Kobold DOG-4 User manual

Operating Instructions
for
Oscillation Flowmeter
Model: DOG-4...
Transducer and Electronic Options A/B…O/P

DOG-4
page 2 DOG-4 K08/0818
1.Contents
1.Contents....................................................................................................... 2
2.Note.............................................................................................................. 4
3.Information on operating the device in potentially explosive environments
(Ex, A0/D0/F0/H0/K0/N0/P0 option)........................................................... 4
3.1General requirements.......................................................................... 5
3.2Startup, installation.............................................................................. 6
3.3Application........................................................................................... 6
3.4Repair, maintenance (for applications in Ex areas)............................. 7
3.1Disposal .............................................................................................. 7
4.Instrument Inspection ................................................................................... 8
5.Regulation Use............................................................................................. 8
6.Operating Principle....................................................................................... 9
7.Mechanical Connection .............................................................................. 10
8.Identification (Ex version) ........................................................................... 11
9.Electrical connections................................................................................. 12
9.1General ............................................................................................. 12
9.2Measuring cable in Ex areas............................................................. 12
9.3Connection to the measuring sensor................................................. 12
9.4Terminal assignment of the DOG-4… reader/transducer.................. 13
9.5Terminal assignment of the electronic option
G0/H0/I0/K0/M0/N0/O0/P0................................................................ 15
9.6Connections of DOG-4 Transmitter with KOBOLD Evaluation
Electronics ZED-X and ZOK-Zx......................................................... 17
10.Startup........................................................................................................ 20
11.Setup and operation of the flow controller/flow computer (option
G0/H0/I0/K0/M0/N0/L0/O0/P0) ................................................................ 20
12.Transmitter error message ......................................................................... 21
12.1Status display not illuminated............................................................ 21
12.2OPERATING illuminated green but no output signal......................... 21
12.3RANGE illuminated yellow................................................................. 21
12.4ERROR illuminated red..................................................................... 21
13.Maintenance............................................................................................... 22
13.1Replacing the sensor......................................................................... 22
13.2Disassembly and cleaning the Flowmeter......................................... 22
14.Technical Data............................................................................................ 24
14.1Electronic options.............................................................................. 25
15.Order Details .............................................................................................. 29
16.Pressure Loss/Flow.................................................................................... 31
17.Dimensions................................................................................................. 32
18.EU Declaration of Conformance................................................................. 34
19.ATEX-Certificate......................................................................................... 35
20.IECEx-Certificate........................................................................................ 41

DOG-4
DOG-4 K08/0818 page 3
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.kobold.com

DOG-4
page 4 DOG-4 K08/0818
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.
as per machine-guidelines 2006/42/EC
CE mark acc. ATEX-guideline 2014/34/EU
When used in machines, the DOG-4 should be used only when the machines fulfil
the EC-machine guidelines.
as per PED 2014/68/EU
Model Connection PN no dangerous gases
(diagr. 7, 2) dangerous gases (diagr. 6, 1)
DOG-4
DN 25 10 article 4, § 3 I
DN 40 until DN 50 10 I II
DN 80 until DN 150 10 I II
DN 200 10 I II
Funded by the Federal Ministry of Economics and Technology based on a decision
of the German Bundestag.
3. Information on operating the device in potentially
explosive environments (Ex, A0/D0/F0/H0/K0/N0/P0
option)
The devices can be used in the following way:
1. DOG-4S Flowmeter: In zones 0, 1 and 2 (gas Ex, category 1G, 2G, 3G) in
explosion groups IIA, IIB and IIC
2. DOG-4A Reader/Transducer Reader: Outside the EX area
Here the following ambient temperatures must be adhered to
-20 °C ≤Ta ≤60 °C
The DOG-4 is suitable for use with gases of the explosion group IIC and temperature
class ≥T4.
Further important details can be found in the EC Type Examination Certificate.

