Operating instructions
Electronic preset counter/timer
KALtrol-SP (KAT-SP/KAT-SPS)
1.1 Foreword personnel.
Please read this instruction manual The device must compulsorily be
entirely and carefully before installa- protected with approved external
tion and start-up. Please observe all fuses. The value of these fuses
warnings and advices, both for your can be found in the technical
own safety and for operating safety. information.
The intended protection can be
impaired If the device is not used This symbol is used on the device
in accordance with this instruction to remind of the existence of dan-
manual. gers, which are referred to in this
manual.
1.2 Safety instructions and warnings
Please use the device only if its 1.3 Use according to the intended purpose
technical condition is perfect. It The preset counter counts pulses and times up
should be used only for its intended to max. 30 Hz and offers various operating
purpose, in accordance with this modes. The present counter simulta-neously
instruction manual. processes a programmed preset value. Any
Defective or damaged devices other use is considered as non compliant with
should be disconnected from the the intended use.
mains immediately and taken out of The application area for this device lies in
operation. industrial processes and controls, in the fields
Repair work may be performed of manufacturing lines for metal, wood, plastics,
only by the manufacturer‘s repairs paper, glass, textile and other like industries.
service. Overvoltages at the terminals of the device
This device may be opened only must be kept within the limits of Overvoltage
for battery replacement. For this Category II. The device must only be operated
purpose, the device must be sepa- when properly mounted in a panel and in accor-
rated from all electric circuits and dance with the section “Technical Data”.
de-energized. The device is not suitable for use in areas with
Only connect the device to the explosion protection and for areas excluded in
electricity networks provided to that EN 61010-1. If the device is used to monitor
purpose. machines or processes in which, in the event of
The safety of the system in which a failure of the device or an error made by the
the device is integrated is the operator, there might be the risk of damaging
responsibility of the installer. the machine or causing an accident to the
Disconnect all electricity networks operators, it is your responsibility to take the
prior to any installation or mainte- appropriate safety measures.
nance work. The device has been designed for indoor ope-
Use exclusively cables approved in ration. It may nevertheless be used outdoors,
your country and designed for your provided the technical data is complied with.
temperature and power ranges. In this case, take care to provide suitable UV
Installation and service work shall be protection.
carried out exclusively by qualified
Page 1
1.4 Mounting in a control panel The device must be protected exter-
Mount the device away from heat nally for proper operation. Informa-
sources and avoid direct contact tion about the prescribed fuses can
with corrosive liquids, hot steam or be found in the technical data.
DANGER
the like. The relay output is not protected /
CAUTION
Provide a free space of 10 mm all overcurrent-limited internally in the
around the device for its ventilation. device. Without suitable protection
The device should be mounted so of the relay output, undesired heat
that the terminals are out of the development or even fire may
reach of the operator and cannot be occur. The relay output must be
touched by him. When mounting the protected externally by the manuf-
device, consider the fact that only acturer of the plant. It must also be
the front side is classified as acces- made sure that, even in case of a
sible for the operator. malfunction, the values stated in the
technical data are under no circum-
1.5 Mounting instructions stances exceeded.
1. Remove the mounting clip from the device.
2. Insert the device from the front into the panel During installation, make sure that the voltage
cut-out, ensuring the front-panel gasket is of the counting and reset inputs and the wiring
correctly seated. of the output contacts are both powered by the
3. Slide the fixing clip from the rear onto the same mains phase, in order not to exceed the
housing, until the spring clamps are under maximum permitted voltage of 250V.
tension and the upper and lower latching lugs
have snapped into place. The cables and their insulation must be desi-
Note: In case of proper installation, IP65 can be gned for the planned temperature and voltage
reached on the front side. ranges. Regarding the type of the cables,
adhere to the applicable country and final device
1.6 Electrical installation standards. The cross sections allowed for the
This device is powered by an internal battery. screw terminals can be found in the technical
data.
