KAM Simple Precision CHA User Manual

KAM® CHA™

COLORIMETER/HAZE ANALYZER

TEL [phone]
FAX [phone]
Email [e-mail]

PTB 04 ATEX 1027
Ex II 2 G Ex db IIB T6 Gb

API COMPLIANT

User Manual

CHAMANUAL-0917

KAM CONTROLS, INC.
3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com

TABLE OF CONTENTS

SECTION TITLE PAGE

1 Introduction 2

• Available models and mounting options 2

• Theory of operation 2

• Features 3

• Applications 3

2 Specifications 4

• Specifications 4

• Dimensional drawings 5

3 Installation 7

• "Do's" and "don't"s 7

• Main line 8

• Removal 11

• Power wiring 12

• Communications wiring 13

4 Operations and maintenance 15

• Calibration 15

• Color scale ranges 15

• Hyperterminal (RS485) 15

• Cleaning and inspection 16

• Readings verification 16

5 MODBUS Configuration 17

CAUTION:

When installing the CHA™ sensor in a pipeline containing petroleum products,
petro-chemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ “Health, Safety and Environmental Policy Procedures” to
ensure safe installation.

KAM CONTROLS, INC. reserves the right to make changes to this document without notice.

CHAMANUAL 0917

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KAM CONTROLS, INC.

INTRODUCTION

AVAILABLE MODELS and MOUNTING OPTIONS

FIG. 1-1 FIG. 1-2 FIG. 1-3

Full-opening
ball valve

Full-opening
ball valve

Rectractable CHA™ on a

main pipe, with 2", 3", or 4"

flanged Seal Housing

Rectractable CHA™

on a main pipe, with

2" MNPT Seal Housing

CHA™ FT Flow Through

with 1" or 2" spool

(Custom flow through models avail.)

THEORY OF OPERATION

Color variations in refined products indicate impurities and/or the presence of water. Refined products are often prone
to haze or diffused water contamination due to cooling towers which use water and in turn can saturate the product.
This can be a significant liability as color differentiation can be easily detected by the end user. The KAM® CHA™
Colorimeter/Haze Analyzer is the ideal quantitative solution for monitoring both the color of refined products, including
dyed product, and the presence of haze (trace/dissolved water) in pipelines following the refining process. The KAM®
CHA™ detects interface color variations within 1%, and unlike most colorimeters can detect the entire range of
visible color as defined by CIE 1931 (International Commission on Illumination). The simplicity of design and quality
of engineering employed in the Colorimeter/Haze Analyzer mean there are no moving parts. Using long-lasting LED
light sources ensures long-term, stable performance with limited maintenance and power requirements. In addition,
locating the electronics within an explosion-proof enclosure directly on the atmospheric end of the optical probe
creates a complete and compact unit with maximum installation flexibility. The KAM® CHA™ easily installs where
other colorimeters, weighed down by large electronics/computer units, cannot.

The five LED sources (Red, Blue, Green, Yellow, and IR) send light via fiber optics to the sensor end inserted into the
pipeline or analyzer loop. These beams of light pass through a 25mm window of pipeline fluids and then are reflected
back through fiber optics to the electronics enclosure for a total path of 50mm. KAM uses four LED's for color
determination to increase the accuracy over three-color (RGB) models. The fifth (IR) LED provides haze detection.

CHAMANUAL 0917

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KAM CONTROLS, INC.

INTRODUCTION CONTINUED

The disparity in light output versus light reflected back is then converted into an electronic or optical signature
which is amplified and sent to the computer. The computer in turn utilizes a mathematical formula to determine the
exact color and haze (turbidity) of the fluid in the pipeline. Final color measurement from the KAM® CHA™ can be
expressed as haze plus three color (X, Y, Z, CIE 1931) or in several other industry-standard color scales including,
Saybolt, Platinum and Cobalt, and ASTM 1500 (see Specifications, Section 2).

The computer automatically adjusts for electronic noise and any LED fluctuations. Because the absorption rates of
the different colored fluids vary resulting in different signal strengths, the computer also automatically adjusts the
amplification or gain accordingly.

