KROHNE DW181, DW182, DW-183, DW-184 User Manual
Installation and
operating instructions
DW 181 – 184
Standard, high-temperature,
tropical and ATEX versions
Flow switches
©
KROHNE 01/2006 7.02125.23.00
CMD
Electromagnetic flowmeters
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Table of contents
General advice on safety………………………………………………………………………….. 4
Standards / Approvals…………………………………………………………………………….. 4
Ex safety instructions……………………………………………………………………………… 4
Handling……………………………………………………………………………………………… 4
Product liability and warranty……………………………………………………………………. 5
Items included with supply……………………………………………………………………….. 5
Documentation supplied………………………………………………………………………….. 5
Official approvals and certificates………………………………………………………………. 5
Principle components……………………………………………………………………………... 6
Equipment labels…………………………………………………………………………………… 7
Type code……………………………………………………………………………………………. 8
1 Mechanical Installation……………………………………………………………………… 9
1.1 Positioning the flow switch……………………………………………………………………. 9
1.2 Installation in hazardous areas (Ex applications)………………………………………….. 9
1.3 Connecting the DW 18 to the pipe…………………………………………………………… 9
1.4 Flow direction…………………………………………………………………………………... 9
2 Electrical Connections…………………………………………………………………….. 10
3 Commissioning……………………………………………………………………………… 11
3.1 General notes………………………………………………………………………………… 11
3.2 Adjusting the limit switches - standard and EEx ia flow switch versions………………. 11
3.2.1 Type G indicator……………………………………………………………………………. 11
3.2.2 Type A indicator…………………………………………………………………………..... 12
3.3 Adjusting the limit switches - EEx d flow switch version…………………………………. 12
3.3.1 MS 12/BRX switch…………………………………………………………………………. 12
4 Display………………………………………………………………………………………... 13
4.1 Local Flow indication………………………………………………………………………… 13
4.2 Limit Switches………………………………………………………………………………… 13
4.3 EEx d version…………………………………………………………………………………. 14
4.4 High-temperature version (KROHNE temperature class H3, non-EEx)………………... 15
4.5 Tropical version (non-EEx)………………………………………………………………….. 15
2 Installation and operating instructions DW 181 - 184
5 Service………………………………………………………………………………………... 16
5.1 Maintenance………………………………………………………………………………….. 16
5.2 Exploded view of instruments………………………………………………………………. 16
5.3 Spare parts……………………………………………………………………………………. 18
5.4 Inspection procedure………………………………………………………………………… 21
5.4.1 Inspection procedure: measuring assembly…………………………………………….. 21
5.4.2 Inspection procedure: housing (DW181 & DW182 models)…………………………... 21
5.5 Basic servicing procedures………………………………………………………………….. 22
5.5.1 Changing the position of the dial on the type A indicator……………………………… 22
5.5.2 Removing the display assembly: operating faults in the housing DW18x Std /EExia flow
controllers equipped with type G or A indicators……………………………………….. 23
5.5.3 Cleaning the springs or changing the measuring system sub-assembly…………….. 24
5.5.4 Changing gaskets in DW 183 flow controllers…………………………………………. 24
6 Technical Data………………………………………………………………………………. 25
6.1 Flow range table by flow range code………………………………………………………. 28
6.2 Instrument version materials………………………………………………………………... 30
7 Dimensions and Weights………………………………………………………………….. 31
8 Measuring Principle………………………………………………………………………… 36
8.1 Measuring systems…………………………………………………………………………... 36
8.2 DW 183………………………………………………………………………………………... 36
Appendix A: Declaration of conformity: CE………………………………………………….. 37
Appendix B: If you need to return a device for testing or repair to KROHNE…………. 38
Installation and operating instructions DW 181 - 184 3
General advice on safety
This manual gives a complete set of instructions for the installation, operation and
maintenance of the standard and ATEX versions of the DW 18 flow switches.
DW 18 flow switches must be used with liquids that do not have any gas pockets.
Special regulations are applicable to the use of equipment in hazardous locations,
and these are described in this booklet. Data is supplied on explosion protection.
