Operating manual
Flow monitor for use in
railway vehicles
UB1, UBX, CRH
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www.ghm-group.de
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1
Operating manual
Flow monitor for use in rail vehicles: UB1, UBX, CRH
Table of contents
1 General safety instructions, use ........................................................................................ 2
1.1 Safety signs and symbols .............................................................................................. 2
1.2 Safety instructions ......................................................................................................... 2
1.3 Product liability and warranty ......................................................................................... 2
1.4 Standards and directives ............................................................................................... 2
2 Product description ............................................................................................................ 2
2.1 Paddle / folding bellows principle .................................................................................. 3
2.2 Scope of delivery ........................................................................................................... 3
3 Configuration of the devices UB1, UBX and CRH ............................................................. 3
3.1 Intended use .................................................................................................................. 3
4 Assembly and installation .................................................................................................. 4
4.1 Mechanical assembly .................................................................................................... 4
4.2 Electrical installation ...................................................................................................... 5
4.3 Electrical connection PG/cable screw fitting .................................................................. 5
4.4 Contact protection measures for devices with switches ................................................ 5
5 Controls and functions ....................................................................................................... 6
5.1 Function/adjustment ...................................................................................................... 6
6 Commissioning, operation and maintenance..................................................................... 7
6.1 Commissioning .............................................................................................................. 7
6.2 Operation ....................................................................................................................... 7
6.3 Maintenance .................................................................................................................. 7
7 Technical data ................................................................................................................... 8
8 Accessories ....................................................................................................................... 8
9 Device transport and storage ............................................................................................ 8
10 Return to manufacturer .................................................................................................. 8
11 Disposal ................................................................ ................................ ......................... 8
12 Imprint ............................................................................................................................ 8
2
This operating manual must be kept in a location where it is available for reference at all times.
Any processes described in this operating manual may only be carried out by trained, qualified
personnel who are authorised by the owner and wearing protective clothing.
1.1 Safety signs and symbols
Danger signs and symbols are identified as described below for this operating manual:
1.2 Safety instructions
1.3 Product liability and warranty
This operating manual includes the instructions to install and operate the device safely in the intended
manner. If difficulties which cannot be resolved using the operating manual and the product
information arise, enquire with the manufacturer for further information. The manufacturer reserves
the right to technical changes and improvements. Appropriate qualification of the user is prerequisite
for use of this operating manual. The operating personnel must be instructed according to the
operating manual.
1.4 Standards and directives1
DIN EN 60947-5-1
Low-Voltage Directive 2014/35/EU
RoHS Directive 2011/65/EU
It is often necessary to ensure the provision of a minimum supply of lubricant or coolant, etc. for an
application.
It is often necessary to ensure the provision of a minimum supply of lubricant or coolant, etc. for an
application.
A flow volume can be monitored with the flow monitors UB1, UBX and CRH. A change to the flow
volume causes a status change of the microswitch (electrical component). A minimum supply
safeguard can be achieved as the flow rate decreases. It is also possible to monitor increasing flow
values.2
1
The listed standards and directives apply for products with an electrical connection.
2
If nothing different has been indicated, the switching points specified in the product information or during
adjustment always apply for falling volume flow (minimum supply safeguard).
1 General safety instructions, use
Warning! This symbol warns of imminent danger which can result in death, severe bodily
injury or severe property damage in case of non-observance.
Attention! This symbol warns of potential dangers or harmful situations which can cause
damage to the device or to the environment in case of non-observance.
Note! This symbol indicates processes which can have a direct influence on operation or
can trigger an unforeseen reaction in case of non-observance.
Table 1
Read the product information before commissioning the device. Ensure that there are no
limitations for use of the product for the relevant application.
The owner is responsible for ensuring the fault-free operation of the device. The owner is
obligated to ensure compliance and to observe the required work and safety measures
of the current applicable regulations for the entire duration of use.
2 Product description
3
2.1 Paddle / folding bellows principle
The UB1, UBX and CRH flow monitors work according to the baffle
plate (paddle) - folding bellows principle (Fig. 1). The medium flowing
through the pipeline moves the paddle against a spring force in the
flow direction. The electrical switching unit (switching head) is
hermetically sealed from the medium by a metallic folding bellows
(Pos. 2). The paddle bar moves the lever of a microswitch (Pos. 1) in
the switch head. The switching takes place with a pre-defined flow rate
depending on the pipeline cross-section which is used.
2.2 Scope of delivery3
An operating manual and the relevant product information are included with the device.
The devices are provided with thread plugs or protective bags to prevent transport damage.
If the paddle is already mounted, it is protected with a protective tube.
3.1 Intended use
3
A different circuit diagram can accompany special devices.
3 Configuration of the devices UB1, UBX and CRH
The flow monitor detects the volume flow in fluid media and actuates the microswitch
according to the flow rate. The device must be used exclusively for the media specified
in the product information.
The device is not designed for operation with gaseous media. This product is intended
for use in machines and systems and for use of media of Fluid Group II in accordance
with Directive 2014/68/EU. The product does not fall under Directive 2014/68/EU and
does not receive a CE mark as specified in this Directive. The specified limit values must
never be exceeded (refer to the product information for the technical data).
