.1.4 Alarm
•Galvanically isolated (dry contact)
•Max. 48 Vdc, 500 mA

Technical data
KEC-2 K06/0622 Page 10 of 38
4.2 Measuring range flow KEC-2
4.2.1 Measuring range end values “Low Speed”

Dimension
KEC-2 K06/0622 Page 11 of 38
4.2.1 Measuring range end values “Standard Version”

Dimension
KEC-2 K06/0622 Page 12 of 38
4.2.1 Measuring range end values “Max Speed Version”

Dimension
KEC-2 K06/0622 Page 13 of 38
4.2.1 Measuring range end values “High-Speed Version”

Dimension
KEC-2 K06/0622 Page 14 of 38
5 Dimensions
5.1 Dimension KEC-2 Thread-version
KEC-2 thread version
Connection
thread
Outer
pipe dia.
[mm]
Inner
pipe dia.
[mm]
L
[mm] L1 [mm] H [mm] H1 [mm] A [mm]
1/2“ 21.3 16.1 300 210 176.4 165.7 20
3/4“ 26.9 21.7 475 275 179.2 165.7 20
1“ 33.7 27.3
475
275 182.6 165.7 25
1 1/4“ 42.4 36
475
275 186.9 165.7 25
1 1/2“ 48.3 41.9
475**
275 189.9 165.7 25
2“ 60.3 53.1
475**
275 195.9 165.7 30
** Attention: Shortend inlet section! Please observe the recommended minimium inlet section
(lenght = 10x inner diameter)

Dimension
KEC-2 K06/0622 Page 15 of 38
5.2 Dimension KEC-2 Flanged-version

Installation
KEC-2 K06/0622 Page 16 of 38
6 Installation
6.1 Pipe/tube requirements
•Correctly sized gaskets
•Correct aligned flanges and gaskets
•Diameter mismatch at the pipe junctions should be avoided but must be less than 1mm.For
further information see ISO 14511
•Ensure clean pipes after installation
6.2 Inlet / outlet runs
The principle of thermal Mass flow measurement is very sensitive against disturbances. Therefore, it is
necessary to ensure the recommended inlet and outlet runs.
Table Inlet / Outlet runs
Flow obstruction before the measurement
section Min length
Inlet run (L1) Min length Outlet run (L2)
Slight curve
(ellbow < 90°)
12 x D 5 x D
Reduction
(Pipe narrows to the measurement section)
15 x D 5 x D
Expansion
(Pipe expands to the measurement section)
15 x D 5 x D
90° ellbow or T-piece
15 x D 5 x D
2x ellbow á 90°
in einer Ebene
20 x D 5 x D
2x ellbow á 90°
3-dimensional
35 x D 5 x D
Control valve
45 x D 5 x D
15 x D 5 x D
15 x D 5 x D15 x D
15 x D 5 x D
20 x D 5 x D
35 x D 5 x D
5 x D45 x D
The values represent the min.lenghts. In case the min. inlet / outlet runs could not be ensured, it must
be expected to get increased or significant d
eviations of the measurement values.

Installation
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6.2.1 Installation of KEC-2
The sensor KEC-2 is pre-supplied with the measuring section.
6.3 Alignment Display (Housing)
The sensor housing KEC-2 can be turned in both directions, max. 345 °. For this purpose, the
housing-connecting nut must be opened. The housing can be rotated to the desired position, a bigger
rotaion angle is prevented by internal stop pins.
After that, the housing-connecting nut is firmly retighten
Housing
connection nut
6.4 Tightening torques
To secure and guarantee of the function and tightness following tightening torques have to be
applied, see table 1.
Table 1
Pos
Description
Tightening torque
[Nm]
20
KEC-2 cover with glass
3
30
KEC-2 cover without window
3
50
Grub screw with hexagon socket M4x6 DIN 914 A2
2
130
KEC-2 nut
15
150
Cylinder screw DIN 6912 - M5x10 A2-70
4

Wiring
KEC-2 K06/0622 Page 18 of 38
7 Connection diagram
7.1 Cable glands - clamping ranges
For ensuring the tightness and strain relief, connector cables with the following diameters must be
used.
KEC-2 Standard clamping range : Ø 5-9 mm

Wiring
KEC-2 K06/0622 Page 19 of 38
7.2 Connector pin assignment
* Outputs are galvanically isolated.
** The Current outputs, X5 and X6, are optional.(Active and passive version available).

Wiring
KEC-2 K06/0622 Page 20 of 38
7.3 Wire connection
7.3.1 General:
•Wiring to be done in strainless state only.
•Length of cable skinning to be minimized
•Not used cable entries must be closed with end caps
•Use of cables with cross section of >= 0.25 mm²
7.3.2 Power supply
7.3.3 Modbus (termination):
If the sensor placed at the end oft he Modbus system a termination is required.
Therfore the enclosed 120R resistor ist o be connected at Pin 1 and Pin 3 of connector „X2“