DOG-4
DOG-4 K08/0818 page 5
3.1 General requirements
In the event of failure to comply with this information or unauthorized tampering with
the device, the manufacturer's liability will no longer apply. Moreover, the guarantee
for the device and accessory parts will become void.
Comply with the information in these operating instructions and adhere to the
conditions of use and permissible data printed on each device / type plates.
Follow the generally accepted rules of technology when selecting and
operating a device.
Take appropriate measures to prevent unintentional activation or inadmissible
impairments.
The devices may be used only in the correct way and for the intended
purpose in a normal industrial environment. Use for unsuitable purposes, will
render all guarantees and liability of the manufacturer void!
Ensure that only devices with ignition protection suitable for the operating
zones are installed.
All electronic operating resources connected must be suitable for the
respective use.
The operator is obligated to provide lightning protection according to local
regulations.

DOG-4
page 6 DOG-4 K08/0818
3.2 Startup, installation
The devices are intended for installation in a higher-level system. The intervals for
cleaning the operating resources (dust deposits) are specified depending on the
degree of IP protection. It is extremely important to ensure that only devices with
suitable ignition protection for the zones/categories are installed! It is essential that
the installation regulations applicable at the national level, e.g. EN 60079-14, are
adhered to during installation. Other important factors:
In the event of adverse environmental conditions, it is necessary to ensure
that the devices are accordingly protected.
Follow the operating instructions for the respective device and adhere to any
special conditions described there.
The device may only be used for the purpose for which it was intended.
It is essential to avoid electrostatic charges.
Any possible metal parts in the device/lines (e.g. shielding) must be
incorporated in the potential equalization PA in compliance with the user’s
country regulations.
Parts that have jammed (e.g. as the result of frost or corrosion) may not be
loosened by force in hazardous atmospheres.
Operate the device only in the completely assembled state and enclosed in
undamaged housing. Operating with a damaged housing is prohibited.
At ambient temperatures of less than -5°C the connecting lines must be
securely laid.
Do not allow the outside of the device to come into contact with strongly
corrosive media.
Do not subject the system to excessive vibrations, bending or torsion.
The devices may not – or only with the manufacturer's permission, and then
only using special measures – be used in systems with electric corrosion
protection. Parasitic currents must not be fed in via the shielding.
Installations in Ex areas may be carried out only in compliance with the local
installation regulations.
Installation and maintenance only in ex-free atmospheres in compliance with
the user’s national regulations.
Additional precautionary measures must be taken if there is a possibility that
hydrogen sulfide, ethylene oxide and/or carbon monoxide could be present. These
compounds have very low ignition power!
Only non-arcing tools may be used for these compounds as well as all compounds
included in explosion group IIC – if explosive atmospheres are still to be expected!
3.3 Application
The devices may be used only in the correct way and for the intended purpose in a
normal industrial environment. Use for unsuitable purposes, will render all
guarantees and liability of the manufacturer void!
See Chapter 4, 5, 7 and 9.

DOG-4
DOG-4 K08/0818 page 7
3.4 Repair, maintenance (for applications in Ex areas)
Definition of terms as defined in IEC 60079-17:
Repair and maintenance: A combination of all activities carried out to maintain an
item or restore the object to a state in which it is able to meet the requirements of the
relevant specification and ensure the execution of its required functions.
Inspection: An activity comprising the careful examination of an item carried out
either without demounting or, if necessary, with partial demounting through such
steps as measurement in order to reliably determines the condition of the item.
Visual inspection: An inspection in which visible faults, e.g. missing bolts, are
detected without the use of equipment or tools.
Close inspection An inspection which comprises the aspects of a visual inspection
in addition to identifying defects, e.g. loose bolts, apparent only by access with the
use of equipment, e.g. steps (when necessary) and tools. Close inspections do not
normally require an open enclosure or the de-energizing of the equipment.
Detailed inspection An inspection which encompasses those aspects covered by a
close inspection and, in addition, identifies those defects, e.g. loose connections
which are only be apparent by opening the enclosure and/or using tools and test
equipment where necessary.
Maintenance work may be performed only by qualified personnel with the
equivalent of or qualification according to TRBS 1203 (German Technical
Rules for Industrial Safety).
Only accessory parts which fulfill all European regulations and national laws
may be used in hazardous areas.
The replacement of components may only take place using original spare
parts approved for use in Ex areas as well.
The devices in Ex areas must be cleaned regularly. The intervals must be
specified by the operator according to the environmental load.
After maintenance and/or repair, replace all barriers and notices removed in
the process in their original positions.
Uninstall the device if any faults are detected. The customer may not repair
internal parts. Send the device to the manufacturer for inspection.
Task Visual inspection
monthly Check every 6 months Detailed inspection every 12 months
Visual inspection of the device for
integrity, remove dust residues ●●
Inspection of the entire system Responsibility of the operator
3.1 Disposal
Disposal of the packaging and the used parts must be carried out according to the
regulations of the country in which the device is installed.