Figure 1: Schematic diagram
1
2
Switch head housing
Electrical connection
Process thread
Paddle
Figure 2: Schematic diagram for the devices UBX and CRH
4
4.1 Mechanical assembly
Use suitable measures to prevent the medium from freezing. If the device is exposed to an
environmental temperature below 4°C, operation must never take place with pure water. Water
remaining in the device could cause frost damage.
Observe the permissible installation position indicated in the product information.
The device must not be used as a fixed point (step/climbing aid).
The process-side connection flange/thread must match the device dimensions.
A filter should be used in heavily contaminated media. Dirty media will impair the function of the
device.
The inflow and outflow line (upstream and downstream form the device) should ideally be 10 x
DN, but at least4 5 x DN.
The maximum permissible volume flow (Qmax) should not be exceeded; otherwise, increased
wear will occur.
Do not exceed the operating pressure specified in the product information and do not
undercut/exceed the specified temperature range.
Observe operating pressure, pressure stage and temperature range.
Compensators must be used to account for thermal expansion of the
pipelines.
It must also be ensured that
the paddle does not strike against the pipe wall and can move freely,
the paddle bar does not strike against the inside of the process connections,
the device and all O-rings should be disassembled for soldering/welding of
process connections in order to prevent damage,
the device can be installed horizontally or vertically (see product
information). The installation position has an influence on the switching point
due to the mass of the paddle elements.
With use of the UB1 in a pipe with diameter DN 25, the paddle (Fig. 3) must
be shortened at the identified dividing line (Pos. 1).
The paddle is fastened with the supplied screws. With continuously
heavily fluctuating flow rates, we recommend using liquid thread lock
(ensure that it is resistant to the media).
The flow direction is indicated by an arrow on the devices. The arrow
points in the flow direction. In order to achieve high precision of the
switching point, the paddle surface must be aligned at an angle of
90° to the flow. This can be achieved by aligning the long edge of the
switch head housing / switching unit parallel to the pipe during
assembly.5
The alignment of the UB1/UBX can be adjusted after it is installed in
the process connection. For this purpose, loosen the threaded pin
with an Allen key (Pos. 1) until the device can be rotated freely
(clockwise/anticlockwise) in the connection fitting (Fig. 4). Re-tighten
the threaded pin with an Allen key (Pos. 1) when the desired position
is reached (torque = 0.8 Nm).
4
See product information.
5
Observe the installation recommendation in the product information.
4 Assembly and installation
In order to guarantee fault-free use of our devices, the following must be observed for
assembly and installation:
Figure 3
Figure 4
1
5
4.2 Electrical installation
The circuit diagram must be used as the basis for the wiring of the device.6
With connection of a switch, a consumer must be connected in series.
The electrical details for switches apply to ohmic loads. Capacitive and inductive loads should be
operated using a protective circuit (see 4.5).
Always de-energise the electrical system before installing the connecting cable!
4.3 Electrical connection PG/cable screw fitting
Unscrew the union nut Pos. 2.
Guide the connecting cable Pos. 1 through the union nut Pos. 2, the moulded seal Pos. 3 and the
intermediate support Pos. 4 (Fig. 10).
Connect the connecting line to the terminal contacts according to the circuit diagram.
Re-tighten the union nut Pos. 2.
4.4 Contact protection measures for devices with switches
Current or voltage peaks can influence the service life of the contacts with capacitive and inductive
loads or the switching of filament bulbs. A suppressor circuit should be used in these cases in order to
achieve a maximum service live or prevent damage to the contacts.
Contact protection with inductive load.
A break-off spark (electric arc) is generated when an electrical contact is opened. There are two
ordinary protective circuits for reduction of the self-induction voltage:
With AC voltage, the Reed switch is protected with an R-C link.
With an inductive load and DC voltage, the Reed switch can be protected with a recovery diode
(e.g. 1N4007).
Contact protection with capacitive load.
Capacitive loads are predominantly generated due to long cables (>50m). In order to counteract the
loads, connection of a resistance in series is frequently adequate. The resistance value should
correspond approximately to the voltage value (e.g. 24 V = 24 Ω).
Contact protection with a lamp load.
In order to circumvent the problem, we recommend using LEDs, etc. instead of filament bulbs.
6
The circuit diagram is included with the device or provided in the corresponding product information.
The device must be installed by an electrician only. Compliance with the national and
international regulations for installation of electrical and electronic systems applicable in
the respective country of use is mandatory.
The resistance of a filament in the cold state is approximately one tenth of the resistance
in the glowing state. The result is 10-fold activation current, even if temporarily, when
switched on.
1 2 3
4
Figure 10: PG / cable screw fitting connection
6
5.1 Function/adjustment
The switching point can be adjusted by adjusting the microswitch and changing the paddle length.
Please refer to the product information for the number of paddles in use. The specification 'Paddle
1,2' indicates that both Paddle 1 and Paddle 2 are used9. Similar to a leaf spring, Paddle 1 supports
Paddle 2, Paddle 2 supports Paddle 3, etc. In the case 'Paddle 1,2', both paddles are installed such
that the larger paddle is arranged in the direction of the inflow and the small paddle is arranged in the
direction of the outflow. With paddle combinations 1, 2, 3 and 1, 2, 3, 4, please proceed accordingly10.
