Kobold DOR User manual

K03/1213
Manufactured and sold by: Kobold Messring GmbH
BI-DIRECTIONAL INSERTION FLOW TRANSDUCER
Model DOR
KOBOLD
LOCK
INSTRUCTION MANUAL
O
Or rd de er r
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fr ro om m: :
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C A A
B
Br ri ig gg gs s
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Co om mp pa an ny y
622 Mary Street; Suite 101; Warminster, PA 18974
Phone: [phone] -
Fax: [phone]
Sa[email protected] -
www.cabriggs.com

IMPORTANT INFORMATION
Thank you for purchasing a Kobold Insertion Flowmeter. It is important that you
read this manual to gain a full understanding of the capability and operational
aspects of the equipment you are about to install.
This information is provided only to assist in the installation of the product and
does not diminish your obligation to read the manual.
1. Select a location that meets the requirements as illustrated on the guideline
sheet (please see the data sheet/order codes). An ideal installation would provide
for 25 diameters of straight pipe upstream from the meter and 10 diameters
downstream.
You will also need to know the pipe internal diameter (NB) and pipe wall thickness
for calculation of the insertion depth. (refer page 5.) Non ideal installations may
require in-situ calibration (refer to the factory for details).
2. After screwing the flowmeter in place ensure the flow alignment mark located
on the top positioning collar of the meter aligns with the flow in the pipe (refer
page 5). This ensures the paddle is correctly aligned to the flow.
Note. the meter is bi-directional so a flow direction arrow is not provided.
3. Calculate and adjust the height of the flowmeter (refer page 5).
4. Electrical Installation depends on the model you have purchased.
If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser
or rate totaliser please refer to the appropriate manual and page 10 of this
manual. For pulse output meters, select the appropriate output and wire to your
receiving device. (refer pages 7 to 9).
5. Calculate the flowmeter K (scale) factor to suit the installation. For ideal
installations refer to page 11 or 12 or 13 of the flowmeter Manual. For non ideal
installations the K-factor may be calculated by performing an in-situ calibration.
Enter the appropriate K-factor into your receiving instrument.
page 1
CONTENTS PAGE
1.0 INTRODUCTION
1.1 Model number designation
1.2Overview
1.3 Operating principal 3
1.4 Specifications 3
2.0 INSTALLATION
2.1Meterlocation
2.2 Meter installation & orientation 4
2.3 Height adjustment 5
2.4 Flow direction orientation 5
2.5 Hot tap installations 6
3.0 ELECTRICAL CONNECTIONS
3.1 Standard outputs 7
3.2 Optional Reed switch output 7
3.3 Instrument cable installation requirements 8
3.4 Pulse output selection ( standard outputs ) 8
3.5 QP Quadrature pulse output option 9
3.6 Bi-directional flow using QP option 9
3.7 Connection to family instruments 10
4.0 K – FACTOR ( calibration factor for meter )
4.1 K-factors for common pipe ID sizes <575mm 11
4.2 K-factors for large pipe ID >460mm 11
4.3 Calculating K-factors ( metric units – litres or M3 ) 12
4.4 Calculating K-factors ( US gallons )
5.0 Declaration of Conformance
3
4
12
14

