Page 1
Oscillating
piston flowmeter
series COVOL
Instructions manual
R-MI-COVOL Rev.: 4 English version
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PREFACE
Thank you for choosing the oscillating piston flowmeter series
COVOL from Tecfluid S.A.
This instruction manual allows the installation and operation of the
oscillating piston flowmeter series COVOL. It is recommended to
read it before using the equipment.
WARNINGS
This document shall not be copied or disclosed in whole or in
any part by any means, without the written permission of
Tecfluid S.A.
Tecfluid S.A. reserves the right to make changes as deemed
necessary at any time and without notice, in order to improve
the quality and safety, with no obligation to update this manual.
Make sure this manual goes to the end user.
Keep this manual in a place where you can find it when you
need it.
In case of loss, ask for a new manual or download it directly
from our website www.tecfluid.com Downloads section.
Any deviation from the procedures described in this instruction
manual, may cause user safety risks, damage of the unit or
cause errors in the equipment performance.
Do not modify the equipment without permission. Tecfluid S.A.
is not responsible for any problems caused by a change not
allowed. If you need to modify the equipment for any reason,
please contact us in advance.
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TABLE OF CONTENTS
1 WORKING PRINCIPLE ......................................................................... 4
2 RECEPTION ........................................................................................... 5
3 INSTALLATION .................................................................................... 5
3.1 Filter .......................................................................................... 5
3.2 Open discharge ........................................................................ 6
3.3 Position ..................................................................................... 6
3.4 Straight pipe sections .............................................................. 6
3.5 Valves ....................................................................................... 6
3.6 Pumps ........................................................................................ 6
3.7 Electrical connection ............................................................... 7
4 MAINTENANCE .................................................................................... 8
4.1 Disassembly ............................................................................. 9
4.2 Mounting ................................................................................... 9
4.3 Replacing the reed switch group ............................................ 10
5 PART LIST ............................................................................................ 11
6 TECHNICAL DATA ................................................................................ 12
7 DIMENSIONS ......................................................................................... 13
8 K FACTOR (PULSES / LITRE) .............................................................. 16
9 ADDITIONAL INSTRUCTIONS FOR THE ATEX VERSION ................. 16
9.1 Intrinsic safety .......................................................................... 16
9.2 Flameproof enclosure .............................................................. 16
9.2.1 Earth connection ........................................................................ 17
9.2.2 Maintenance ............................................................................. 17
9.2.3 Technical data for the ATEX version ...................................... 17
9.2.4 Marking ..................................................................................... 18
9.2.5 Dimensions ............................................................................... 19
10 TROUBLESHOOTING ........................................................................... 23
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1 WORKING PRINCIPLE
By means of oscillating piston and an annular measuring
chamber.
1– The first figure shows the COVOL flowmeter at the beginning
of a cycle, when the measuring chamber (in blue) is
completely full.
2– The flow of the liquid through the flowmeter makes a force on
the oscillating piston, so that it starts turning. From this moment
the measuring chamber is divided in two parts: inlet (in red) and
outlet (in blue).
3– The liquid fills progressively the inlet measuring chamber (in
red), as it is getting emptied on the outlet (in blue). In the middle
of the cycle (see figure) the two chambers are the same size.
4– At this stage the outlet measuring chamber has already
emptied almost all the liquid corresponding to a cycle, while on
the inlet it is almost filled with the liquid corresponding to the next
cycle.
5- At the end of the cycle, the inlet measuring chamber takes all
the space. From this moment it can be considered that this is
already the outlet chamber, so we are again at the beginning of
the cycle.
As one can see, a constant volume of liquid is moved in each
cycle.
The piston includes a magnet inside that activates a reed switch
each complete turn. The output signal can be treated by means of
an electronic converter.
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2 RECEPTION
COVOL oscillating piston flowmeters are supplied individually packaged for protection during
transport and storage, including their corresponding instructions manual, for their installation
and use.
All the flowmeters have been verified in our flow rigs, obtaining the K factor for each
device.
3 INSTALLATION
The installation must be made in a point that ensures that the pipe is completely full of
liquid.
Highest points in the installation as well as downwards pipes must be avoided, since air
pockets or vacuums might occur.
In installations where air can be present, a degasser must be installed before the
flowmeter.