Fine-tuning of the switching point can be carried out by adjusting the microswitch. The desired
switching value can be adjusted with an adjusting screw after removal of the housing cover for the
devices UB1, UBX and CRH (Fig. 11 and 12). For the device UB1 (Fig. 13) unscrew the Allen screw
(Pos. 1). Slide the switching unit (Pos. 2) until the desired switching point is reached. Re-tighten the
Allen screw (Pos. 1). Replace the cover.
7
Observe the notices of the accompanying product information for assembly of the process connections.
8
See section 7 Accessories.
9
'Paddle 1' identifies the smallest paddle; 'Paddle 4' identifies the largest.
10
For additional information about the paddles, refer to the product information.
5 Controls and functions
Our devices can be adapted to various process connections7. The flange connection is
available as an accessory8. Various control and adjustment options are available
depending on the application.
2
1
Figure 12: CRH/CRE
Figure 13: UB1/UBX
Adjustment
screw
7
6.1 Commissioning
If provided, the transport lock must be removed.
When protective caps are provided, they must be removed immediately before installation.
Flush the pipe system in order to eliminate contamination prior to assembly.
Observe the flow direction. This is normally indicated on the device with an arrow and must run
parallel to the pipe axis after installation.
Seal the device correctly during installation.
Observe that the switching point / display value can change with a fluctuating media viscosity.
The media resistance must be checked when the device is used with aggressive media.
A change of the medium and/or its composition can result in an incorrect display and/or incorrect
switching point.
In order to avoid heavy pressure surges, we recommend filling and bleeding the system prior to
commissioning. Pressure surges must not exceed the value of PN/PS.
The specified switching range is basically related to decreasing flow (minimum supply safeguard).
Deactivation point + hysteresis11= activation point. Check whether the device switches on. The
pump output must be sufficient to actuate the contact.
The pressure upstream from the flow monitor must be above the value of the pressure loss
caused by free outflow.
Ensure that the assembly and electrical connection are carried out correctly.
Ensure that protective devices are re-installed/recommissioned.
6.2 Operation
The housing cover must be removed to observe whether the paddle bar moves freely in case of a
change of the volume flow during operation.12
6.3 Maintenance
The devices are maintenance free when used in a clean medium. When operated in dirty medium, we
recommend checking the freedom of movement of the paddle regularly, as described in section 6.2.
11
Hysteresis: All mechanical devices have a hysteresis (switching point, display difference between increasing
and decreasing flow volume).
12
The device must be de-energised for removal of the housing cover.
6 Commissioning, operation and maintenance
Prior to commissioning, observe the limit values specified in the product information for
current, voltage, pressure stage, temperature range, maximum permissible flow rate,
etc.
GHM Group ● Honsberg
Tenter Weg 2-8 ● 42897 Remscheid ● GERMANY
Telephone +49 (0) 2191 9672-0 ● www.ghm-group.de
8
The technical data is provided in the product information. It is provided with the device
or can be downloaded from http://www.ghm-messtechnik.de/produkte/b-sensorik-undmesstechnik/b2-durchfluss.html.
FL-032 S/K flange with weld-on nozzle, bolts, nuts and flat seal
Filter TYPE ZV
Filter TYPE ZE13
Storage
Please observe the storage temperature.
A desiccant or heating to prevent formation of condensate is recommended in damp rooms.
Transport
Please observe the transport temperature.
Protect the device against environmental influences such as jarring, impact, dust and vibrations.
A return form can be downloaded on our home page under: www.ghmmesstechnik.de/downloads/ghm-formulare.html.
Acceptance of the device by GHM Honsberg can only take place if
1. a filled-in form is provided for each returned device,
2. packaging which prevents damage to the device is used,
3. the device is cleaned so that it does not pose a potential hazard,
4. the filled-in form and any necessary safety data sheet (hazardous material) for the
measured medium are affixed on the outside of the packaging.
Separation by material and recycling of device components and packaging must take place at the
time of disposal. The valid legal regulations and directives applicable at the time must be observed.
The device may not be disposed of with household waste. If the device should be disposed of, return
it to us with the return shipment form filled in under section 10. We will then arrange for the proper
disposal.
© GHM-Messtechnik GmbH, Remscheid
Status: 20/04/2018
13
Refer to the product information for more information about our filters.
14
See product information: Environmental temperature / transport temperature
7 Technical data
8 Accessories
9 Device transport and storage14
10 Return to manufacturer
The legal regulations for protection of the environment and our personnel require that
devices which are sent back which have come into contact with liquid are handled
without risk to people or the environment.
If you send a device back to us for inspection, repair or disposal, we request that you
strictly observe the following requirements:
11 Disposal
12 Imprint
All rights to the original document and the translation are reserved.
Reproduction, duplication or dissemination of any part of this operating manual
requires the consent of GHM Messtechnik in Remscheid.
Subject to changes.
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