Assembly, installation, commissioning and maintenance of equipment in
hazardous areas must only be carried out by qualified personnel with
relevant explosion protection training.
Standards / Approvals
DW 18 flow switches meet the protection requirements of Directive
89/336/EEC in conjunction with EN 50081-1 and EN 50082-2, and Directives
73/23/EEC and 93/68/EEC in conjunction with EN 61010-1, and also bear the
CE symbol.
These instruments, when ordered with the appropriate options, are certified for
use in hazardous locations by the INERIS certification agency under INERIS
03ATEX0045X. They respect the Health & Safety regulations in force by
conforming to EN 50014 (+ A1 & 2), EN 50018, EN 50020, EN50284, EN
50281-1-1 (+ A1) and EN 13463-1.
Ex safety instructions
The DW 18 flow switch series are suitable for monitoring flow of liquid in pipes in hazardous
areas. They may be approved for use in explosive atmospheres of all flammable substances in
Gas Group IIC in Zone 1 and applications requiring Category 2 equipment for EEx d applications
and Gas Group IIC in Zone 0 requiring Category 1 equipment with an intrinsically-safe power
supply for
EEx ia applications.
Ex Equipment Category Definitions
Category 1 G/D – instruments: for intrinsically-safe applications
The signal converter for the limit switch options and the measuring components are located in
hazardous areas requiring instruments qualified as being category 1. The G/D rating states that
the instrument is qualified for gas and dust environments. EEx ia-approved devices must be used
with a certified intrinsically-safe power supply.
Category 2 G/D – instruments: for applications using the EEx d-rated explosion-proof box
The signal converter for the limit switch options and the measuring components are located in
hazardous areas requiring instruments qualified as being category 2. The G/D rating states that
the instrument is qualified for gas and dust environments.
Handling
The device weighs between approx. 2 kg (4.5 lb) and 14 kg (30 lb). Carry using both hands to lift
the device carefully by the tube. If necessary, use lifting gear.
Avoid hard blows, jolts, impacts, etc. when handling the DW 18.
4 Installation and operating instructions DW 181 - 184
Product liability and warranty
The DW 18 flow meter is designed solely for measuring the flow rate of liquids without any gas
pocket. Special codes and regulations apply to its use in hazardous areas.
Responsibility as to suitability and intended use of these level gauges rests solely with the user.
Improper installation and operation of our level gauges may lead to loss of warranty.
In addition, the "General conditions of sale", forming the basis of the purchasing contract, are applicable.
If you need to return the level gauge to the manufacturer or supplier, please refer to the information
given in Appendix B.
Items included with supply
The scope of supply encompasses, in the version ordered:
• Flow meter
Documentation supplied
• Installation and operating instructions (this manual) including description of special versions and
functions.
Official approvals and certificates
Application Approved by Instrument version Certification mark
ATEX certification
*This EC-type Examination Certificate is available in KROHNE’s download centre on
http://www.krohne.com/.
INERIS DW 18 TYPE 18. Certificate no.
INERIS 03ATEX0045X*
Installation and operating instructions DW 181 - 184 5
Principle components
DW 18 Standard or EEx ia version
1 Indicator type G (linear scale) or A
(dial)
2 Equipment label*
3 Flange (illustrated) or screwed
connection
4 Indicator cover locking pin
5 Flow direction arrow (DW183/4)
6 Wiring compartment cover
7 Gland (plugged)
8 Cable fitting (PG 13.5)
9 Measuring tube
DW 18 EEx d version
DW 18 HT (H3) version
1 Equipment labels*
2 MS 12/BRX switch housing
3 Cable fitting (to be supplied by the
customer)
4 PE terminal
5 Flow direction arrow (on measuring
tube for DW181/2)
