Kobold KMT-1, KMT-3, KMT-2, KMT-4 User Manual
Manual
Hardware and Software
BA_KMT_e // V5.1 // technical data are subject to change // 193624
Thermal
Mass flow meter
for COMPRESSED AIR and GASES
Model KMT
2
We doesn't accept warranty and liability claims neither upon this publication nor in case of improper treatment of the described products.
The document may contain technical inaccuracies and typographical
errors. The content will be revised on a regular basis. These changes
will be implemented in later versions. The described products can be
improved and changed at any time without prior notice.
© Copyright
All rights reserved.
USA
FCC notice:
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and,
if not installed and used in accordance with the installation manual, may cause
harmful interference to radio communications. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
- Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
- Consult the dealer or an experienced radio/TV technician for help.
Caution:
Any changes or modifications not expressly approved by the party responsible for
compliance could void the user's authority to operate this device.
CANADIAN
ICES-003 notification:
This Device B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du
Canada.
3
1. GENERAL
............................................................................................................ 4
1.1. Symbol Clarification ................................................................................................. 4
1.2. Safety Instructions .................................................................................................. 4
1.2.1. Intended Use ................................................................................................... 4
1.2.2. Installation, start up and control
.................................................................................. 5
1.3. Environmental aspects .............................................................................................. 5
2. PRODUCT DESCRIPTION ....................................................................................... 6
3. INSTALLATION ...................................................................................................... 7
3.1. Mounting dimensions ............................................................................................... 7
3.1.1. KMT-1, KMT-2 and KMT-3 ....................................................................................... 7
3.1.2. KMT-4
......................................................................................................... 8
3.2. Determining installation site .........................................................................................8
3.2.1. Process pressure ............................................................................................... 8
3.3. Installation position .................................................................................................. 9
3.4. Required length of straight pipe.....................................................................................10
3.5. Installation KMT-1, KMT-2 and KMT-3 .............................................................................. 11
3.5.1. Measurement ball valve ......................................................................................... 11
3.5.2. Assembly without flow meter, but with screw cap instead (blind cap)
................................................ 11
3.5.3. Shut off the measurement ball valve
.............................................................................. 11
3.5.4. Installation of the flow meter sensing probe
....................................................................... 12
3.5.5. Removal of the sensing probe of the flow meter
................................................................... 12
3.6. Installation KMT-4 in the pipe line .................................................................................. 13
3.7. Setting the pipe diameter ...........................................................................................15
4. ELECTRICAL CONNECTIONS ................................................................................. 16
4.1. Connection diagram ................................................................................................. 16
4.1.1. Relay and pulse output, internal switching ........................................................................ 16
5. CONTROL COMPONENTS ...................................................................................... 17
5.1. Jumper for Output ................................................................................................... 17
5.2. Digital interface USB ( for configuration)............................................................................17
5.3. Display / Indicator with keypad (optional) ........................................................................... 18
5.3.1. Indication of the analogue and pulse output ....................................................................... 18
5.3.2. Indication of the switch output
.................................................................................... 18
5.3.3. Indication of the MIN / MAX values
............................................................................... 19
5.3.4. Reset of the consumption counter or the MIN / MAX value
......................................................... 19
5.3.5. Maximum consumption counter
.................................................................................. 19
6. ERROR MESSAGES .............................................................................................. 20
7. MAINTENANCE ..................................................................................................... 20
7.1. Cleaning of the sensor of the flow meter ...........................................................................20
8. REPLACEMENT PARTS / ACCESSORIES ................................................................. 20
8.1. Order Code Replacement Sensor ..................................................................................20
8.2. Order Code Replacement sensor cable ............................................................................21
8.3. Order Code Accessories for KMT-4 ................................................................................. 21
9. TECHNICAL DATA KMT-1, KMT-2 and KMT-3 ............................................................ 22
