Kobold KAL-E EX Series Manual de usuario

Operating Instructions

for

Flow sensor model KAL-****Ex

with

Electronic Analyzer

Model: KAL-E**Ex

KAL-EX

Seite 2 KAL-EX K05/0322

1. Contents

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

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

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

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

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

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

6.1Before installation ................................................................................ 6

6.2Installation ............................................................................................ 6

6.3Mounting position ................................................................................. 6

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

8.Operation / Configuration / Adjustments ....................................................... 8

8.1Putting in operation .............................................................................. 8

8.2Zero-point adjustment .......................................................................... 8

8.3Expanding the trend indicator .............................................................. 8

8.4Resetting the adjustment ..................................................................... 9

8.5Switching point setting ......................................................................... 9

8.6Temperature compensation ............................................................... 10

9.Fault alarms ................................................................................................ 10

10.Maintenance ............................................................................................... 10

11.Brief operating instructions commissioning ................................................. 11

12.Technical Data ............................................................................................ 12

13.Ordering details ........................................................................................... 13

14.Dimensions ................................................................................................. 14

15.EU Declaration of conformance .................................................................. 15

16.EC-type examination certificate .................................................................. 15

17.IECEx-certificate ......................................................................................... 19

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-EX

KAL-EX K05/0322 Seite 3

2. Note

Please read these operating instructions before unpacking and putting the unit into

operation. Follow the instructions precisely as described herein.

The instruction manuals on our website www.kobold.com are always for currently

manufactured version of our products. Due to technical changes, the instruction

manuals available online may not always correspond to the product version you

have purchased. If you need an instruction manual that corresponds to the

purchased product version, you can request it from us free of charge by email

([email protected]) in PDF format, specifying the relevant invoice number and

serial number. If you wish, the operating instructions can also be sent to you by

post in paper form against an applicable postage fee.

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.

When used in machines, the measuring unit should be used only when the

machines fulfil the EC-machine guidelines.

as per PED 2014/68/EU

for KAL-sensors with fittings model: KAL-11.. and KAL-12..

In acc. with Article 4 Paragraph (3), "Sound Engineering Practice", of the

PED 2014/68/EU no CE mark.

Diagram 8, Pipe, Group 1 dangerous fluids

3. Instrument Inspection

These devices are inspected before shipping and sent out in perfect condition.

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

delivery packing. In case of damage, please inform your parcel service/ forwarding

agent immediately, since they are responsible for damages during transit.

The standard scope of supply includes the following components:

 Sensor with PVC-coated cable

 Electronic analyzer

 100  1% resistor

KAL-EX

Seite 4 KAL-EX K05/0322

4. Regulation Use

The devices in model series KAL-EX are used to monitor the flow of combustible

liquids up to explosion category IIB. They satisfy the European standards

EN 60079-0:2012 + A11:2013 and EN 60079:11:2012 for explosion protection and

are thus suitable for use in hazardous areas of Zone 0 as per DIN VDE 0165

(applies to the flow sensor only; the electronic analyzer must not be used in

hazardous areas).

Limit contacts

The devices are equipped with relays to monitor the flow speed of liquids. An

additional temperature sensor triggers a relay if the set temperature is exceeded.

Trend indicator

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

LED strip display. The currently set switching point is indicated on the LED strip

display by the individually blinking LED.

Sensors

These sensors are available as screw-in (insertion style) or in-line versions.

Model KAL-EX devices always consist of two components:

 KAL-...Ex sensor

 KAL-E...Ex electronic analyzer

Electronics

KAL-E3...Ex electronic analyzer

1 voltage-free changeover contact for temperature

1 voltage-free changeover contact for flow speed

The devices must only be used for liquids that will not damage the sensor housing.

When properly installed and maintained, the sensors are unaffected by dirt and

cause essentially no loss of pressure. The length of the device lead should not

exceed 100 meters.

Caution! Errors will result in zone carry-over. Danger of

explosion!

