Operating Instructions DV04 - PKP Prozessmesstechnik GmbH
Contents
1. rows s 5 5 s mw 3 9 9 m ao _ 6 ve a 2 pes 7 in Kg Design S and X Connection Dimensions pn P N Pd 6 1 AM op i En p EN p ON PON DV04 B 2 SAM 15 09 05 Page 12 Connection flanges cast iron Weig B 1 e pvo42 pvoa4 18 85 90 35 65 76 7 11 7 70 40 20 65 mo 17 07 25 638 13 wa Le el Oe e was 29 lioli so n 7 2 ss ws vs oz gt ain is sowas ao 120 65 so 7 u s 12 ws 1 e a is sowas u _ 6s nao 15 a5 5 50 25 iz 1 e is in kg View X DV04 B 2 SAM 15 09 05 Page 13 DV04 B 2 SAM 15 09 05 Page 14 Flow Measurement and Monitoring 0104 High precision Gearwheel flow meter for viscous liquids e For fluids with viscosities of at least 20 cSt e Very cost effective e Cast iron or stainless steel designs available e Accuracy better than 0 3 of measured value e High resolution e Pressure proof construction withstands up to 400 bar e Small inst2. If high humidity or other unfavorable aggressive polluted ambient conditions are expected to be encountered during transport appropriate steps must be taken to prevent corrosion of the gearwheel flow meter DV04 B 2 SAM 1850905 Pageh Caution When applying an anti corrosion treatment first check to be sure that the material to be used 1s compatible with the elastomers used in the construction of the gearwheel flow meter and will not harm them You should also check that the material used 1s compatible with the fluid flowing through the flow meter 7 Mechanical Installation Depending on the installation the device is connected to the system by means of a connection plate or pipe connections in its housing Caution Only piping and connections that are approved for the expected pressure range may be used The specifications of the respective manufacturer must be followed The device must be installed so that it is not subject to excessive vibration Installation above hot parts is not allowable since liquids that could possibly leak from the device may then be ignited When being placed in operation the device must be checked for leaks under normal operating conditions Connection Plate Before installing the gearwheel flow meter carefully clean the piping system Then mount the connection plate at the prescribed location in the system Caution Make sure that the gaskets are seated properly The joint surface must be free of dirt and
3. PKP Prozessmesstechnik GmbH Borsigstrasse 24 D 65205 Wiesbaden Nordenstadt Tel 06122 7055 0 Fax 06122 7055 50 Operating Instructions DV04 High precision Gearwheel flow meter for viscous liquids Contents 1 Introduction 2 Safety Information 3 Functional Description and Design 4 Special Conditions 5 Installation and Removal of the Gearwheel Flow Meter 6 Corrosion Protection 7 Mechanical Installation 9 Electrical Connection 9 Maintenance and Cleaning 10 Returning 11 Disposal 12 Troubleshooting 10 13 Dimensions 11 13 14 Specification See data sheet in the appendix lt lt Introduction Series DV04 gearwheel flow meters are noted for their reliable function and easy operation To obtain the greatest benefit from this device please observe the following cautionary Statement Persons who are responsible for setting up or operating this device must be sure to read the and understand the operating instructions and the safety information pertaining to it 2 Safety Information 2 1 General Instructions To ensure safe operation the device must only be operated according to the information in the operating instructions When the device is 1n use the regulations and safety standards applicable to the specific application must also be observed This statement also applies to the use of accessories 2 2 Proper Usage Series DV04 gearwheel flow meters are designed for
4. 49 0 6122 7055 0 49 0 6122 7055 50 Email info pkp de Internet www pkp de Designs table 1 Depending on application and medium properties the DV04 is available in 8 different model ranges Minimum Accuracy Medium properties viskosity of mea mm s sured value Lubricity 66640 good average Stainless steel 0 5 0 04 2 3 Stainless steel 20 0 3 low 1 4404 Stainless steel 20 1 1 4404 average O lo i EARLE Bude 1 2 bearing bronze Hard alloy Hard alloy Hybrid Hybrid ball ball sleeve sleeve sleeve PaA ball ball Type bearing bearing bearing bearing bearing bearing bearing bearing overs eas E Leg a G 3 4 G 3 4 oi jer or for Measuring ranges in l min table 3 IO a Se Range 2 4 5 fost warbssweosswe osto ves 1280 vw vo be Parameters table 4 0 04 4 0 16 16 0 16 16 0 16 16 0 16 16 0 16 1610 16 1610 16 16 Peak Sound pressure Resolution pressure pressure level impulses bar bar dB A 04042 40 000 0043 25 000 00444 4 081 63 PKP Prozessmesstechnik GmbH BorsigstraBe 24 D 65205 Wiesbaden 49 0 6122 7055 0 49 0 6122 7055 50 Ema