10. TECHNICAL DATA KMT-4 ...................................................................................... 24
Table of contents - HARDWARE
Table of contents - SOFTWARE
1. General ................................................................................................................ 26
2. Installation ........................................................................................................... 26
2.1. Configuration of the USB Interface (VirtualCOM) ................................................................... 27
3. User Interface ....................................................................................................... 28
4. Menu toolbar ........................................................................................................ 28
4.1. File .................................................................................................................. 28
4.2. Transmitter .......................................................................................................... 29
4.3. Extras ............................................................................................................... 29
5. Input Screen ......................................................................................................... 29
5.1. Output 1, Output 2 ..................................................................................................29
5.1.1. Output mode ................................................................................................... 29
5.1.2. Measurand
..................................................................................................... 29
5.1.3. Units
........................................................................................................... 29
5.1.4. Output mode – analogue
........................................................................................ 29
5.1.5. Output mode – switch (relay)
.................................................................................... 30
5.1.6. Output mode – pulse
............................................................................................ 31
5.2. Minimum flow shutdown ............................................................................................31
5.3. Display .............................................................................................................. 31
5.4. Adjustment .......................................................................................................... 32
5.4.1. 1-point adjustment .............................................................................................. 32
5.4.2. 2-point adjustment
.............................................................................................. 33
5.4.3. Reset to factory settings
......................................................................................... 33
5.5. Measuring values overview ......................................................................................... 34
5.5.1. Reset of the MIN / MAX values .................................................................................. 34
5.5.2. Reset of the consumption counter (totalizer)
....................................................................... 34
5.6. Setting up Process Parameters ..................................................................................... 34
5.6.1. Change the Process Gas ........................................................................................ 34
5.6.2. Changing the standard conditions
................................................................................ 35
5.6.3. Pressure compensation
......................................................................................... 35
5.6.4. Setting the pipe diameter
........................................................................................ 35
5.7. External pressure transmitter for pressure compensation .......................................................... 35
5.8. Declaration of Conformance ........................................................................................35
4
1. GENERAL
This manual is a part of the scope of supply and serves to ensure optimal operation and functioning of the
equipment.
For this reason, the manual must be read before start-up.
Therefore, it is necessary that this manual is read and understood by those responsible for the handling,
installation, and maintenance of the equipment.
This manual may not be used for competitive purposes or passed on to third parties
without the written consent.
It is permitted to make copies for personal use.
All information, technical data and illustrations contained in these instructions are based on
information available at the time of publication.
1.1. Symbol Clarification
This symbol indicates safety instructions.
The safety instructions have to be carried out unconditionally. If disregarded loss, injury, or damage may be
inflicted to people and property. In any case we cannot be hold responsible.
This symbol indicates attention.
The note should be observed to achieve an optimal functioning of the equipment.
1.2. Safety Instructions
1.2.1. Intended Use
The flow meter is intended to be used for the measurement of air and other non-corrosive gases in pipelines
only. Consult the factory first before the measurement of wet or filthy gases.
The design of the flow meter allows for the KMT to be installed in a pressurized system up to PN16 – is
16 bar (230 psi).
For KMT-1, KMT-2 and KMT-3:
Prior to the start of the installation, the system has to be depressurized. Before the installation or
removal of the sensing probe or the screw cap, the measurement ball valve should be closed.
Mounting, electrical installation, putting in operation and maintenance should only be done by qualified
personnel.
The use of the flow meter in any other way than described in this manual bears a safety risk for people and
the entire measurement installation and is therefore not allowed.
The manufacturer cannot be hold responsible for damages as a result of incorrect handling, installation, and
maintenance of the equipment.
To avoid health risks or damage to the equipment, the installation should not be operated on with tools, which
are not specifically mentioned or described in this manual.
Excessive mechanical stress and inappropriate handling must be avoided.
For KMT-1, KMT-2 and KMT-3:
A short interruption of the flow using the measurement ball valve cannot be avoided when exchanging the
sensing probe.
