Operating Instructions for Compact Calorimetric Flow
Contents
1. 3 Regulation use This device must be installed operated and maintained per these installation instructions 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 velocity of liquids in pipes the device is fitted with a PNP switch NPN optionally available Trend indicator The actual flow value is indicated by a series of constantly illuminated LEDs on the LED bargraph display The current switchpoint is indicated on the LED bargraph by the individually blinking LED Sensor The model KAL D flow monitor consists of a sensor with an electronic measuring circuit The KAL D is in an electronic housing which meets IP 65 NEMA 4X protection requirements when properly installed The sensor is designed for minimal pressure loss when operating Material Sensor Stainless steel 316L 1 4404 Electronics housing Stainless steel 304 1 4301 KAL D 10 03 page 3 KAL D KOMPONENTAUTOMATIC AB LEIF LINDGREN MI Measuring and switching ranges These figures are based on nominal pipe size NPS NPS mm Approximate measuring NPS mm Approximate measuring range l min range l min water water 0 12 6 0 3 0 152. 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 e Flow Monitor Model KAL D e Operating Instructions 6 Mechanical connection Before installation e Make sure that the actual flow speed corresponds to the switching range of the device e Make sure that the maximum process pressures and service temperatures specified for the device will not be exceeded See Technical details 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 gt 5 mm into the pipe see below Mounting position The sensor can be mounted in any position provided that the pipe is completely filled with the liquid to be monitored 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 KAL D 10 03 page 5 KAL D KOMPONENTAUTOMATIC AB LEIF LINDGREN MA 7 Electrical connection Caution Make sure that the electrica
3. LED blinks red 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 The potentiometer is also used during the setup mode 9 Type of output PNP output type of contact N O or N C 1 The PNP semiconductor output either outputs 24 Vpc or Vs is high resistance open circuit 4 The maximum output current is 400 mA The reference point of the PNP output is GND GROUND GND 0 Voc KAL D 10 03 page 7 KAL D KOMPONENTAUTOMATIC AB LEIF LINDGREN MI NPN output type of contact N O or N C 1 Vs The NPN semiconductor output either grounds the output 4 ar pin GROUND O Vpc or is high resistance open circuit 3 GND The maximum output current is 400 mA The reference point of the NPN output is 24 Voc 9 1 Output function Normally Open N O contact type of contact NPN or PNP 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 DUAL LED actual flow gt switch closed switch closed green setpoint setpoint failure Since the N C switch function will go to an alarm ope
4. 0 0 19 9 4 4 7 235 0 42 21 2 6 8 340 0 75 37 7 12 0 603 1 18 59 0 18 8 942 1 70 84 8 42 4 2120 Caution In determining the specified measuring ranges the flow velocities were based on nominal pipe sizes However please note that depending on the nominal pipe size the sensor installation depth and the flow profile there may be some significant deviations from these indicated flow values and those in the actual installation 4 Operating Principle Theory of operation The operation of the model KAL D 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 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 If the actual flow speed is less than the setpoint flow speed the output switches The micro controller in the flow monitor allows easy calibration and ideal temperature compensation to account for variations in liquid temperature page 4 KAL D 10 03 LEIF LINDGREN EEE KOMPONENTAUTOMATIC AB KAL D 5 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
5. Operating Instructions for Compact Calorimetric Flow Monitor Model KAL D OBOLD MN O KAL D KOMPONENTAUTOMATIC AB LEIF LINDGREN EEN 1 Contents ll Contents rererere ore ere eae ae 2 Be IONS A A E ET 3 SA 6 ag cl Seen ee eee a a A RAE 3 4 Operating Principle avus 4 Di Instrument IS PO GION iris AA 5 6 Mechanical connection unicidad 5 7 Electrical connection iii its 6 8 Function elements ni a a a aia dadai 6 97 TO UO kecer E 7 9 1 Output TURGHON Sa 8 10 OT A NN 9 AT ENON A paar ap nae apa aar apaa eiaeiiai 11 12 Technical Data A a A TON 11 130rd r COdes sentra a 12 14 gt de ote Set 12 15 DIMENSIONS ti A ii 12 16 Declaration Of COntomante sind 13 Manufactured by Kobold Messring GmbH Sold by Komponentautomatic AB Box 265 771 26 Ludvika Tel 46 0 240 150 09 Fax 46 0 240 61 11 08 Internet www komponentautomatic se page 2 KAL D 10 03 LEIF LINDGREN EEE KOMPONENTAUTOMATIC AB KAL D 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 amp Safety and prevention of accidents By usage in machines the measuring unit should be used only when the machines fulfil the EWG machine guidelines