Switching ranges based on nominal pipe size (NPS).

KAL-EX

KAL-EX K05/0322 Seite 5

NPS (mm) Measuring Range

(L/min)

Wate

NPS (mm) Measuring Range

(L/min)

Wate

8 0.12 - 6.0 40 3.0 - 150

10 0.19 - 9.4 50 4.7 - 235

15 0.42 - 21.8 60 6.8 - 340

20 0.75 - 37.7 80 12.0 - 603

25 1.18 - 59.0 100 18.8 - 942

30 1.7 - 84.8 150 42.4 - 2120

Caution! In determining the specified measuring ranges the flow

speeds were based on nominal pipe sizes. However, please note

that the force exerted by the flow speed against the pipe wall is

essentially zero. Depending on the nominal pipe size, the sensor

installation depth and the flow profile, there may be some

significant deviations from the indicated flow values in the actual

installation. Any use of the flow sensor, model: KAL-EX, which

exceeds the manufacturer’s specifications, may invalidate its

warranty. Therefore, any resulting damage is not the responsibility

of the manufacturer. The user assumes all risk for such usage.

5. Operating Principle

The operation of the model KAL-EX electronic flow 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 it, i.e. the sensor is cooled. The rate-of-cooling process

is an accurate measure of the flow speed.

The sensor signal is compared with the reference data (set threshold value) and

stored in a microcontroller. If the actual flow speed is less than the desired flow

speed, the electronic analyzer actuates an output relay. The microcontroller in the

flow monitor permits easy calibration, allowing ideal temperature compensation of

the device.

KAL-EX

Seite 6 KAL-EX K05/0322

6. Mechanical Connection

6.1 Before installation

Make sure that the actual flow speed corresponds to the switching range of the

device. Make sure that the maximum process pressures and service temperatures

specified for the device will not be exceeded. (See section 12, “Technical details”)

6.2 Installation

Mount the sensor in the piping 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).

6.3 Mounting position

The sensors can be mounted in any position,

provided that the piping is completely filled

with the liquid to be monitored. The

installation position must be free of swirling

and turbulence (the recommended inlet and

outlet area: 4x 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 illustrated mounting position is

recommended (see figure at the left).

Caution: Improper installation can result in zone carry-over.

Danger of explosion!

Ablagerungen

Deposits

KAL-EX

KAL-EX K05/0322 Seite 7

7. Electrical Connection

Caution! Make sure that the supply voltage of your system is the same as

that specified on the device nameplate.

 Make sure that the electrical supply lines are de-energized when

connecting the device.

 Connect the sensor cable to terminals 6 and 8 of the electronic analyzer.

 Connect the supply line (power supply) to terminals 15 and 16.

Caution: The relays are shown in the rest positions. The

intrinsically safe input from electronic analyzer should only be

connected to a KAL-...Ex sensor.

AC power supply:

230 VAC, ± 10%, 50-60 Hz

24 VAC, ± 10%, 50-60 Hz

Sensor

230 V

L N

Flow Temp. 24 V

9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

Flow Temp.

KAL-EX

Seite 8 KAL-EX K05/0322

8. Operation / Configuration / Adjustments

8.1 Putting in operation

 Install the sensor in the piping (be sure the installation position is correct.

Refer to Section 6 Mechanical Connection).

 Connect the sensor cable to the electronic analyzer.

(Refer to section 7 Electrical Connection).

 Fill the piping with liquid.

Caution! There must be no air bubbles present at the sensor tip.

The flow speed must be 0.

8.2 Zero-point adjustment

 Place the electronic analyzer in operation (switch on the supply voltage)

Rotate the flow potentiometer (1) (refer to section 11, “Brief operating

instructions”) counterclockwise as far as it will go (to the left-hand stop).

 Rotate the temperature potentiometer (2) counterclockwise as far as it will go

(to the left-hand stop).

