Kobold DON-H05G User Manual

Page 1
Operating Instructions
for
Oval Wheel Flowmeter
High pressure
Model:
DON-H...
Page 2
DON-H
1. Contents
1. Contents ........................................................................................................ 2
2. Note .............................................................................................................. 3
3. Instrument Inspection .................................................................................... 3
4. Regulation Use ............................................................................................. 4
5. Operating Principle ........................................................................................ 4
6. Mechanical Connection ................................................................................. 5
6.1 General ................................................................................................ 5
6.2 Orientation ........................................................................................... 6
7. Electrical Connection .................................................................................... 8
7.1 Connecting Cable ................................................................................ 8
7.2 Electrical connection for integrated electronics options ....................... 8
7.3 Internal wiring with electronic options –Zx ......................................... 11
7.4 External wiring with electronic unit ZOK-Zx ....................................... 13
8. Commissioning............................................................................................ 15
9. Maintenance ............................................................................................... 16
9.1 Disassembly of DON-H with Pulse meter .......................................... 17
9.2 Demounting of the electronics mounted on a DON with Zx and 1A…5A
9.3 Spare Parts ........................................................................................ 19
9.4 Inspection (refer Exploded View) ....................................................... 19
9.5 Re-assembly of DON-H ..................................................................... 19
10.Technical Data ............................................................................................ 23
11.Pressure drop curves .................................................................................. 26
12.Order codes ................................................................................................ 27
13.Dimensions ................................................................................................. 28
14.Troubleshooting .......................................................................................... 29
15.Use in Ex areas ........................................................................................... 31
15.1General information ........................................................................... 31
15.2ATEX version Exi (electronics options xA) ......................................... 34
16.EU Declaration of Conformance ................................................................. 41
17.Statement of Conformity ............................................................................. 43
18.State of safeness ........................................................................................ 48
options ............................................................................................... 19
page 2
Manufactured and sold by:
KOBOLD Instruments Inc.
1801 Parkway View Drive
Pittsburgh PA 15205-1422
Tel.: 412-788-2830
: 412-788-4980
Fax
E-Mail: info@koboldusa.com
Internet: www.koboldusa.com
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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
In acc. with Article 4 Paragraph (3), "Sound Engineering Practice", of the PED 2014/68/EU no CE mark.
DON-H
Model DON-* DN
DON-05 400­DON-10 ¼ 400 DON-15 ¼ 400 DON-20 ½ 400
P
max
[bar]
Diagram8
Group1
dangerousfluids
§4 Abs.3 §4 Abs.3
Diagram9
Group2
nodangerousfluids
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 Wheel Flowmeter, High pressure model: DON-H... Operating Instructions
Each DON volume counter has been calibrated to function with mineral oil, which means the remainder of the calibration oil still remains in the device. The oil used is: for measurement ranges H05 for high viscosities: SHELL Morlina 10 for measurement ranges H10 to H20: EXXSOL D120
DON-H 01/0721
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DON-H
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 operation of the offered electronics (Zx, 1A…5A) is described in the separate ZOK- (Ex) operating instructions.
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.
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.
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OPERATION:
Liquid travels around the crescent
d chambers created by the
shape rotational movement of the rotors
liquid entering measuring chamber
6. Mechanical Connection
DON-H
liquid exits the measuring chamber
liquid in transit
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.
the measuring instrument is not subjected to process temperatures and
pressures that convert the liquid medium into a gas inside the device.
DON-H 01/0721
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DON-H
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.
C O R R E C T I N S T A L L A T I O N S
C O R R E C T I N S T A L L A T I O N S
I N C O R R E C T
Incorrect installations will cause the
rotor weight to be felt on the bottom of
the measuring cavity.
page 6
Note: orient the conduit entry downward to avoid moisture migration into the electronic cavity.
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-H05 .. DON-H20. The flowmeter calibration data refers to this arrow direction. This is also the preferred flow direction.
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DON-H
Flow Conditioning and installation location Filter: It is highly recommended to INSTALL a filter immediately before (prior to) the meter. Filters are available and sold separately.
Recommended Filter: DON-H05…DON-H15: < 75 µm particle size (200 mesh) DON-H20: < 150 µm particle size (100 mesh)
Flow conditioning: Flow conditions are 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 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. Pulsation dampeners are highly recommended.
DON-H 01/0721
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DON-H
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 Electrical connection for integrated electronics options
The electrical connection of the integrated electronics options always requires the electronics cover to be dismantled. High pressure models incorporate the cable inlet into the electronics cover. 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.
7.2.1 Hall-effect sensor with active pulse output (H0 option)
The H0 electronic option combines a hall-effect sensor with an active push-pull output stage. 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 V up 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).
. No additional external wiring is required (e.g. pull-
DC
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DON-H
Note! The electronic option H0 is available with reed switch output.
DON-H 01/0721
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DON-H
7.2.2 Reed Switch Pulse Output (option H0/HA)
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.
Average electrical endurance of switching contact (MTTF – Mean Time To First Failure): Max. switching voltage (30 V/10 mA) 5x105 switching cycles Max. current load (20 V/10 mA) 5x106 switching cycles Min. load (<5 V/10 mA) 5x108 switching cycles
Switching capacity: Max. 30 VDC, max. 20 mA
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).
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.
