Kobold KAL-7000 Series User manual

KOBOLD KAL-A (KAL-7000 Series)
Thermal Flow Transmitter
User Instructions
KAL-A_manual_8-22-06

Table of Contents
FM Rev. 8/22/06
1.0 General 1
2.0 Specifications 1
2.1 Dimensions 3
3.0 Mechanical Installation 4
4.0 Electrical Connections 5
5.0 Operation 6
5.1 Calibration 6
5.1.1 Zero Flow Calibration 6
5.1.2 Adjustment of the Trend Indicator Span 7
5.2 Flow Setpoint adjustment 7
5.3 Setting the Transistor Switch Output Type 8
5.4 KAL-A Diagnostics 8
6.0 Maintenance 8
7.0 Arrival of Damaged Equipment 8
8.0 Need Help With Your KAL-A 9
9.0 Getting the Most out of Your KAL-A Transmitter 9
10.0 Application Hint: Relay Switching with the KAL-A Transistor Switch 11
List of drawings
2.1 Dimensions 3
3.1 Mechanical Installation 4
5.1 Electrical Connections and Controls 5
5.2 Transmitter and Switch Wiring Configuration 5

KAL-A
FM Rev. 8/22/06
CAUTION: For safety reasons, please read the cautionary information located at
the end of the manual, before attempting installation.
1.0 General
The KOBOLD KAL-A (a.k.a. KAL-7000 Series) flow transmitter is intended for use in measuring
and control applications involving moderate flowrates of non-viscous or dirty liquids. The KAL-A
flow transmitter uses the proven thermal dispersion principle and operates as follows:
1. The probe is heated internally to a few degrees above the temperature of the medium
into which it extends.
2. The flowing medium removes this heat from the probe by convective heat transfer.
The rate at which heat is removed is proportional to the liquid velocity across the
probe tip.
3. The electronics module converts the signal from the probe to a 4-20 mA signal which
can be used to indicate flowrate.
4. For units provided with the optional flow switch, the measured flowrate is compared to
the setpoint value selected by the user. If the setpoint is reached, the electronic
circuitry activates a transistor switch and bi-colored alarm LED.
5. The electronic circuitry also controls an LED trend indicator which can be used to
indicate relative system flow.
The microprocessor-controlled design permits simple calibration and setup. The compact probe
design permits monitoring of flowrate with minimal head pressure loss.
2.0 Specifications
Measuring Range: 0.13-6.6 feet/sec.
(0.04 - 2 meter/sec.)
Fitting Size: 1/2”, 3/4” NPT
Optional: 1-1/2” Tri-Clamp®
Maximum Pressure:
NPT: 1450 PSIG
Tri-Clamp: Per users’ clamp rating to 1450 PSIG Max.
Operating Temperature:
Medium: 0 to 176°F
Ambient: 0 to 176°F
Clean-in-place: 290°F max. for up to 10 minutes
Wetted Parts:
KAL-7215: 304 Stainless Steel
KAL-7315, 7320: 316-Ti Stainless Steel
KAL-7340S 316-Ti Stainless Steel

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Electrical Specifications:
Supply Power: 24 VDC ± 10%, 300 mA Max.
Analog Output: 4-20 mA, 3 wire, 500 ohm Max. load imped-
ance
Accuracy: ±10% of full scale
Repeatability: ±1% of full scale
Transistor Switch (optional):
Switchpoint Adjustment: By internal potentiometer
Switch Type: Normally open (N/O)
NPN or PNP transistor (user selectable)
Max. 24 VDC, 400mA
Housing: Reinforced Polycarbonate (NEMA 4)
Calibration Data: Stored in non-volatile memory, data retained
for at least 10 years in the event of a power
failure
Table 2.1Switching Ranges Vs. Pipe Diameter
Note: The flow ranges specified in the table above have been calculated for each pipe diameter based on the
known velocity range of the KAL-A. It must be noted that flow in pipes is non-uniform across the pipe cross
section, and approaches zero at the pipe wall. This means that in practice, the depth of installation of the
probe, the internal pipe diameter, and the effect that elbows valves and fittings can have on the flow profile of
the liquid in the pipe can interact to produce significant deviations from the flow ranges in the above table.
Nominal I.D
Inches
Range
GPM Water
Nominal I.D
Inches
Range
GPM Water
1/4 0.05-0.8 2-1/2 4.4-80
5/16 0.08-1.4 3-1/4 7.9-140
3/8 0.1-2.2 4 12-220
1/2 0.3-5.0 6 28-500
3/4 0.5-8.9 8 50-900
1 0.8-14 10 78-1400
1-1/4 1.1-20 12 110-2000
1-1/2 2.0-35 16 200-3600
2 3.1-55 20 310-5600