Measurement is fully automatic without the need for operator intervention or supervision. The output signal can be
sent to the SCADA, PLC’s, or to a Central Control Room for logging or display on chart recorders or monitors.

The KAM® CHA™ probe can be installed in an analyzer loop or in the main line, and because it’s easily mounted
through a full-opening ball valve, you can insert or retract the probe without having to ever drain the pipe.

FEATURES

• 5-LED design offers greater accuracy over other, 3-LED models

• Uses LEDs for long-term performance with minimal power and maintenance requirements

• Inserts in directly in pipeline under process conditions

• Outputs for industry scales ASTM D1500, Platinum-Colbalt, Saybolt plus Haze

• All requisite electronics housed on atmospheric end of probe; requires no additional controller

APPLICATIONS

• Multi-product pipeline interface detection

• Transmix/regrade reduction

• Haze monitoring/quality control at refineries and pipeline terminals

• Haze monitoring/quality control for incoming diesel fuel in power and marine applications

• Haze/quality control for aviation fuels at pipeline, tank farm, fuel trucks and carts

CHAMANUAL 0917

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KAM CONTROLS, INC.

SPECIFICATIONS

Media: Refined products

Material: Wetted parts–316 stainless steel, sapphire

Power: 12–24 VDC 5 Watts max

Outputs: 4-20 mA (2) reflect values for Haze plus designated color scale (see Color Range P15)

Communication
Interface: RS-485 MODBUS (X,Y, Z values plus all color scales, and individual LED readings)

Fluid temperature: -40º to 200º F (-40º to 93º C)

Electronics temp.: -22º to 185º F (-30º to 85º C)

Pressure ratings: ANSI 150, 300, 600

Hazardous area: PTB04 ATEX 1027
(Ex II 2 G Ex db IIB T6 Gb)
NEMA4 (IP66 equivalent)

Accuracy: Haze ± 5%, Color ± 1%

Repeatability: Haze ± 1%, Color ± 1%

Reproducibility: Haze ± 1%, Color ± 1%

Haze Range: 0-100%

Color Range: Complete range of: ASTM D 1500; ASTM D 156 (Saybolt);
ASTM D 1209 (APHA Platinum-Cobalt)

Mounting: 1" or 2" flanged flow through spool (custom sizes available)
2" MNPT Seal Housing
2", 3", or 4" Flanged Seal Housing

Sensor Dimensions: 3.5" x 1.25"Ø (89 mm x 32 mm)

EX enclosure: 4.6" x 7.1" x 4.4" (117 mm x 180 mm x 112 mm)

Shaft length: 12" to 60" – Off-the-shelf lengths are 12", 24", 36", 48", and 60"
(305 mm, 610 mm, 762 mm, 914 mm, 1219 mm, 1524 mm)

Pipe size: 1" to 48" (25 mm to 1219 mm)

Weight: from 20 lbs. (9 kg)

CHAMANUAL 0917

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KAM CONTROLS, INC.

SPECIFICATIONS CONTINUED

DIMENSIONAL DRAWINGS

FIG. 2-1 CHA™ SENSOR

SL

A

Seal Housing

B

E

F

Sensor Profile

TABLE 2-2 FLANGE SIZE AND CLASS (SL)

150

"

2

3

INCHES

8.40

8.60

MM

213

218

INCHES

8.50

8.75

Shaft Length ± .5"

300

MM

216

222

INCHES

8.90

9.15

600

MM

226

232

C

¾" FNPT

INCHES

9.40

9.40

D

900

MM

240

240

4

8.60

218

TABLE 2-3 DIMENSIONS

INCHES

A

B

C

D

E

F

CHAMANUAL 0917

1.25

3.5

7. 1

4.6

.47

1

MM

32

90

180

117

12

25

Shaft Lengths are available in .5" (12.7
mm) increments.

Standard sizes are 24", 30", 36", 48",
and 60". (609.6 mm, 762 mm, 914.4
mm, 1219 mm, 1524 mm)

8.90

226

9.40

240

5

9.65

245

KAM CONTROLS, INC.