Page 2
1.1 Model no. designation
Please see the data sheet
1.2 Overview
Kobold insertion flow transducers provide a cost effective and simple means of measuring
the flow of a wide range of low viscosity liquids. Installation is quick and inexpensive for
pipe diameters ranging from 40mm to 900mm (1.5-36") and up to 2500mm (100") nominal
bore for the Hot tap capable model DOR-52.
The flowmeter has a linear measuring range of 0.3~10.0 metres/sec. (1~33 ft/sec.).
Minimum detectable flow velocity is 0.15 m/sec. (0.5 ft/sec.). When used in conjunction with
the ZOD-Z3 flow rate totaliser NLC feature the linear flow range is extended down to 0.15
m/sec. (0.5 ft/sec.) with an improved linearity.
The flowmeter is constructed from 316 L (1.4404) stainless steel enabling use in many
applications for metering water and low viscosity chemicals.
Two independent pulse outputs are standard & can directly input to a wide range of
ancillary instruments, PLC’s and computers. Both pulse outputs have a high level of
immunity to electrical interference. Options include a reed switch.
1.3 Operating principle
Flow passes through a pipe causing the rotor to spin. Magnets installed in the rotor pass by
pulse sensors within the transducer body & inturn this produces frequency outputs
proportional to flow rate.
page 3
1.4 Specifications
Velocity measuring range (linear): 0.3...10 m/s equates to approx.0.25...49,000 l/s in
DN40 to DN2500 pipes; 0.15...10 m/s when using the
linearisation function of electronic type Z3
Linearity: ±1.5% with well est. flow profile
Repeatability: ±1% of f. s. at factory conditions and optimal straight
runs
Max pressure: 80 bar
Temperature range: -40…+100°C standard, see max.allowable medium
temperature table for other options and restrictions
Material
Body: stainless steel 1.4404 (316L)
Rotor: PVDF or PEEK (depending on model)
Rotor shaft: stainless steel 1.4404 (316L)
Bearing: graphite/PTFE
Seals: FPM (standard): -15…+200°C
EPR (ethylene propylene rubber): -20…+120°C, for
ketones only
PTFE encapsulated FPM: -20…+200°C
NBR (Nitril): -65…+125°C
Electronics
Output frequency at max. velocity: 220...240 Hz (hall effect and voltage output),
73...80 Hz (reed switch output)
Supply voltage: see electrical output specifications and electronics
comparison table in the data sheet
Electronic features: see electronics comparison table in the data sheet
Wiring (standard): 5 core, screened cable, length 3 meters
Transmission distance: 1,000 meters maximum, without integrated electronics
Cable entry (terminal box): M20x1.5 (standard), 1/2“ NPT adapter (optional)
Protection Class: IP68 (cable connection),
IP66/67 (all other electrical connections)
Straight piping requirement: Minimum: 10xd (upstream), 5xd (downstream)
Optimal: 25xd (upstream), 10xd (downstream)
Weight: (approx., without electronics):
1.6 kg (DOR-4), 2.5 kg (DOR-5)

page 4
2.0 INSTALLATION
2.1 Meter location
Choose an appropriate section of horizontal or vertical pipe as per the guidelines below.
With vertical pipe installations the media should be pumped up through the pipe past the
flow sensor so that any entrained air will pass freely.
The DOR flow sensor requires a fully developed turbulent flow profile to ensure maximum
measurement accuracy and repeatability. This can be achieved by installing the DOR in a
straight run of pipe. We recommend at least 10 but ideally 25 straight pipe diameters
upstream & at least 5 but ideally 10 pipe diameters downstream of the flowmeter. Major
obstructions such as pumps, valves or strainers will require longer straight runs before and
after the flowmeter.
10 pipe dia. minimum
25 pipe dia. prefered 5 pipe dia. min.
10 pipe dia. prefered
FLOW
Major obstructions such as
pumps,valves,reducers or strainers
to be kept well outside the straight
run pipe sections
2.2 Meter installation & orientation
Cut a 40mm diameter hole (1.6") on either the 2, 10 or 12 o’clock positions of the pipe. If
there is any likelihood of air entrainment in a horizontal pipe do not locate the flow
transducer in the 12 o’clock position.
Install a female threaded weld on fitting (threadolet) or service saddle.
Wrap the threads of the flowmeter with PTFE tape or sealing compound & screw the unit
into the installed fitting.
page 5
2.3 Height adjustment calculation
Calculate the adjustment height A for DOR-42 (or AA for the DOR-52) as follows:
A( for DOR-42 ) = 175mm ( 6.9") - ( B + C + D )
AA ( for DOR-52 ) = 420mm (16.5") - ( B + C + D )
Where :
B= Distance between the top of the pipe & the top of the hex adaptor.
C= Pipe wall thickness
D= Insertion depth ( pipe ID ÷ 8 )
Examples of insertion depth D:
For 40mm pipe ID ( D= 5.0 mm )
For 50mm pipe ID ( D= 6.25 mm )
For 100mm pipe ID ( D= 12.5 mm )
For 400mm pipe ID ( D= 50.0 mm )
Turn the height adjustment nuts (1) as required so that the distance between the top of the
hex adaptor (2) and the top of the positioning collar (3) equals your calculated distance A
(for DOR-42) or AA for model DOR-52. Retighten the height adjustment nuts (1).
2.4 Flow direction orientation
The unit is bi-directional however the paddle must be aligned with the direction of flow.
Using a 2mm hex key (Allen key), unlock the locking screw located on the positioning collar
(3) then insert the hex key (as a lever) in the body rotating hole located above the collar,
turn the body until the alignment slot is parallel with the direction of pipe. Retighten the
locking screw.
12 o’clock 2 o’clock
Other positions
around the pipe are
acceptable
D
3
2
A (AA)
BC
LOCK
C
1
ALIGNMENT SLOT TO
PARRALLEL PIPE

