Kobold KEC-2 User manual

KEC-2/KEC-4 K10/0124 Page 1 of 43
Operating Instructions
for
Thermal Mass Flowmeter
for gases
Model: KEC-2/KEC-4

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I. Foreword
Dear customer,
thank you very much for deciding in favour of the KEC-2/KEC-4. 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/KEC-4 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
([e-mail])in PDF format, specifying therelevant invoicenumber 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: [e-mail]
Internet: www.kobold.com

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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 Information................................................................................................... 8
5Order Codes.................................................................................................................. 8
6Dimensions ................................................................................................................... 8
6.1 Signal circuits......................................................................................................................... 8
6.1.1 Modbus .............................................................................................................................. 8
6.1.2 Current output.................................................................................................................... 8
6.1.2.1 Active.......................................................................................................................... 8
6.1.2.2 Passive....................................................................................................................... 8
6.1.2.3 Pulse........................................................................................................................... 8
6.1.2.4 Alarm .......................................................................................................................... 8
6.2 Measuring range flow KEC-2/KEC-4 .................................................................................... 9
6.2.1 Measuring range end values “Low Speed”........................................................................ 9
6.2.2 Measuring range end values “Standard Version”............................................................ 10
6.2.3 Measuring range end values “Max Speed Version” ........................................................ 11
6.2.4 Measuring range end values “High-Speed Version”........................................................ 12
7Dimensions ..................................................................................................................13
7.1 Dimension KEC-2/KEC-4 Thread-version.......................................................................... 13
7.2 Dimension KEC-2/KEC-4Flanged-version ......................................................................... 14
8Installation....................................................................................................................15
8.1 Pipe/tube requirements....................................................................................................... 15
8.2 Inlet / outlet runs.................................................................................................................. 15
8.2.1 Installation of KEC-2/KEC-4 ........................................................................................... 17
8.3 Alignment Display (Housing).............................................................................................. 17
8.4 Tightening torques............................................................................................................... 17
9Connection diagram ....................................................................................................18
9.1 Cable glands - clamping ranges......................................................................................... 18
9.2 Connector pin assignment.................................................................................................. 18
9.3 Wire connection................................................................................................................... 20
9.3.1 General ............................................................................................................................ 20
9.3.2 Power supply ................................................................................................................... 20
9.3.3 Modbus RTU.................................................................................................................... 20
9.3.4 Pulse Output.................................................................................................................... 20

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10 Operation KEC-2/KEC-4 ...........................................................................................21
10.1 Main menu (Home)............................................................................................................... 21
10.1.1 Intialization....................................................................................................................... 21
10.2 Main menu ............................................................................................................................ 22
10.3 Settings................................................................................................................................. 22
10.3.1 Sensor Setup................................................................................................................... 23
10.3.1.1 Input / change tube diameter.................................................................................... 23
10.3.1.2 Input / change consumption counter........................................................................ 24
10.3.1.3 Definition of the units for flow, velocity, temperature and pressure ......................... 24
10.3.1.4 Definition of the reference conditions....................................................................... 25
10.3.1.5 Setting of Zeropoint and Low-flow cut off................................................................. 27
10.3.2 Modbus Setup.................................................................................................................. 29
10.3.2.1 Modbus Settings (2001…2005)............................................................................. 30
10.3.2.2 Values Register (1001 …1500)................................................................................ 31
Remark:............................................................................................................................................. 32
10.3.3 Pulse /Alarm..................................................................................................................... 33
10.3.3.1 Pulse output.............................................................................................................. 33
10.3.4 User Setup....................................................................................................................... 34
10.3.5 Advanced......................................................................................................................... 35
10.3.6 4 -20mA ........................................................................................................................... 36
10.3.7 KEC-2/KEC-4 Info............................................................................................................ 38
11 Disposal ....................................................................................................................39
12 EU Declaration of Conformance..............................................................................40
13 UK Declaration of Conformity..................................................................................42

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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

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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/KEC-4operates 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/KEC-4
Faulty installation and insufficient maintenance may lead to malfunctions of the
KEC-2/KEC-4which 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/KEC-4operates only within the permissible and listed
limits on the nameplate
• Ensure the operation within the performance data of KEC-2/KEC-4in 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.