5. 1 15 P 09 W P 0 3 W short circuit proof Prerequisite A 24V DC line 20 must be provided to supply power to the pre amplifier The terminal assignment for channel or 2 has an influence on the displayed direction of rotation of the gearwheels and thus on the preceding sign or that 15 used when displaying the measured volumetric flow rate on the evaluation device DV04 B 2 SAM 15 09 05 Page 6 0 Volt Securing screw for connector Channel 2 Sensing element for channel 2 Cable gland Channel 1 Sensing element for channel 1 24 Volt Caution After assembly the mounting screw slightly and the cable gland nut must be tightened 9 Maintenance and Cleanin Gearwheel flow meters are generally maintenance free However if fluids that can leave deposits flow through the device cleaning may be necessary Otherwise the device can be cleaned with the rest of the system during the standard cleaning procedure Indications of wear may be evident by a change in measuring accuracy It is recommended the device be inspected regularly Caution If fluids harden in the gearwheel flow meter it must be cleaned as quickly as possible with suitable cleaning agents The mounting screws must be regularly checked for tightness If necessary retighten them in such case observe the tightening torque specified in the section Installation and Removal of the Gearwheel Flow Meter Caution B
6. paint residue Place the housing on the connection plate so that the mounting holes are in alignment Fasten the housing to the connection plate with the screws and tighten them down Caution The mounting screws for the DV04 mountings plate must be tightened crossways Be sure to apply the correct amount of torque Installation on connection plates not supplied with the device on valve manifolds Be sure to observe the specified values for surface flatness and surface roughness DV042 6 DVO4 7 Surface roughness R 1 1000 mm Surface flatness 1 1000 mm In this case the gearwheel flow meter must also be installed as described above DV04 B 2 SAM 15 09 05 Page 5 Pipe Connection Before installing the gearwheel flow meter completely clean the piping system Connect the piping to the inlet and outlet of the measuring device Be sure to observe the specifications of the respective manufacturer During installation be sure than no sealant gets inside the piping system Caution The gearwheel flow meter must not be subjected to excessive mechanical stress during installation After gearwheel flow meter is installed and the piping system 15 placed back in service check all connections for leakage 8 Electrical Connection Number of measuring channels Operating voltage U 24 V DC 20 protected against polarity reversal Pulse amplitude gt 0 8 U Pulse from with symmetric output signal channel 1
7. allation dimensions Description The measuring mechanism in the DVOA flow meter consists of a pair of gearwheels that are driven by the fluid stream much like a gearwheel pump The measuring mechanism is supported by sleeve bearings or ball bearings Two anti magnetic sensors with a relative phase offset of 90 and hermetically isolated from the measuring chamber sense the movement of the gear wheels This two channel sensing system used with appropriate electronics permits a higher measurement resolution as well as detection of flow direc tion All flow meters are optionally available in a explosion proof design with a separate switching amplifier The DV04 gearwheel flow meter features very low resistance to flow and particularly low sound pressure levels e PKP Process Instruments Inc 10 Brent Drive Hudson 01749 4 1 978 212 0006 4 1 978 568 0060 Email info pkp eu Internet www pkp eu Applications Their outstanding measuring accuracy and high resolution make these devices particularly suitable for use in test stands when measuring small and very small flow volumes Other areas of application e Measuring consumption rates e Controlling and regulating filling processes e Dosing of oils and chemicals e Flow measurement of paints and varnishes e Controlling the ratio of polyalcohol polyhydroxy alcohol and isocyanate PKP Prozessmesstechnik GmbH 10 11 BorsigstraBe 24 D 65205 Wiesbaden
8. e sure to relieve the pressure in the piping before performing any work on the gearwheel flow meter or removing it The gaskets in the joints between the gearwheel meter and the piping system must be checked regularly for leakage DV04 B 2 SAM 15 09 05 Page 7 Cleaning Devices series 1 2 6 7 and 8 These devices must never be opened by the customer They must only be opened by trained service personnel because only such specialists can reassemble them properly so that they will function correctly Devices 1n series 3 4 and 5 If due care 15 used these devices may be opened and cleaned by the customer Caution Be sure to relieve the pressure in the piping and ensure that the electrical supply 15 de energized before opening and cleaning the device The device and the piping may still contain the transported fluid or a cleaning agent All guidelines governing the handling of the fluid that was last sent through the system must be followed Before opening the system make sure that containers of sufficient capacities are available to catch any escaping fluid If necessary the work area must also be sufficiently ventilated Removing the gearwheel flow meter see section Installation and Removal of the Gearwheel Flow Meter Drain the measuring device Loosen the screws that hold the two halves of the housing together bolts The 4 or 8 internal hexagon drive screws Allen screws are accessible from the bottom of the hous
