halstrup-walcher KAL 100, KAL 200 Instruction Manual

Document 7100.004364 10/2015

Instruction Manual

KAL 100/200 Calibration Device

with Rechargeable Battery

halstrup-walcher GmbH

Stegener Straße 10
D-79199 Kirchzarten, Germany

Tel.: [phone]
Fax: [phone]

E-mail: [e-mail]
Internet: www.halstrup-walcher.com

Instruction Manual KAL 100/200

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Table of Contents

1 Purpose of instruction manual 3

2 Conformity 3

3 Safety precautions 4

3.1 Appropriate use 4

3.2 Shipping, assembly, electrical connections and start-up 4

3.3 Troubleshooting, maintenance, repairs, disposal 4

3.4 Symbols 4

4 Instrument description 6

4.1 Functions 6

4.2 User interfaces 7

4.2.1 Power input, primary on/off switch, micro fuse 8

4.2.2 I/O switch 9

4.2.3 Menu key 9

4.2.4 Target value key 10

4.2.5 "Test" key 11

4.2.6 Pressure key 11

4.2.7 Pressure input port 12

4.2.8 Purge feature 12

4.3 Menu items 12

4.3.1 Incrementation 12

4.3.2 P-input 12

4.3.3 Units of pressure 13

4.3.4 Unit 2 (optional) 13

4.3.5 Zeroing 13

4.3.6 Language 13

4.3.7 Rechargeable battery 14

4.3.8 Default settings 14

5 Battery operation 15

5.1 Charging the rechargeable battery 15

5.2 What to do in the case of total discharge 16

6 Zeroing 17

6.1 Manual zeroing 17

7 Overpressure protection 17

8 USB port 18

8.1 Commands for the serial interface 19

8.1.1 Operating modes 19

8.1.2 Setting parameters 20

8.1.3 Miscellaneous 20

8.1.4 Query values 21

8.2 Interface configuration 23

9 PC software 24

9.1 Software downloads 24

10 Troubleshooting 25

11 Technical data 25

Instruction Manual KAL 100/200

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1 Purpose of instruction manual

Please read this instruction manual thoroughly before operating the instrument in order to avoid
injury or equipment damage caused by improper use of this instrument or failure to follow these
instructions.

This instruction manual describes the features of the KAL 200 calibration device and provides
guidelines for its use.

Any individual charged with handling this instrument must be trained in proper instrument
operation and informed of all potential hazards. The instruction manual, and in particular the
safety precautions contained therein, must be followed carefully. Please contact the

manufacturer immediately if you do not understand any part of this instruction manual or
if you require additional information.

Handle this manual with care and ensure that it

 is readily available throughout the lifecycle of the instrument,

 is provided to any individuals who assume responsibility for operating the instrument at a

later date, and

 includes any supplementary materials provided by the manufacturer.

halstrup-walcher GmbH reserves the right to continue developing this instrument model without
documenting such development in each individual case. We will be happy to determine whether
this manual is up-to-date.

2 Conformity

This device is state of the art. It complies with the legal requirements of EC directives. This is
shown by the CE mark.

© 2010, 2014, 2015

The manufacturer owns the copyright to this instruction manual. It contains technical data,
instructions and drawings detailing the device’s features and how to use it. It must not be copied
either wholly or in part or made available to third parties.

Instruction Manual KAL 100/200

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3 Safety precautions

3.1 Appropriate use

The KAL 200 calibration device is used for testing and calibrating pressure sensors.

Always observe the operating requirements – particularly the permissible supply voltage –
indicated on the rating plate and in the “Technical data” section of this manual.

The instrument may only be handled as indicated in this manual. Modifications to the instrument
are prohibited. The manufacturer is not liable for damages caused by improper use or failure to
follow these instructions. Violations of this type render all warranty claims null and void.

3.2 Shipping, assembly, electrical connections and start-up

Please do not close the pressure inlets during shipping! Changes in barometric pressure may
damage devices with low measuring ranges.

Assembly and the electrical connections should only be handled by professionals. Only
technical personnel who are appropriately trained and authorized by the operator of the facility
may assemble the instrument and set up its electrical connections.

Pressurized air or breath is not to be used for performance tests, as this could damage
instruments with low measurement ranges.

Measurement errors may occur if the instrument is not kept protected from sunlight.

See the individual sections of this manual for specific safety precautions.