The device must be disconnected
from any power supply prior to any Before starting the device, check the cables
installation or maintenance work. for proper wiring and tightening. The screws of
Make sure that no more voltages unused screw terminals must be screwed to the
DANGER
LIABLE TO CAUSE AN ELECTRO- stop, so that they cannot loosen and get lost.
CUTION are present.
Installation or maintenance work
may only be carried out by qualified
personnel and in compliance with
the applicable national and internati-
onal standards.
Take care to separate all extra-low
voltages entering or exiting the
device from hazardous electrical
conductors by means of a double or
reinforced insulation (SELV circuits).
Page 2
The device has been designed for overvoltage 1.8 Start-up
category II. If higher transient voltages cannot • Is the device properly set and programmed
be excluded, additional protection measures (function; max. counting frequency for coun-
must be taken in order to limit the overvoltage to ters)?
the values of CAT II.
1.9 Failure possibilities and causes
Advice on noise immunity Impossible to use the keys:
All connections are protected against external • Key lock input activated
sources of interference. The installation location Counter does not count:
should be chosen so that inductive or capacitive • Wrong or reversed wiring of the counting input
interference does not affect the device or its • Setting of an input signal not matching the
connecting lines! Interference (e.g. from switch- pulse generator.
mode power supplies, motors, clocked control- • No ground connection between the pulse
lers or contactors) can be reduced by means of generator and the counter.
appropriate cable routing and wiring. • Signal levels do not reach the switching
threshold of the counter.
Measures Relay output signal missing:
• Use only shielded cable for signal and control • Output contact short-circuited
lines. Connect cable shield at both ends. Mini- • Output signal (fugitive signal duration) pro-
mum cable conductor cross-section 0.14 mm2. grammed too short
• The shield connection to the equipotential • Relay contact defective due to excessive load
bonding should be as short as possible and • Relay current below min. value
with a contact area as large as possible (low- Displaying noFunc:
impedance). • Battery is unloaded and must be replaced.
• Only connect the shields to the control panel, if
the latter is also earthed. If, despite all, your device still does not operate,
• Install the device as far away as possible from contact your local representative or call us
noise-conducting cables. directly for technical support.
• Avoid routing signal or control cables parallel
to power lines. When sending your device back, please attach
a short description of the failure, of the program-
1.7 Cleaning and maintenance ming and of the connection diagram, in order to
The front side of the unit should only be cleaned allow us to reproduce a possibly existing defect
using a soft damp (water!) cloth. Cleaning of and to repair your device as quickly as possible.
the embedded rear side is not planned and is
the responsibility of the service personnel or of 2. Inputs
the installer. 2.1 Reset input terminal 6
This input is connected functionally in parallel
In normal operation, this device is maintenance- with the red Set key and sets the counter to
free. Should the device nevertheless not ope- zero in case of adding counting and to the pre-
rate properly, it must be sent back to the manuf- set value in case of subtracting counting. The
acturer or to the supplier. Opening and repairing reset function is dynamic.
the device by the user is not allowed and can
adversely affect the original protection level.
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2.2 Counting input (Start input) terminal 5 during this countdown, the device switches back
Input damped to 25 Hz for pulse counting with to the previous operating mode. If the keys are
the pulse preset counter or static start input with released after 0 is reached, parameter setting is
the time preset counter (time counting active activated and the first parameter is displayed.
when input is active, time indicator located on
top left flashes when time counting is active). 4.2 Setting the parameters
The key of the 1st decade allows switching
Note: The reset input (terminal 6) and the coun- among the available parameters (e.g. add-sub)
ting input (terminal 5) are inputs with a common and the key of the 6th decade allows switching
connection (terminal 7) and must be controlled over to the following function. The duration of the
wit the same polarity. fugitive pulse is set using the keys of decades
1-3. After the last input (dP), the key of the 6th
2.3 Key lock input decade allows jumping back to the start of the
Tre front keys (including the set key) are locked programming routine; pressing simultaneously
when this input (terminal 2) is set to +3 VDC the reset key and the keys of the 5th and 6th
(terminal 1). decades allows saving the parameters.
