Kobold KAL-8115FL User manual

KOBOLD Instruments Inc. 1801 Parkway View Drive Pittsburgh PA 15205
Phone [phone] • Fax [phone]
KOBOLD KAL-L (KAL-8000 Series)
Thermal Air Flow Switch
User Instructions
Manual-KAL-L_5-12

Table Of Contents
FM Rev. 5/17/12
KAL-L
1.0 General .......................................................................................................1
2.0 Specifications..............................................................................................1
3.0 Mechanical Installation................................................................................3
3.1 Installation General ..........................................................................3
3.2 Installation of Units with NPT Thread Connection............................5
3.3 Installation of Units with HVAC Flange Connection..........................5
4.0 Electrical Connections ................................................................................5
5.0 Operation ....................................................................................................6
5.1 Flow Setpoint Adjustment ................................................................6
5.2 Adjustment of the Start-up Time Delay ............................................8
6.0 Maintenance ...............................................................................................9
7.0 Need Help with Your KAL-L Flow Switch? ..................................................9
List of Diagrams
Diagram 2.1: Dimensions............................................................................2
Diagram 3.1: General Installation ...............................................................4
Diagram 3.2: Required Straight Pipe Runs.................................................4
Diagram 4.1: Electrical Connections...........................................................5
Diagram 5.1: Interior Controls Layout for the KAL-L...................................6
List of Tables
Table 2.1: Model Number Codes ...........................................................3

KAL-L
FM Rev. 5/17/12
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
1.0 General
The KAL-L (KAL-8000 Series) Thermal Air Flow Switch uses the proven calorimetric
principle to monitor the flow of air or non-hazardous gases. A sensing resistive thermal
device (RTD) is heated to a few degrees above the temperature of the flow medium. As
the medium flows across the sensing RTD it cools the RTD. The rate of cooling is
proportional to flowrate. A second RTD measures medium temperature and the KAL-L
electronics uses this measurement to compensate for changes in medium temperatures
thus preventing false readings due to medium temperature transients. If the measured
flow value drops below the setpoint value, an output relay is activated providing an alarm
or control input.
2.0 Specifications
Switching Range: 3.3 to 66 feet/second @ 68°F/14.5 PSIA
Restricted span for other pressure and
temperature conditions
Accuracy: ±10% of flow rate
Repeatability: ±1% of flow rate
Display
Flowrate: 8 LED trend indicator
Switchpoint: Flashing LED in trend indicator
Switch Status: Dual colored LED
RED = Flow below switchpoint
GREEN = Flow above switchpoint
Max. Temperature Gradient: 30°K(°C)/Min. @ 25 feet/sec and 190°F
Response Time: Adjustable 1 to 60 seconds
Warm-up Time: 30 seconds
Max. Pressure: 120 PSIG
Temperature Range
Process: -10 to +250°F
Ambient: +15 to +140°F
Wetted Parts: Ni-Plated brass
Electrical Data
Power Requirements: 24 VDC/VAC +10%/-15%
Switch Characteristics: 1-SPDT relay Max. 250 VAC/4 A/1000
VA
Electrical Connection
Standard: Cable gland
Optional: 1/2” NPT Conduit or M-12 plug
Protection: NEMA 4/IP 65
Housing: Polyamide

KAL-L 2
FM Rev. 5/17/12
7.0
4.0
φ15.5mm
4.3
PG 13.5
Hex 41mm
Diagram 2.1 Dimensions
All dimensions in inches
Unless otherwise noted
HVAC Duct Mount
Flange
1/2” NPT
Compression Fitting
Cable Gland