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2.1 Dimensions
KAL-7215, 7315, 7320
KAL-7340S

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3.0 Mechanical Installation
To install the KAL-A flow transmitter into your piping system, proceed as follows:
3.0.1 The KAL-A flow transmitter can be mounted in virtually any orientation as long
as the piping is completely filled with liquid. It is recommended that the unit be
installed in the upper hemisphere of the pipe when being used in horizontal
piping runs. This ensures that sediments do not deposit on the probe. It is also
recommended that the probe not be installed in the very top of the pipe. In low
pressure systems air bubbles which collect at the top of the pipe may keep the
liquid from contacting the probe.
Diagram 3.1Mechanical Installation
3.0.2 For optimal measuring accuracy, allow for a minimum of 5 pipe diameters of
straight-run piping both upstream and downstream of the flow transmitter. This
ensures that flow profile at the sensing probe is fully developed turbulent flow.
3.0.3 Prior to installation, ensure that the actual system flowrate is within the mea-
suring range of the KAL-A. Additionally, ensure that the maximum system tem-
perature and pressure are within the limits specified per Section 2.0,
Specifications.
3.0.4 It is recommended that a thread sealant such as PTFE sealing tape be applied
to the probe threads to ensure a leak-tight seal.
3.0.5 Using an appropriate sized wrench, carefully thread the sensor probe into the
piping system. The probe must be installed such that at a minimum, the probe
tip extends beyond the inner diameter of the piping and into the liquid stream.
If this is not the case, the unit may still function but the measuring range will be
somewhat higher than those stated in Table 2.1, Switching Ranges vs. Pipe
Diameter.
Correct
Sediments cannot
on the probe
Incorrect
Bubbles can insulate the
probe from the process liquid
collect

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4.0 Electrical Connections
Diagram 4.1 shows the layout of electrical connections, as well as other controls for the KAL-A.
Diagram 4.2 shows typical electrical wiring for the KAL-A transmitter and optional transistor
switch configured as either a NPN (sinking) or PNP (sourcing) transistor switch. Instructions for
selecting between the PNP or NPN output are provided in section 5.3, Switch Logic Selection.
The KAL-A requires a 24 VDC, 300 mA power supply regulated to within ±10%. If the same
power supply will be used to provide current to devices being controlled by optional transistor
switch (e.g. relays), sufficient additional current must be available to power these devices.
Diagram 4.1Electrical Connections and Controls
Diagram 4.2Transmitter and Switch Wiring Configuration
Transistor switch selector SW 2
Right = PNP
Left = NPN
Setpoint Potentiometer P1
Terminal Block
4 = 4-20 mA Out
3 = +24 VDC Supply
2 = Power Supply Neutral
1 = Switch Output
LED Trend Indicator
Calibrating Switch SW 1
Bi-colored LED
Green = Switch Activated
Red = Switch not activated
1
2
3
4
24 VDC ±10%
+-
Current input device
(e.g. PLC/display)
Open collector transistor switch
selectable between PNP and NPN
PNP: Switches 24 VDC to pin 1
when activated
NPN: Switches ground to pin 1
when activated
Transmitter 4-20 mA output
Switch Output (option)
+
-
Standard version w/ terminal block
Optional M-12 connector version
1
2
34
1 = Brown (+24 VDC)
2 = White (+4-20 mA output)
3 = Blue (-DC Common)
4 = Black (Optional Switch Output)