Partially full pipe can involve important measurement errors.
3.1 Filter
The installation of a filter before the COVOL oscillating piston is mandatory. This way a
correct performance is guaranteed and severe damage is avoided.
The mesh size must be between 0.1 and 0.2 mm², in order to avoid that bigger particles
can block or get embedded in the oscillating piston, stopping or slowing it and providing
false readings.
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3.2 Open discharge
When the flow measurement is to be made before an open discharge, it is necessary to
install the flowmeter in a section of pipe with a trap which avoids the presence of air inside
the meter.
3.3 Position
The installation and position of the flowmeter can be either vertical, horizontal or inclined.
The flow direction does not affect the flowmeter accuracy.
3.4 Straight pipe sections
Straight pipe run is not required, the flowmeter can be installed just before or after
disturbing elements.
3.5 Valves
Regulating or shut-off valves must always be installed after the flowmeter, in order to
assure that pipe is full of liquid.
3.6 Pumps
Pumps must always be installed before the flowmeter in order to avoid cavitations.
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This way the presence of air pockets in the flowmeter is avoided, which could cause false
readings. In particular, the associated electronics would show a volume higher than real.
Note: In order to avoid cavitations, the API Std 2534 standard must be taken into
account. This standard states that on the outlet of the flowmeter the pressure must be at
least twice the pressure drop of the flowmeter (in case of COVOL, this pressure drop is
3 mH2O or 0.3 bar, for fluids with viscosity 1 mPa·s at maximum flow rate), plus 1.25
times the vapour pressure of the liquid or its most volatile components.
3.7 Electrical connection
It is important to keep the connecting cable between the flowmeter and the associated
electronics away from mains or power supply cables, in order to avoid interferences. In
any case, those should be separated at least 5 cm.
The COVOL oscillating piston flowmeter has a connector fastened to the counter by
means of 4 screws. The connector consists of 3 parts joined by threaded nuts. (See
figure).
Loosening the larger nut in the middle of the connector allows us to withdraw the half
where the cable will be later soldered.
The other half of the connector is fixed to the counter and should not be removed, except
when servicing the detector (See point 4.3 of the MAINTENANCE section).
The removable part of the connector consists of the cable gland at the top and the
electrical connection protector housing.
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Before starting the installation, check that the cable gland is the right size for the cable to
be used. This will guarantee the instrument will stay watertight. The cable gland used is
for cables with outside diameters between 6 mm and 10 mm.
The electrical connection protector housing is dismounted by loosening the second nut.
When this is removed, the three connector terminals are visible.
The terminals are numbered 1 to 3 and the connection is as follows:
N. 1 & 2: Electrical switch connection.
N. 3: This terminal has a shortcircuit with terminal N.1. Don’t connect
Before soldering the connections, unscrew the cable gland and feed it, together with the
electrical connection protector housing, over the cable.
The joint between the cable and the connector should always be soldered, and should be
tidy and without short circuits between terminals.
Peel the outside insulation to free the inner cables. It is recommended to tin the ends of
the wires to avoid loose ends.
Once the connections have been made, the housing should be mounted screwing it on
and then the cable gland should be tightened to avoid entry of any liquid or humidity.
Once assembled the half of the connector, the mounting in the base has only one position
defined by the keyway between the two parts.
Check that the rubber seal is in its position inside the connector base. If this is the case,
introduce the connector half in the base, positioning by the keyway, and screw on the nut
until the end of the thread is reached.
anything to this terminal.
4 MAINTENANCE
In normal working conditions the COVOL flowmeter has a long life. Normally it will not be
necessary to change any parts.
The life of the parts depends mainly on the abrasive characteristics of the product to be
measured and the flow rate.
The combination of these two factors, together with the construction material of the
flowmeter, makes it difficult to estimate the life of the device in good working conditions
If the maximum flow rate for each DN shown in the chart below is exceeded the life of the
pieces can be considerably reduced.
Flow ranges
DN
10 / ¼" (H) 25-250 500 100
10 40-350 800 100
15 150-1500 2700 20
25 500-4500 9000 10
40 800-8500 15500 4
50 1500-16000 28000 2
80 3000-28000 50000 1
100 5000-60000 104000 0.2
Flow scales
l/h water
Max. intermittent
l/h water
8
pulses / litre
approx.