DOG-4
page 8 DOG-4 K08/0818
4.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:
DOG-4S Flowmeter including flange housing, measuring head, thermal wire
sensor and connection box.
Measuring cable from the Flowmeter to the measuring converter (optional).
DOG-4A/B…O/P reader/transducer.
Operating instructions.
5.Regulation Use
DOG-4 type devices are used for measuring and monitoring the rate of flow. Only
clean media may be measured, against which the materials used are resistant. Dirt
particles and other impurities can impair the measurement results, in spite of the fact
that the continuous change in direction of the flow ensures a self-cleaning effect. The
measuring sensor may be used only with the corresponding transducer.
Connectioon box
Measuring cable
Reader/
Transducer
Flowmeter
Flange housing
Measuring head
Direction
of flow

DOG-4
DOG-4 K08/0818 page 9
6.Operating Principle
This device is a oscillating beam device and works without any movable parts. An
orifice plate in the base creates flow resistance, which forces a partial flow to be
directed into the measurement head. The gas in the measuring head begins to
oscillate. The frequency of oscillation is proportional to the flow of volume. As the
ratio between the flow through the measuring head and the flow through the
measuring housing is constant, the frequency of oscillation is directly proportional to
the entire flow of volume through the device. A platinum sensor determines the
oscillation in the measuring head. The measuring converter normalises the
measured oscillation to 0 Hz (without flow) and to 150 Hz for the end of the
measuring range.
View from underneath Platinum sensor
View from above

DOG-4
page 10 DOG-4 K08/0818
7.Mechanical Connection
The measuring sensor should be installed in a horizontal position with the measuring
head facing upwards. A slight inclination in the direction of flow is permitted. The
arrow on the flange housing must point in the direction of flow. The recommended
minimum inlet path is 10 times the diameter of the pipe and the maximum outflow
zone 5 times the diameter of the pipe. To prevent any possible rotational flow, it is
recommended that a flow straightener be fitted upstream of the counter. For damp
media, slightly inclined installation in the direction of flow is recommended in order to
ensure the removal of condensate from the oscillator.
Direction of flow

It is also recommended to install a condensate separator, preferably in a vertical pipe
in front of the flow meter (see figure below). The condensate can thus be removed
before entering the flow meter.
Should the temperature difference between ambient and medium be +20 °C or
greater, the pipeline and the flow meter should be thermally insulated to prevent
condensation.

DOG-4
DOG-4 K08/0818 page 11
8.Identification (Ex version)
Flowmeter (DOG-4S) type plate
(flange housing, measurement tube)
There is a warning label on the plastic housing “WARNING – DANGER Of
ELECTROSTATIC DISCHARGE – SEE OPERATING INSTRUCTIONS”
Transducer (DOG-4A) type plate
(see left)

DOG-4
page 12 DOG-4 K08/0818
9.Electrical connections
9.1 General
Install the measuring sensor near the transducer (max. 100 m cable length,
depending on the electrical interference zone).
The measuring cable must be laid well away from strong sources of electrical
interference and not parallel to power cables.
The measuring cable of several DOG-4s must not be laid over long distances
next to one another or bundled together.
The DOG-4A transducer must be installed outside of the Ex zone.
Lay the electrical cabling according to the following wiring diagram.
Each transducer is matched specifically to the respective measuring sensor
and must not be swapped over.
The pipelines and the flange housing must be grounded.
9.2 Measuring cable in Ex areas
An Ölflex EP (without shield) or Ölflex EBCY (with shield) may be used as measuring
cable between the sensor and transmitter. Alternatively a cable with comparable
properties may be used.
Ölflex EB Li=0.65 mH/km Cisy=110 nF/km
Ölflex EBCY Li=0.65 mH/km Cisy=135 nF/km Ciasy=185 NF/km
The length of the cable may not exceed 100 m. The maximum permitted cable
inductance is Limax=65 µH and the maximum capacitance Cimax=32 nF.
9.3 Connection to the measuring sensor
To connect the measuring cable, first unscrew the lid of the connection box and
remove the lid. Feed the cable through the cable gland and connect it to the
connecting terminal (independent of polarity). When using a shielded cable, the
shield must be connected to the grounding screw.