SPECIFICATIONS CONTINUED

FIG. 2-4 FLOW THROUGH CHA™

A

ANSI FLANGES

D

C

TABLE 2-5 DIMENSIONS

A

B

C

D

INCHES

11. 8

11

7.25

4.7

MM

299

279

184

119

B

CHAMANUAL 0917

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KAM CONTROLS, INC.

INSTALLATION

PRIOR TO INSTALLATION

Remove all the protective packaging materials , and ensure that the CHA™ sensor was not damaged
during transit.

INSTALLATION DOs and DONTs

Do not install the CHA in direct sunlight

Ensure there is no entrained air in the line or excessive levels
of organic compounds such as rouge.

CHA should be installed after a minimum of 4 pipe diameters
of straight run to reduce flow turbulence. Fig. 3-1

The CHA should be installed on a vertical line. If the unit
must be intalled on a horizontal line, it should be at 3 or 9
o'clock position. Fig. 3-2

The KAM CHA probe must be oriented so that the flow
indicator is parallel to the flow direction of the pipe to
enable flow through the measurement window. Fig. 3-3

FIG. 3-1 VERTICAL INSTALLATION

MINIMUM 4 PIPE

DIAMETERS BEFORE

METER

MINIMUM 4 PIPE

DIAMETERS BEFORE

METER

FIG. 3-2 HORIZONTAL INSTALLATION FIG. 3-3

9 O'clock

NOTE: Installation at the 12 O'clock or 6 O'clock position
could result in the accumulation of fluid contaminents
(dirt, etc.) on the lenses, causing measurement malfunc­tion.

CHAMANUAL 0917

3 O'clock

7

Flow
indicator

KAM CONTROLS, INC.

INSTALLATION CONTINUED

MAIN LINE INSTALLATION

CAUTION: For probe installations and removal when
line pressure is above 100 psi, a KAM® IT Insertion Tool
must be used.

Without the IT, pressure above 100 psi could cause the
probe to forcibly move outward from the pipeline,
risking bodily injury and/or damage to the probe

The KAM® CHA™ sensor should be installed
according to FIG. 3-4, ideally at the 3 or 9 o'clock
position within the pipeline. Installing the
instrument horizontally prevents the long-term buildup
of any sediment on the sapphire windows. A full-open­ing ball valve is used to isolate the CHA™ sensor from
the pipeline during installation or removal. The Seal
Housing of the CHA™ sensor allows the probe to be
inserted and removed from the pipe under
pressure and flow conditions. The CHA™ sensor
should be inserted so that the window of the probe
is fully located within the pipeline. See page 9 of this
manual to determine the proper insertion depth.

Prior to mounting verify that the tip of the sensor

1.

is fully inside the Seal Housing. FIG. 3-5, 3-6

FIG. 3-4 KAM® CHA™ INSTALLED ON A MAIN PIPE

Locking Collar

Seal Housing

Full-opening

Ball Valve

Socket Cap Screw

FIG. 3-5

2.

If sensor is not fully enclosed inside the Seal
Housing, loosen the Socket Cap Screws and pull
the shaft back until the probe is all the way in
the Seal Housing and re-tighten the Socket Cap
Screws on the Locking Collar. This will prevent
the CHA™ shaft from ejecting and the probe
from getting damaged during mounting.

FIG. 3-6

CHAMANUAL 0917

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KAM CONTROLS, INC.

INSTALLATION CONTINUED

3.

To ensure proper installation depth, measure the distance (D1) from the outside diameter of main pipe to the end
of the connection where the CHA™ sensor is going to be installed. FIG. 3-7

FIG. 3-7

D1

D1

4.

You must now calculate the minimum insertion distance for the CHA (minimum depth to ensure probe is fully
in flow)

Minimum Insertion Distance (MID) = D1 + Pipeline Wall Thickness + 2"

Example for D1=16", pipe WT =1/4", Seal Thickness=1/8":

MID = 16 + 1/4 + 1/8 + 2
MID = 18 3/8"

5.

Measure the calculated MID from the top of the
seal clamp and place a mark with a permanent

FIG. 3-8

marker or tape on the Shaft. FIG. 3-8

MID

6.

Bolt or screw the CHA™ sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded CHA™).

7.

Open full-opening valve.

8.

Loosen Socket Cap Screws on the Locking Collar.