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4.1 Disassembly
The list of the different elements is shown in the chart and figure in “Part List” on page 11.
The device consists of the following elements:
- Flowmeter body (chamber and connections)
- Oscillating piston
- Inlet / outlet separator
- Chamber guide disks (2 off)
Flowmeter body
The disassembly of the body should be started at the side marked with the number 2, and
this is done by loosening the hexagonal bolts (8) situated on the periphery of the cups (1)
and central ring of the counter (4).
Once loosened and removed (it only has to be done on the number 2 side of the counter),
we can detach the cup (1). The o-ring (2) and the smooth exterior part of the metering
chamber's disk (3), marked with number 1, can now be seen.
The disk (3) has a threaded hole that takes a screw to allow us to withdraw the disk
smoothly.
The disk should be withdrawn perpendicularly, uncovering the metering chamber (4) with
the rotary piston (10) and inlet/outlet separator (5).
The piston (12) is easily removed and it has a drop form opening to fit the inlet/outlet
separator (5) which acts as a guide for the rotation of the piston.
The inlet/outlet separator (5) joins the metering chamber ring to the central circular guide
of the guide disk (3). It can be removed by pulling it out perpendicularly.
In this way the metering chamber (4) is completely dismounted for inspection and
thorough cleaning if necessary.
If the metering chamber (4) is damaged due to the effect of abrasive products or nonfiltered hard particles that scratched its inner wall, said chamber must be machined at
Tecfluid S.A. facilities and proceed with the re-adjustment with a new rotary piston as well.
In case it was necessary to clean the chamber (7) marked with number 1, the external
screws (13) must be loosen. Once removed the inlet chamber, the gasket and the
external smooth side of the inlet guide disk (6) can be seen.
Then the cleaning of all components can be carried out.
Rotary piston
This is the only mobile piece of the COVOL oscillating piston flowmeter.
It has a long life due to the Teflon and graphite composition, that makes it very wear
resistant and gives it a low friction coefficient.
Premature wear can only be due to abrasive products and flow rate higher than those
indicated in the table of page 8, which can cause excessive knocks at the inflection point
of the oscillating turning of the piston, producing breakage at very high speeds. Other
materials for the piston can be used depending on the application without affecting
significantly its working life. Non-filtered particles can also damage the piston.
4.2 Mounting
If the flowmeter body has been completely disassembled, reassembly should start by
placing the guide disk (6) in the metering chamber (4), matching the positioning hole with
the metering chamber (4) pin. Then place the o-ring and the inlet chamber (7), which is
marked with number 1.
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Mount the inlet chamber (7) together with the metering chamber (4) by tightening the
screws (13) and washers until a rigid assembly is obtained (the final tightening will be
done later).
The inlet/outlet separator is fitted with the bevelled part in the groove of the guide disk (6)
rings and the part with sharp edges in the groove of metering chamber (4).
The piston (12) is mounted taking care that the drop form opening fits over the inlet/outlet
separator (5) and that the piston shaft fits into the circular groove formed by the two rings
of the guide disk (6). Check that the piston rotates smoothly without rubbing in its
complete path.
With the help of the extractor screw that we have mounted during disassembly, mount the
guide disk (3) with the flat side outwards, coupling the inlet/outlet separator (5) in its
position.
Note that the guide disk (3) has its mounting position defined by the groove for the inlet/
outlet separator.
If this is not done as indicated, the guide disk (3) could be damaged also avoiding a
hermetic sealing of the flowmeter.
Check the perfect fitting of the guide disk (3), place the O-ring (2) on the guide disk and
adjust it around the edge of the metering chamber (4).
Mount the cup or coupling piece (1), checking the position of the O-ring (2). Assemble the
fixing screws and tighten them until the two pieces are firmly against each other.
Tighten the screws of the other cup (13).
The flowmeter is ready for installation and operation.
4.3 Replacing the reed group
The female connector (10), as already indicated in the Installation section, is removed
from the base by the larger nut. The connector base is mounted together with the reed
switch group (9).
Unscrew the female connector (10) to separate the cable and then loosen the 4 screws of
the reed switch group (9).
In order to replace the reed switch group please follow the opposite procedure taking care
that the gasket (11) is correctly positioned.