6. cation with 8 position LED strip display With potentiometer optical indicator on LED strip display blinking LED 1 dual LED Semiconductor PNP or NPN max 400 mA short circuit proof N O or N C contact set at the factory M12 x 1 plug connector IP 65 Housing stainless steel 1 4301 Housing cover stainless steel 1 4301 G 1 4 G 1 2 1 4 NPT 1 2 NPT M12 x 1 stainless steel 1 4404 page 11 KAL D 13 Order Codes KOMPONENTAUTOMATIC AB LEIF LINDGREN MI Example KAL D1408 N ST3 Connection Model Type of contact Electrical connection G 1 4 KAL D1408 N NPN N O contact ST3 plug connector M 12x1 24 Voc G 1 2 KAL D1415 P PNP N O contact 1 4 NPT KAL D5408 M NPN N C 1 2 NPT KAL D5415 R PNP N C M 12x1 KAL D0412 14 Maintenance This device is maintenance free The sensor tip should be checked for the presence of mineral deposits lime etc and cleaned if necessary 15 Dimensions Fitting size Length Wrench size mm mm M121 G 1 4 114 NPT G 1 2 40 5 27 12 NPT page 12 KAL D 10 03 KOMPONENTAUTOMATIC AB KAL D LEIF LINDGREN EEE 16 Declaration of Conformance We Kobold Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Compact Calorimetric Flow Monitor Model KAL D to which this declaration relates is i
7. et the device KAL D 10 03 page 9 KAL D KOMPONENTAUTOMATIC AB LEIF LINDGREN EEE measuring range so that it now extends across the entire LED strip at the maximum system flow e 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 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 If the extent of the illuminated LED light strip actual flow value reaches the position of the blinking LED 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 ojojojejojojo o DUAL LED illuminated red Slowly blinking switching point LED setpoint eje ejbjojoo o light strip actual value DUAL LED illuminated red Quickly blinking switching point LED setpoint elelelejojo o o light strip actual value DUAL LED illuminated green Slowly blinking switching point LED setpoint elelelelelejo o light strip actual value DUAL LED illuminated green actual flow lt set
8. l supply lines are de energized when connecting the device Make sure that the supply voltage of your system is the same as that specified on the device nameplate e Connect the KAL D according to following wiring diagram e Switch on the operating voltage 24 Vpc 10 see Technical details e Check the electronics for proper function the switching point LED must be blinking e Adjust the setting of the flow monitor see Putting in operation Pin 1 Vs 24 Voc nc 2 1 Vs Pin 2 n C x Pin 3 GND OVpc Pin 4 Switch out GND Switch 3 4 Out 8 Function elements View with cover removed SET button 3 Potentiometer 4 LED strip 1 DUAL LED 2 page 6 KAL D 10 03 KOMPONENTAUTOMATIC AB KAL D LED strip display 1 The strip of LEDs 8 segments displays the flow value e The flow value is shown on the strip of LEDs starting at the left The blinking LED displays the switching point e 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 e The switching point Red ALARM actual flow below setpoint Green FLOW actual flow above setpoint In the standard operating mode the DUAL LED is constantly illuminated e Setup mode display If an adjustment zero or span is being performed the DUAL LED blinks green e Error message display In the event of an error message the DUAL
9. n conformity with the standards noted below EN 50081 2 1994 03 Generic emission standard EN 61000 6 2 2 2000 03 Generic immunity standard Also the following EWG guidelines are fulfilled 89 336 EWG Electromagnetic compatibility ao yuu Signed date 29 06 02 H Peters M Wenzel KAL D 10 03 page 13
10. n 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 NPN or PNP 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 P PNP NPN DUALTED actual flow gt switch open switch open green setpoint setpoint switch closed switch closed failure page 8 KAL D 10 03 LEIF LINDGREN EEE KOMPONENTAUTOMATIC AB KAL D 10 Operation 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 To set the no flow adjustment proceed as follows e 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 b
11. point no flow Alarm status no LEDs lit no flow actual flow lt flow below set point Alarm status Actual flow below setpoint actual flow setpoint output switches Actual flow has just reached setpoint actual flow gt setpoint Flow status ideal conditions This is the most desirable status After the settings are completed screw the cover tightly back on the housing make sure that the window for viewing the LED strip is aligned with the strip page 10 KAL D 10 03 KOMPONENTAUTOMATIC AB 11 LEIF LINDGREN EEE Error Messages KAL D 12 The sensor element itself is monitored for short circuits open circuits and electronics failure Should a fault occur this will be indicated by a red blinking light at the DUAL LED and the LED strip display In this event contact the KOBOLD service department Technical Data Power supply Power consumption Ambient temperature Liquid temperature CIP compatible Max pressure Time delay before availability Switching range Temperature gradient Response time Flow indication Switching point setting Output status indicator Switching output Electrical connection Protection type Housing material Process connection KAL D 10 03 24 Voc 10 max 3 6 W 20 C to 60 C 20 C to 80 C max 140 C without function 40 bar max 12 s approx 0 04 m s to 2 m s Unlimited 5 6 to 12 s typical Trend indi
12. ubbles 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 e The flow monitor is now ready for operation b Measuring range span adjustment To set the measuring range proceed as follows 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 e 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 system flowrate e Now press the SET button The DUAL LED blinks green e Do not make any changes potentiometer setting etc while the DUAL LED is blinking This adjustment phase will last approx 5 15 sec e The span adjustment procedure is now complete The device now switches automatically to the monitoring mode This adjustment has s
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