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5.0 Operation
This section will provide details on the following aspects of KAL-A operation:
• Calibration of the zero-flow reference and trend indicator span.
• Adjustment of the flow switch setpoint.
• Switching between PNP and NPN transistor switch output.
• Self diagnostics within the KAL-A software.
5.1 Calibration
5.1.1 Zero Flow Calibration
Calibration of the KAL-A electronics at zero system flow is necessary in order to obtain optimal
performance from your KAL-A. This procedure is allows the KAL-A to store data pertaining to the
thermal characteristics of the liquid being monitored.
To perform the zero flow alignment, refer to Diagram 4.1 Electrical Connections and Controls, on
page 5, and proceed as follows:
5.1.1.1 Ensure that the liquid system is in a no-flow condition.
5.1.1.2 Ensure that the system is completely filled and that the KAL-A sensing
probe is completely immersed in liquid.
5.1.1.3 With power connected to the unit, turn setpoint adjustment
potentiometer P1 counter-clockwise to its far left-hand stop.
5.1.1.4 Momentarily depress the calibrating switch SW1 and release. The bi-
colored LED will flash green for a brief period while the unit is zeroing.
Note: Do not adjust the setpoint potentiometer P1 while the bi-colored LED is
flashing. Doing this will invalidate the zero calibration and the
procedure will have to be repeated.
5.1.1.5 When the bi-colored LED stops flashing, the zero flow calibration is
complete

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5.1.2 Adjustment of the Trend Indicator Span
The KAL-A is factory preset to an arbitrary span value. The user must recalibrate the unit to a
flow value consistent with his operating conditions. The maximum possible span corresponds to
a flow velocity of 2 meters/second (6.6 feet/second). Full span flow will result in the illumination of
all eight flow trend indicator LEDs and a transmitter current output of 20 mA. The KAL-A may be
spanned to any flow value within its flow rate operating range. This allows the user to take
advantage of the full range of the trend indicator and 4-20 mA transmitter.
To adjust the trend indicator span, refer to Diagram 4.1 Electrical Connections and Controls, on
page 5, and proceed as follows:
5.1.2.1 With the system completely filled, adjust flow to its maximum
value.This flow will correspond to the maximum transmitter output
current of 20 mA when the span adjustment procedure is complete.
5.1.2.2 With power applied to the KAL-A, turn the setpoint potentiometer P1
clockwise to its far right-hand stop. Momentarily depress the calibrating
switch SW1 and release. The bi-colored LED will flash green for a brief
period while the unit self-adjusts the span.
Note: Do not adjust the setpoint potentiometer P1 while the bi- colored LED
is flashing. Doing this will invalidate the span adjustment and the
procedure will have to be repeated.
5.1.2.3 When the bi-colored LED stops flashing, the span adjustment is
complete. When the first measuring cycle after span adjustment is
completed (approximately 10 seconds) all eight of the trend indicator
LEDs should be lit and the transmitter should indicate 20 mA.
5.2 Flow Setpoint adjustment
The KAL-A thermal flow transmitter can be provided with an optional, adjustable, normally open
(N/O) transistor switch. To adjust the flow switch setpoint, refer to Diagram 4.1 Electrical
Connections and Controls, on page 5, and proceed as follows:
5.2.0.1 Adjust system flow to the value at which the setpoint is desired.
5.2.0.2 Potentiometer P1 adjusts the flow setpoint. the flashing LED on the
trend indicator signifies the switch point. You will notice that the
flashing LED moves along the trend indicator scale as potentiometer
P1 is adjusted.
5.2.0.3 With system flow adjusted to the desired value, adjust potentiometer
P1 until the KAL-A output switches state and the bi-colored LED
changes color.
5.2.0.4 The KAL-A flow setpoint is now adjusted and system flow can be
restored to normal.