3. Output Note: Every time the programming routine is
Relay with potential-free contact, contact pro- called up, the counter switches back to the
grammable as normally open or normally closed basic parameter setting, i. e. the previous pro-
(terminal 3 and terminal 4). For the adding count, gramming is lost and the counter and preset
the relay is activated when > preset value, for values are reset to zero.
the subtracting count, it is activated when < 0.
The output signal is programmable as a fugitive 4.3 Parameters description
signal between 0.1 and 99.9 seconds or as a (see also the function sequence)
bistable signal with the setting 0.0 (Loop OFF) no Funct.Count: Pulse preset counter operating
automatic repetition. When the relay is active, a mode
colon symbol is displayed on the left end of the Funct.Time: Time preset counter operating
lower row. The output relay shall not exceed a mode
switching frequency of 4 Hz. tMode: Programmable time range (only
for Funct.Time), SEC=seconds,
etting the operating mode and the
4. S Min=minutes, hour=hours
operating parameters Count Add: Adding counting mode
4.1 New installation Count Sub: Subtracting counting mode
In case of a new installation of the counter, after LooP off: Automatic repetition off
a battery replacement that lasted more than 20 When parameter LooP is „off“ and
seconds, or if the counter switched over to the dELAY time is 0.0, the output is
„NoFunc“ safety mode because of a too low activated when the preset value
battery voltage, the preset counter switches is reached and remains activated
until reset is performed.
automatically to the programming mode. All
LooP on: Automatic repetition on
parameters must then be input again (see 4.2).
When parameter „LooP is „on“, the
Parameter modification is also possible during
counter is reset automatically and
operation. For safety reasons, to access the the output emits a fugitive pulse
programming mode, the reset key and the keys for the time of the duration set in
of the 5th and 6th decades must be pressed dELAY.
simultaneously. The lower display line then dis- rELAY no: Normally open contact
plays the message INIT. If these 3 keys remain rELAY nc: Normally closed contact
pressed, a countdown from 5 to 0 takes place dELAY: Output signal duration: fugitive
in one-second intervals. If the keys are released signal programmable from 0.01
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– 99.9 seconds, 0.0 = bistable allows preventing malfunctions. After battery
output (active until reset) program- replacement in „noFunc“ mode, the device
mable only for Loop off, in case of requires re-parameterizing. Please read chapter
Loop on, 0.0 is set automaticaly to Battery replacement to that purpose.
1.0 second.
dP: Programmable decimal point: Note: In order to avoid loosing the
pulse preset counter: 0 - 0.00000 settings and values because of
only for display purposes, switching to Safe Mode, the service
time preset counter 0 – 0.0 plan of the device should include
(seconds) 0 – 0.00 (minutes, timely battery replacement in func-
hours) determines the resolution. tion of the ambient temperature and
If the relay output is switched from of the switching cycles of the relay.
„no“ to „nc“, the relay condition
must be taken over by pressing 5.5 Battery replacement
the reset key. Before replacing the batteries, disconnect the
voltages or switch the device off. Disconnect
5. Operating the counter the connector from the device. This also makes
5.1 Setting or resetting sure that no untimely pulses set the device in
The red set key or a pulse on the reset input an undefined state during battery replacement.
sets the counter to zero in adding mode and to Then push the battery lid backwards and remo-
the preset value in subtracting mode. ve the 2 batteries. Position the new batteries
so that the „-“ pole is connected to the battery
5.2 Preset setting holder marked with „-“ on the printed circuit.
The preset value is displayed in the lower dis- After battery replacement, the display may go
play line. Setting is carried out with the 6 preset on displaying the LowBat message for 2 more
keys, each assigned to a decade. The set or minutes. Pressing the reset key can shorten this
modified preset value is taken over at the sub- delay, as the device checks the current battery
sequent setting or resetting of the counter. voltage every time this key is pressed. However,
this also resets the current counter value.