DOG-4
DOG-4 K08/0818 page 13
9.4 Terminal assignment of the DOG-4… reader/transducer
230 VAC
110 VAC
24 VAC
24 VDC
Output
Sensor
L = 230 V/110 V/24 V outer conductor + = supply DC+
N= 230 V/110 V/24 V neutral conductor - = supply DC-
E = emitter optical coupler
C = collector optical coupler
I-= sensor conductor
I+= sensor conductor
Supply
black
1 2 3 4
L N
+ -
Output
orange
1 2 3 4
E C
Sensor
blue
1 2 3 4
+ -
for AC
for DC

DOG-4
page 14 DOG-4 K08/0818
UHIGH = ; ULOW < 0.5 V
Example: Vs = 24 VDC: UHIGH=17 VDC@ R=10 kOhm, UHIGH=23 VDC@R=80 kOhm,
R
R+4.4 kΩ
Optical coupler output, external supply max. 30 VDC, Imax = 50 mA

DOG-4
DOG-4 K08/0818 page 15
9.5 Terminal assignment of the electronic option
G0/H0/I0/K0/M0/N0/O0/P0
With the electronic option G0/H0/M0/N0, the reader/transducer is located together
with the flow controller/flow computer prewired in the plastic wall housing. The
connection terminal strip is located underneath the terminal cover. This must be
removed for the electrical connection.
Note:
Additional pressure and temperature sensors are required for the electronic options
M0/N0/O0/P0 (flow computer). These sensors are not included in the scope of delivery.

DOG-4
page 16 DOG-4 K08/0818
Wiring diagram electronic option DOG-4 G0/H0/I0/K0
Wiring diagram electronic option DOG-4 L0
Wiring diagram electronic option DOG-4 M0/N0/00/P0
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Note:
There is installation space for 2 additional Zener barriers in the housing if the
pressure/temperature sensors do not have the required certification. Establishing
contact in Ex areas can take place via terminals 17 to 20. The required cabling is the
responsibility of the installer.

DOG-4
DOG-4 K08/0818 page 17
9.6 Connections of DOG-4 Transmitter with KOBOLD Evaluation
Electronics ZED-X and ZOK-Zx
DOG-4 connection with ZED-Zx
1,2 kOhm

DOG-4
page 18 DOG-4 K08/0818
DOG-4 connection with ZOK-ZxP
Notes:
* The sensor supply from ZOK-ZxP must be set to 8 VDC.
From the software menu of ZOK-Zx, the ‘Sensor type’ must be set to ‘PNP’
(For details please see the operating manual of ZOK-Zx electronics).

DOG-4
DOG-4 K08/0818 page 19
Connection example for DOG-4 with ZOK-ZxK
The sensor type must be set to "PNP" in the ZOK-ZX software menu (see operating
manual ZOK-Zx electronics).

DOG-4
page 20 DOG-4 K08/0818
10. Startup
During startup, ensure that the shut-off valves upstream and downstream of the
device are opened slowly. Avoid increasing the flow velocity to prevent the discharge
rate from damaging the sensor.
The output frequency of the DOG-4 is proportional to the measuring range.
In the event of a sensor fault (breakdown or short circuit) the transistor output is
permanently connected. During self-diagnosis, the transistor output is switched to the
high-resistance state.
11. Setup and operation of the flow controller/flow
computer (option G0/H0/I0/K0/M0/N0/L0/O0/P0)
The integrated flow controller/flow computer are preset and calibrated at the factory.
See the separate operating instructions for the DOG-4G0/H0 and the DOG-4M0/N0
for details.