page6
2.5 Hot tap installation
( model DOR-52 )
CAUTION : Hot tap installation
should only be performed by
qualified personal. Installation
procedures should be in accordance
with the safety rules, regulations and
requirements applying to the territory
in which the flow transducer is being
installed.
If necessary extend valve
port using a 2” nipple &
socket combination to
ensure the paddle is clear
of the ball valve.
IMPORTANT
Before removing the
DOR-52 from the
installation first
withdraw the
transducer body to
the maximum
distance allowed by
the three height
adjusting threaded
rods. This will enable
the isolating valve
to be fully closed
without damaging the
paddle.
FLOW
2" Nipple
2" Weld-O-let
( threadolet )
2" ball or gate
isolation valve.
(Allow min. 40mm I.D. to
clear metering head)
Clean & lubricate screw
threads before
withdrawing the
transducer body in order
to avoid nut seizure
Hot tap clearance hole in
pipe wall to be a minimum
of 40mm diameter (1.6").
page 7
3.0 ELECTRICAL CONNECTIONS
( see page 9 for QP outputs )
3.1 Standard outputs
Conductor color coding also applies to the Non-magnetic
sensor and high temperature output options
A1 A2
B2B1
b1
VOLTAGE PULSE
OUTPUT
Screen
Yellow (+ )
Green ( - )
SQUARE WAVE
PULSE OUTPUT
Red (VDC supply )
White (+ Sig. output )
Black (-0v ground )
Terminal box option
terminal connections
Pull up resistor
required, they are
generally incorporated
in most receiving
instruments
Hex adaptor
Rotor
Body
Positioning
collar
Height
adjustment
1.5” or 2” BSPT
or NPT
KOBOLD
LOCK
3.2 Optional Reed switch output
HAZARDOUS AREAS
The REED SWITCH output is classed as a
“simple apparatus“ as defined in the
CENELEC standard EN50020 &
recognized ATEX directive. It can be
connected to an approved I.S. secondary
instrument with both being located in the
hazardous area.
The Reed Switch may also be connected
through an approved I.S. barrier.
Note: The Reed switch produces 1/3rd
the normal pulse output value
( eg. 1/3 the standard K-factor )
REED SWITCH
OUTPUT
To -0V
Screen
Yellow
Green
KOBOLD
LOCK

page8
3.3 Instrument cable installation requirements
Use twisted multi-core low capacitance shielded instrument cable (22 AWG ~ 7x 0.3
stranded) for electrical connection between the flow meter and the remote instrumentation.
The screen should be earthed at the readout instrument end only to protect the transmitted
signal from mutual inductive interference.
The cable should not be run in a common conduit or parallel with power and high inductive
load carrying cables as power surges may induce erroneous noise transients onto the
transmitted pulse signal. Run the cable in separate conduit or with other low energy
instrument cables .
3.4 Pulse output selection ( standard outputs )
The standard flowmeter has two independent pulse output signals that are linearly
proportional to volumetric flow rate. Pulse transmission can be up to 1000 metres (3300 ft ).
An optional I.S. Reed Switch output is available (see page 7).
Voltage pulse (pulse wire) output
A self generating pulse output which produces a strong 1.5 volt voltage spike of
approximately 10 micro/second duration with no dependence on rotor speed.
Yellow ( + )
Green ( - )
Screen
Square Wave Pulse (Hall sensor) ( also applies to non-magnetic & QP Hall outputs )
An NPN open collector transistor pulse output produced by a solid state Hall Effect device.
This three wire device requires 5~24vdc and produces an NPN square wave output (20mA
max. sink), pulse width is 2~75 mSec. The Hall output requires a pull up resistor, these are
generally incorporated in most receiving instruments. For (QP) Quadrature pulse output
refer details page 9.
Screen
Red
Black
White
(5-24vdc supply )
signal output
( -0v ground )
Page 9
3.5 Quadrature outputs
DOR series flow meters supplied with the QP option produce two NPN open collector pulse
outputs from two Hall Effect sensors. The outputs are “ phase offset ” in their timing so that
external electronics are able to differentiate. These outputs may be used to assure output
signal integrity or to measure bi-directional flow.
Screen
Red ~ Vdc
Black ~ -0V
White ~ output 1
Blue ~ output 2
3.6 Bi-directional flow
The DOR flow transducer is capable of accurately measuring flow in both directions without
modification. Meters fitted with the QP output option (quadrature pulse output) may be
interfaced with the Pulse Discriminator Module (PD2). The PD2 accepts the Quadrature
pulse inputs & from these will discriminate between forward & reverse flow. Two individual
& proportional pulse outputs can then be sent to appropriate totalising registers or an Z3
add and subtract flow rate totaliser.
It is important to note that the Quadrature Pulse option has the same pulse resolution
(pulses/unit volume) as a standard flowmeter for both forward & reverse outputs.
Flowmeter with QP outputs
PD2 Pulse Discriminator
5~24Vdc maximum
(forward flow)
Output Signal 1
Ground
(reverse flow)
Output Signal 2 Reverse flow Sig.
Forward flow Sig.
-0V
+8~24Vdc
1
2
5
4
Output signals
Sig.1
Sig.2
-0V
+Vdc
7
Reg
Reg
X
X
Vdc
+
+
-0V
9
6
10

