Kobold PSR User manual

KOBOLD PSR/PS FLOW SWITCH
User Instructions
Manual-PSR-PS_3-13
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Table Of Contents
PSR/PS
KOBOLD PSR/PS FLOW SWITCH
1.0 General .......................................................................... 1
2.0 Specifications ................................................................ 2
3.0 Installation ..................................................................... 5
3.1 Contact Protection ......................................................... 5
4.0 Operation ....................................................................... 6
4.1 Adjusting Setpoint .......................................................... 6
5.0 Maintenance .................................................................. 7
6.0 Damaged Equipment ..................................................... 7
7.0 Need Help with your PSR/PS ........................................ 7
LIST of DIAGRAMS
Diagram 2.4 Diagram of Dimensions ................................................ 4
Diagram 2.5 Diagram of Pressure loss vs. Flow rate ........................ 4
Diagram 4.2 Diagram of Reed Contact ............................................. 6
LIST of TABLES
Table 2.1 Table of Technical Data ............................................... 1
Table 2.2 Table of Construction ................................................... 2
Table 2.3a & b Table of Switching Ranges ........................................... 3
Table 3.2 Table Reed Contact - Data ........................................... 5
Rev. 3/13
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1PSR/PS
KOBOLD PSR/PS FLOW SWITCH
User Instructions
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
1.0 General
The KOBOLD PSR/PS flow switch is intended for applications in which an electrical
switching function is required once a specific flow is achieved.
The PSR/PS can be set to operate as either a normally-open (N/O) or normally-closed
(N/C) switch. Switching is done with a reed contact which is electrically isolated from the
flowing medium.
The device operates through use of a paddle-spring arrangement. The flowing medium
exerts force on the lower part of the paddle ( in the T-piece ). The paddle pivots about a
point higher in the PSR/PS body but is resisted by a leaf spring. On the upper part of the
paddle is a magnet, which moves as the paddle pivots about its center. A reed switch is
located outside the PSR/PS housing ( thus hermetically isolated ) inside a movable
plastic housing. As the magnet nears the reed switch, the switch closes. By moving the
switch, with adjustable switch point.
2.0 Specifications
Table 2.1: Technical Data
Operating Principle: Spring resisted paddle
Dimensions: See Diagram 2.4
Ranges: See Diagram 2.3a & 2.3b
Maximum Pressure: Most Brass/SS units:1450 PSIG (100 Bar)
NOTE: PSR-5132 & PSR-5140: 360 PSIG (25 Bar)
Maximum Medium Temperature: 230 Degrees F (110 Degrees C)
Maximum Ambient Temperature: 150 Degrees F ( 65 Degrees C)
Reed Switch Specifications: See Table 3.2
Rev. 3/13
reed switch, the flow required to close it is altered. The result is a flow-sensitive reed
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PSR/PS 2
Table 2.2: Construction
Housing
(1,4,6)
Brass SS
Impact Plate
(3.1)
304 SS 304 SS
Leaf Spring
(3.4)
301 SS 301 SS
Lever (3.2) 301 SS 301 SS
Locking Plate
(5)
Brass Brass
Housing (7) Polyamide
GFR*
Polyamide
GFR*
Cabling (8) PVC PVC
Magnet (3.3) Ceramic Ceramic
*GFR - Glass Fiber Reinforced
Rev. 3/13
O-Ring (2) Buna-N FKM
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3PSR/PS
Stand
Conn.
NPT
Stand. switching ranges
Increasing Decreasing
GPM Water GPM Water
Flow switch model PSR
Brass SS
1/4” 0.9-1.3 0.6-1.2 PSR 5105 PSR 5205
3/8” 1.0-1.6 0.7-1.5 PSR 5110 PSR 5210
1/2” 1.3-2.1 1.0-2.0 PSR 5115 PSR 5215
3/4” 3.0-4.0 2.2-3.0 PSR 5120 PSR 5220
1” 3.2-5.0 2.4-4.5 PSR 5125 PSR 5225
1 1/4” 4.9-8.5 3.8-7.8 PSR 5132 PSR 5232
1 1/2” 9.2-15.0 7.9-14.3 PSR 5140 PSR 5240
Pipe
Size
Stand. switching ranges
Increasing Decreasing
GPM Water GPM Water
Stand.
conn.