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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:
DON-H 01/0721
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DON-H
7.3 Internal wiring with electronic options –Zx
The -Zx electronic options are pre-configured ex works in connection with the sensor boards. Reconfiguration is available on request.
7.3.1 For Z1/Z2/Z3/Z5 electronic options (reed switch and Hall sensor)
a) Wiring diagram with reed switch (ex works standard, mandatory
for supply with battery or in 2-wire 4-20 mA operation)
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DON-H
b) Wiring diagram with Hall sensor (recommended in connection
with external supply)
7.3.2 For 1A…5A electronics options
See supplement to operating instructions ZOK-Ex for electronics options 1A… 5A
7.3.3 Calibration Factor (scale or K Factor)
The DON flowmeter is delivered with a factory calibration certificate. Within this certificate, a calibration factor is provided. The calibration factor is a specific representation of pulses per unit volume. (i.e. pulses per liter) for that specific meter. Measurement devices with attached electronics are factory pre-configured to the corresponding calibration factor. Depending on the model, the calibration protocol is based on either the flow rate display or the analog output. For further details on the operation and parameterization of the electronic option Zx and 1A…5A see operating instructions ZOK- (Ex).
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DON-H 01/0721
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7.4 External wiring with electronic unit ZOK-Zx
7.4.1 Wiring with ZOK-ZxK
a) Circuit with Hall sensor (not for battery operation)
DON-H
b) Circuit with Reed switch
DON-H 01/0721
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DON-H
7.4.2 Wiring with ZOK-ZxP
a) Circuit with Hall sensor
b) Circuit with Reed switch
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DON-H 01/0721
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8. Commissioning
The piping MUST be flushed of debris before installation. Debris such as slag from welding, grinding dust, rust, pipe tape or sealing compound are common within new piping installations and will damage the flowmeter if not flushed or filtered from the process piping before installation and operation.
A by-pass system is common for frequent system flushing or frequent meter removal. If a by-pass system is not practical or possible, removal of the gears before flushing is necessary. (refer to section 9.1 “Disassembly of Pulse meter”).
DON-H
For proper operation the flowmeter must be purged of air. During long periods of inactivity or after a flushing, air may be in the piping. Elimination of the air may be achieved by operating the meter at a low flow rate until all the air is eliminated. Damage may occur to the flowmeter if it is run above the maximum rated flow rate or if the maximum differential pressure of 15 psi (1 bar, 100 kPa) is exceeded.
After mechanical and electrical installation according to the guidelines set forth within this user manual, the DON flowmeter is ready for operation.
Warning! Risk of damage by blocking of measuring mechanism. A missing count signal may indicate a blocked measuring mechanism. The resulting increase in pressure before the device can lead to further damage to the unit and / or the plant. Remove the unit or shut down the plant immediately, if an unplanned absence of the counter signal takes place. Eliminate the cause of the malfunction.
DON-H 01/0721
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DON-H
9. Maintenance
Flowmeter maintenance precautions:
Remove/disconnect power to the flowmeter.Ensure that flow supply to the meter is turned off and the system is not
under pressure.
Completely drain the flowmeterConfirm that any signal output(s) will not affect the system when de-
energized or removed from the circuit.
Oval gear positive displacement flowmeters are mechanical by nature. A periodic maintenance/inspection schedule is suggested for an extended service life. Follow the guidelines within this user manual for the maximum flowmeter performance.
The maintenance/inspection schedule should be determined based off of application factors such as media type (abrasiveness, lubricity, and/or chemical compatibility), flow rate, and operating/maximum temperature and pressure.
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DON-H
9.1 Disassembly of DON-H with Pulse meter
Concerning option H0/HA
9.1.1 Pulse output board removal (refer exploded view diagram
To remove the pulse output board, remove the 4 electronic cover screws (10), and remove the electronic cover (9). The pulse output board (6) can now be accessed and removed via the removal of the electronic board screws (7).
9.1.2 Oval gear removal for DON-H05…DON-H10 (refer exploded view diagram
For access to the oval gears, remove the 4 lower meter body screws (5). With care, remove the upper meter body assembly (4) being careful not to damage or misplace the O-ring (3). You can then remove the oval gears (2). For the small flowmeters (4 mm & 6 mm), when disassembling, please notice the dimples located on the meter body (1 & 4) face just outside the o-ring groove. The referencing dimples must be in alignment when reassembling. In addition, with the small flow meters, only one oval gear is equipped with magnets. The oval gear without magnet must be mounted on the axle that is closest to the dimple. With all other devices, both oval gears are equipped with magnets and can be mounted in any position.
5
2
3
1
4
Assembly alignment
dimple
2
6
7
Optional
8
9
10
DON-H 01/0721
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DON-H
9.1.3 Removal of oval gears for DON-H15...H20 (refer exploded view)
For access to the oval gears, remove the 8 or 10 upper meter body screws (5). With care, remove the upper meter body assembly (4) being careful not to damage or misplace the O-ring (3). You can then remove the oval gears (2).
DON-H15...
DON-H20...