The flow meter can only be utilized in accordance with the conditions defined in the technical data. Otherwise,
inaccuracies of the measurement will occur and equipment failures cannot be ruled out.
For the safety of the user and for the functionality of the equipment the recommended steps by the
manufacturer to put into operation, to test and to maintain should be taken and completed.
5
1.2.2. Installation, start up and control
The flow meter is designed and built in accordance with the latest state in technology, tested adequately and
has been shipped from the factory in good order and condition.
As the user, you are responsible to comply with all applicable safety regulations amongst others:
• Instruction for the installation
• Local standards and codes
The manufacturer has taken all measures to assure safe operation. The user has to make sure that the
equipment is positioned and installed in such a way that safe operation is not impaired.
The equipment is tested in the factory and shipped in good order and condition.
This manual contains information and notes of caution, which have to be adhered to by the user to assure a
safe operation.
• Mounting, electrical installation, putting into operation and maintenance should only be done by
qualified personnel. The plant operator should authorize qualified personnel to operate on the
installation.
• It is necessary that this manual is read and understood by these professionals and that they follow
the instructions as detailed in this manual.
• Check all connections of the entire installation thoroughly, before putting the system into operation.
• Disconnect the device from power supply before opening or closing to avoid damages.
• Do not put a damaged product into operation and make sure that that does not happen inadvert-
ently.
• A malfunction of the equipment should only be handled and fixed by authorized and qualified
personnel.
• If it is not possible to repair the malfunction, put the equipment out of operation and make sure that
it cannot be put back into operation again.
• Repairs not described in this manual may only be carried out by the manufacturer or by the
respective service organization.
Disclaimer of Liability
The manufacturer or their delegated representative is only liable in case of intend or gross negligence. The
accountability is limited to the value of the order issued at the time to the manufacturer.
The manufacturer is not liable for damages, originated from disregarding the safety instructions or violating
the instructions of the manual or operating conditions.
Consequential damages are excluded from the any liability.
1.3. Environmental aspects
The products are developed and designed in due consideration to the importance of the protection of the
environment. Therefore, disposal of the product also should not lead to pollution of the
environment.
The single-variety components must be separated before the transmitter is disposed of. The electronic
components must be collected and as electronic scrap properly be disposed of.
6
2. PRODUCT DESCRIPTION
The flow meter of the series KMT, based on the measurement principle of thermal mass flow, is suited for the
measurement of flow of air and gases in pipelines. Measurement of for instance the consumption of compressed air, nitrogen, CO2, oxygen or other non-corrosive and non-flammable gases.
The KMT measures the volume flow at standard conditions according to DIN 1343 (P0 = 1023.25 mbar;
t0 = 273.15 K or 0 °C (32 °F). In addition to the standard volume flow, the measurand mass flow, norm flow
and temperature are available.
The KMT has an integrated consumption counter. The consumption quantity is indicated in the display and is
not lost after a power failure. Two signal outputs are available. Depending on the application, the outputs can
be configured as analogue (current or voltage), switch output or as pulse output for the measurement of the
consumption.
Measurement ball valve
The measurement ball valve allows for the easy and reliable installation within the pipeline. During installation in the pipeline, observe the
required inlet and outlet paths (see page 10). The nominal size of
the measurement ball valve must match the nominal size of the pipe.
The measurement valve with shut-off function allows for the instalment and removal of the sensing probe with only interrupting the
process flow for a short moment. The measurment ball valve is suitable for pressures up to 16 bar (PN16) and available for pipe
diameters DN15 (1/2”) to DN50 (2”).
Signal conditioning with optional display
The enclosure with the signal conditioning is mounted either on the
measurement probe (model 1 or 2 compact) or is remote with a pluggable sensor cable up to 10 meter (33 feet) – (model 3 with remote
probe).