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FM Rev. 8/22/06
5.3 Setting the Transistor Switch Output Type
The optional normally open transistor switch can be switched from NPN (current sinking) to PNP
(current sourcing) by switching the DIP switch, SW 2, on the KAL-A circuit board (see Diagram 4.1).
Switching the SW 2 to the left makes the switch NPN. Switching to the right makes it PNP.
The characteristics of the N/O switch, the bi-colored LED and the PNP or NPN transistor switch
outputs are as follows:
N/O Switch:
System flow above the flow setpoint: Switch = ACTIVATED
Bi-colored LED = GREEN
NPN Switch = Pin 1 SWITCHED TO GROUND
PNP Switch = Pin 1 SWITCHED TO +24VDC
System flow below the flow setpoint: Switch = DE-ACTIVATED
Bi-colored LED = RED
NPN Switch =Pin 1 HIGH RESISTANCE (open switch)
PNP Switch = Pin 1 HIGH RESISTANCE (open switch)
5.4 KAL-A Diagnostics
The KAL-A has several diagnostic features. The KAL-A continuously self-monitors the sensing probe
and micro-processor systems. Any fault in these portions of the electronics will be signaled by a
flashing red bi-colored LED.
6.0 Maintenance
The KAL-A thermal flow transmitter is an electronically controlled device with no moving parts. As a
result the unit is virtually maintenance free. Occasional cleaning of the immersed probe may be
required if the liquid media is such that it tends to deposit or build up a film layer on the probe. If this
occurs, the unit should be removed from the system any deposits or coatings on the probe should be
removed.
7.0 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. The carrier is liable for a replacement under these
circumstances. If your claim is refused, please contact KOBOLD Instruments.

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FM Rev. 8/22/06
8.0 Need Help With Your KAL-A
Call one of our friendly engineers at 412-788-2830.
9.0 Getting the Most out of Your KAL-A Transmitter
This section provides information on using the automatic spanning features and superior repeat-
ability of the KAL-A transmitter to optimize its flow transmitting capability in your system. With a
proper understanding of how to set this unit up in a particular system and of the benefits and lim-
itations of the thermal flow sensing technology we are quite certain that you will be pleased and
satisfied with it’s performance.
Accuracy Versus Repeatability
Accuracy is defined as the closeness of agreement between the result of a measurement (in this
case transmitter output) and the true value of the process being measured. The accuracy of the
KAL-A is ±10%. What this means is that the current value transmitted from the KAL-A can be
within ±10% of the expected current value for a perfectly linear transmitter with 0% error.
Some of the factors that affect accuracy in a thermal type sensing probe are thermal lag between
the liquid and the sensing element inside the probe, variations in probe insertion depth and the
sensitivity and tolerances of the temperature sensing element and electronics. Although many of
these errors can be overcome, the expense to do so would make our economical transmitter cost
prohibitive.
Numerous applications require repeatability more so than they require high accuracy. Repeat-
ability is defined as the closeness in agreement among a number of consecutive measurements
taken under the same operating conditions. KAL-A transmitter has a repeatability of ±1%.
This means that the current output of the transmitter will repeat to within ±1% for any given flow
rate when that flow rate is reproduced at a later time. For applications where repeatability is most
important, the KAL-A transmitter can be used with great success.
Microprocessor Controlled
Digital Temperature Compensation
Analog Transmitter
Optional Flow Switch Capability
Compact Package
LED Flow Trend Indicator
•
•
•
•
•
•

KAL-A 10
FM Rev. 8/22/06
The Added Benefit of Microprocessor Controlled Temperature Compensation
Thermal type flow devices measure flow by heating a probe tip immersed in liquid. As the liquid
flows across the tip, the tip is cooled. The rate at which the tip is cooled is proportional to flow-
rate. The cooling rate is sensed by the electronics and converted to a flow signal. Liquid temper-
ature also affects the probe cool-down rate. Without temperature compensation within the flow
measuring device, changes in liquid temperature would be misunderstood by the measuring
electronics as a change in flowrate resulting in a false flow measurement. Temperature compen-
sation is achieved by taking liquid temperature measurements at the beginning and end of each
measuring cycle (approximately every six seconds). Any change in liquid temperature is sensed
and a correction is applied to the transmitted flow signal.
What makes our thermal flow transmitter unique and superior to all others is that we employ a
microprocessor to compensate for temperature changes rather than a single solid state elec-
tronic circuit. The main benefit of using microprocessor controlled temperature compensation is
that digital compensation is not subject to errors and setpoint drift which are caused by varying
tolerances of the individual components in a solid state compensation circuit. Additional benefits
are increased response time and the ability to store a large volume of liquid compensation data.
The following are some examples of applications where the KAL-A transmitter’s high degree of
repeatability is important and high accuracy is not necessarily required:
Example 1:
A particular user has a mechanical flowmeter in a system where it is desired to transmit a 4-20
mA signal to a remote device. The KAL-A can be installed in this system and the mechanical
flowmeter can be used as a reference to determine what the current output will be for corre-
sponding flow rates. Although not necessarily linear this current output characteristic will be
repeatable to within ±1%.
Example 2:
The KAL-A is to be used with a PLC or data acquisition device which is capable of linearizing a
non-linear signal. If there is an ability to take a direct measurement of flow rate at various points
over the desired measuring range, the current output of the KAL-A can be measured and linear-
ization performed. This method again takes full advantage of the high degree of repeatability of
the KAL-A transmitter.
Example 3:
It is desired to transmit system flow rate to a 4-20 mA control room indicator that indicates 0 to
100% flow. For this particular application 100% flow is the normal, steady-state operating system
flow rate. Flows of less than or greater than normal steady-state operating system flow would
only be encountered during start-up, shutdown or abnormal conditions such as equipment fail-
ure. In this application the KAL-A can be easily spanned to indicate 20 mA (or 100% flow) at the
normal system flow rate. This is done by installing the KAL-A in the system, adjusting the span
potentiometer to the far right-hand stop and depressing the span/calibrate push-button while the
system is flowing at steady state. Additionally, the optional flow alarm switch can be used to
alarm a high flow condition. and the 4-20 mA signal transmitted to the control room display can
be used to monitor system flows below 100% during start-up and shut down.