9. er cable and fuses Immediately remove the gearwheel flow meter from operation Return devices in series 1 2 6 7 and 8 to the manufacturer for repair Devices in series 3 4 and 5 may be disassembled and cleaned see Maintenance Return devices in series 1 2 6 7 and 8 to the manufacturer for repair and request advice on the specific application Check devices in series 3 4 and 5 for seal compatibility with the particular fluid being transported If necessary contact the manufacturer and install a new gasket set can be ordered from the manufacturer Check seal compatibility install new O rings Check measuring device or return to the manufacturer for repair Page 10 Dimensions series 1 2 3 4 7 Moat wae a 68 KT Power is as 0 o 20 os 2 o 20 os esp e spepspw am m e s pw was x sm s a 6 Dwar o res is ae 5 ws we ass 2m 25 12 amp us amp in Kg Design S and Design H Connection Dimensions DV04 B 2 SAM 15 09 05 Page 11 Dimensions series 5 6 8 stainless steel version Wee
10. il info pkp de Internet www pkp de Model coding Order number 0 04 3 1 PS 10 5 10 Gearwheel flow meter Measuring ranges 2 9 as per table Series 1 8 as per table 1 Seal F Viton E EPDM P PTFE Kalrez Connection PS with mounting plate connection at the side PU with mounting plate connection at bottom R without mounting plate connection at the side model ranges 5 6 8 only Process connection see table 2 04 G 1 8 IG 05 G 1 4 IG 10 G 3 8 IG 15 G 1 2 IG 20 G 3 4 IG 25 GIG 40 2 G 1 1 21G Electronics S Standard H1 High temperature design up to 150 C H2 High temperature design up to 220 C FEP Gasket and clamp connection Intrinsically safe with separate switching amplifier EEx ia Special features 0 None 1 Please specify in writing Technical details 20 to 100000 mm s depends on viscosity and load on the device exact values available upon request Viscosity range Pressure loss Temperature range Standard design 30 120 C High temperature design 30 150 C Materials Series 1 4 7 housing GGG 40 GGG60 0 04 9 04 10 Measuring mechanism 1 7139 Series 5 6 8 housing stainless steel 1 4404 Measuring mechanism stainless steel 1 4462 Electronics Standard 2 sensors 90 phase offset Ex design with separate switching amplifier Supply vo
11. ing Caution When removing the upper half of the gearwheel flow meter do not pry the halves apart at the joint with screwdrivers or similar tools The gearwheels must not be removed from the housing with pliers or similar tools Cleanthe interior of the housing the gearwheels and the bearings with a suitable cleaning agent Insert both gearwheels with the bearings in the lower housing Position the o ring in the grooved seat in the housing Place the upper part of the housing on the bottom part insert the locating pins Insert the screws and snug them down crossways Then tighten them crossways to the specified torque see below Caution All parts being assembled must be free of dirt and deposits During installation of the gearwheel flow meter make sure that no foreign objects enter the assembly Nominal Size DV04 DVO4 DV04 DVO4 DV04 DVOA DVO4 DV04 2 3 4 5 6 7 8 9 120 120 290 Install the housing again in the system as described in the section Installation and Removal of the Gearwheel Flow DV04 B 2 SAM 15 09 05 Page 8 10 Returning If service or repair to the device is necessary or if the device needs to be inspected at the factory it must be suitably packed for shipment Furthermore the device must be accompanied by a material safety data sheet indicating the fluid that was used in it In the case of common mineral oils an exact type designation 1s required Cauti
12. ltage 12 30 VDC Protected against polarity reversal Square wave pulse minimum 0 8 UB Scanning ratio 1 1 15 Protection type IP 65 Output signal PKP Process Instruments Inc Ex 10 Brent Drive Hudson MA 01749 gt 1 978 212 0006 1 978 568 0060 Email info pkp eu Internet www pkp eu
13. nsor 5 Device connector 9 O ring DV04 B 2 SAM 15 09 05 Page 3 4 Special Conditions Special conditions and or limitations apply to the safe application of gearwheel flow meters in the approved operating environment These conditions and or limitations must be met by the customer and or system operator by means of appropriate technical and or organizational measures Gearwheel flow meters must only be operated in the specified environment and under the specified ambient conditions Gearwheel flow meters must only be used if the materials used in their construction are resistant to mechanical and or chemical influences or corrosion under the given service conditions The fluid must at least have minimum lubricating properties lubricity Gearwheel flow meters are intended for use with liquids Dry operation is not approved Operation outside of the specified parameters is not allowed If necessary a filter must be installed to prevent the gearwheel from being blocked by foreign objects The specified installation service and maintenance schedules must be strictly followed Gearwheel flow meters must only be used in closed operation and not be subject to excessive vibration Only genuine spare parts must be used for service and maintenance 5 Installation and Removal the Gearwheel Flow Meter This gearwheel flow meter was thoroughly tested and checked at the factory before shipment It will be full