5.3 Overflow or underflow
In adding mode, overflow passes from 999999 Important: If battery replacement
to zero, in subtracting mode from zero to lasts longer than 20 seconds, the
999999. The output signal remains unchanged. parameters, the preset value and
The display flashes in case of overflow or the current counter value can be
underflow. The counter stops after the overflow erased. In order to prevent this loss
or underflow of an additional decade. of information, we strongly recom-
mend replacing the batteries one
5.4 Lo-Bat indicator after the other.
In case of a too low battery load, the message
Lo-bat is diaplayed and the display flashes. Only use the batteries described in the Techni-
The batteries must be replaced when „Lo-bat“ cal Data. Otherwise, proper operation cannot be
is displayed. If the battery voltage decreases in guaranteed.
such a way that safe relay switching cannot be
ensured any more, the counter switches to Safe
Mode and displays the message „noFunc“. In
this mode, the device does not count any more
pulses or times, and the relay remains in its
last position. Thys way, the user knows exactly
whether the plant is operating optimally, which
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5.6 Segments test 7. Connection example
Segments test is activated by pressing simul-
taneously the reset key and the keys of the Device type:
5th and 6th decades. Init 5 is then displayed; KAT-SP
release immediately the keys, the segment test 12 ... 250 VAC/VDC
is started and all display segments are displa-
yed. Pressing the 1st decade key calls up the V AC/DC Key lock
programming mode; all parameters must then
be re-programmed.
Count/
Start
6. Terminal assignment
Reset
Device type:
KAT-SPS
Switch Closure/NPN
Key lock
Terminal
no.
1 +3 VDC for key lock on terminal 2
2 Key lock input
Count/ Reset
3 Relay contact Start
4 Relay contact
AC/DC optocoupler counting input / 8. Factory programming:
5 start input (.820) / NPN counting input Function(Funct): counter(Count)
/ start input (.850) Counting mode(Count): adding(add)
AC/DC optocoupler reset input (.820) Auto. repetition(LooP): none(oFF)
6 Output contact(rELAY): normally open
/ NPN reset input (.850)
Output signal duration(dELAY):
Common AC/DC input (.820) / 0V bistable output(0.0)
7
input (.850) for terminals 6 and 5 Decimal point(dP): none(0)
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9. Interference suppression measures Application area: Pollution level 2
The following interference suppression Insulation
measures may be required: if the output swit- Front side: Double /
ches inductive loads (relays, solenid valves), reinforced insulation
interferences must be suppressed by means of Relay: Basic insulation
a freewheeling diode for direct current and of UL approval: File no.: E128604
an RC element for alternating current. For safe
and EMC-compliant operation, use shielded 10.3 Mechanical data
cables for the control inputs (counting, reset and Protection level: IP65 (font side)
key lock inputs). The shield must be connected Weight: appr. 80 g
at both ends. If this is not possible, a capacitor
(e.g. 10 nf) may be integrated on one side in the 10.4 Inputs
shield connection. Inputs: Reset, counting and key
lock inputs
10. Technical data Input polarity
10.1 General technical data (for reset and counting/start inputs):
Display: 2-line LCD display, each 12 ... 250 V AC/DC: bidirectional optocoupler
with 6 decades 999999; input
height 7 resp. 4,5 mm NPN: NPN input activated by
Operating temperature: -20°C ... +65°C transistor or contact
(not condensing) Key lock input: is switched to +3 V DC
Storage temperature: -25°C ... +70°C (terminal 1)
Altitude: up to 2000 m Min. input pulse duration:
Reset input: 50 ms
10.2 Electrical data Key lock input: 15 ms
Voltage supply: 2 replaceable lithium Input switching level:
batteries type 1/2 AA 12 ... 250 V AC/DC: LOW: < 1 V AC/DC
Lithium 3.6 V HIGH: 12...250 V AC/DC
Data backup: min. 8 years for 5 x 106 NPN: LOW: 0 ... 0,8 V DC
output relay switching HIGH: 2.5 ... 30 V DC
cycles and 25°C opera- Input frequency
ting temperature Pulse counter: max. 30 Hz
EMC Time counter: Measuring pulses
Interference emission: EN 55011 Class B < 200 ms are not
Interference immunity: EN 61000-6-2, measured accurately
EN 61326-1 Accuracy: System error
Device safety +/- 100 ms per
Designed to: EN 61010 measuring pulse
Protection class: 2 (front side) Time accuracy: 200 ppm
Input resistance: 110 kΩ
Only the front side is classified as
accessible for the operator.