Optional
page 18
Optional
DON-H 01/0721
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DON-H
9.2 Demounting of the electronics mounted on a DON with Zx and 1A…5A options
To access the electronic cover with display must first be removed in case of flowmeters with built-in electronics. To do this, loosen the 4 screws of the display cover and carefully remove it without pulling out or damaging the connecting cable. During this procedure, be careful not to lose or damage the O-ring. The terminal connection, device battery and pulse output board are now freely accessible. To remove the electronics, the screws used to connect the electronics housing to the oval gearbox housing should be loosened.
device battery, terminal connections and pulse output board, the
9.3 Spare Parts
Please consult your closest KOBOLD-Office Internet: www.koboldusa.com
9.4 Inspection (refer Exploded View)
Inspection points will be the following:
O-rings – Inspect for physical or chemical damage or deformation. Rotors – Inspect for physical damage due to unfiltered media or damage due to
chemical attack. Also observe also the magnets, if exposed, for chemical attack.
Measuring Cavity – Inspect for physical damage (scoring) due to improperly
filtered media or long term wear and tear.
Axle Shafts – Inspect for physical damage and ensure that the shafts are not
loose and do not rotate.
9.5 Re-assembly of DON-H
Before re-assembly, please be sure to thoroughly clean all parts.
Care must be taken when reinstalling the rotors such that the magnets should face the pulse output board.
DON-H 01/0721
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DON-H
9.5.1 Re-assembly of DON-H05...DON-H10
The (1 and 4). The referencing dimples must be in alignment when reassembling. In addition, with these small flow meters, only one oval gear is equipped with magnets. The oval gear without magnet must be mounted on the axle that is closest to the dimple. Both oval gears are correctly installed when they are at an angle of 90 ° to each other. The oval gears must be able to rotate freely. Check the correct fit and the friction between the axle and the bearings by slowly rotating the oval gears by hand.
Thereafter, the O-ring (3) is inserted into the groove of the measuring housing (1) and both parts (1 and 4) are reassembled. It must be ensured that the markings are in alignment with each other.
The screws (5) are inserted and tightened crosswise opposite one another. Tighten the screws with a torque of 3.5 Nm. The alternating tightening procedure is preferred for proper and even assembly.
small flowmeters DON-H05 to DON-H10 have dimples on both housing parts
If necessary, the pulse output board, the cover with the cable gland or the attached electronics are installed. Make sure that the O-ring (8) is seated correctly.
Assembly alignment
dimple
1
2
8
5
6
9
10
2
3
4
7
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Optional
DON-H 01/0721
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DON-H
9.5.2 Re-assembly of DON-H15...DON-H20
Both oval gears are placed on the axle shafts with the magnets oriented towards the upper meter body (4). Verify that the axle shafts are not loose. Both oval gears are equipped with embedded magnets, allowing them to each be mounted on either axle. Install the rotors exactly perpendicular from each other (90° in orientation). They will only work if installed precisely. Manually test full rotation after installation as the rotors will not completely rotate freely unless installed precisely 90° from each other.
Proper placement of the O-ring within the groove is necessary for leak free operation. After placement, items (1 & 4) will then require assembly.
Tighten the upper meter body to the lower meter body (1 & 4) with the screws (5) in an alternating pattern (1, 3, 2, 4). Tighten to each to a torque of 3.5 Nm. The alternating tightening procedure is preferred for proper and even assembly.
Install the pulse detector board, the o-ring into the provided groove, and then install either the electronic cover (9) or optional electronic assembly.
Exploded view of DON-H15...DON-H20
DON-H15...
DON-H 01/0721
optional
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DON-H
A2
DON-H20...
Tightening torques of the screws used
Thread Quality Material Tightening torques
M5 80 A4 6 Nm M6 80 A4 10 Nm M6 12.9
M10 70
Optional
Steel
20 Nm 40 Nm
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DON-H 01/0721
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10. Technical Data
Material:
Body: stainl. Steel 1.4404 DON-H05...DON-H20 Oval wheels: stainl. Steel 1.4404 DON-H05...DON-H20 Bearing: carbon graphite Axes: stainl. Steel 1.4404
DON-H
O-Rings: medi
Note: Choose appropriate sealing according to permissible temperature limits of the flowmeter.
Cover for cable connection: polyamide PA6 GF35 UL94 HB/VO
Screws: coated steel, GEOMET® 321 Magnet cover: DON-H05, -H10: PEEK
Accuracy (under reference conditions*): ± 1 % of reading (DON-H05...DON-H15)
Protection class: IP 66/67
a temperature: -20 °C…+80 °C for options Zx and
Medi
Ambient temperature: -20...+80 °C Cable entry: M20x1.5, ½“ NPT
a temperature FKM: -20...+150 °C NBR: -20...+100 °C FEP-O-seal: -15…+130 °C (FEP-O-seal, FEP encased, with solid core EPDM) Fluoroprene® acc. to EN 1935
stainless steel 1.4404
DON-H15, -H20: stainless steel 1.4404
± 0.5 % of reading (DON-H20) ± 0.2 % of reading (DON-H20; with optional Z3-electronics based on linearization function
-20 °C…+120 °C with pulse output and options Zx with cooling fins
ATEX approval
Mechanical explosion protection:
Options 1A/2A/3A/5A: Intrinsic safety II 2G Ex ia IIC T4 Gb (-20 °C ≤Ta≤+60 °C)
Option HA: Intrinsic safety II 3G Ex ic IIC T4/T3 Gc
* Reference conditions: -H05 (mineral oil 10 cSt, 20 °C, 5 bar)
DON-H 01/0721
II 2G Ex h IIC T4/T3 Gb
-H10…-H20 (calibration oil 4.6 cST, 25 °C, 1 bar) Accuracy data is valid for given viscosities and higher
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DON-H
(cP)
H0/HA electronics options: Supply voltage: 8 to 30 VDC
(Hall sensor + reed switch Supply current: max. 5 mA (without load) pulse output) Hall pulse output: active push-pull, max.