REMINDER: Line pressure must be below 100 psi for CHA installation and removal or a KAM® IT Insertion
Tool must be in place.

CHAMANUAL 0917

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KAM CONTROLS, INC.

INSTALLATION CONTINUED

Push CHA™ sensor in until the minimum insertion distance mark is at the top edge of the Locking Collar. FIG. 3-9

9.

Ensure that CHA™ flow indicator is aligned with pipeline flow direction. FIG. 3-10

CAUTION: Inserting CHA™ beyond MID mark into opposing pipeline wall could result in probe damage, include
damage to sapphire windows. FIG. 3-11

FIG. 3-9

Minimum insertion distance mark

Socket Cap

Screw

Hex Nuts

Re-tighten the Socket Cap Screws with a torque of 750-800 lb-in or 62.5 to 66.6 lb-ft.

10.

11.

Tighten the Hex Nuts on the top of the Locking Collar one half turn. These nuts should never be over-tightened.
Their major function is to apply light pressure on the chevron packing to ensure a seal between the Seal Housing
body and the insertion shaft.

FIG. 3-10 FIG. 3-11

Flow Indicator

Flow Direction

CHAMANUAL 0917

Flow
Measurement
Area

10

KAM CONTROLS, INC.

INSTALLATION CONTINUED

REMOVING THE CHA™ SENSOR

1.

To remove the CHA™ sensor, first disconnect all electrical connections to the CHA™ enclosure.

Make sure that the line pressure is below 100 psi. If line pressure is over 100 psi, install a KAM IT Insertion tool

2.

onto the unit and follow extraction directions per the IT manual.

3.

If pressure is under 100 psi, then loosen Hex Nuts on top Locking Collar, then slowly and with caution loosen
the Socket Cap Screws. Fig. 3-12

NOTE: Once the Socket Cap Screws have been loosened, the CHA shaft may push out from the line.

Slide the CHA™ sensor away from pipeline until it cannot go further and the probe rests inside the Seal Housing.

4.

Fig. 3-12 The mechanical stop prevents further movement or ejection of the shaft and/or sensor.

5.

Close the Full-opening Ball Valve tightly. The CHA™ sensor may now be unbolted from the system.

FIG. 3-12

Hex Nuts

Mechanical

Stop

Socket Cap Screws

CHAMANUAL 0917

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KAM CONTROLS, INC.

INSTALLATION CONTINUED

LED3

LED1

LED2

POWER IN

J5

1

2

3

4

J7

ASTM

SAYBOLT

PT/CO

HAZE

POWER WIRING

CAUTION: When electronics enclosure is open, be extremely careful to avoid any contact with interior fiber optic
connections. Failure to do so could result in the CHA malfunctioning.

DO NOT open electronics enclosure, even when isolated, when an explosive atmosphere may present.
To reduce the risk of ignition to hazardous atmospheres, disconnect the equipment from the supply circuit before
opening, keep assembly tightly closed when in operation.

For installation using conduit: All conduit runs must have a sealing fitting connected within one conduit diameter or
2”(50mm), whichever is less.

For installations in the EU: all cable entries stopping cables or plugs shall be certified per the requirements in
EN60079-1.

CAUTION: The KAM® CHA™ is NOT loop powered. Connection of power wiring to 4-20 mA (LOOP1 and LOOP2, Fig.
3-13) will result in malfunctioning of the instrument and damage to the electronics boards.

FIG. 3-13

Vin ( + )

Vin ( – )

{

KAM CHA

3939 Ann Arbor Drive
Houston, Texas
77063, USA
[phone]
www.KAM.com

GND

Loop1 IN

Loop1 RTN

Loop2 RTN

Loop2 In

485 -

485 +

CHAMANUAL 0917

Power Wiring (12-24 VDC, 5 watts maximum)

12

KAM CONTROLS, INC.

LED3

LED1

LED2

POWER IN

J5

1

2

3

4

J7

ASTM

SAYBOLT

PT/CO

HAZE

INSTALLATION CONTINUED

1.

To connect the power for the CHA™ sensor, first check both wires from the source for polarity and voltage, then
label appropriately. Shielded twisted pair wire is recommended for both power and signal.