6 Socket set screw for adjusting
switch position
7 Pressure housing
8 Equipment dog-tag (tag no., etc.)
9 Screw-on connection
1 Pressure housing
2 Switch sheathed in a PTFE
cartridge
3 Measuring tube
4 Electric cable in fibre glass
sheathing
5 MS 14 switch information label
6 Wiring box
7 Cable fitting (PG 9)
* Equipment labels shown on next page
6 Installation and operating instructions DW 181 - 184
Equipment labels
Standard label (all devices)
EEx ia supplementary information label (e.g. version K1 NO)
EEx d supplementary information label (e.g. version NC)
1 Designation code acc. to order
2 Type code
3 Purchase order number
4 Factory serial number
5 Customer tag number
1 ATEX gas group and equipment
2 Year built
3 ATEX certification code
4 Electrical safety values
5 Wiring diagram
6 Protection concept & gas group +
1
2 ATEX certification code
3 Year built
4 ATEX gas group and equipment
5 Protection concept & gas group +
6 Factory serial number
7 Maximum switching capacity
8 Wiring diagram
options list (e.g.V7BD1...)*
(e.g. DW181/C/011/B/G/KA/N/G1)**
category (e.g. II 1 GD)
sub-div. and temperature class (e.g.
EEx ia IIC T3...T6)
Limit switch code
category (e.g. II 1/2 GD)
sub-div. and temperature class
(e.g. EEx d IIC T3...T6)
* See DW 181-184 Data sheet for a list of order options and designation codes
** See type code definitions on the next page
Installation and operating instructions DW 181 - 184 7
Type code
Refer to the standard device label, item 2 on the previous page.
DW . . .
1 2 3 4 5 6 7 8
Type code element Code Code definition
1 Type series 181
2 Measuring system C
3 Code number 011 - 204 See section 7.1: Flow range table for the
4 Material of construction
- see also section 7.2
5 Indicator system G
6 Limit switches K1
7 Application field N
8 Connection G ¾…G2
* Refer to section 9.1
** Bistable.
NO is a “normally open” switch during operation (closed switch when flow is decreasing)
NC is a “normally closed” switch during operation (closed switch when flow is increasing).
/ . / . . . . / . . / . / . . . / . . / . .
182
183
184
E
P
B
RR
R
N
A
K2
KV1
KV2
Ex d
Ex ia
DN15…200
(½”…8”)
For horizontal or vertical pipes, screw
connection G¾…G2, measuring system C or
E*
For horizontal or vertical pipes, flange
connection DN15…65 and ½”…2”-150 lbs,
measuring system C or E*
For horizontal or vertical pipes, flange
connections DN65…200 and 3”…8”-150 lbs,
measuring system P*
For horizontal pipes (DN ≥250 or 10”, mounting
flange DN150 PN16 or 6”-150 lbs, measuring
system P*
Measuring disc in tapered tube
Nozzle with baffle
Baffle in constant diameter pipe
characteristics of each code number.
Bronze
Stainless steel (SS) 316 L
SS 316L measuring tube, steel connection
Steel
Linear scale marks
Dial with flow units
1 NC or 1 NO switch**
1 NC and 1 NO switch**
Amplifier relay: 1 change-over switch**
Amplifier relay: 2 change-over switches**
Normal locations
Hazardous locations
Intrinsically-safe applications
Pipe thread
Flange connection
8 Installation and operating instructions DW 181 - 184
1 Mechanical Installation
1.1 Positioning the flow switch
No obstacles along the pipe within five diameters (D) upstream and two diameters downstream of
the instrument.
1.2 Installation in hazardous areas (Ex applications)
Read all instructions referring to flow switches in hazardous locations before installation.
Check that the flange, gasket and other materials in contact with the product are compatible. Refer
to the information given on the converter nameplate, the flange markings and specifications given
in the ATEX approval certificate.
1.3 Connecting the DW 18 to the pipe
• Before installation, clean the piping to remove any dust or weld debris.
• Fit the instrument on the pipe with the arrow on the housing pointing in the direction of flow.
• Flange connections: ensure that the gaskets are in place, flange facings are aligned and parallel
and that the bolts have been tightened with the amount of torque specified in European or local (if
outside the E.U.) standards.