page 10
3.7 Voltage Pulse Connection to family instruments
Flow instruments or a
terminal box can be
directly mounted to the
flowmeter using ST4 (for
DOR-42) or ST5 (DOR-
52) mounting stem kits
Note:For other output styles see
receiving instrument manual
yellow
green
Screen
6
5
4
3
2
1
7
-0V (ground)
8
9
10
11
12
13
14
All flow DIP
switches in the
OFF position
3
2
1
O
N
Z3 & B1 SERIES
INSTRUMENTS
The flowmeter cable should
not be run with other high
energy cables ( clause 3.3 ).
yellow
green
Screen
+Vdc +∏-gnd
4 5 6
Z1 TOTALISER
DIP switch 1 in
the ON position
( 2 Khz max.)
1 2 3 gnd
+-
1 2 3
ON
1 2 3
RATE TOTALISER
RESET
>PROGRAM
ENTER
gal
RUN ACCUM. TOTAL STOP BAT LOW
RATE
TOTAL
ACCUM
TOTAL ^
KOBOLD
LOCK
FLOMEC
LOCK
page 11
4.0 K – FACTORS ( calibration factors for meter )
The K-factor (pulses / litre, gallon etc.) will vary in relation to the bore size of the pipe in
which the flowmeter is installed.
The K-factors and formula shown are a result of factory testing using smooth bore piping
under ideal conditions. Variations to the given K-factors may occur when using rough bore
piping or inadequate flow conditioning on either side of the flow transducer (refer clause
2.1). In these instances on site calibration may be used to determine the K-factor.
4.1 Flow transducer K- factors for common pipe sizes
Pipe detail K-factors ( standard K-factors for voltage & square wave outputs )
NB ID (#40) Schedule 40 pipe -
(
#40
)
Schedule 80 pipe -
(
#80
)
inches mm p / litre p / m3 p / USgal p / litre p / m3 p / USgal
1.5" 40.9 18.678 18678 70.695 21.524 21524 81.468
2" 52.6 11.238 11238 42.534 12.818 12818 48.517
2.5" 62.7 7.880 7880 29.824 8.899 8899 33.682
3" 78.0 5.062 5062 19.161 5.676 5676 21.485
3.5" 90.2 3.768 3768 14.263 4.200 4200 15.896
4" 102 2.912 2912 11.021 3.233 3233 12.237
5" 128 1.839 1839 6.959 2.025 2025 7.665
6" 154 1.268 1268 4.798 1.402 1402 5.307
8" 203 0.719 719.0 2.721 0.787 787.2 2.980
10" 255 0.450 450.3 1.705 0.496 495.9 1.877
12" 303 0.316 316.0 1.196 0.347 347.4 1.315
14" 333 0.261 260.5 0.986 0.286 285.7 1.081
16" 381 0.198 198.0 0.750 0.217 217.0 0.821
18" 429 0.156 155.8 0.590 0.171 170.6 0.646
20" 478 0.125 125.4 0.475 0.138 137.8 0.521
24" 575 0.087 86.64 0.328 0.095 95.39 0.361
For other pipe sizes below 610mm (24") not listed above, use the graphs and apply the
formula on the following pages ( 12 & 13 ).
4.2 K-factors for large pipes 460mm ID (18") and above use:
Pulses per litre = 28647 ÷ pipe ID² (mm)
Pulses per M³ = 28647000 ÷ pipe ID² (mm)
Pulses per US gallon = 168.14 ÷ pipe ID² (inches)
Pulses per Imp. gallon = 201.94 ÷ pipe ID² (inches)
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
pulse output.

