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DON-55Lx

Kobold DON-06Lx, DON-10Lx, DON-20Lx, DON-25Lx, DON-30Lx Operating Instructions Manual

...
Operating Instructions
for
Oval Gear Flow Meter
Model:
DON-...Lx/Hx/Rx/Dx/Gx/Kx/Bx/Zx/M4
DON
1. Contents
1.Contents ........................................................................................................ 2
2.Note .............................................................................................................. 3
3.Instrument Inspection .................................................................................... 5
4.Regulation Use .............................................................................................. 5
5.Operating Principle ........................................................................................ 6
6.Mechanical Connection ................................................................................. 7
6.1 General ................................................................................................ 7
6.2 Orientation ........................................................................................... 8
6.3 Flow Conditioning and Location ........................................................... 9
7.Electrical Connection .................................................................................. 10
7.1 Connecting Cable .............................................................................. 10
7.2 Hazardous area wiring ....................................................................... 10
7.3 Electrical connection for integrated electronics options ..................... 11
7.4 Internal wiring with electronic options –Ex/Zx .................................... 15
7.5 External wiring with electronic unit ZOK-Zx ....................................... 19
8.Commissioning ............................................................................................ 21
9.Maintenance ............................................................................................... 22
9.1 Disassembly of DON with Pulse meter .............................................. 23
9.2 Demounting of the electronics mounted on a DON with Zx and Ex
options ............................................................................................... 30
9.3 Spare Parts ........................................................................................ 30
9.4 Inspection (refer Exploded View) ....................................................... 30
9.5 Re-assembly of DON ......................................................................... 30
10.Technical Data ............................................................................................ 33
11.Pressure drop curves .................................................................................. 38
12.Order codes ................................................................................................ 40
13.Dimensions Electronic Options Ex/Zx ......................................................... 41
14.Troubleshooting .......................................................................................... 42
15.ATEX Exd version ....................................................................................... 44
16.EU Declaration of Conformance .................................................................. 46
17.Manufacturers declaration – Switches for use in Explosive Atmospheres . 47
18.Exd Certificate ............................................................................................. 48
19.IECEx Certificate ......................................................................................... 51
20.State of safeness ........................................................................................ 55
Manufactured and sold by:
KOBOLD Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: +49(0)6192-2990
Fax: +49(0)6192-23398
E-Mail: info.de@kobold.com
Internet: www.kobold.com
DON
DON K18/0418 page 3
2. Note
Please read these operating instructions before unpacking and putting the unit into operation. Follow the instructions precisely as described herein. The devices are only to be used, maintained, and serviced by persons familiar with these operating instructions and in accordance with local regulations applying to Health & Safety and prevention of accidents.
When used in machines, the measuring unit should be used only when the machines fulfil the EC-machine guidelines.
as per PED 2014/68/EU DON 1 Aluminum-Version
Model DON DN
P
max
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-105 ⅛ 64
art. 4, par. 3 art. 4, par. 3
DON-110 ¼ 64 DON-115 ⅜ 64 DON-120 ½ 64 DON-125 25 64 DON-130 40 40 DON-135 50 40 DON-140 50 16 DON-145 80 16 DON-150 80 16 DON-155 100 16 DON-160 100 16
DON 2/8 Stainless steel version
Model DON
2/8
DN
P
max
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-05 ⅛ 100 art. 4, par. 3
art. 4, par. 3
DON-06 ⅛ 100 art. 4, par. 3 DON-10 ¼ 100 art. 4, par. 3 DON-15 ⅜ 100 art. 4, par. 3 DON-20 ½ 100 art. 4, par. 3 DON-25 25 100 category II DON-30 40 50 category II DON-35 50 50 category II DON-40 50 16 category II DON-45 80 16 category II DON-50 80 16 category II DON-55 100 16 category II DON-60 100 16 category II
DON
DON-1 M4 Aluminum version with mechanical totalizer
Option M4
Model DON-1
DN
P
max
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids DON-05 ⅛ - - ­DON-10 ¼ - - ­DON-15 ⅜ - - ­DON-20 ½ 40 art. 4, par. 3
art. 4, par. 3
DON-25 1 40 art. 4, par. 3 DON-30 1½ 40 category II DON-35 2 40 category II DON-40 2 16 category II DON-45 3 16 category II DON-50 3 16 category II DON-55 4 16 category II DON-60 4 16 category II
DON 2/8 Stainless steel with mechanical totalizer
Option M4
Model DON
2/8
DN
P
max
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids DON-05 ⅛ - - ­DON-06 ⅛ - - ­DON-10 ¼ - - ­DON-15 ⅜ - - ­DON-20 ½ 40 art. 4, par. 3
art. 4, par. 3
DON-25 1 40 art. 4, par. 3 DON-30 1½ 40 category II DON-35 2 30 category II DON-40 2 16 category II DON-45 3 16 category II DON-50 3 16 category II DON-55 4 16 category II DON-60 4 16 category II
DON
DON K18/0418 page 5
3. Instrument Inspection
Instruments are inspected before shipping and sent out in perfect condition. Should damage to a device be visible, we recommend a thorough inspection of the delivery packaging. In case of damage, please inform your parcel service / forwarding agent immediately, since they are responsible for damages during transit.