 Briefly press the SET button for the zero-point adjustment (5)

(press it with a suitable object, such as a ball point pen)

 The flow LED (6) will blink for approximately 30 seconds.

After this time has expired, the flow LED (6) will stop blinking.

 If the system is not functioning properly, the flow LED (6) will blink

continuously. In this case, press the SET button (5) once again. The device

then switches back to measuring mode. Before continuing, inspect the

mechanical and electrical installation. Then follow the “Putting in operation”

instructions once again.

 Switch on the system and set the maximum rated flow rate.

If the whole LED strip display is not illuminated, then the display can be

expanded so that the range from 0.25 to 1.8 m/s extends across the entire

LED strip display (see section 8.3 below).

8.3 Expanding the trend indicator

 Rotate the flow potentiometer (1) (see illustration) clockwise as far as it will go

(to the right-hand stop). Then rotate the temperature potentiometer (2)

counterclockwise as far as it will go (to the left-hand stop).

 Briefly press the SET button (5).

 The flow LED (6) will blink for approximately 30 seconds. After this time has

expired, the flow LED (6) will stop blinking.

KAL-EX

KAL-EX K05/0322 Seite 9

8.4 Resetting the adjustment

You can reset the electronic analyzer so that it once again uses its full range

(0 - 2.0 m/s)

 Rotate the flow potentiometer (1) clockwise as far as it will go (to the right-hand

stop).

 Rotate the temperature potentiometer (2) counterclockwise as far as it will go

(to the left-hand stop).

 Press and hold the SET button (5) until the flow LED stops flashing

 The device is now reset to its initial state (0 - 2 m/s).

8.5 Switching point setting

After the device is adjusted to the specific liquid being measured (see above), you

can then set the switching point.

 Adjust the flow rate.

 Rotate the flow potentiometer (1) counterclockwise as far as it will go (to the

left-hand stop). The first LED in the LED strip display (3) starts to blink.

 Any number of LEDs in the LED strip display (3) is illuminated constantly.

 Rotate the flow potentiometer (1) clockwise to the desired switching point.

The switching point selected is indicated by the blinking LED.

Display 3

X X X X X

X X X X X X

X X X

explanation output

flow > setpoint Flow relays

activated

Flow LED li

hts

flow = setpoint Flow relays

activated

Flow LED lights

flow < setpoint Flow relays

deactivated

Flow LED off

blinks Flow speed

LED indicator blinks

KAL-EX

Seite 10 KAL-EX K05/0322

8.6 Temperature compensation

If the length of the cable connecting the sensor and the electronic analyzer is greater than 10

meters or if increased accuracy in temperature measurement is desired, we recommend that

device be compensated as described below.

Caution! Be sure to switch off the power supply

 Connect the entire length of the cable to be used to terminals 6 and 8.

Instead of the sensor, connect a 100 ohm ±1% resistor (included in the delivery).

 Set the temperature potentiometer (2) to 80° C (rotate to right-hand stop) Switch on the

power source and place the electronic analyzer in operation.

 Briefly press the SET button (5).

The temperature LED and the flow LED will start to blink. After 10 seconds, they will go

out.

 If the system is not functioning properly, the flow LED (6) will blink continuously. In this

case, press the SET button (5) once again. The device then switches back to measuring

mode. Before continuing, inspect the mechanical and electrical installation. Then follow the

“Temperature compensation” instructions once again.

 If the temperature LED blinks faster, then the error could be caused because the sensor is

still connected instead of the 100 ohm resistor.

 Finally, remove the 100 ohm resistor and reconnect the sensor.

9. Fault alarms

In alarm mode the current relay stops functioning.

This occurs under the following conditions:

 Actual value < Setpoint value

 Short circuit (at sensor)

 Line break

 Power failure

10. Maintenance

This device is maintenance-free. Once a month, the sensor tip should be checked for the

presence of mineral deposits (lime, etc.) and cleaned if necessary.

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