Kobold KAL-D Manual de usuario

Operating Instructions

for

Compact Calorimetric

Flow Monitor

Model: KAL-D

KAL-D

page 2 KAL-D K03/0516

1.Contents

1.Contents........................................................................................................2

2.Note ..............................................................................................................3

3.Instrument Inspection....................................................................................3

4.Regulation Use..............................................................................................4

5.Operating Principle........................................................................................5

6.Mechanical Connection.................................................................................5

7.Electrical Connection ....................................................................................6

8.Indicators and Controls.................................................................................7

9.Signal Output ................................................................................................8

9.1.Output function ....................................................................................8

10.Commissioning..............................................................................................9

11.Error Messages...........................................................................................11

12.Maintenance ...............................................................................................11

13.Technical Information..................................................................................12

14.Order Codes ...............................................................................................12

15.Dimensions .................................................................................................13

16.EU Declaration of Conformance..................................................................14

Manufactured and sold by:

Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

E-Mail: [email protected]

Internet: www.kobold.com

KAL-D

KAL-D K03/0516 page 3

2.Note

Please read these operating instructions before unpacking and putting the unit

into operation. Follow the instructions precisely as described herein.

The devices are only to be used, maintained and serviced by persons familiar

with these operating instructions and in accordance with local regulations

applying to Health & Safety and prevention of accidents.

By usage in machines, the measuring unit should be used only when the

machines fulfil the EC-machine guidelines.

3.Instrument Inspection

Instruments are checked before dispatch and should arrive in perfect condition.

In case of damage, please inform your local Kobold office or if you had the parcel

delivered by a parcel service, contact your parcel service / forwarding agent

immediately, since they are responsible for damages during transit. Should the

damage to a device be visible, we recommend a thorough inspection of the

delivery packing.

Scope of delivery:

Flow Monitor Model KAL-D

Operating Instructions

KAL-D

page 4 KAL-D K03/0516

4. Regulation Use

This device must be installed, operated and maintained according to this

installation instruction. Any damages resulting from mis-use or mis-application

are not the responsibility of the manufacturer. The user assumes all risk for such

usage. The application specifications include the installation, start-up and service

requirements specified by the manufacturer.

The model KAL-D flow monitor is used to monitor the flow of liquids.

Limit value / output

To monitor the flow of liquids in pipes, the device is fitted with a PNP transistor

switch (NPN optionally available). The switch setpoint is field adjustable via

potentiometer.

Trend indicator

The actual flow value is indicated by a serial of constantly illuminated LEDs on

the LED bargraph display. The current switchpoint relative to flowrate is indicated

on the LED bargraph by the individually blinking LED.

Sensor

The model KAL-D flow switch consists of a sensor with an evaluating electronic

circuit. The unit should only used for water like liquids for which the sensor

material is chemically resistant. Medium up to high viscous liquids as well as

strong temperature absorbing media are not suited for operation. In case of doubt

please contact the manufacturer.

The KAL-D is an electronic housing which meets IP 65/NEMA 4X protection

requirements when properly installed. There are no moving parts in the flow

stream and the smooth sensor surface is designed for minimal pressure loss

when operating.

Materials of Construction

Sensor Stainless steel 1.4404

Electronics housing Stainless steel 1.4301

Measuring and switching ranges

These figures are based on nominal pipe size (NPS).

NPS (mm) Approximate measuring

range (L/min)

water

NPS (mm) Approximate measuring

range (L/min)

water

8 0.12 - 6.0 40 3.0 - 150

10 0.19 - 9.4 50 4.7 - 235

15 0.42 - 21.2 60 6.8 - 340

20 0.75 - 37.7 80 12.0 - 603

25 1.18 - 59.0 100 18.8 - 942

30 1.70 - 84.8 150 42.4 - 2120

KAL-D

KAL-D K03/0516 page 5

Caution! The flow ranges specified in the table above have been

calculated for each pipe diameter based on the known velocity

range. It must be noted, that flow in pipes is non-uniform across

the pipe cross section, and approaches zero at the pipe wall.

Depending on the pipe size, immersion depth of the sensor and

flow profile it may lead to significant deviations of the flow

ranges above.