2.

Connect positive wire to 24/12 VDC (+). Fig. 3-13

3.

Connect negative wire to 24/12 VDC (-). Fig. 3-13

WARNING: Connecting a power source to the 4-20 mA ports on the TB will damage the 4-20 mA output and
resulting failure of the unit.

4.

Check voltage and polarity at terminal block.

COMMUNICATION WIRING

FIG. 3-14

Vin ( – )

Vin ( + )

KAM CHA

3939 Ann Arbor Drive
Houston, Texas
77063, USA
[phone]
www.KAM.com

GND

Loop1 IN

Loop2 RTN

Loop1 RTN

{

485 -

Loop2 In

{

4-20 mA
Connections

485 +

{

Serial Port

Connect the wiring to the desired outputs and/or serial port. Fig. 3-14

1.

2.

For 4-20 mA outputs, LOOP1 will be set to Haze and LOOP2 to specified color range unless otherwise noted. To
change selected ranges see pg. 14 of this manual.

3.

The RS485 serial port can be used for X,Y,Z data or MODBUS (see pg. 17 of this manual).

4.

When wiring is complete ensure that the lid is properly placed back in place and that all bolts are tightened.

CHAMANUAL 0917

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KAM CONTROLS, INC.

INSTALLATION CONTINUED

J5

1

2

3

4

J7

ASTM

SAYBOLT

PT/CO

HAZE

CHANGING THE SCALE FOR 4-20 mA OUTPUTS

LOOP1 and LOOP2 can output signals for any 2 of 4 different scales: ASTM, Saybolt, Platinum/Cobalt, and Haze. This
will be set at factory according to end user specifications.

To change 4-20 mA output scale, insert a jumper across the pins next to the label for the desired scale. See Fig. 3-15
Place ONE jumper in J5 (LOOP 1) and one in J7 (LOOP2) to select two scales total. The CHA does not require
recalibration after changing scales. In most cases LOOP1 will be set for haze and LOOP2 to the specified color scale.

CAUTION: Inserting more than one jumper for either LOOP or inserting the jumper across two inputs or two outputs
will result in the malfunctioning of the instrument.

FIG. 3-15

SCALE

JUMPER INPUT
JUMPER OUTPUT

PROPER JUMPER
PLACEMENT ACROSS INPUT
AND OUTPUT

CHAMANUAL 0917

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KAM CONTROLS, INC.

OPERATIONS AND MAINTENANCE

CALIBRATION

The CHA is factory calibrated to ASTM certified color standards. It should not require recalibration for any reason.

COLOR SCALE RANGES

Scale Range

ASTM .5 to 8
Saybolt 30 to –16
Platinum/Cobalt 0 to 500
Haze 0 to 100

To change scale(s), see directions on page 14 of this manual.

HYPERTERMINAL PROMPTS FOR RS485 CONNECTION

Once Hyperterminal software is launched, a dialogue window will prompt you to "Enter a name

1.

and choose an icon for the connection." Name the connection whatever you want, for example
"CHA 1." Ignore the choose icon option. Hit OK.

The "Connect To" dialogue box will now appear. On the last line where it says "Connect using"

2.

choose the name of the communication port connected to the CHA via RS-485 from the drop­down menu. Hit OK.

3.

The "Port Settings" dialogue box will now appear. Enter the following values from the drop-down
menu:

Bits per second: 1200

Data bits: 7

Parity: Even

Stop bits: 2

Flow control: None

Hit OK.

A blank screen with prompt will now open. To display CHA readings type one of three prompts, E1, E2, or E3.

4.

E1: Displays values for Z, Y, Z, and T (haze)
E2: Displays values for ASTM, Saybolt, PtCo (Platinum Cobalt), and T (haze)
E3: Displays all values

CHAMANUAL 0917

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KAM CONTROLS, INC.