proof
Electronics options Z1… Z5: see operating instructions ZOK-
Electronics options 1A… 5A: see operating instructions supplement ZOK-Ex
100 mA, short-circuit-
HIGH level: Min. +Vs 1.3 V LOW level: max. 1.3 V
Reed switch pulse output:
max. switching voltage: 30 V max. switching current: 20 mA max. switching capacity: 0,6 W
DC
Maximum Pressure (threaded version)
DON-H05...-20: 400 bar
Max. Flowrate Multiplier (for higher viscosities)
Viscosities
≤ 1000 1 1 ≤ 2000 0,5 1 ≤ 4000 0,42 0,84 ≤ 6000 0,33 0,66
≤ 8000 0,25 0,5 ≤ 30000 0,15 0,3 ≤ 60000 0,12 0,25
≤ 150000 0,1 0,2 ≤ 250000 0,05 0,1
≤1000000 0,025 0,05
Special cut rotors for higher viscosities
For viscosity > 1000 cP, special c be used to reduce pressure drop. This applies to DON-H15 and larger sizes. For higher viscosities, the flowmeter max. flowrate is de-rated according to the attached chart.
Standard rotor Special cut rotor
ut rotors option „S“ should
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Example: DON-H20 measuring oil at 8000 cP, max. flow 150 LPM x 0.5 = 75 LPM new maximum flow rate.
DON-H 01/0721
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Output Pulse Resolution -H0/HA
2163
DON-H
Measuring
Model
DON-H05 0,5 - 36 L/h 2670 2670 DON-H06 2-36 L/h 2670 2670 DON-H10 2 - 100 L/h 1054 1054
DON-H15 15
DON-H20 1-40 8
range
[L/min]
550 L/h 355 710
Reedswitch Hall sensor
Pulse / litre
The values in above table are only approximate guidelines. The actual value for pulse rate can deviate from the values
in this table and is mentioned in
calibration certificate delivered with the flowmeter.
DON-H 01/0721
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DON-H
11. Pressure drop curves
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Pressure d
The curves above represent the pressure drop for standard cut oval rotors. Special cut rotors option "Y" have alternate tooth relieve which effectively reduces the pressure drop by 50%. When sizing a meter, be sure your selection falls below the 1 bar maximum allowable pressure drop line on
the graph.
rop limit versus flowrate
DON-H 01/0721
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12. Order codes
Order Details (Example: DON-H10G N1 1 R0 M 0)
DON-H
Measuring
Range
0.13...9.5 GPH DON-H05G..
0.5...27 GPH DON-H10G..
4...145 GPH DON-H15G
Stainless Steel
2)
Housing
1)
Connection O-Ring Material Electronics Cable Entry Option
1
..N1.. =
..R1.. = G
..N2...=
..R2.. =
..N2.. =
..
..R2.. =
8" NPT
1
8
¼" NPT
G ¼
¼" NPT
G ¼
..1.. = FKM
..3.. = FEP-O-Ring
..4.. = NBR
..5.. = Fluoroprene
..N4.. =
..R4.. =
½" NPT
G ½
0.26...10.6 GPM DON-H20G
1) Replace Hxx with Sxx for special rotors for viscosities > 1000 cP
2) Replace 'G' with 'H' to order LPH (LPM) (e.g. 15 H instead of 15 G)
3) Only for electronic options ..Zx
4) E1/E2/E3/E5 = Z1/Z2/Z3/Z5 in ATEX version (Exi), without backlighting
1)
..
..9.. = Special
Materials (not for ATEX)
..H0.. = Hall Sensor (Push-Pull) /
Reed Switch, Pulse Output
..HA.. = H0 + ATEX (Exi)
..Z1.. = Dual LCD Totalizer
..Z2.. = Batching Unit LCD
..Z3.. = LCD Totalizer, Rate, Outputs:
4-4-20 mA, Alarm, Pul
®
(ZOK-Z3) (Impulses not for Battery Supply)
..Z5.. = Z3 + 2 SPDT Relays
4)
..1A
.. = E1 + HA ATEX (Exi) ..2A4).. = E2 + HA ATEX (Exi) ..3A4).. = E3 + HA ATEX (Exi) ..5A4).. = E5 + HA ATEX (Exi)
..M = M20
..N = ½" NPT
3)
= M20 with
..S
Cooling Fin
3)
= ½" NPT
..T
with Cooling Fin
..0 = without
..N = Without
Battery
..Y = Special
Option (Specify in Clear Text, not for ATEX)
Example: DON-H10H R1 1 H0 M 0
Measuring
range
[l/min] Stainless
0.5 – 36 l/h DON-H05H
2 – 100 l/h DON-H10H1)
15 – 550 l/h DON-H15H1)
1 – 40 DON-H20H1)
1)
Replace Hxx with Sxx for special rotor for higher viscosities ˃ 1000 cP
3)
Only for electronic options -Zx 4) E1/E2/E3/E5 = Z1/Z2/Z3/Z5 in ATEX version (Exi), without backlighting
Housing
material
steel
2)
Connection
R1 = G ⅛ N1 = ⅛” NPT
R2 = G ¼ N2 = ¼“ NPT
R2 = G ¼ N2 = ¼“ NPT
R4 = G ½ N4 = ½“ NPT
O-ring
Material
1 = FKM 3 = FEP-
O-ring
4 = NBR 5 = Fluoroprene® 9 = Special
materials (not for ATEX)
Electronics Cable entry Option
H0 = hall sensor (Push-Pull)/
reed switch, pulse output
HA = H0 + ATEX (Exi) Z1 = dual LCD totalizer Z2 = Dosing unit LCD Z3 = LCD totalizer/rate,
outputs:
4-20 mA, alarm, pulse (Z
OK-Z3) (impulses not
for battery supply Z5 = as Z3, but with 2 relays/ SPDT relays
4)
= E1 + HA (ATEX Exi)
1A
4)
2A
= E2 + HA (ATEX Exi)
4)
3A
= E3 + HA (ATEX Exi)
4)
= E5 + HA (ATEX Exi)
5A
2)
Replace ‘H’ with ‘G’ to order GPH (GPM) (e. g. 15 G instead of 15H)
M = M20 N = ½“ NPT
3)
S
= M20 + cooling fin
3)
T
= ½“ NPT
+ cooling
fin
0 = without N = without batte Y = special
option, (specify in clear text; not for ATEX)
ry
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13. Dimensions
[mm]
Electronic Options -Zx/1A…5A
Option -M/-N (standard)
Option -S/-T (with cooling fin)
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14. Troubleshooting