Sensing probe with measurement electronics
The interchangeable sensing probe contains the sensor element and
the measurement electronics, in which the data of the factory calibration is stored. The sensing probe is easy and quickly interchangeable
intheeld,independentoftheelectronicsforthesignalconditioning.
Aftertheexchange,thecongurationoftheoutputsisunchanged.
Screw cap
The screw cap, with female thread, is screwed in place if the flow
meter is not installed and the pipeline has to be used.
Sensor cable (only by model 3 with remote sensing probe)
The sensor cable allows for the remote installation, up to 10 meter
(33 feet), of the sensing probe from the housing with the signal
conditioning.
1
5
3
4
2
1
2
3
5
4
KMT-1, KMT-2 and KMT-3
KMT-4
1
2
36
7
7
3. INSTALLATION
3.1. Mounting dimensions
3.1.1. KMT-1, KMT-2 and KMT-3
115
145
129
60
56
60
40
cable gland
M16x1.5
cable gland
M16x1.5
Cross-section
bore hole:
Drilling Plan:
The bottom part of the housing is mounted with
4 screws (not in the scope of supply)
Max. screw diameter: 4.5 mm (0.17 inch).
e.g. 4.2 x 38 mm DIN 7938H Screws
Measurement ball valve
Non-return protection for secure mounting
The patented non-return protection combines three functions in one device:
• Non-return protection
The sensor can only be pushed in one direction during installation. The sensor cannot return at all,
even if it is released.
• Seal
By means of an encapsulated O-ring, no compressed air can escape under pressure during assembly.
• Precise positioning
The precise positioning with respect to immersion depth and orientation is easy to perform, guaranteeing accurate measurement results.
Mounting grip
With the mounting grip, the sensing probe is inserted and correctly positioned into the pipe line.
7
6
183 (7.2)
173 (6.81)
A A B
Only at DN15:
Reduction
3/4“-1/2“
173 (6.81)
Measurment
ball valve
Thread A B
DN15 R
p
1/2" 100±8 (3.94±0.32) 92 (3.62)
DN20 Rp or NPT 3/4” 72 (2.83) 92 (3.62)
DN25 Rp or NPT 1” 83 (3.27) 124 (4.88)
DN32 Rp1 1/4" 100 (3.94) 124 (4.88)
DN40 Rp or NPT 1 1/2" 110 (4.33) 147 (5.79)
DN50 Rp or NPT 2” 131 (5.16) 147 (5.79)
dimensions in mm (inch)
Female thread: BSP thread acc. EN 10226 (old DIN 2999) or NPT
8
3.2. Determining installation site
•
The installation site should be easy accessible and free of vibrations and shocks
• Observe enough clearance above the mounting position, in order to be able to install and remove
the sensing probe:
at least 120 mm (4.72) for KMT-1, KMT-2 and KMT-3
at least 450 mm (17.7”) for KMT-4 probe length 165 mm (6.5”) DN65 (2 1/2”) up to DN100 (4”)
at least 600 mm (23.6”) for KMT-4 probe length 315 mm (12.4”) DN125 (5”) up to DN300 (12”)
at least 750 mm (30.0”) for KMT-4 probe length 465 mm (18.3”) DN305 (14”) up to DN700 (28”)
• The ambient temperature should not exceed the value as stated in the specifications
(see page 22) – consider heating by radiation.
• The fluid should not condense at the installation site. Condensation on the tip of the sensing probe
must be avoided.
• In compressed air systems, the installation should be downstream of the dryer.
• Observe the direction of the flow by the installation (see page 11).
• Observe the required straight pipe lengths up and downstream, in order to warrant the specified
measurement accuracy.
• The flow meter should be installed as far as possible from any flow disturbance. Valves or check-
valves should be installed in a respective distance from the flow meter.