5.Operating Principle

The operation of the model KAL-D electronic switch monitor is based on the

calorimetric principle. The sensor tip is heated to a few degrees above the

temperature of the flowing liquid. When the liquid is flowing, the heat generated in

the sensor is transferred to the liquid, i.e. the sensor is cooled. The cooling time is

an accurate measure of the flow speed. The sensor signal is compared with the

reference data (setpoint) stored in a micro-controller. The micro-controller allows

easy calibration and ideal temperature compensation to account for variations in

liquid temperature.

6.Mechanical Connection

Before installation

Make sure that the actual flow velocity corresponds to the switching range of

the device.

Make sure that the maximum operating pressures and service temperatures

specified for the device will not be exceeded.

(See 13 Technical Information)

Installation

Mount the sensor in the pipe and ensure that the tip is covered by the liquid to be

monitored. The sensor tip must extend at least 5 mm (better > 5 mm) into the

pipe (see below).

KAL-D

page 6 KAL-D K03/0516

Mounting position

The sensor can be mounted in any position, provided that the pipe is completely

filled with liquid. The installation position must be free of swirling and turbulence

(the recommended inlet and outlet pipe runs 5x the diameter of the pipe with

straight pipe sections immediately upstream and downstream of the sensor). If it

is expected that the liquid will leave deposits in the piping, the following mounting

position is recommended (see figure below).

7. Electrical Connection

Caution! Make sure that the electrical supply lines are de-energized

when connection the device! Make sure the the supply voltage of

your system is the same as that specified on the device nameplate.

Connect the KAL-D according to following wiring diagram.

Switch on the operating voltage of 24 VDC ±10 % (see 12 Technical

Information).

Check the electronics for proper function (switching-point LED must be

blinking)

Adjust the setting of the flow monitor (see 10 Commissioning).

Pin 1 +Vs / 24VDC

Pin 2 n.c.

Pin 3 GND / 0VDC

Pin 4 Switch out

+Vs

Switch

Out

n.c.

GND

KAL-D

KAL-D K03/0516 page 7

8.Indicators and Controls

(View with cover removed)

LED bargraph display (1)

The strip of LEDs (8 segments) displays the flow value

The flow value is shown of the strip of LEDs, starting at the left.

The blinking LED displays the switching point:

When flow is at the flow setpoint, the switching-point LED starts to blink more

rapidly.

DUAL LED (2)

The DUAL LED display indicates the following:

The switching point:

Red = ALAM (actual flow below setpoint)

Green = FLOW (actual flow above setpoint)

In the standard operating mode, the DUAL LED is constantly illuminated. Bi-

Setup mode display

If an adjustment (zero or span) is being performed, the DUAL LED blinks

green.

Error message display

In the event of an error message, the DUAL LED blinks red.

SET button (3)

Potentiometer (4)

LED bargraph (1)

DUAL LED (2)

KAL-D

page 8 KAL-D K03/0516

SET button (3)

Press the SET button to start the adjustment (zero or span) procedure.

Potentiometer for setting the switching point (4)

The potentiometer is used to set the switching point. Depending on the

potentiometer setting, the location of the blinking LED on the LED strip will

change to indicate that the setpoint, relative to actual flow is being changed. The

potentiometer is also used during the setup mode.

9.Signal Output

PNP output (type of contact P or R)

The PNP transistor output either +24 VDC or is high

resistance (open circuit). The maximum output current is

400 mA.

The reference load is typically connected between the

output and ground GND (GROUND = 0 VDC)

NPN output (type of contact N or M)

The NPN transistor output either grounds the output pin

(GROUND = 0 VDC) or is high resistance (open circuit).

The maximum output current is 400 mA.

The load is typically connected between the output and

+24 VDC.

9.1.Output function

Normally Open (N/O) contact (type of contact: N or P)

The N/O contact switches the output to the low-resistance state ("switch" closed)

whenever the flow is above the switching point.

The N/O contact switches the output to the high-resistance state ("switch" open)

whenever flow is below the switching point.

