Kobold KAL-K Manuel utilisateur

Operating Instruction

for

Electronic Flow Monitor

Compact Version

Model: KAL-K

KAL-K

Page 2 KAL-K K11/0623

1. Contents

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

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

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

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

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

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

7.Electrical Connection and Operational Elements .......................................... 6

8.Characteristics .............................................................................................. 8

9.Output Characteristic (only for 24 VDC).......................................................... 9

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

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

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

13.Order Codes ............................................................................................... 12

14.Dimensions ................................................................................................. 12

15.Disposal ...................................................................................................... 13

16.3A certificate 28-05 ..................................................................................... 14

17.EU Declaration of Conformance ................................................................. 15

18.UK Declaration of Conformity ...................................................................... 17

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-K

KAL-K K11/0623 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 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.

Operating instructions, data sheet, approvals and further information via the QR

code on the device or via www.kobold.com

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 2006/42/EG.

3. Instrument Inspection

Instruments 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 packaging. In case of damage, please inform your parcel service /

forwarding agent immediately, since they are responsible for damages during

transit.

Scope of delivery:

The standard delivery includes:

 Electronic Flow Monitor, Compact Version model: KAL-K

KAL-K

Page 4 KAL-K K11/0623

4. Regulation Use

The KOBOLD KAL-K Flow Monitor is intended for use in monitoring and control

applications involving moderate flow rates of aqueous liquids.

Limiting Signal

The devices are equipped with NPN or PNP signals (24 VDC- power supply) or

relay (110 VDC, 110 VAC, 230 VAC power supply) for monitoring the flow velocity of

water.

Trend Display

A LED bar graph display indicates the current flow rate and the set point via a

flashing LED.

Sensor

The model KAL-K consists of a sensor with integrated electronic.

The devices may only be used for aqueous liquids to which the probe material is

resistant. With proper installation and maintenance, the probes are not sensitive

to soiling and cause practically no pressure loss.

Materials

Sensor Stainless steel 1.4301, 1.4305, 1.4571, 1.4404 (Tri-clamp)

Electronic housing Polyamide (glass fibre reinforced)

Setting ranges

in relation to nominal tube diameter

ND (mm) Meas. range (L/min)

wate

ND (mm) Meas. 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 - 21,2 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

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

calculated for each pipe diameter based on the known velocity

range of the KAL-K. 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 flow profile of the

liquid in the pipe can interact to produce significant deviations from

the flow ranges in the above table.

KAL-K

KAL-K K11/0623 Page 5

5. Operating Principle

The KAL-K Flow Monitor uses the proven thermal dispersion principle and

operates as follows. The probe is heated internally to a few degrees above the

temperature of the medium into which it extends. The flowing medium removes

this heat from the probe. The cooling rate is proportional to the flow rate. The

measured flow rate is compared to the set point value selected by user. If the set

point is reached, the electronic circuit activates a transistor switch and bi-coloured

alarm LED. The electronic circuit also controls an LED trend indicator which can

be used to indicate relative system flow. The microprocessor- controlled design

permits sample calibration and set-up. The compact probe design permits

monitoring of flow rate with minimal pressure loss.

KAL-K

Page 6 KAL-K K11/0623

6. Mechanical Connection

Prior to installation

 Ensure that the actual system flow rate is within the switching range of the

KAL-K.

 Ensure that the maximum system temperature and pressure are within the

limits specified per section. (see section Fehler! Verweisquelle konnte nicht

gefunden werden.. Fehler! Verweisquelle konnte nicht gefunden werden.)

Fitting

Mount the sensor into the piping and make sure that it is completely filled with

fluid. The probe tip has to reach at least 5 mm (better > 5 mm) into the pipe (see

below).

Fitting position

The sensor can be mounted in any orientation

as long as the piping is completely filled with

fluid. The mounting position has to be smooth

and free of turbulence.

(Recommended input and output length: 5 x

pipe diameter, of straight - run piping both

upstream and downstream of the flow switch).

In case of sediments in the pipe the shown

mounting position is recommended.

7. Electrical Connection and Operational Elements

Attention! Ensure that the power is disconnected during the

connection of the cable.

Ensure that the voltage of your installation corresponds to the

voltage values given on the device's specification plate.

24 VDC-Version (terminal connector)

 Remove electronic cover

(The fixing screws are secured against falling out)

 Strip 3-wire cable (approx. 40-60 mm), strip single

wires (approx. 4-6 mm) and pull through cable

gland.

Se d i m e n t s

KAL-K

KAL-K K11/0623 Page 7

 Connect wires to terminal connector block according to the drawing.

 Tighten cable gland.

 After connection, apply supply voltage of 24 VDC ± 20%. (see Fehler!

Verweisquelle konnte nicht gefunden werden.. Fehler! Verweisquelle

konnte nicht gefunden werden.)