3.2.1. Process pressure
Because of the measuring principle the thermal mass flow meter KMT is largely independent of the process
pressure and is factory calibrated at a pressure of 7 bar (100 psi) (KMT-1, KMT-2 and KMT-3) or 9 bar (130.5
psi) (KMT-4).
In order to achieve the highest measurement accuracy, the slight dependence on process pressure can be
compensated for in two ways:
• if the process pressure is stable, by programming the pressure value in the configuration software
(see page 35).
• in case of strong fluctuations of the process pressure (e.g. 3 to 10 bar (40 to 150 psi)) an external
pressure transmitter can be installed and connected to the pressure-compensation input
(see page 35).
R 1/2“ thread
M12x1 Connector
for probe cable
B
variable insertion depth
max. A
45
(1.77“)
38 (1.5“)
20 (0.79“)
15
(0.59“)
12
(0.47“)
120 (4.72“)
180 (7.09“)
Ø 40 (1.57“)
Ø 13 (0.51“)
Ø 14 (0.55“)
Ø 40 (1.57“)
SW 36 (1.42“)
see accessories for NPT adapter
3.1.2. KMT-4
Pipe Ø
A [mm] B [mm] A [inch] B [inch]
DN50...DN100 165 285 6.5 11.22
DN125...DN300 315 435 12.4 17.13
DN350...DN700 465 585 18.3 23.03
9
Model
Vertical Mounting Compact Remote
+ ++
Horizontal Mounting, sensor upwards
++ ++
Horizontal Mounting, sensor downwards
- -
Horizontal Mounting, sensor across
+ ++
3.3. Installation position
Make sure that the arrow on the tip of the sensing probe is pointing in the direction of the flow.
++ ... recommended installation position
+ ..... not recommended if there is vibration on the pipeline
-....... not recommended
10
Type
(DN = Nominal Pipe Size)
Straight inlet pipe Straight outlet pipe
Extension 15 x DN 5 x DN
Reduction 15 x DN 5 x DN
90° - elbow 20 x DN 5 x DN
Two 90° - elbows,
in one level
25 x DN 5 x DN
Two 90° - elbows,
in two levels
30 x DN 5 x DN
Valve, gate valve 50 x DN 5 x DN
3.4. Required length of straight pipe
The flow meter should be installed as far as possible from disturbances of the flow. The causes for disturbance
of the flow are for instance, reducers, elbows, T-pieces, valves, gate valves, etc. The specified measurement
accuracy can be achieved only when the following straight inlet and outlet pipe lengths are installed:
• The stated values are as a minimum. If possible, allow for greater distances.
• Valves or gate valves should be installed downstream of the flow meter.
• With lighter gases the inlet straight pipe should be longer.
• Only for KMT-1, KMT-2 and KMT-3: The wall thickness of the inlet and outlet pipe should be 2,6 mm
owdirection
straight inlet pipe
nominal pipe size (DN)
straight outlet pipe
11
3.5. Installation KMT-1, KMT-2 and KMT-3
3.5.1. Measurement ball valve
• all connections to be made with appropriated sealing material on the threads.
• the sealing material should not change the area of the inner cross section of the pipe. It must be
warranted that the connections after installation are free of leaks.
• All fittings must be tested on seal tightness.
• Observe the required length of inlet and outlet pipe section.
• The recess for the alignment pin must be at the side of the outlet.
recess for
alignment pin
Flow Direction
3.5.2. Assembly without flow meter, but with screw cap instead (blind cap)
In order to use the measurement section without the flow meter, the blind screw cap (in
the scope of supply) must be screwed tight onto the opening of the measurement ball
valve. If not needed the screw cap can be screwed and stored on the handle of the measurement valve with shut-off function.
3.5.3. Shut off the measurement ball valve
The measurement ball valve allows for the installation and removal of the flow meter within seconds, with only
a very short interruption of the flow.
OPEN
CLOSED
Never remove the flow meter
or the blind screw cap while
the measurement ball valve is
open.
That is extremely dangerous!
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