3 KAL-L
FM Rev. 5/17/12
Table 2.1 Model Number Codes
3.0 Mechanical Installation
CAUTION
Prior to mechanical installation, ensure that the process flow velocity to be monitored is
within the switching range of the device. Also ensure that system temperature and
pressure are within the limit of the device. See Section 2.0 ”Specifications”.
3.1 Installation General
The following general installation instructions and precautions apply to all KAL-8000
series installations:
3.1.1 The probe tip must be inserted a minimum of 3/8” beyond the
inside diameter of the pipe or duct into which it is to be installed.
Best results are obtained if the probe is inserted into the pipe or duct 1/
2” or greater.
3.1.2 In order to ensure that the sensing elements are facing directly into the
flow stream, a notch has been placed on the probe hex nut to aid in
alignment. For optimal results, the probe should be installed so that the
notch is aligned directly over the centerline of the pipe or duct.
3.1.3 In order to ensure a uniform flow profile across the probe tip, install the
probe to allow for 10 pipe diameters of straight run piping upstream and
5 downstream. This piping should be free of tees, elbows, bends,
valves, dampers or any other such appurtenances.
3.1.4 The probe should not be installed in the lower hemisphere of the pipe or
duct. Liquid and debris which collect in the lower portion of the pipe will
cause the probe to function erratically if they come in contact with the
probe.
Model Code Description
KAL-8115 15mm smooth bore probe with 1/2” NPT compression fitting
KAL-8115FL 15mm diameter probe with clamping flange per DIN 43 743
Options
Option Suffix Description
-M12 NEMA 4 electrical plug connector
-C 1/2” NPT conduit connection

KAL-L 4
FM Rev. 5/17/12
Diagram 3.1 General Installation
Diagram 3.2 Required Straight Pipe Runs
3.2 Installation of Units with NPT Thread Connection
Mount the unit
in the pipe upper
hemisphere
Liquid and sediment
which settle at the bottom
cannot cause measuring
errors
C
L
Mount probe such that
the notch cut into the
hex is perpendicular to
the pipe centerline to
ensure that the probe is
properly oriented in the
flow stream.
3/8” Min. probe
insertion depth.
1/2” or greater is
optimal
Flow
10XD Upstream 5XD Downstream

5 KAL-L
FM Rev. 5/17/12
3.2.1 Units with NPT threaded connections are best suited for round pipes or
ducts in which systems are under pressure. The NPT connection
makes a leaktight seal to 120 PSIG.
3.2.2 The threaded connection should be installed into a pipe via a 1/2” weld
coupling or a pipe tee with 1/2” connection. If a bushing is used to
reduce a larger fitting size to 1/2”, ensure that the probe insertion
requirements are met. See Section 3.1 ”Installation General”.
threads.
3.3 Installation of Units with HVAC Flange Connection
3.3.1 Units with flanged connections are best suited for square ducts in HVAC
applications where adding an NPT connection is impractical.
3.3.2 Prior to installing the flange, the flange face which contacts the surface
of the HVAC duct should be sealed using a field manufactured gasket
or RTV compound. This will minimize leakage at the flange face.
4.0 Electrical Connections
4.0.1 All electrical connections are made at the terminal blocks inside the
electronics enclosure of the KAL-L.
4.0.2 The KAL-L can operate using a power supply of 24 VAC or DC. When
DC voltage is used, the input supply is non-polarized. The polarity
of the DC input voltage does not matter and can be wired in either
direction without affecting the operation of the unit.
Diagram 4.1 Electrical Connections
Relay Output
SPDT
Max. 4A @ 250 VAC
3.2.3 Ensure that a thread sealant such as PTFE tape is used to seal the

KAL-L 6
FM Rev. 5/17/12
5.0 Operation
Diagram 5.1 Interior Controls Layout for the KAL-L
5.1 Flow Setpoint Adjustment
The section describes the procedures for adjustment of the flow setpoint for three
scenarios:
• Adjustment of precise setpoint on falling flow.
• Adjustment of precise setpoint on rising flow.
• Setup for flow/no flow detection.
5.1.1 Flow Setpoint Adjustment - General
The flow switch point on the KAL-L is fixed at 50% of its span. Because of the trend
indicator’s non-linear response, this corresponds to the third LED on the indicator bar.
The third LED is wired to flash permanently to allow users to judge the location of the
flow setpoint relative to system flow.
The flow switch point is set by adjusting the span potentiometer P1. Doing this increases
or decreases the span of the trend indicator thereby changing the point at which the
KAL-L switches. The next three sections describe how to set the KAL-L switchpoint in
specific situations
24V AC/DC
RELAY
Trend Indicator
8 LEDs
DUO-LED
Green= Flow > Setpoint
Relay Activated
Red = Flow < Setpoint
Relay Deactivated
Start-up Time Delay P2
Holds the relay in activated
state for 0 to 60 seconds after
power-up
Span Adjustment P1
Setpoint LED
Fixed at 3rd LED
(flashing)