Scope of delivery:
The standard delivery includes:
Oval Gear Flow Meter model: DON Operating Instructions Calibration Certificate
4. Regulation Use
The oval gear meter is a precise positive displacement flowmeter incorporating a pair of oval geared rotors. These meters are capable of measuring the flow of a broad range of clean liquids.
Stainless Steel flowmeters are suited to most water based products and chemicals and aluminium meters are suitable for fuels, fuel oils, & lubricating liquids. It is important to ensure that the medium to be measured is compatible with the materials used in the instrument. (See section 10 “Technical Data”) It is also imperative to comply with the maximum permissible operating parameters specified in the “Technical Data” section.
The flowmeter is available as a measurement transducer with pulse output or with other forms of evaluation electronics. Details of how to operate the electronics are included in a separate instruction manual.
These flowmeters DON can be installed within hazardous areas when ordered with optional Exd approval, or by using the reed switch pulse output in Intrinsically Safe loops or installing Intrinsically Safe certified Instruments.
Any use of the oval gear flow meter model: DON, which exceeds the manufacturer’s specification, may invalidate its warranty. Therefore, any resulting damage is not the responsibility of the manufacturer. The user assumes all risk for such usage.
DON
5. Operating Principle
Oval gear flowmeters are categorized as positive displacement flow technology. When liquid flows through this type of positive displacement flowmeter, two oval geared rotors measure a constant volume per rotation within a precisely machined measuring chamber. With each rotation, a constant volume of liquid is measured. The rotation of the oval gears is sensed via magnets embedded within the rotors. These magnets transmit a high resolution pulse output. The output signal can be process externally via a remote display controller or PLC or via a variety of output/display options available as accessories attached to the flowmeters.
The positive displacement flow technology allows for precise flow measurement of most clean liquids regardless of the media conductivity. Other liquid properties also have a minimal effect on the performance of this type of meter. Flow profile conditioning is not required as with alternative flow technology options making oval gear installations simple to install in tight spaces and at an economical price.
OPERATION:
Liquid travels around the crescent shaped chambers created by the rotational movement of the rotors
liquid exits the measuring chamber
liquid entering measuring chamber
liquid in transit
DON
DON K18/0418 page 7
6.Mechanical Connection
6.1 General
Points to verify before meter installation:
Chemical compatibility of the liquid. Be sure that all wetted parts are
identified and confirmed suitable for use with the media being measured. If unsure, please contact a KOBOLD engineer for guidance in obtaining the proper reference materials.
Verify that the operational pressure and temperature limits are within
capability of the fully specified meter. Verify that the operational flow rates are within the specified flow range. Viscous liquids may limit the maximum allowable flow based on the viscosity. The max allowable flow rate may need to be limited to ensure the differential pressure across the flowmeter does not exceed 1 Bar, (100 kPa, 15 PSIG).
Be sure that the flowmeter is not subject to any process temperatures and/or
pressures that can cause the measured liquid to freeze or flash inside the meter.
DON
Incorrect installations will cause the
rotor weight to be felt on the bottom of
the measuring cavity.
6.2 Orientation
When installing the flowmeter, orientation must be considered. The rotor shafts must be in a horizontal plane. To verify that the rotor shafts are in a horizontal plane, electronic cover or optional digital display will be facing in a horizontal direction. For modification in the field, the electronic cover or digital display can be rotated in any 90 degree position. This accommodates access to the electrical entry and allows the electronic display orientation to best suit the installation.
The DON flowmeter accommodates both horizontal and vertical flows. It is recommended that for vertical flow installations that the liquid flow up through the meter (i.e. bottom to top). This orientation assists in air or entrained gas removal. The flow meter is bidirectional. To identify the flow direction, in which the flowmeter was calibrated, the flowmeters are marked with arrows. These arrows are placed on the lower side for models DON-x05 .. DON-x15 and on the top side for models DON x20..DON-x60. The flowmeter calibration data refers to this arrow direction. This is also the preferred flow direction.
