Kobold KAL-K, KAL-4215, KAL-4315, KAL-4320, KAL-4340-S User Instructions

KOBOLD KAL-K (KAL-4000 Series)

Thermal Flow Switch

User Instructions

KOBOLD Instruments Inc. 1801 Parkway View Drive Pittsburgh PA 15205

Phone [phone] • Fax [phone]

KAL-K_manual_8-29-06

KAL-K

Table of Contents

1.0 General............................................................................................. 1

2.0 Specifications................................................................................... 1

3.0 Mechanical Installation...................................................................... 4

4.0 Electrical Connections...................................................................... 5

5.0 Operation.......................................................................................... 7

5.1 Calibration............................................................................. 7

5.2 Flow Setpoint Adjustment...................................................... 8

5.3 Setting the KAL-K Output Transistor Type............................ 9

5.4 KAL-K Diagnostics and Troubleshooting.............................. 9

5.5 Applications........................................................................... 10

6.0 Maintenance..................................................................................... 11

7.0 Arrival of Damaged Equipment........................................................ 11

8.0 Need Help With Your KAL-K............................................................ 11

List of Diagrams

Diagram 2.1 Dimensions................................................................ 3

Diagram 3.1 Mechanical Installation............................................... 4

Diagram 4.1 Interior Controls Layout for 24 VDC Versions............ 5

Diagram 4.2 Interior Controls Layout for 110 VAC Versions........... 5

Diagram 4.3 KAL-K Wiring 24 VDC Versions................................. 6

Diagram 4.4 KAK-K Wiring 110 VAC Versions............................... 6

Diagram 4.5 Quick Disconnect (option M-12) Wiring 7

List of Tables

Table 2.1 Switching Ranges Vs. Pipe Diameter.......................... 2

FM Rev. 8/29/06

KAL-K

CAUTION: For safety reasons, please read the cautionary information located at

the end of the manual, before attempting installation.

1.0 General

The KOBOLD KAL-K (a.k.a. KAL-4000 Series) flow switch is intended for use in
monitoring and control applications involving moderate flowrates of non-viscous or dirty
liquids. The KAL-K flow switch uses the proven thermal dispersion principle and operates
as follows:

1. The probe is heated internally to a few degrees above the temperature of the
medium into which it extends.

2. As the medium flows past the probe it removes heat from the probe tip. The
rate at which heat is removed is proportional to the flowrate.

3. The measured flowrate is compared to the setpoint value selected by the user.
If the setpoint is reached, the electronic circuitry activates a transistor switch
and bi-colored alarm LED. The electronic circuitry also controls an LED trend
indicator which can be used to indicate relative system flow.

The microprocessor-controlled design permits simple calibration and setup. The compact
probe design permits monitoring of flowrate with minimal head loss.

2.0 Specifications

Measuring Range: 0.05 - 2 meters/sec.
Available Fitting Sizes: 1/2” NPT

1-1/2” Tri-Clamp®
3/4” NPT

Maximum Pressure: 1450 PSIG for threaded units,

Tri-Clamp® versions to clamp rating

Maximum Temperature:

Ambient: 0 to 140°F
Medium: 32° to 250°F
Clean in Place (CIP): 280°F (non-operating)

Supply Power:

Standard: 24 VDC ± 10%, 300 mA Max.
Optional: 110 VAC Nominal

Wetted Parts:

KAL-4215: 304 Stainless Steel
KAL-4315: 316 Stainless Steel
KAL-4320: 316 Stainless Steel
KAL-4340-S 316 Stainless Steel

FM Rev. 8/29/06

KAL-K 2

Housing: Reinforced Polyamide (NEMA 4)

Switching Characteristics:

Switchpoint Adjustment: By internal potentiometer
Switch Type:

Standard: NPN or PNP transistor (selectable)

Suffix P03R: SPST relay, 5 A @ 250 VAC Max.

Calibration Data: Stored in non-volatile memory, data

Table 2.1 Switching Ranges Vs. Pipe Diameter

Max. 24 VDC, 400mA

retained for at least 10 years in the event
of power failure

Nominal I.D

Inches

Range

GPM Water

Nominal I.D

Inches

Range

GPM Water

1/2 0.3-5.0 4 12-220

3/4 0.5-8.9 6 28-500

1 0.8-14 8 50-900

1-1/4 1.1-20 10 78-1400

1-1/2 2.0-35 12 110-2000

2 3.1-55 16 200-3600

3 7.9-140 20 310-5600

Note: 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.

FM Rev. 8/29/06