Oval gear flowmeters have two clearly distinct portions: one of which is mechanical, wetted areas with the oval gears surrounded by a housing, and the other is the electrical area, which includes the pulse output board.
Details of some key troubleshooting steps will now be provided. Please also refer to the instructions on troubleshooting errors contained on the following page.
Step 1 - Check application, installation and set-up. Carefully read the section on mechanical installation to ensure full knowledge of all relevant installation and application factors which may affect the operation of the counter. These include pulsation, trapped air or selecting the wrong counter, including incorrect flow rate, temperature or pressure, or material incompatibility. Refer to the section on electrical installation to ensure correct cabling.
Step 2 - Check for blockages. For new and modified systems in particular, the most frequent cause of error or sub-optimal counter operation is internal system or counter blockages due to foreign particles, such as beads of condensate, sealing tape residues or mixtures of deposits, rust, etc.
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Step 3 - Guarantee flow rate.
Flow stopping or a flow rate declining below the usual limit may be attributable to a blocked screen, flowmeter rotors which are stuck or damaged, a defective pump, closed valves or an insufficient liquid level in the storage tank.
Step 4 - The oval gears in the counter must revolve. This rotation is audible: try holding a screwdriver blade against the counter housing and push the handle right against your earlobe. Test the counter as required with flow switched on and off, to ensure you are familiar with the audible sound of rotation.
Step 5 - Ensure that pulses are generated when liquids flow. Here, a multimeter is often not fast enough to capture the pulse sequence of the reed switch or the Hall Effect sensor. However, an oscilloscope will allow you to observe the output pulse sequence. When testing the reed switch pulse, a pull-up resistor must be installed between the single connection of the reed switch and the supply voltage, while the other connection must be connected to the reference potential of the measurement device (oscilloscope) (see electrical installation).
Step 6 - Confirm device operation. If a mounted electronic component is connected to the DON, check the functions by simulating a pulse input. A reed switch pulse input can be simulated by a swift and pulse-driven short-circuiting of the input terminals.
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Problem Possible cause Solution
1. Ground shielding of the signal cable
2. Re-lay the cable away from sources of high current
1. Eliminate the source of the air or gas pocket
2. Install an upstream air separator
1. Increase back-pressure to the pump
2. Install a quick-response one-way check valve
3. Install a pulsation damper between the pump and the counter
4. Recalibrate the counter on site, to compensate for pulsations
5. Replace the pump type for a pump allowing smooth supply
n
1. Check, repair, clear or replace rotors
1.
Check me
2. Check concentricity of the rotor shafts in the chamber
1. Ground shielding of the signal cable
2. Re-lay the cable away from sources of high current
3. Check all electrical connections and wires for the presence of current.
Che
1. visi
2. Check for any obstructing foreign particles
3. Clear, repair or replace rotors
1. See instructions for re-mounting the counter, focusing on the positioning of rotors and magnets above all
1. Check screw terminal connections and soldering joints
2. Ensure the presence of DC voltage at +Vs and 0V/GND and that the analytical electronics connected include a pull-up resistor when using the reed switch
3. Replace output plate
1.
Check
2. Check screw terminal connections and the presence of electrical current
3. Repair/replace analytical electronics
Counter values too high
Counter values are too low
No output from counter
No flow signals indicated on the analytical device
1. Disruption of the output signal
2. Air or gas pockets
3. Pulsating flow from the piston pump
1. Damag rotors
2. Damaged or worn measurement cham
3. Disruption of the output signal
1. Soiled rotors
2. Counter incorrectly mounted
3. No output from the output board
1. Defective analytical electronics
ed or wor
ber
asurement chamber for damage - repair as required
whether the rounded teeth at the base of the chamber are
ck
ble
settings and parameter data in the set-up menu
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15. Use in Ex areas
15.1 General information
The flow meter is intended for commercial systems and may only be used in accordance with the information in the technical documentation from Kobold and the information on the nameplate. It is operated exclusively together with certified products via an intrinsically safe circuit. They correspond to the applicable standards and regulations. The installation regulations (e.g. EN 60079-14) for systems in potentially explosive areas must be considered.