NPT
Flow switch Model PS
Material
Brass SS
2” 18-24 16-22 1/2”
PS-5149 PS-5249
3” 48-66 45-62 1/2”
4” 84-106 79-101 1/2”
6” 185-242 176-237 1/2”
2” 13-16 11-15 1/2”
PS-5152 PS-5252
3” 41-48 38-44 1/2”
4” 57-70 53-66 1/2”
6” 147-159 137-156 1/2”
4” 24-30 19-27 1/2”
PS-5114 PS-5214
6” 53-75 44-62 1/2”
8” 101-141 88-123 1/2”
Table 2.3a: Switching Ranges - PSR
Table 2.3b: Switching Ranges - PS
Rev. 3/13
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PSR/PS 4
Diagram 2.4 Dimensions - PSR/PS

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Order Number
Thread
(NPT)
PS-5149/PS-5249 3.66 2.32 1.34 0.78 0.87 - 1/2"
PS-5152/PS-5252 5.25 2.22 3.03 0.75 1.06 1.18 1/2"
PS-5114/PS-5214 7.55 4.52 3.03 0.75 1.06 1.18 1/2"
PSR-5105/PSR-5205 1.97 0.39 3.15 - 1.06 1.18 1/4"
PSR-5110/PSR-5210 1.97 0.39 3.15 - 1.06 1.18 3/8"
PSR-5115/PSR-5215 1.97 0.39 3.15 - 1.06 1.18 1/2"
PSR-5120/PSR-5220 2.05 0.59 3.21 - 1.25 1.18 3/4"
PSR-5125/PSR-5225 2.2 0.59 3.31 - 1.54 1.18 1"
PSR-5132/PSR-5232 2.6 - 3.5 - 1.97 1.18 1 1/4"
PSR-5140/PSR-5240 2.6 - 3.62 - 2.36 1.18 1 1/2"
Dimensions (inches)
HEX2HEX1DCBA

Pressure Drop:
The pressure drop of the flow switch is mostly due to
the size of the paddle and resulting resistance to flow.
The data given in the diagram is valid for units with the
standard set point ranges. The pressure drop is less for
units with the special set point ranges in the table. The
set point ranges are those over which the contact can
be adjusted. The high grade stainless spring steel
beam enables actual flow rates to be significantly
higher without causing damage. There would however
be a higher pressure drop.
Diagram 2.5: Pressure Loss vs. Flow Rate
Rev. 3/13
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5PSR/PS
3.0 Installation Instructions
CAUTION: For Safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
Note that the PSR must be installed so that flow direction in the pipe is as indicated by
the arrow on the T-piece. The flow direction arrow on the PS series is stamped on the
clamp plate.
that loads on the switch do not exceed the maximum ratings as given in Table 3.2.
Remember that capacitive and inductive loads (such as motors) exhibit much greater
voltage/current requirements at start-up and shut-down than the typical operating values.
3.1 Contact Protection
When driving inductive or capacitive loads, we recommend the use of an isolation
relay. KOBOLD supplies a line of relays for such instances.
Table 3.2: Reed Contact - Electrical Data
Maximum Current: 1.5A
Environmental Protection: NEMA 4 / IP 65
Rev. 3/13
The PSR/PS is installed directly in the pipeline. The PSR/PS is supplied with NPT or BSP
The reed contact is simply an open/closed type of switch - connect appropriately. Ensure
Maximum values of current and voltage must not be exceeded on the reed switch.
Maximum Voltage (SPST): 250 VAC
Maximum Voltage (SPDT): 150 VAC
Maximum Power Dissipation (SPDT):20 VA / 20 W / 0.5 A
Electrical Cable Length: 5 ft. (Std.)
Maximum Power Dissipation (SPST):50 VA / 50 W / 1.5 A
threads. Use of PTFE tape is recommended to aid installation.
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PSR/PS 6
4.0 Operation
As described in Section 1.0, the PSR/PS uses a paddle to activate a reed contact
wired as such.
4.1 Adjusting the Setpoint
Diagram 4.2: Adjusting the Setpoint
Construction, and do as follows:
(N/C) switching function. The switch functions as an N/O switch when the switch
housing (4). The switch functions as an N/C switch when the switch assembly (7)
Rev. 3/13
located at the top of the instrument. The reed contact is simply a N/O or N/C switch, and should be
approximately the middle of its range. To change the setpoint, consult Table 2.2:
Decide whether you want to retain the normally open (N/O) or change to the normally closed
assembly (7) is positioned such that the tip of the red arrow is just emerging from flow switch
is positioned such that the tip of the white arrow is just emerging from flow switch housing (4).
The switch becomes less sensitive to flow (i.e activates at a higher flowrate) as more of
N/C. The N/C switching sensitivity can then be adjusted in similar fashion as noted above.
The PSR/PS is pre-adjusted at the factory as a normally open (N/O) switch, set to switch in
Slightly loosen the clamp plate screws (5) to allow movement of the reed contact (7).
the arrow point is displayed (pulled out)of the housing. When the red arrow is almost completely
pulled out from the flow switch housing, the switch function will transition from N/O to
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7PSR/PS
5.0 Maintenance
Due to the simple construction of the PSR/PS, it is nearly maintenance free. Should
cleaning ever be required, simply release pressure in your system, loosen the lock nut
(Diagram 2.2, Item 6) on the PSR/PS and pull the body straight up. Clean as necessary
and replace. During replacement, note that the pivot plate of the balance arm (Item 3.2)
is keyed to the T-piece (Item 1). The instrument must be reassembled with the keys
properly aligned in order to function properly.