PNP NPN DUAL LED

actual flow >

setpoint "switch" closed

24 V DC at output "switch" closed

Ground at output green

actual flow <

setpoint "switch" open

high impendance "switch" open

high impendance red

power supply

failure "switch" open

high impendance "switch" open

high impendance off

+Vs

GND

+Vs

GND

KAL-D

KAL-D K03/0516 page 9

Since the N/C switch function will go to an alarm (open switch) state on a loss of

power, it is the preferred switch logic when a failsafe or loss of power is desired.

Normally Closed (N/C) contact (type of contact M or R)

The N/C contact switches the output to the low-resistance state ("switch" closed)

whenever the flow is below the switching point.

The N/C contact switches the output to the high-resistance state ("switch" open)

whenever the flow is above the switching point.

PNP NPN DUAL LED

actual flow >

setpoint "switch" open

high impendance "switch" open

high impendance green

actual flow <

setpoint "switch" closed

24 VDC at output "switch" closed

Ground at output red

power supply

failure "switch" open

high impendance "switch" open

high impendance off

10.Commissioning

When used in machinery in accordance with EU Directive 89/392/EEC, this

device may not be placed in operation until it has been determined that the

machine in use complies with this directive.

First install the sensor (complete the "Mechanical connection"), then connect the

electrical lines (complete the "Electrical connection"). After these steps are

completed, the zero, span and setpoint adjustments may be made.

To make the settings on the flow monitor, unscrew the cover to access the

controls.

Adjustment

a) No-flow (zero) adjustment

Stop the flow of the liquid in the piping in which the sensor is installed. It

is important that the pipe is filled with liquid and the sensor tip be immersed in

the liquid. There should be no bubbles around the sensor tip.

Rotate the potentiometer (4) counterclockwise as far as it will go (to the

left-hand stop).

Now press the SET button. The DUAL LED blinks green.

Do not make any changes (potentiometer setting, etc.) while the DUAL

LED is blinking. This adjustment phase will last approx. 5-15 sec.

When the DUAL LED stops blinking, the zero adjustment is set. The

device now switches automatically to the monitoring mode. The display must

indicate no flow. The LED strip should not be illuminated; only the first LED in

the strip should be blinking.

The flow monitor is now ready for operation.

KAL-D

page 10 KAL-D K03/0516

b) Measuring range (span) adjustment

The flow monitor is set at the factory for the greatest possible range of flow

speed (2 m/s). At lower flow speeds, not all 8 LEDs will illuminate. To achieve

finer monitoring resolution, the measuring range can be adjusted to better fit the

actual flow speed.

Rotate the potentiometer clockwise as far as it will go (to the right-hand stop).

The extreme right-hand LED in the LED bargraph will blink. Set the desired

maximum system flowrate.

Now press the SET button. The DUAL LED blinks green.

Do not make any changes (potentiometer setting, etc.) while the DUAL LED

is blinking. This adjustment phase will last approx. 5-15 sec.

The span adjustment procedure is now complete. The device now switches

automatically to the monitoring mode. This adjustment has set the device

measuring range so that it now extends across the entire LED bargraph at

the maximum system flow.

The adjustment procedure is now complete. It may be repeated as often as

necessary.

c) Measuring mode

After adjustment, the flow monitor is once again in measuring mode.

The flow is constantly monitored and the actual value of the flow speed is

displayed on the LED bargraph.

Switching point setting

The potentiometer is now used to set the switching point (threshold) of the flow

switch. The switching point is displayed as a blinking LED on the bargraph. If the

flow rate increases to the point that illuminated LEDs on the bargraph (actual flow

value) reaches the position of the blinking LED (setpoint), the flow monitor

switches over from ALARM to FLOW. This can be seen at the display: the DUAL

LED that was showing a steady red light now switches to a steady green light.

The output is also switched at the same time.

Slowly blinking

switching point LED (setpoint) actual flow < setpoint (no flow)

  Alarm status

DUAL LED illuminated red no LEDs lit = no flow

Slowly blinking

switching point LED (setpoint) actual flow < flow below set-point





  Alarm status

light strip actual value Actual flow below setpoint

DUAL LED illuminated red

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