3.3 Troubleshooting, maintenance, repairs, disposal

The individual responsible for the electrical connections must be notified if the instrument is
damaged or if errors occur that cannot be corrected as indicated in Section 10.

This individual must take the instrument out of service until the error has been corrected and
ensure that it cannot be used unintentionally.

Always unplug the power cord before opening the instrument!

This instrument requires no maintenance.

Only the manufacturer may perform repairs that require the housing to be opened.

The electronic components of the instrument contain materials that can be reused. The
instrument must therefore be sent to a recycling plant when you no longer wish to use it. The
environment codes of your particular country must be complied with.

3.4 Symbols

The symbols shown here are used throughout the following text to highlight the hazards
associated with using the KAL 200 and to point out important information for operating the
instrument.

Instruction Manual KAL 100/200

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WARNING!

This warns you of a potential hazard that could lead to bodily injury up to and
including death if the corresponding instructions are not followed.

WARNING:

This warns you of a potential hazard that could lead to significant property
damage if corresponding instructions are not followed.

INFORMATION:

This indicates that the corresponding information is important for operating the
instrument properly.

Instruction Manual KAL 100/200

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4 Instrument description

4.1 Functions

The KAL 200 microprocess-controlled pressure calibration device can be used for the following:

 Simply generating positive and negative reference pressures

 Measuring positive and negative pressures
 Measuring differential pressure

 Identifying leaks in a test object

 Determining dynamic response behaviour of a test object

Fig. 1 Basic circuit diagram

Pressure
measurement

Controller

Pump

Pressure
actual value

Pressure
target value

actual and target values

USB

pos. pressure

Comparison of

neg. pressure

Microprocessor

PC interface

Display

+

Valves

Instruction Manual KAL 100/200

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4.2 User interfaces

1 2 3 4 5 6 7 8 9

Fig. 2 Front

1

Secondary on/off switch

2

Menu

3

Positive pressure input/output

4

Negative pressure input/output

5

Target value

6

Pressure measurement

7

Test

8

Alphanumeric display

9

Navigation keys

Instruction Manual KAL 100/200

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11 12 13

Fig. 3 Rear

10

USB port

11

Inlet connector for non-heating apparatus

12

Micro fuse, 315 mAT, 5 x 20 mm

13

Primary on/off switch

14

Power supply +24V/125mA, galvanic separation

15

Ground for 24V/125mA

16

Input port for current measurement 0…20 mA,
input resistance 240 Ohm

17

Ground connector for voltage and current input
port

18

Voltage input 0…10V, Ri = approx. 40kOhm

4.2.1 Power input, primary on/off switch, micro fuse

The KAL 200 calibration device is designed at the factory to
accommodate a supply voltage of 230 VAC/50-60 Hz (115 VAC/50-60
Hz is optional). Voltage fluctuations of +6% to -15% are permissible.

The supply voltage connector (11) is located on the rear of the
instrument (inlet connector for non-heating apparatus + ground wire).
The instrument’s micro fuse (12) is located above this connector. Value:
315 mAT; dimensions: 5 x 20 mm. Located above the micro fuse is the
double-pole, primary on/off switch (13), which separates the KAL 200
from the supply voltage.

WARNING! Risk of Electrical shock! Failure to unplug the power supply cord
before replacing the fuse may result in fatal injuries!

10

14

15

16

17

18

11

13

12

Instruction Manual KAL 100/200

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4.2.2 I/O switch

Secondary on/off switch; in standby mode the power input is approx. 5 W.

Pressing the primary on/off switch, a double-pole switch located on the rear of the
instrument, separates the instrument from the power supply.

4.2.3 Menu key

Pressing the menu key allows the operator to adjust the following 8 settings:

 Target value increments: 5, 10, 20, 25, 50, 100%

 Pressure input: +P, -P, Diff (both)

 Units of pressure: kPa, hPa, Pa, mbar, Torr, mmHg, mmH2O, inH2O

 (Optional) Unit in the 2nd line (unit of pressure, V, mA)

 Zeroing: on, off

 Language: German, English, French, Italian, Spanish

 Battery data: Voltage, present current, present current source, battery charge status

 Default settings

Navigation keys

Item 1 is displayed when the menu function is first activated; users may select
other items by pressing the right/left navigation keys. The arrows on the
display indicate which navigation keys are active. Pressing any of the
operating mode keys (target value, pressure, test) exits the menu. Exiting the
menu saves user preferences, which will be automatically set the next time
the instrument is switched on.

I/O