6.0 Arrival of Damaged Equipment
Your instrument was inspected prior to shipment and found to be defect-free. If damage
is visible on the unit, we advise that you carefully inspect the packing in which it was
delivered. If damage is visible, notify your local carrier at once, since the carrier is liable
for a replacement under these circumstances. If your claim is refused, please contact
KOBOLD Instruments for further advisement.
7.0 Need help with your PSR/PS
Call one of our friendly engineers at 412-788-2830.
Note: If during adjustment, the switch assembly (7) is pulled too far out of
the flow switch housing (4), the switch will not function when the impact
plate (3.1) is deflected. If this occurs, simply slide the switch assembly
back into the housing until the contact functions as desired.
Rev. 3/13
If switch is removed, note that the arrow points face opposite tothe normalflow direction.
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9PSR/PS
Caution
PLEASE READ THE FOLLOWING GENERAL FLOW METER /
MONITOR WARNINGS BEFORE ATTEMPTING
INSTALLATION OF YOUR NEW DEVICE. FAILURE TO HEED
THE INFORMATION HEREIN MAY RESULT IN EQUIPMENT
FAILURE AND POSSIBLE SUBSEQUENT PERSONAL
INJURY.
Rev. 3/13
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PSR/PS 10
• KOBOLD manufactures a wide range of process sensors and technolgies.
While each of these technologies are designed to operate in a wide variety
of applications, it is the user’s responsibilty to select a technology that is
appropiate for the application, to install it properly, to perform tests of the
installed system, and to maintain all components. The failure to do so could
result in property damage or serious injury.
• Inspect instrument for damage upon arrival. Cracked, fractured, bent, or
otherwise damaged instruments must not be put into use, since the device
is weakened to an unknown extent. (The opeartions and installation guide
will explain how to make a claim on damaged instruments.)
• Make sure that the model which you have selected is chemically
compatible with the application liquids. While the meter is liquid and spray
resistant when installed properly, it is not to be immersed.
• Under NO circumstances must the maximum tolerances (temperature and
pressure) be exceeded.
• The maximum tolerances of the device have been determined using water,
air and/or oil. If using other media, especially corrosive ones, it is critically
important that the user determine chemical compatibility with our
instruments. A list, detailing material composition of our instruments, is
available from KOBOLD Instruments Inc. upon request. KOBOLD
Instruments Inc. cannot accept responsibilty for failure and consequences
resulting from use of media other than water, mineral oil, air, and nitrogen.
• Install the devices in a fully supported position within your flow system. This
avoids excessive stresses which may damage the instrument. In particular:
a. Ensure that the plumbing leading to and from the instrument is fully
supported and that the instrument does not perform the physical function
of a joint.
b. When calculating stress on the device caused by plumbing, the weight of
the medium in the pipes must be considered as well.
c. Misaligned runs of rigid piping can cause large stresses when connected
to the instrument. Do not connect in such a fashion.
• During installation, avoid stresses on the instrument by following guidelines
given below:
a. When connecting fittings, hold the instrument fittings rigid with a
correctly sized wrench. Do not install by twisting the instrument into the
pipe fittings.
b. Do NOT install holding the device housing to provide counter-torque to
the pipe fitting.
Rev. 3/13
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11 PSR/PS
reduces the twisting stresses produced by tightening the fittings into
each other.
d. Do not use pliers or wrenches on the housing, as this may damage it.
e. Do not overtighten, as this may fracture the fittings.
• During operation, there are a number of situations to avoid:
a. The sudden cessation of fluid flow causes what is typically referred to as
“water hammer”. Most people are famailar with this phenomenon from
their home experience - it is the cause behind the loud clank of water
pipes which occurs when faucets are turned off too suddenly. The cause
behind this “water hammer” is quite easy to visualize. Water is fairly
massive. The amount of water in long runs of pipe is quite substantial.
When the faucets are turned off suddenly, especially from a full on
condition, the water has considerable momentum and does not want to
stop flowing. The situation is similar to stopping a car by running into a
wall, rather than by applying brakes. Both are sudden rather than
gradual. The damage to the wall can be substantial (not to mention the
car).
The “water hammer” causes surges in fluid pressure which could cause
the measurement instrument’s pressure limit to be exceeded, resulting in
failure and possible personal injury.
b. Fluid surges, as well as the water hammer, can be particularly damaging
to empty flow meters since there is no back pressure in the device. The
damage is caused, once again, by momentary excess pressure. To
avoid these surges, fluid lines should remain full (if possible) and water
flow should be introduced to the device slowly.
c. If the instrument is isolated with inlet and outlet valves, the flow meter
must be completely drained when said valves are both closed. Failure to
do so could result in damage to the device caused bt thermal expansion
of fluid.
d. Freezing of water in the instrument must be avoided since the resultant
expansion will damage the flow meter and make it unsafe for use.
• Design a fail-safe system
a. Design a fail-safe system that accomodates the possibilty of switch or
power failure. In critical applications, KOBOLD recommends the use of
redundant backup systems and alarms in addition to the primary system.
Rev. 3/13
c. Use an appropiate amount of PTFE tape on male threads of fitting. This
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