15.1.1 General safety information
The flow meter corresponds to the state of the art and is operationally safe. The flow meter can bear a residual risk if it is used and operated improperly by untrained personnel. Every person who is entrusted with the installation, commissioning, maintenance or repair of the flow meter must have read and understood the assembly instructions and in particular the safety instructions.
a) When selecting a product and using it as intended, follow the general rules of
technology.
b) All connected electrical and mechanical equipment must be suitable for the
respective application.
c) Observe the information in these operating instructions as well as the
conditions of use and permissible data that appear on the imprints / nameplates of the respective products.
d) It must be ensured that only the product types of protection that correspond
to the zones are installed!
e) The product is only approved for appropriate and intended use in a normal
industrial atmosphere. Immersion in liquids is not permitted.
f) It must be ensured that no falling objects can hit the product. If there is a risk
of impact sparks, external housing parts made of light metal must be installed in a protected manner.
g) The operator must ensure lightning protection for the entire system in
accordance with local regulations.
h) It is the responsibility of the installer to ensure that the flow meter functions
properly in connection with the individual evaluation devices and that it is approved for the intended purpose.
i) A safe to operate and non-critical medium is elementary for this type of
protection and must be strictly adhered to!
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15.1.2 Intended use
a) To ensure safe operation, the products may only be used in accordance
with the information in the assembly instructions. When using the device, the legal and safety regulations required for the respective application must also be considered. This also applies analogously to the use of accessories.
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b) If the instructions given here are not followed or if the product is handled
c) The products are not safety elements in the sense of their intended use. d) Only original parts from the manufacturer may be used. e) Flammable media within the flow meter must not be heated in Zone 1
f) Charging of the medium is not permitted; measures by the operator are
15.1.3 Temperature classes and medium temperatures
Z
Material seal Marking Cat. 2 (Zone 1) TC Cat. 3 (Zone 2) TC
1 2 3
FEP / EPDM 92 e = 3
4 5 6 7
Fluoroprene e = 5
8
improperly, our liability is void. In addition, the warranty on products and spare parts does not apply.
above 80% of their ignition temperature without taking special measures
necessary.
FKM e = 1
NBR e = 4
-20 °C .. 80 °C T4
-20 °C .. 100 °C T3
-20 °C .. 80 °C T4 -20 °C .. 90 °C T4
-20 °C .. 110 °C T3
-20 °C .. 80 °C T4
-20 °C .. 100 °C T3
-20 °C .. 80 °C T4
-20 °C .. 130 °C T3 -20 °C .. 130 °C T3
-20 °C .. 90 °C T4
-20 °C .. 110 °C T3
-20 °C .. 120 °C T3
-20 °C .. 90 °C T4
-20 °C .. 110 °C T3
-20 °C .. 90 °C T4
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15.1.4 Servicing, maintenance
Definition of terms according to IEC 60079-17:
Maintenance and repair: A combination of all activities carried out in order to keep an object in a condition or to bring it back into a condition that meets the requirements of the relevant specification and ensures the execution of the required functions.
Inspection: An activity that involves the careful examination of an object with the aim of making a reliable statement about the condition of this object, without dismantling or, if necessary, with partial dismantling, supplemented by measures e.g. measurements is carried out.
Visual inspection: A visual inspection is an inspection in which visible defects are found (e.g. missing screws) without the use of devices or tools.
Close-up inspection: An inspection that, in addition to the aspects of the visual inspection, identifies defects such as loose screws that can only be removed through the use of access devices (e.g. if necessary stairs) and tools. For close­up tests, a housing usually does not need to be opened or the equipment needs to be de-energized.
Detailed inspection: An inspection in which, in addition to the aspects of close­up inspection, defects such as loose connections, which can only be identified by opening housings and / or, if necessary, using tools and testing equipment, are treated.
Maintenance measures may only be carried out by qualified persons. Only accessories that meet all the requirements of the European directives and national legislation may be used in potentially explosive areas.
Maintenance measures including dismantling the flow meter may only be carried out in a non-explosive atmosphere. Components may only be replaced with original spare parts that are also approved for use in Ex areas. Repairs only by the manufacturer or specialist workshop. The products must be regularly serviced and cleaned in the Ex area. The intervals are determined by the operator in accordance with the environmental stresses on site.
Detailed
inspection
every 12
months
Activity
Visual
inspection
per month
Close-up
inspection
every 6 months
Visual inspection of the flow
1
meter for damage and remove
dust deposits
2
Check for integrity and function
Examination of the entire
3
system
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In the operator's area of responsibility
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15.1.5 Troubleshooting
No changes may be made to products that are operated in connection with potentially explosive areas. Repairs to the product may only be carried out by specially trained and authorized specialists.
15.1.6 Disposal
The packaging and used parts must be disposed of in accordance with the regulations of the country in which the product is installed.