 Check function of electronic (set point LED must flash)

 Calibrate flow switch (see 10. Commissioning)

24 VDC-Version (plug or plug with cable)

 Connect wires to terminal connector block according to drawing below.

 After connection apply supply voltage of 24 VDC ± 10 %. (see Fehler!

Verweisquelle konnte nicht gefunden werden.. Fehler! Verweisquelle

konnte nicht gefunden werden.)

 Check function of electronic (set point LED must flash)

 Calibrate flow switch (see 10. Commissioning)

110 VDC, 110 VAC or 230 VAC-version

 Remove electronic cover.

(The fixing screws are secured against falling out)

 The devices are supplied either with coded cables or a plug connection.

 Connect single wires or plug according to drawings below.

 After connection apply supply voltage according to label on the device and

technical data (for tolerances see section Fehler! Verweisquelle konnte nicht

gefunden werden.. Fehler! Verweisquelle konnte nicht gefunden

werden.).

 Check function of electronic (set point LED must flash).

 Calibrate Flow Monitor (see 10. Commissioning).

KAL-K

Page 8 KAL-K K11/0623

8. Characteristics

LED Trend Indicator (1)

The LED trend indicator (8 LEDs) is used to indicate

 the flow rate (LED, starting left). The adjusted

switching point is indicated by a flashing LED.

 If the flow rate has reached the set point value

selected by the user, then the LED is flashing faster.

Bi-coloured LED (2)

The bi-coloured LED serves

 to display the switching point.

RED = ALARM (flow below the set point)

GREEN = (flow above the set point)

The bi-coloured LED is lit all time during this

operation mode.

 If a calibration is done the bi-coloured LED flashes

green (see also section 10. Commissioning. ).

 If any signal error occurs the bi-coloured LED flashes

red.

SET pushbutton (3)

The calibration switch (set) is used to start the flow

calibration procedure.

Set point Potentiometer (4)

The set point potentiometer is used to adjust the flow set point. You will notice

that the flashing LED moves along the trend indicator scale as the set point

potentiometer is adjusted.

Output Selector Switch (only for 24 VDC) (5)

The output selector switch is used to select between the output logic NPN and

PNP.

(Output selector switch right: NPN-output

Output selector switch left: PNP-output)

KAL-K ...24 VDC

KAL-K..., 110 VDC

110 VAC, 230 VAC

KAL-K

KAL-K K11/0623 Page 9

9. Output Characteristic (only for 24 VDC)

The output characteristics can be set by the output selector switch.

NPN output:

The semiconductor output switches to GND (GROUND =

0 VDC) or is highly resistant. The maximum output current is

400 mA.

The reference point for the NPN-output is +24 VDC.

PNP-output

The semiconductor output switches to +24 VDC or is highly

resistant. The maximum output current is 400 mA. The

reference point for the PNP-output is GND

(GROUND = 0 VDC).

Output function

N/O function

In the N/O function the output switches into the low resistance state.

PNP NPN DUO-LED

Actual value > set point green

Actual value < set point red

Break down power supply off

It is recommended to operate with the N/O switch output because in case of

system flow being above the flow set point - which means that the N/C switch is

de-activated - and the power supply breaks down the output switch will not be

able to switch an "ALARM" anymore.

N/C Switch

(Not recommendable for safety reasons)

PNP NPN DUO-LED

Actual value > set point

green

Actual value < set point

red

Break down power supply

off

3+Vs

GND

+Vs

KAL-K

Page 10 KAL-K K11/0623

10. Commissioning

The use of this meter in machines according to directive 2006/42/EG is prohibited

until the complete machine complies to this directive.

After mechanical (“Mechanical Connection”) and electrical (“Electrical

Connection”) installation of the sensor the KAL-K has to be put into operation as

described in this section.

Calibration

a) Zero flow calibration

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

important that the sensor tip be immersed in the liquid. There should be no

bubbles around the sensor tip.

 Turn set point adjustment potentiometer counter clockwise to its far left-hand

stop and now briefly press the SET button.

 The bi-coloured LED will flash green.

 Do not make any changes (potentiometer setting, etc.) while the bi-coloured

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

 When the bi-coloured LED stops flashing, the zero flow calibration is set.

 The device now switches automatically to the monitoring mode and displays

no flow. The LED strip is not illuminated; only the threshold value LED is

flashing.

 The Flow Monitor is ready for operation.

b) Calibration of the trend indicator span

The KAL-K is factory checked and pre-set at its maximum span.

At a lower flow speed, not all 8 LEDs will illuminate. To achieve finer monitoring

resolution, the measuring range can be adapted 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 strip will blink. Set the desired

maximum flow speed.

 Now press the SET button. The bi-coloured LED blinks green.

 Do not make any changes (potentiometer setting, etc.) while the bi-coloured

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

 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 strip to indicate the flow value.

 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 strip.

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