14. on If the device was used with fluids whose residues will become hard or sticky it must be rinsed out before being returned 11 Disposal The device packing material as well as used devices and device parts must be disposed of in accordance with applicable regulations of the country in which the device 1s installed DV04 B 2 SAM 15 09 05 Page 9 12 Troubleshooting _____ Posibecame Remedy ____ The two LED displays on the isolating switch amplifier are illuminated but incorrect values displayed One of the LED displays does not illuminate during operation The two LED displays do not illuminate during operation Leakage fluid leak Reduced measuring accuracy DV04 B 2 SAM The connection between gearwheel flow meter and evaluation device is faulty The wiring between the sensor and the circuit board or individual soldered points on the circuit board are damaged No voltage supply present Since it 15 unlikely that both sensors will fail at the same time it should then be assumed that the measuring mechanism has stopped for some reason O ring in housing defective allowing leakage O ring between gearwheel flow meter and connection plate defective allowing leakage Device wear 15 09 05 Check the connection and if necessary replace the cable or plug connector Return the measuring device to the manufacturer for repair The associated sensor is faulty MEM Check the pow
15. the continuous measurement of the flow of low viscous fluids Any application extending beyond this specific intended use does not constitute proper usage series DV04 must not be employed as the sole means of avoiding hazardous conditions in machinery and installations The machinery and installations must be designed in such a manner that faulty conditions and malfunctions will not present hazardous situations for operating personnel DV04 B 2 SAM 15 09 05 Page 2 2 3 Qualified Personnel Series DV04 must only be used by qualified knowledgeable personnel trained in correct use of these devices Qualified personnel are those persons familiar with setting up and assembling these devices placing them in service and operating them In addition such personnel must also be qualified to perform the work associated with the application for which the device is being used 3 Functional Description and Design Within the DV04 there two gearwheels that are supported in low friction bearings During operation the gearwheels are driven by the flowing liquid The movement of the gearwheels is sensed by two non contact sensors located in the cover and converted into electrical signals Between the sensor area and the measuring chamber there is a pressure resistant antimagnetic separator The signals are transmitted to the connected display device 1 Cover i 2 Housing Cu 3 Gearwheel i 4 Journal 5 Bearing 6 Anti magnetic separator 7 Se
16. y functional and immediately ready for use after it has been installed in position and the electrical lines have been connected The space required by the installed device 15 specified in the Dimensions section Once installed the measuring device should also be accessible for safe visual inspection at any time Caution To prevent possible damage to the gearwheel flow meter a pressure regulating device must be present in the installation to prevent the maximum permissible pressure from being exceeded in the volume sensor or other parts of the installation pressure limiting valves During transport and installation the gearwheel flow meter must only be held by its housing must never be suspended from the plugged in connector 6 Corrosion Protection All gearwheel flow meters are checked for proper function at the factory with mineral based hydraulic oil Following testing the connections are sealed with plugs so that the internal parts are protected against corrosion for a moderate amount of time During transport and storage gearwheel flow meters must not be exposed to the harmful effects of ambient weather conditions and great variations in temperature They must be stored under dry conditions If a gearwheel flow meter is to be stored for a longer period of time both its interior and exterior must be protected by application of a suitable anti corrosion oil In addition it must be protected from humidity by means of a desiccant material
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