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5 PART LIST
Materials
Nº Description
1 Inlet / outlet chamber + connection EN 1.4404 (AISI 316L) PTFE / PVC / PP
2 O-ring
3 Guide disk EN 1.4404 (AISI 316L) PTFE / PVC / PP
4 Measuring chamber EN 1.4404 (AISI 316L) PTFE / PVC / PP
5 Separator EN 1.4404 (AISI 316L) PTFE / PVC / PP
6 Screws EN 1.4401 (AISI 316)
7 Reed sensor group ———
8 Connector Aluminium alloy + Polyamide
9 Gasket NBR
10 Piston PTFE + Graphite / Bronze / Aluminium
AISI 316L PTFE / PVC / PP
NBR / PTFE / EPDM / VITON®
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TECHNICAL DATA
6
Accuracy
± 0.8% measured value
Repeatability
± 0.3% measured value
Measuring range: 30:1.
Installation: Horizontal or vertical.
Connections
EN 1092-1 PN16 flanges. Others on request.
Materials
Body: AISI 316L, PVC, PTFE, PP
Piston: PTFE-Graphite, PVDF, Aluminium, Bronze, others on request.
Working pressure
AISI 316L: PN 16
PVC / PTFE / PP: PN 10
Others on request
Working temperature
AISI 316L: -40ºC ... +150ºC
PVC: 0ºC ... +40ºC
PTFE: -20ºC ... +130ºC
PP: -10ºC ... +80ºC
Electrical connection
By means of IP65 connector.
Recommended cable
Shielded bifilar up to 50 m length.
Reed switch characteristics
V max: 30 VDC. I max: 20 mA.
Conforms with the Pressure Equipment Directive 97/23/EC.
This equipment is considered as being a pressure accessory and NOT a safety accessory
as defined in the 97/23/CE directive, Article 1, paragraph 2.1.3.
Associated electronics
CIP / CIP II: Battery powered volumetric counter.
CP ... CH420: 2-wire analog transmitter with flow rate and volume indication.
HART protocol optional.
MC01: Flow rate and volume indicator with relay output for batching.
MT02: Volume counter with relay output for batching.
DFD2: Frequency divider.
CI420: Analog transmitter.
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7 DIMENSIONS
DN
10
15
25
40
50
80
100
PN
(flanges)
16 90 60 40 14 x 4 180 14
16 95 65 45 14 x 4 180 14
16 115 85 68 14 x 4 200 16
16 150 110 88 18 x 4 220 16
16 165 125 102 18 x 4 240 18
16 200 160 138 18 x 8 260 20
16 220 180 158 18 x 8 340 20 360 245
INOX
D K g l x nº L b
A H (max)
80 105
105 115
140 135
180 155
200 165
250 190
DN
10
15
25
40
50
80
100
PVC, PTFE, PP
PN
(flanges)
10 95 60 40 M10 x 4 150 20
10 100 65 44 M12 x 4 210 30
10 120 85 64 M12 x 4 230 30
10 150 110 84 M16 x 4 250 30
10 175 125 98 M16 x 4 270 30
10 230 160 138 M16 x 8 305 45
10 250 180 158 M16 x 8 450 55 420 275
D K g l x nº L b
13
A H (max)
90 110
145 140
170 150
200 165
225 180
300 215
Page 14
Model AISI 316L
DN D g K (l x nº) x b
10 77 40 60 (M12 x 4) x 15 90 100 110
15 84 45 65 (M12 x 4) x 15 110 110 115
25 107 68 85 (M12 x 4) x 15 120 140 135
40 135 88 110 (M16 x 4) x 20 150 180 155
50 154 102 125 (M16 x 4) x 20 180 200 165
80 200 138 160 (M16 x 8) x 20 200 250 190
Available for DN100 with special design. Please consult factory
L A H
Models PTFE / PVC / PP
DN D g K (l x nº) x b
10 90 40 60 (M12 x 4) x 18 100 115 120
15 95 45 65 (M12 x 4) x 20 125 125 130
25 115 68 85 (M12 x 4) x 25 140 150 140
40 145 88 110 (M16 x 4) x 25 160 180 155
50 160 102 125 (M16 x 4) x 25 195 200 165
80 200 138 160 (M16 x 8) x 25 235 250 190
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L A H
Page 15
COVOL-H DN10 / ¼” low flow, horizontal
COVOL + CIP … CIP II / CP … CH420L
DN HC * HC **
10 (H) 130 130
10 135 145
15 140 155
25 160 165
40 180 180
50 190 190
80 215 215
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8 K FACTOR (PULSES / LITRE)
DN
10 / 1/4” (H)
10
15
25
40
50
80
100
Measured values for water at 20 ºC
Pulses / litre
± 12%
100 10
100 10
20 50
10 100
4 250
2 500
1 1000
0,2 5000
cm3 / pulse
± 10%
9 ADDITIONAL INSTRUCTIONS FOR THE ATEX VERSION
This chapter only applies to equipment intended for use in explosive atmospheres.