15.2 ATEX version Exi (electronics options xA)
While evaluating the product, following Norms were considered:
a) EN IEC 60079-0: 2018 Ed. 7 Hazardous areas - Part 0: Equipment -
b) IEC 60079-11: 2011 Ed. 6 + Corr. 2012 / EN 60079-11: 2012 Hazardous
c) EN ISO 80079-36 2016 Explosive atmospheres - Part 36: Non-electrical
d) EN ISO 80079-37 2016 Explosive atmospheres - Part 37: Non-electrical
General requirements
areas - Part 11: Equipment protection by intrinsic safety "i"
devices for use in explosive atmospheres - Basics and requirements.
equipment for explosive atmospheres – Non electrical type of protection constructional safety "c", control of ignition source "b", liquid immersion "k"
15.2.1 General information on explosion protection
The electrical connection is made via a plug in a separate inductively coupled electronics compartment - exclusively in intrinsically safe systems. The electronics option HA is combined with the electronics models ZOK-E * M (compact version) or ZOK-E * K (remote electronics) in accordance with LOM 16 ATEX 2062 to form the electronics options 1A, 2A, 3A and 5A.
Permitted use
The intrinsically safe flow meter can be used as follows:
In Zone 2 (Gas-Ex, Category 3G, EPL Gc) in explosion groups IIA, IIB and
IIC.
The requirements for simple electrical equipment in intrinsically safe circuits
in Zone 1 according to EN 60079-11 are met for various versions.
The qualification with regard to the surface temperature is T4 / T3; for all
gases, vapours and fog with an ignition temperature ≥ 135 ° C / ≥ 200 ° C, the products are not an ignition source.
The permissible ambient temperature range is from -20 ° C ≤ Ta ≤ 80 ° C. In accordance with the installation regulations, housing must be grounded using the earthing clamps. The maximum connection cross-section is 4 mm2.
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External earthing clamp
15.2.2 Electrical parameters of the electronic option HA when used in Zone 1/2
Electrical data:
• Pi ≤ 1 W @ max. 80 ° C ambient temperature
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Electronics option
Hall sensor HA
Reed switch HA
Use in zone
1
2
1 2
Ui Ii Ci
270 nF
UiIIB ≤ 32 VDC ≤ 100 mA
10 nF
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,2µ
15.2.3 Wiring examples for electronics option HA with Zener barriers
Control Drawing for DON-***HA - Oval Gear Flowmeter with pulse output
(Reedswitch, usage with zener barrier) for Group IIB zone 1
Supply
max. 26VDC
Supply
Uo = max. 28 Vdc Io = max.100 mA Po = max. 700 mW
zener barrier
8
7
28V
300R
PA
P&F Z728
BAS 01 ATEX 7005
II (1) GD [Ex ia Ga] IIC
-20 °C ≤ Ta ≤ 60 °C
Uo = 28 Vdc Io = 93 mA Po = 650 mW C = 650nF
OIIB
L = 16,4 mH
OIIB
1
2
Safe Area
PA
LiYCY
2 x 0,5 mm
Lmax = 100 m
C ≤ 1µH/m
C
F/m
C ≤ 0
L
Hazardous Area
Group IIB, zone 1
-20°C ≤ Ta ≤ +60°C
2
Flowmeter DON-* ** ** ** HA * *
simple apparatus
GND
ExGuide 19 ATEX 0007
II 3G Ex ic IIC T4/T3 Gc
OUT HA/GA
GND
+Vs
OUT DA
HA
ExGuide 19 ATEX 0007
II 2G Ex h IIC T4/T3 Gb
Sensor
Ui ≤ 32 Vdc Ii ≤ 100 mA Pi ≤ 1 W Ci = negligible Li = negligible
-20 °C ≤ Ta ≤ 80
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Control Drawing for DON-***HA - Oval Gear Flowmeter with pulse output
(Hallsensor, usage with zener barrier) for group IIB zone 1
Supply
12 - 26VDC
Signal output
Load < 5mA
Supply
Uo = max. 28 Vdc Io = max.100 mA
Po = max. 700 mW
Zener barrier
8
7
6
28V
300R
28V
36R
PA
P&F Z787
BAS 01 ATEX 7005
II (1) GD [Ex ia Ga] IIC
-20 °C ≤ Ta ≤ 60 °C
Uo = 28 Vdc
Io = 93 mA Po = 650 mW C = 650 nF
OIIB
L = 16,4 mH
OIIB
1
2
3
45
Safe Area
PA
Hazardous Area
Group IIB, zone 1
-20°C ≤ Ta ≤ +60°C
LiYCY
3 x 0,5 mm Lmax = 100 m
C ≤ 1µH/m C ≤ 0,2nF/m
2
L C
Flowmeter DON-* ** ** ** HA * *
simple apparatus
GND
ExGuide 19 ATEX 0007
II 3G Ex ic IIC T4/T3 Gc
OUT HA/GA
GND
+Vs
OUT DA
HA/KA/BA/GA
ExGuide 19 ATEX 0007
II 2G Ex h IIC T4/T3 Gb
Sensor
Ui ≤ 32 Vdc Ii ≤ 100 mA Pi ≤ 1 W Ci = 270 nF Li = negligible
-20 °C ≤ Ta ≤ 80
15.2.4 Electronics options 1A to 5A when used in Zone 1/2
With the electronics options 1A to 5A, the electronics option HA in connection with a flow meter / doser / controller of the type ZOK-E * K * F3 or ZOK-E * M * F3 ** according to LOM 16 ATEX 2062 X is a simple electrical equipment used and supplied electrically by this equipment only. Interconnection examples for options 1A to 5A can be found in the instruction manual supplement Zok-Ex-supplement.