OPERATIONS AND MAINTENANCE CONTINUED

Register

Type Description

Expected values with

probe in air

Expected values with

probe in mineral spirits

40111

32 bit Float

Blue LED signal

transmission percent

50 to 65

90-100

40113

32 bit Float

Green LED signal

transmission percent

50 to 65

90-100

40115

32 bit Float

Yellow LED signal

transmission percent

50 to 65

90-100

40117

32 bit Float

Red LED signal

transmission percent

50 to 65

90-100

40119

32 bit Float

IR LED signal

transmission percent

54 to 65

90-100

40121

32 bit Float X color coordinate 90-100 90-100

40123

32 bit Float Y color coordinate 90-100 90-100

40125

32 bit Float Z color cooridnate 90-100 90-100

40127

32 bit Float Haze output signal 0-100 51-65 90-100

40129

32 bit Float ASTM 1500 Color Signal .5 to 8 0.5 90-100

40131

32 bit Float Saybolt Color Signal 30 to -16 15-25 20-30

40133 32 bit Float PT-Cobalt Color signal 0-500 0 0

CLEANING AND INSPECTION

Under normal operation, the KAM CHA should not require cleaning, unless pipeline usage is limited to a small
number of products, or products are contaminated with debris, organics, etc. Gasoline products or jet fuel in the
pipeline will clean the CHA without removal.

To remove any oil residues for visual inspection use a clean cloth with oil solvent or part washer.
Preferred solvents include, any petroleum solvent such as mineral spirits, xylene, toluene, gasoline, or diesel. Do not
use WD40 or other chemicals.

If you have a question regarding cleaning solvents, please contact KAM CONTROLS directly at [phone], or
email: [e-mail]

READINGS VERIFICATION

The following steps allow operators to check for proper operation of the KAM CHA's individual signals and
outputs outside of process conditions. To test unit with mineral spirits, fill a clear vessel (beaker, etc.) with
enough mineral spirits to fully submerge the CHA probe–approximately 2.5".

1.

Connect power to the CHA per
instructions on pg. 12 of this manual.

Table 4-1

2.

Connect to the RS-485 Serial Port
using a RS485 to USB converter or
RS485 to Serial converter.

3.

Place CHA probe in a clear vessel
with mineral spirits (if desired).

Configure Modbus software using

4.

the settings on pg. 17 of the manual.

Modbus addresses from 40111 to

5.

40129 should conform to the values
listed in Table 4-1.

CHAMANUAL 0917

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KAM CONTROLS, INC.

MODBUS CONFIGURATION

MODE RTU

BAUDRATE 9600

DATABITS 8

STOPBITS 1

PARITY None

SLAVEID 1

OFFSET 0

RegisterNo Type Description

40100 16bitinteger Amplifiergain

40101 16bitinteger BlueLEDrawsignalfromprobe

40102 16bitinteger GreenLEDrawsignalfromprobe

40103 16bitinteger YellowLEDrawsignalfromprobe

40104 16bitinteger RedLEDrawsignalfromprobe

40105 16bitinteger IRLEDrawsignalfromprobe

40106 16bitinteger BlueLEDsignalfromreferencefiber

40107 16bitinteger GreenLEDsignalfromreferencefiber

40108 16bitinteger YellowLEDsignalfromreferencefiber

40109 16bitinteger RedLEDsignalfromreferencefiber

40110 16bitinteger IRLEDsignalfromreferencefiber

40111 32bitFloat BlueLEDsignaltransmissionpercent

40113 32bitFloat GreenLEDsignaltransmissionpercent

40115 32bitFloat YellowLEDsignaltransmissionpercent

40117 32bitFloat RedLEDsignaltransmissionpercent

40119 32bitFloat IRLEDsignaltransmissionpercent

40121 32bitFloat Xcolorcoordinate

40123 32bitFloat Ycolorcoordinate

40125 32bitFloat Zcolorcoordinate

40127 32bitFloat Hazeoutputsignal0-100

40129 32bitFloat ASTM1500colorsignal.5to8

40131 32bitFloat Sayboltcolorsignal30to-16

40133 32bitFloat PT-Cobaltcolorsignal0-500

CHAHoldingModbusRegisters

SETTINGS

MODBUS SETTINGS AND REGISTERS

Recommendations for CHA Modbus TCP Client devices:
Enable serial port FIFO. Add a delay between Modbus TCP request of at least 500ms.

CHAMANUAL 0917

17

KAM CONTROLS, INC.