9.1 Intrinsic safety
The flowmeters of series COVOL, when include just the reed sensor and the connector,
can be considered simple apparatus as defined in the EN 60079-11 standard. In these
cases it can be installed in hazardous areas provided that they are connected to a zener
barrier or to an intrinsic safety isolator. Please consult factory for the recommended
models.
9.2 Flameproof enclosure
These equipment conform with the directive 94/9/CE (Equipment and protective systems
intended for use in potentially explosive atmospheres) as indicated in the EC-type
examination certificate LOM 14ATEX2006 X and its marking.
Given that this instrument belong to group II, it is intended for use in places likely to
become endangered by explosive atmospheres, but not in mines.
The category is 2GD, that is, it is intended for use in areas in which explosive
atmospheres caused by mixtures of air and gases, vapours, mists or air/dust mixtures are
likely to occur.
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9.2.1 Earth connection
When the instrument is not grounded securely through the connection process, it should
be grounded through the housing screw, as shown in the figure.
9.2.2 Maintenance
NOTE: When the flameproof enclosure contains an electronics model CIP or CIP II, it
should never be opened in presence of explosive atmosphere.
For the rest of models, before any maintenance that involves opening the flameproof
enclosure, make sure there is no voltage in any of internal components.
The is no special maintenance for the ATEX version.
9.2.3 Technical data for the ATEX version
Temperature
Ambient temperature: -20 ... +60 ºC
Electrical connection
Inside the flameproof enclosure.
Recommended cable
The standard thread supplied for the cable gland connection is 3/4” NPT.
ATEX cable glands for non-armoured or armoured cables can be placed .
The outer diameter of the cables that fits the 3/4” NPT cable glands is between 6 and 21
mm.
Associated electronics
CIP / CIP II: Battery powered volumetric counter.
CP ... CH420: 2-wire analog transmitter with flow rate and volume indication.
HART protocol optional.
Conforms to 94/9/EC Directive (equipment and protective systems
intended for use in potentially explosive atmospheres).
The rest of characteristics are the same as in the point 6.
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9.2.4 Marking
The marking of the equipment shows the following characteristics:
- Manufacturer
- Model
- Serial number (year of construction and number)
- CE marking
- ATEX marking
- Certification number
- Address of the manufacturer
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9.2.5 Dimensions
DN
15
25
40
50
80
100
DN
15
25
40
50
80
100
INOX
PN
(flanges)
16 95 65 45 14 x 4 180 14
16 115 85 68 14 x 4 200 16
16 150 110 88 18 x 4 220 16
16 165 125 102 18 x 4 240 18
16 200 160 138 18 x 8 260 20
16 220 180 158 18 x 8 340 20
PN
(flanges)
10 100 65 44 M12 x 4 210 30
10 120 85 64 M12 x 4 230 30
10 150 110 84 M16 x 4 250 30
10 175 125 98 M16 x 4 270 30
10 230 160 138 M16 x 8 305 45
10 250 180 158 M16 x 8 450 55
D K g l x nº L b
PVC, PTFE, PP
D K g l x nº L b
19
HA1
A
(max)
105 205
140 225
180 245
200 255
250 280
360 335
HA1
A
(max)
145 230
170 240
200 255
225 270
300 305
420 365
Page 20
DN
15
25
40
50
80
100
DN
15
25
40
50
80
100
INOX
PN
(flanges)
16 95 65 45 14 x 4 180 14
16 115 85 68 14 x 4 200 16
16 150 110 88 18 x 4 220 16
16 165 125 102 18 x 4 240 18
16 200 160 138 18 x 8 260 20
16 220 180 158 18 x 8 340 20
PN
(flanges)
10 100 65 44 M12 x 4 210 30
10 120 85 64 M12 x 4 230 30
10 150 110 84 M16 x 4 250 30
10 175 125 98 M16 x 4 270 30
10 230 160 138 M16 x 8 305 45
10 250 180 158 M16 x 8 450 55
D K g l x nº L b
PVC, PTFE, PP
D K g l x nº L b
20
HA2
A
(max)
105 250
140 270
180 290
200 300
250 325
360 380
HA2
A
(max)
145 275
170 285
200 300