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15.2.5 Commissioning, installation
Depending on the IP degree of protection, the time for cleaning the equipment (dust deposits) must be specified. Other important facts: a) The product may only be put into operation in Zone 2 (Cat. 3G, EPL Gc) or in
b) The requirements for simple electrical equipment, which apply to the
c) The products may only be used in a normal industrial atmosphere. If
d) The operation of the product is only permitted in the completely assembled
e) The environmental conditions specified in the operating instructions must be
f) The flow meter may only be operated when it is completely filled. Exceptions
g) Thermal radiation from third-party products / components must be taken into
h) The flow meter must be protected against inadmissible ingress of liquids and
i) Stuck parts (e.g. due to frost or corrosion) must not be loosened with force in
j) The flow meter may only be exposed to low vibrations, see also IEC 34-14. k) A direct electrostatic discharge of high energy onto the equipment is not
l) In particular, isolated established capacities must be prevented. m) All construction parts must be connected to one another in metal, central
n) Equalizing currents must not be routed through the metallic structures. o) The intrinsically safe connection must be made using approved / tested
p) Only Zener barriers or switching amplifiers whose output circuits are
q) The voltage of the supply devices must be less than or equal to the voltage Ui
r) The total current Io of the supply devices must be less than or equal to the
Zone 1 (Cat. 2G, EPL Gb) in intrinsically safe circuits by specialists with a qualification similar to a qualified person in accordance with TRBS 1203.
potentially explosive area of zone 1 according to EN 60079-11, are met.
aggressive substances are present in the air, the manufacturer should always be consulted. The products must be appropriately protected in adverse environmental conditions.
and undamaged housing. In the event of possible damage, the operator may have to consider the spread of zones. In addition, operation is not permitted if the housing is damaged.
strictly followed. Appropriate protection against adverse environmental conditions needs to be realised.
according to the operator's risk assessment are only permitted for start-up and shutdown.
account.
/ or contamination.
the presence of an explosive atmosphere. Icing must therefore be avoided.
permitted (usually cannot be generated by human contact). To ensure that electrostatic charges are discharged, the national requirements must be taken into account.
connection for equipotential bonding.
evaluation devices that may have to be equipped with suitable Zener barriers or switching amplifiers.
approved / tested for use in an explosive atmosphere may be used. In Europe, use in Zone 1 requires an EC type-examination certificate for the equipment in question, which is issued by a body designated for explosion protection.
of the flow meter.
current Ii of the flow meter.
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s) The ignition limit curves from EN 60079-11 must be taken into account in
Zone 2 without a safety factor and must be observed during installation. The safety factor 1.5 is to be used in zone 1. A control drawing (system description) to be created by the installer / operator is required for the installation of the intrinsically safe circuit.
t) Equipotential bonding must be established along the intrinsically safe circuit.
The certificates, including the special conditions specified therein, must be taken into account.
u) Within the potentially explosive area, assembly may only be carried out in
accordance with the locally applicable installation regulations. The following conditions must be observed (incomplete):
a) Installation and maintenance may only be carried out in an explosion-free
atmosphere and in compliance with the regulations applicable in the operator's country.
b) Additional precautions must be taken if the presence of hydrogen sulfide,
ethylene oxide and / or carbon monoxide is to be expected: These substances have a very low ignition energy!
c) If these substances are present and if a substance of explosion group IIC
is present and an explosive atmosphere is likely to be present, only non­sparking tools may be used!
d) The flow meters must not be used in systems with cathodic corrosion
protection; in borderline cases, consult the manufacturer.
e) Particular care must be taken to ensure that no stray currents (e.g.
generated by motors that are operated on frequency converters, welding systems and / or cathodic corrosion protection systems) are fed through the flow meter.
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15.2.6 Identification of the flow meter (nameplate)
Basic device label DON-H (example)
Device label for Ex version intrinsically safe, option HA (example)
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16. EU Declaration of Conformance
We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:
Oval Gear Flow Meter Model: DON-H...
to which this declaration relates is in conformity with the directives noted below:
2014/68/EU PED
Category II Diagram 8, pipes, group 1 dangerous fluidsModule D, marking CE0575Notified body: DNV GLCertificate No. PEDD000000R
2011/65/EU RoHS 2015/863/EU Delegated Directive (RoHS III)
All devices with electronic are in conformance with:
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2014/30/EU EMC Directive 2014/34/EU ATEX Directive
Notified body BVS 0158 (DEKRA EXAM, Bochum)
EN 61326-1:2013 Electrical equipment for measurement, control and
laboratory use - EMC requirements – Part 1: General requirements
EN 60079-0: 2018
Explosive atmospheres - Part 0: Equipment – General requirements
EN 60079-11: 2012
Explosive atmospheres - Part 11: Equipment protection by intrinsic safety "i"
DIN EN 80079-37:2016
Explosive atmospheres - Part 37: Non-electrical equipment for explosive atmospheres - Non-electrical type of protection constructional safety "c", control of ignition sources "b", liquid immersion "k"
EN 60079-1:2014 Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures 'd'
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Also complies with the following European and national standards and technical regulations:
Technical rules for hazardous substances (TRGS) 727: 2016, avoidance of
Hofheim, 30 July 2021
ignition hazards due to electrostatic charges
H. Volz M. Wenzel
General Manager Proxy Holder
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17. Statement of Conformity
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18. State of safeness
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