C O R R E C T I N S T A L L A T I O N S
Note: orient the conduit entry downward to avoid moisture migration into the electronic cavity.
I N C O R R E C T
C O R R E C T I N S T A L L A T I O N S
DON
DON K18/0418 page 9
6.3 Flow Conditioning and Location
It is highly recommended to INSTALL a filter immediately before (prior to) the meter. Filters are available and sold separately.
Recommended Filter: DON-x05…DON-x15: < 75 µm particle size (200 mesh) DON-x20…DON-x35: < 150 µm particle size (100 mesh) DON-x40…DON-x60: < 350 µm particle size (45 mesh)
Flow conditioning: Flow conditions is not required since the DON flowmeter does not require any straight pipe runs before or after the flowmeter.
Location: The recommended installation would be before of any flow control and/or shut off valves, this installation prevents complete emptying of the meter. This minimizes the risk of leakage and/or air entrapment which could result in damage to the flowmeter or inaccurate initial readings.
A by-pass installation is recommended for process or safety critical meters. Isolation valves enable the meter to be isolated from the system and serviced as needed. System purging is also possible with a by-pass arrangement. Accommodate all meter ratings and locate the meter on the discharge side of the process pump.
For outdoor applications, be sure all electrical entries are sealed properly via the proper glands, mounting, sealing or containment. For humid environments, mount the instrument appropriately as to avoid condensation build up. Generally these installations have the conduit connection pointing downward as to drain any condensate away from the electronics.
Liquid State: Liquid within the flowmeter must not freeze. If heat tracing is necessary, please be sure to adhere to the temperature limits of the flow meter. Ensure the liquid does not flash, do not exceed the max DP of the flowmeter.
Hydraulic shock: Surge dampeners or pressure relief valves must be installed if hydraulic shock or pressure spikes are present. Highly pulsating flow can also damage the DON flowmeter. Diaphragm pumps and specific application profiles can cause high frequency pulsating flow. Proper pulsating dampers are highly recommended.
DON
7.Electrical Connection
7.1 Connecting Cable
Proper shielded instrument cable is highly recommended. Low capacitance twisted pair 7 x 0.3 mm (0.5 mm²) for use with the DON and any remote receiving instrumentation. Typical cable would be Belden® 9363 or similar. Connect the cable shield to DC common or designated grounding terminal at the receiving instrument. Remember to only connect the end of the cable shielding at the receiving instrument (not the DON) to ensure proper interference protection.
Please be sure not to run the connecting cable within a common conduit or in close proximity to conduit with high inductive loads or power sources. This could result in noise or inducted errors to the output signal or result in damage to the electronic components. Always run the instrument cables in a separate conduit or within a common conduit with other low power cables. Max cable length should be limited to 3280 ft (1000 m).
7.2 Hazardous area wiring
The instrument can only be operated in the ATEX area as “Simple Apparatus” in accordance with ATEX Article 1 §2 and 3 with the “Reed contact” (R0) option and without ATEX labelling. For this purpose, intrinsically safe cabling must be laid between the instrument, the hazardous area and an approved isolation switching unit outside the hazardous area. (See section 17 Manufacturers declaration – Switches for use in Explosive Atmospheres)
Alternatively, the device can be operated using option E1 to E5 with Ex ia IIC T4 Gb approval [see separate operating instructions] or with explosion­protected housing (Exd) option RE, BE, GE, KE, LE, HE or DE. Only Exd-certified cable conduits and cable glands with corresponding temperature limits may be used. Hall-effect sensor output is not possible if the DON flowmeter is operated in an ATEX zone as simple apparatus or using the E1/E3 option.
When operating the electronic options LE, BE, GE, RE, HE and DE, suitable operating materials must be used to ensure that the maximum operating voltage of 28 VDC and the maximum operating current of 200 mA are not exceeded.
The wiring methods used must be in accordance with the applicable rules, provisions and requirements at the location where the device is installed. The measuring devices may only be connected by qualified personnel who are familiar with the protection classes, provisions and specifications for the device in areas at risk of explosion.
DON
DON K18/0418 page 11
In accordance with the installation regulations, both, the housings and the electronic covers must be grounded using the earthing clamps. The maximum connection cross-section is 4 mm2.