page 12
4.3 Calculating K-factors ( litres or m³ )
22
22.5
23
23.5
24
24.5
25
40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460
(A)
pipe ID (mm)
Pipe ID 450mm & above (A) = 22.5
See
example a
Calculate K-factor ( pulses / litre ) using the above graph and the metric constant of 1273.2
as follows :
Pulses / litre = 1273.2 x (A) from graph
pipe ID² (mm)
Example ‘a’ :
K-factor for 100mm pipe: 1) from graph 100mm ID (A) = 24.0
2) pulses/litre. = 1273.2 x 24.0
10000 = 3.056 p/litre
K-factor for m³ :multiply by 1000 eg. K = 3056 p/m³
K-factor for megalitres :multiply by 1000000 eg. K = 3056000 p/megalitre
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage
pulse output.
page 13
4.4 Calculating K-factors ( US gallons )
6.8
6.9
7.0
7.1
7.2
7.3
7.4
7.5
7.6
1234567891011 12 13 14 15 16 17 18 19 20
(A)
pipe ID (inches)
Pipe ID 19.5 ” & above (A) = 6.86
Calculate K-factor ( pulses / gallon ) using the above graph and the volumetric
constant of 24.51 as follows :
Pulses / US gal. = 24.51 x (A) from graph
pipe ID² (inches)
Example ‘b’ :
K-factor for 10" pipe: 1) from graph 10" ID (A) = 7.01
2) pulses/gal. = 24.51 x 7.01
100 = 1.718 p/gal
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.

page 14
5.0 Declaration of Conformance
We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:
Bi-Directional Insertion Flow Transducer Model: DOR
to which this declaration relates is in conformity with the standards noted below:
97/23 EC Pressure Equipment Directive
Pressure Accessory – Insertion Flowmeter – No CE Marking
Article 3, Paragraph 3; Diagram 9, Piping, Group II Liquids
Article 3, Paragraph 3; Diagram 8, Piping, Group I Liquids – with the following restrictions
Connection Nominal Size Maximum Pressure Rating
For Group I Liquids
1.5“ (40 mm) 50 bar
2” (50 mm) 40 bar
2002/96/EC Waste Electrical & Electronic Equipment (WEEE)
2002/95/EC Restriction of Hazardous Substances (RoHS)
Also the following EEC guidelines are fulfilled:
2004/108/EC EMC Directive – Electromagnetic Compatibility Directive
When fitted with an optional Reed Switch ONLY pulse output, which is classified as a simple apparatus, and
when installed in accordance with Hazardous Area standards by a competent professional the product also
complies with:
EN 60079-11: 2011 – Section 5.7
Equipment protected by Intrinsic Safety – Simple Apparatus
EN 13463-1: 2009
Non electrical equipment for use in potentially explosive atmospheres
When fitted with an integral EX-ia certified instrument such as the ZOD-Z3 or ZOD-Z1, in combination with a
Reed Switch only output, the product also complies with:
94/9/EC
ATEX Directive
page 15
Certificate about acknowledgement of quality assurance production
Certificate number: BVS 12 ATEX ZQS/E110
Certification body: DEKRA EXAM GmbH, notified body No 0158
SIRA 06 ATEX M348 – Only when equipped with integral ZOD-Z3 or ZOD-Z1 options
Issued by Sira Certification – United Kingdom
EN 13980:2002
Potentially Explosive Atmospheres – Application of Quality Systems
94/9/EC Articles IV and VII
ATEX Directive
Hofheim, 12. Nov. 2013
H. Peters M. Wenzel
General Manager Proxy Holder

11. Declaration of Conformance
We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that
the product:
Batch Controller Model: ZOD-B1K
to which this declaration relates is in conformity with the standards noted below:
EN 60529, DIN VDE 0470-1 1992-11
I.P. Ingress Protection Classifications
EN 61326-1: 2006-10
Electrical equipment for control, instrumentation technology and laboratory use – EMC
requirements (Industrial area)
EN 61010-1: 2002-08
Safety requirements for electrical equipment for measurement, control, and laboratory use
2008/35/EC Waste Electrical & Electronic Equipment (WEEE)
Also the following EWG guidelines are fulfilled:
2004/108EC EMC Directive
2006/95 EC Low Voltage Directive
Hofheim, 8. Nov. 2010
H. Peters M. Wenzel
General Manager Proxy Holder
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: [phone]
Fax: [phone]
K01/1110
I N S T R U C T I O N M A N U A L
BATCH CONTROLLER Model ZOD-B1K
Universal Mount Series