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10.5 Outputs
Outputs: bistable relay with poten-
tial-free contact – pro-
grammable as normally
open or normally closed
Max. switching voltage:250 V AC / 30 V DC
Max. switching current: 2 A
Max. switching capacity:
60 VA / 30 W
Mechanical service life:1x107
Electrical service life: 5x105 (1A 30Vdc)
Output response time: < 20 ms, max. 4 Hz
Insulation coordination: Basic insulation
UL ratings: 2A, 30Vdc, 50°C
10.6 Fuses / overcurrent limitations
Input signals: In case of a failure, the current
must be limited to a safe value via the inputs.
We recommand a 0.1A/T fuse.
Relay: The maximum switching current of 2A
shall in no case be exceeded.
10.7 Connections
7 plug-in screw terminals, pitch 5.08, cable
cross section max. 2.5 mm.
10.8 Insulation coordination
Connections among each other
KAT-SP: only the counting and reset inputs
have double / reinforced insulation
KATS-SPS: generally only basic insulation
10.9 Consumables
Battery: order code: N060045 Tadiran Lithium
SL350/S ½ AA 3.6V 1.2Ah
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11. Programming menu
Funktionsablauf
Press Reset
key together
with
5 + 6 button change battery
count down <20s
with 1sec clock timefor
<5s <1s batterychange
>20s
Init 5 Init 4,3,2, 1 Init 0
=5s
8.8.8.8.8.8 Operating
Segmenttest : 8.8.8.8.8.8 1 Mode
Funct. Funct.
1
Count tImE
6 tModE select one
1
hour, Min, SEC value
Count select one Count select one
1 1
Add, Sub value Add, Sub value
6 6
LooP select one LooP select one
1 1
oFF;on value oFF;on value
6 6
rELAY select one rELAY select one
1 1
no, nc value no, nc value
6 6
1 1
dELAY to change dELAY 2 to change
2
01.0 value 01.0 value
3 3
6 6
dP dP
0, 0.0, 0.00, 0.000, 1 select one SEC: 0, 0.0 1 select one
0.0000, 0.00000 value hour+Min: 0, 0.0, 0.00 value
6 6
PressResetkey
togetherwith
5+6button
SAVE
1-2 Sec
Operating
Mode
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12. Dimensions 13. Scope of the delivery
Dimensions in mm [inch] Counter KALtrol-SP
2 lithium batteries
1 plug-in screw terminal
1 front bezel for screw mounting, installation
cross-section 50 x 50 mm
1 front bezel for clip mounting, installation cross-
section 50 x 50 mm
1 mounting clip
1 template for front panel cut-out
1 operating instructions manual
14. Order code
KAT-SP = 12 … 250 V AC/DC inputs
KAT-SPS = Switch Closure/NPN inputs
15. Battery ordinance
This device includes lithium batte-
ries. In compliance with the Battery
Ordinance, we want to point out the
following:
Batteries shall not be disposed of in the residual
waste; you are obliged by law to return them. You
can send the complete devices back to us after
use. If you can remove the batteries properly, you
can also dispose of them at a municipal collection
point or at a retailer collecting batteries.
Specific provisions on the return of lithium
batteries:
Avoid short-circuits! Protect the poles of the
battery with insulating adhesive tape. The poles
of a lithium battery shall not come in contact
with metal objects, neither by accident nor inten-
tionally !
Pollutant-containing batteries bear a symbol
made of a crossed-out bin and the chemical
symbol of the heavy metal that determines their
classification as containing pollutants. Thank you
for your help!
Contact: Kessler-Ellis Products TEL: 732-935-1320 Web:www.kep.com
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