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10.0 Application Hint: Relay Switching with the KAL-A Transistor Switch
How is it done?
The diagram shows the wiring interconnections
required to connect a relay coil to our transistor
switch. Any 24 volt DC relay will work as long as
the coil current is less than the 400 mA current
rating of the KAL-A transistor switch. The diode
is installed across the relay coil and acts as a
voltage spike suppressor protecting the KAL-A
transistor. Any 1N4000 series diode will work,
and any electronics supply house will have
these diodes. Also, it is important that the
KAL-A is switched to the NPN output mode.
This is done by switching the red DIP switch on
the upper left hand portion of the circuit board to
the left. (see diagram 4.1, page 5.)
3
2
1
GND
+24 VDC
1N4003
24 VDC Relay
400 mA Max.
Coil Current
4

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CAUTION
PLEASE READ THE FOLLOWING WARNINGS BEFORE ATTEMPTING
INSTALLATION OF YOUR NEW DEVICE. FAILURE TO HEED THE
INFORMATION HEREIN MAY RESULT IN EQUIPMENT FAILURE AND
POSSIBLE SUBSEQUENT PERSONAL INJURY.

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•User's Responsibility for Safety: KOBOLD manufactures a wide range of
process sensors and technologies. While each of these technologies are
designed to operate in a wide variety of applications, it is the user's
responsibility to select a technology that is appropriate for the application,
to install it per these installation instructions, 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.
•Proper Installation and Handling: Use a proper sealant with all
installations. Never overtighten the unit within the fitting. Never use the
housing to thread the unit into its fitting. Always use only an
appropriate sized wrench on the hex portion of the probe. Always check for
leaks prior to system startup.
•Wiring and Electrical: In all versions, a supply voltage of 24 VDC ±10% is
used to power the KAL-A. The sensor systems should never exceed this
rating. Electrical wiring of the sensor should be performed in accordance
with all applicable national, state, and local codes.
•Temperature and Pressure: The KAL-A is designed for use in application
temperatures from 0 to 176°F, and for use at pressures up to 1450 PSIG
for threaded probes. Tri-Clamp® probes are rated to the pressure rating of
the user supplied clamp. Operation outside these limitations will cause
damage to the unit and possible personnel injury.
•Material Compatibility: The KAL-A sensor probe is made of either 304 or
316 stainless steel. The housing is constructed of polycarbonate. Check
your model number with the wetted materials specification in Section 2.0,
"Specifications”, on page 1 of this manual. Make sure that the model which
you have selected is chemically compatible with the application liquids.
While the switch housing is splash resistant when installed properly, it is
not designed to be immersed. It should be mounted in such a way that it
does not normally come into contact with fluid.
•Flammable, Explosive and Hazardous Applications: KAL models
should not be used in areas where an explosion-proof design is required.
•Make a Fail-Safe System: Design a fail-safe system that accommodates
the possibility of switch or power failure as well as operator error. In critical
applications, KOBOLD recommends the use of redundant backup systems
and alarms in addition to the primary system.