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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/KEC-4can 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. and with ATEX approval explosive gases such as natural gas, methane,
propane and hydrogen.
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/KEC-4itself.
•The installer has to ensure that the KEC-2/KEC-4is 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.
•When using the KEC-4 (ATEX Version) hazardous areas, in addition with the
standard manual a separate Ex documentation is enclosed. The installation
instructions and connection values indicated in these must also be observed.
•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.

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4 Technical Information
Operating instructions, data sheet, approvals and further information via the QR
code on the device or via www.kobold.com
5 Order Codes
Operating instructions, data sheet, approvals and further information via the QR
code on the device or via www.kobold.com
6 Dimensions
Operating instructions, data sheet, approvals and further information via the QR
code on the device or via www.kobold.com
6.1 Signal circuits
6.1.1 Modbus
•According Standard EIA/TIA-485
6.1.2 Current output
6.1.2.1 Active
•Galvanically isolated
•4 … 20 mA
•RL< 500 Ohm
6.1.2.2 Passive
•Galvanically isolated
•4 … 20 mA
•RL< 500 Ohm
•Vin 12-36 Vdc
6.1.2.3 Pulse
•Galvanically isolated (dry contact)
•Passive: 48 Vdc , 500 mA
•Max. pulse output freq. 50 Hz
6.1.2.4 Alarm
•Galvanically isolated (dry contact)
•Max. 48 Vdc, 500 mA

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6.2 Measuring range flow KEC-2/KEC-4
6.2.1 Measuring range end values “Low Speed”

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6.2.2 Measuring range end values “Standard Version”

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6.2.3 Measuring range end values “Max Speed Version”

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6.2.4 Measuring range end values “High-Speed Version”

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7 Dimensions
7.1 Dimension KEC-2/KEC-4 Thread-version
KEC-2/KEC-4 thread version
Connect
ion
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)

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7.2 Dimension KEC-2/KEC-4Flanged-version

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8 Installation
8.1 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
8.2 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

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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.

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8.2.1 Installation of KEC-2/KEC-4
The sensor KEC-2/KEC-4 is pre-supplied with the measuring section.
8.3 Alignment Display (Housing)
The sensor housing KEC-2/KEC-4 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
8.4 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/KEC-4 cover with glass
3
30
KEC-2/KEC-4 cover without window
3
50
Grub screw with hexagon socket M4x6 DIN
914 A2
2
130
KEC-2/KEC-4 nut
15
150
Cylinder screw DIN 6912 - M5x10 A2-70
4

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9 Connection diagram
9.1 Cable glands - clamping ranges
For ensuring the tightness and strain relief, connector cables with the following
diameters must be used.
KEC-2/KEC-4 Standard clamping range : Ø 5-9 mm
9.2 Connector pin assignment
Version with option board 2x analogue outputs galvanically isolated

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Connector Pin Signaldescription
X1
Power
supply
1 VB - (GND)
2 VB+
X2
Modbus
1 Modbus (B)
2 Modbus shield
3 Modbus (A)
X4
Direction / Pulse
1 Pulse / Alarm *
2 Pulse / Alarm *
3 Direction input
4 GND
X5
Current output
1
1 I- Active**
2 I+ Active **
X6
Current output
2
1 I- Active **
2 I+ Active **
* Outputs are galvanically isolated.
** The Current outputs, X5 and X6, are optional.(Active and passive version
available).

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9.3 Wire connection
9.3.1 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
9.3.2 Power supply
9.3.3 Modbus RTU
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“
9.3.4 Pulse Output