7.3 Electrical connection for integrated electronics options
The electrical connection of the integrated electronics options always requires the electronics cover to be dismantled. Models from size X05 to X20 incorporate the cable inlet into the electronics cover, while models from the X25 size onwards accommodate the cable inlet in the housing cover. The use of an EXD-certified cable gland is imperative for explosion-protection options HE, GE and LE etc. (M20x1.5 or ½” NPT) (not included in delivery). The connecting cable must be routed through the cable duct and connected in accordance with 7.3.1 to 7.3.4. The connecting terminals are of the plug-in type, and can be taken out of the terminal compartment to facilitate connection.
7.3.1 Hall-effect sensor with active pulse output (H0/HE/B0/BE/ options)
The H0/HE/B0/BE electronics options combine a hall-effect sensor with an active push-pull output stage. The B0/BE options involve combining bipolar Hall sensors with alternating polarised magnets. This option is particularly suitable for pulsating currents, although the pulse rate is halved compared to the H0/HE option. A three-phase electrical connection is used. The output is actively switched, either to the input terminal voltage +Vs or to GND. The external input terminal voltage is 8 to 30 VDC. No additional external wiring is required (e.g. pull­up resistor). The high signal corresponds approximately to the +Vs input terminal voltage and the low signal approximately to 0 V. The electrical load can be connected to either the input terminal voltage or GND
Max. output current (power source or sink): 100 mA (short-circuit protected). The hall-effect sensor pulse output is not available if a device is ordered for use in
the explosion hazard area as “Simple Apparatus” (e.g. if the “E1” option is ordered).
Note! The electronic options H0/HE are available with reed switch output while options B0/BE are not equipped with reed switch.
External earthing clamp
Internal earthing clamp electronics cover
DON
7.3.2 Reed Switch Pulse Output
The DON reed switch output is a SPST potential free N/O 2-wire output. This is a passive output so no power is required. The output may also be used with an appropriate intrinsically safe barrier for use in hazardous locations. If the intention is to operate the dry-reed contact impulse output in ATEX areas as simple apparatus, only the R0 option may be used. Note: when using the reed switch output the liquid temperature must not change at a rate greater than 10 ºC per minute (50 ºF per minute). Average electrical endurance of switching contact (MTTF – Mean Time To First Failure): Max. switching voltage (100 V/10 mA) 5x105 switching cycles Max. current load (20 V/500 mA) 5x10
6
switching cycles
Min. load (<5 V/10 mA) 5x10
8
switching cycles
Switching capacity: Max. 30 VDC, max. 200 mA
DON
DON K18/0418 page 13
The individually specified maximum electrical values of the reed switch must never be exceeded, even for a moment. Higher switching values may reduce the service life or even destroy the contact. For capacitive and inductive loads (e.g. via long lines), we recommend the following protective circuits:
Lamp load with series or parallel Protection with a RC suppressor resistance to the reed switch. For a.c. current and inductive load.
Protection with a diode Protection with an inductance or for d.c. current and inductive load. Resistance for capacitive load.
DON
7.3.3 Quadrature Pulse Output (QUAD, Option D0/DE)
For the D0/DE option, the DON devices come with 2 independent hall-sensor elements. The hall-effect sensors are arranged so that they emit separate phase­shifted signals to one another. The QUAD output is best-suited for verified use with a redundant signal or for counting bidirectional currents (detecting the current direction).
Max. output current per channel (power source or sink): 100 mA (short-circuit protected).
The current direction of the medium is defined as follows: a.) Hx signal leading over Dx signal: Current flowing in the direction of the
marked arrow (positive)
b.) Hx signal lagging behind Dx signal: Current flowing against the direction of the
marked arrow (negative)
DON
DON K18/0418 page 15
7.4 Internal wiring with electronic options –Ex/Zx
The Ex/Zx electronic options are pre-configured ex works in connection with the sensor boards. Reconfiguration is available on request.
7.4.1 For Z1/Z3 electronic options (reed switch and Hall sensor)
a) Wiring diagram with reed switch (ex works standard)
DON
b) Wiring diagram with Hall sensor (recommended in connection
with external supply)
7.4.2 For Z6/Z7 electronics options (bipolar Hall sensor)
The circuitry corresponds to 7.4.1 b.)
7.4.3 For E1...E5 electronics options
Refer operating instructions supplement ZOK-Ex wiring options E1...E5
DON
DON K18/0418 page 17
7.4.4 For Z2/Z8/Z9 electronics options (2 Hall sensors for direction detection)
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