1.4 Flow direction
The DW 183 and DW 184 can be installed in any position on the piping. However, the position of
installation and the flow direction must be indicated in the customer order (i.e. up, down, left to right
and right to left) as the weight of the baffle disc is taken into account when calibrating the
instrument. Flow direction must be indicated for DW 181 and DW 182 instruments equipped with
type A indicators.
The DW 184 is used for high-velocity or turbulent flows in pipes with diameters greater than
DN250. A special device, called a stilling well, is immersed in the liquid flow and channels the fluid
through a tube in which the disc moves, secured to the end of a rigid support. This reinforced pivot
enables the flow switch to be used in difficult conditions.
These instruments are only supplied with an index display (indicator type “G”) and switches. They
are not equipped with a graduated dial. The heights of the connection piece indicated for the
production of the mating flange must be respected.
Installation and operating instructions DW 181 - 184 9
2 Electrical Connections
Disconnect the power supply before opening the housing
• The electrical connection
conforms to the standard
EN61010-1, protection
class 1 (for aluminium
housing) or class 2 (for
PVC housing), voltage
category III, and
interference degree 2.
• The DW range conforms
to EMC directives NF EN
50 081.1 (Emission) and
NF EN 50 082.2
(Immunity).
• It is obligatory to have a
switching or circuit
breaking device, following
present regulations. The
devices should completely
isolate the unit and be
easily accessible, close to
the unit.
• Both the live (L) and
neutral (N) wires should
be protected by a fuse
(4…6.3 A Time Lag).
During the wiring
procedure the ground wire
should always be
connected first (relevant
only for aluminium
housing).
• EEx ia versions must be
used with a certified
intrinsically-safe power
supply.
N.B. Use of the unit
outside the specifications
detailed in this manual can
compromise the safety
measures designed into the
unit. Always disconnect the
power supply before
accessing the terminals.
Number
of
switches
1
2
1
1
K1
+
K2
Switch
types
Type
K1
Type
K1
Type
K2
Type
K2
Type
K2
Type
K2
Type
KV1
Type
KV2
Change
over
(SPDT)
Limit switch adjustable over entire range
A
B
C
D
E
F
G
H
10 Installation and operating instructions DW 181 - 184
3 Commissioning
3.1 General notes
The flow switch is delivered pre-calibrated and ready for use. Open the valves slowly when starting
operation.
3.2 Adjusting the limit switches - standard and EEx ia flow switch versions
The limit switches can be adjusted individually over the entire measuring range. To adjust, remove
the locking pin securing the cap and remove the cap.
3.2.1 Type G indicator
The limit switch adjustment is indicated by a green strip (normally closed switch) or a black strip
(normally open switch) in a graduated window. For flow switches manufactured before September 1,
1991, the strips are red (normally closed switch) or orange (normally open switch).
Each graduation corresponds to 1/10 of the total measuring range, i.e. 35 l/h for a flow range of
50…400 l/h. This system enables the limit switch to be adjusted without having to circulate fluid in
the pipe. It is only necessary to adjust the micrometer screw (item 2) in order to move the switch
support (item 3) which has the coloured strip on its upper section.
“G” linear index indicator assembly
1
Index
2 Micrometer screw
3 Switch support
4 Switch
5 Control magnet
6 Following magnet
Installation and operating instructions DW 181 - 184 11
3.2.2 Type A indicator
The switch is adjusted by unlocking the adjustment screw (item 7) and repositioning the switch
support arm (item 8).
“A” graduated dial indicator assembly
1
Pointer
2 Dial
3 Following magnet
4 Control magnet
5 Mechanism
6 Switch
7 Adjustment screw
8 Switch support
3.3 Adjusting the limit switches - EEx d flow switch version
3.3.1 MS 12/BRX switch
The switch is adjusted by unscrewing the limit switch adjustment screw M8x10 (2) on top of the
pressure housing with a 4mm hexagon key. The switch (in its metal sheath) may then be
repositioned as required before retightening the screw. The original position is etched onto the
sheath.
MS 12/BRX switch assembly
1
MS 12/BRX switch
2 Limit switch adjustment
screw
3 Switch sheath
4 Switch magnet
5 Pressure housing
12 Installation and operating instructions DW 181 - 184
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