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

KAL-A 2
FM Rev. 8/22/06
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

3 KAL-A
FM Rev. 8/22/06
2.1 Dimensions
KAL-7215, 7315, 7320
KAL-7340S

KAL-A 4
FM Rev. 8/22/06
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

5 KAL-A
FM Rev. 8/22/06
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)

KAL-A 6
FM Rev. 8/22/06
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