225 315
300 350
420 410
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Model Exd ADF30
DN
15 205 220
25 225 230
40 245 245
50 255 255
80 280 280
Exd models are not available for flowmeter sizes DN10 (H) and DN10
HA1
AISI 316L
DN100 on request
21
HA1
PP/PVC/PTFE
Page 22
Exd housing model ADF60V
DN
15 250 265
25 270 275
40 290 290
50 300 300
80 325 325
Exd housings are not available for flowmeter sizes DN10 (H) and DN10
HA2
AISI 316L
DN100 on request
22
HA2
PP/PVC/PTFE
Page 23
TROUBLESHOOTING
10
Problem Possible cause Solution
The associated
electronics does not
totalize
The associated
electronics totalize less
than the actual volume
The associated
electronics totalizes
more than the actual
volume
The flow rate indicated by
the associated equipment
is unstable
Blockage or friction of the piston
by particles
Damaged reed group Change the reed group
Disconnected cables between the
COVOL and the associated
electronics
Operating liquid with properties
very different from water at 20ºC
(calibration liquid)
Blockage or friction of the piston
by particles
Operating liquid with properties
very different from water at 20ºC
(calibration liquid)
Presence of air pockets
Excessive emptying of storage
tanks
The pipe is not completely full
Install a filter according to
specification (maximum mesh
size between 0.1 y 0.2 mm²).
Check the cable connection
Correct the i/l factor
Install a filter according to
specification (maximum mesh
size between 0.1 y 0.2 mm²).
Correct the i/l factor
Control the minimum tank level.
Provide an air degasser
upstream of the counter if air
intakes can be expected.
Make sure that the pipe is
completely full, for example,
installing the counter in a vertical
pipe with upwards flow
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WARRANTY
Tecfluid S.A. guarantees all the products for a period of 24 months from their sale, against all faulty
materials, manufacturing or performance. This warranty does not cover failures which might be
imputed to misuse, use in an application different to that specified in the order, the result of service
or modification carried out by personnel not authorized by Tecfluid S.A., wrong handling or
accident.
This warranty is limited to cover the replacement or repair of the defective parts which have not
damaged due to misuse, being excluded all responsibility due to any other damage or the effects
of wear caused by the normal use of the devices.
Any consignment of devices for repair must observe a procedure which can be consulted in the
website www.tecfluid.com, “After-Sales” section.
All materials sent to our factory must be correctly packaged, clean and completely exempt of any
liquid, grease or toxic substances.
The devices sent for repair must enclose the corresponding form, which can be filled in via website
from the same “After-Sales” section.
Warranty for repaired or replaced components applies 6 months from repair or replacement date.
Anyway, the warranty period will last at least until the initial supply warranty period is over.
TRANSPORTATION
All consignments from the Buyer to the Seller´s installations for their credit, repair or replacement
must always be done at freight cost paid unless previous agreement.
The Seller will not accept any responsibility for possible damages caused on the devices during
transportation.
TecfluidS.A.
NarcísMonturiol33
08960SantJustDesvern
Barcelona
Tel:+34933724511
QualityManagementSystemISO9001cerfiedby
PressureEquipmentDirecve97/23/CEcerfiedby
ATEXEuropeanDirecve94/9/CE
cerfiedby
Fax:+34934734449
tecfluid@tecfluid.com
HART®isaregisteredtrademarkofHARTCommunicaonFoundaon
www.tecfluid.com
Thetechnicaldatadescribedinthismanualissubjecttomodificaonwithoutnoficaonifthetechnicalinnovaonsin
themanufacturingprocessessorequire.
24
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