Kobold DON-H Series User manual

Operating Instructions
for
Oval Wheel Flowmeter
High pressure
Model:
DON-H...

DON-H
page 2 DON-H 01/0721
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
options ............................................................................................... 19
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
15.1General information ........................................................................... 31
15.2ATEX version Exi (electronics options xA) ......................................... 34
16.EU Declaration of Conformance ................................................................. 41
17.Statement of Conformity ............................................................................. 43
18.State of safeness ........................................................................................ 48
Manufactured and sold by: KOBOLD Instruments Inc.
1801 Parkway View Drive
Pittsburgh PA 15205-1422
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.koboldusa.com

DON-H
DON-H 01/0721 page 3
2. Note
Please read these operating instructions before unpacking and putting the unit
into operation. Follow the instructions precisely as described herein.
The devices are only to be used, maintained, and serviced by persons familiar
with these operating instructions and in accordance with local regulations
applying to Health & Safety and prevention of accidents.
When used in machines, the measuring unit should be used only when the
machines fulfil the EC-machine guidelines.
as per PED 2014/68/EU
In acc. with Article 4 Paragraph (3), "Sound Engineering Practice", of the PED
2014/68/EU no CE mark.
Model DON-* DN Pmax
[bar]
Diagram8
Group1
dangerousfluids
Diagram9
Group2
nodangerousfluids
DON-05 ⅛ 400-
§4 Abs.3 §4 Abs.3
DON-10 ¼ 400
DON-15 ¼ 400
DON-20 ½ 400
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
page 4 DON-H 01/0721
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.

DON-H
DON-H 01/0721 page 5
6. Mechanical Connection
6.1 General
Points to verify before meter installation:
Chemical compatibility of the liquid. Be sure that all wetted parts are
identified and confirmed suitable for use with the media being measured. If
unsure, please contact a KOBOLD engineer for guidance in obtaining the
proper reference materials.
Verify that the operational pressure and temperature limits are within
capability of the fully specified meter. Verify that the operational flow rates are
within the specified flow range. Viscous liquids may limit the maximum
allowable flow based on the viscosity. The max allowable flow rate may need
to be limited to ensure the differential pressure across the flowmeter does not
exceed 1 bar, (100 kPa, 15 PSIG).
Be sure that the flowmeter is not subject to any process temperatures and/or
pressures that can cause the measured liquid to freeze or flash inside the
meter.
the measuring instrument is not subjected to process temperatures and
pressures that convert the liquid medium into a gas inside the device.
OPERATION:
Liquid travels around the crescent
shaped chambers created by the
rotational movement of the rotors
liquid exits the
measuring chamber
liquid entering
measuring chamber liquid in transit

DON-H
page 6 DON-H 01/0721
Incorrect installations will cause the
rotor weight to be felt on the bottom of
the measuring cavity.
6.2 Orientation
When installing the flowmeter, orientation must be considered. The rotor shafts
must be in a horizontal plane. To verify that the rotor shafts are in a horizontal
plane, electronic cover or optional digital display will be facing in a horizontal
direction. For modification in the field, the electronic cover or digital display can
be rotated in any 90 degree position. This accommodates access to the electrical
entry and allows the electronic display orientation to best suit the installation.
The DON flowmeter accommodates both horizontal and vertical flows. It is
recommended that for vertical flow installations that the liquid flow up through the
meter (i.e. bottom to top). This orientation assists in air or entrained gas removal.
The flow meter is bidirectional. To identify the flow direction, in which the
flowmeter was calibrated, the flowmeters are marked with arrows. These arrows
are placed on the lower side for models DON-H05 .. DON-H20. The flowmeter
calibration data refers to this arrow direction. This is also the preferred flow
direction.
C O R R E C T I N S T A L L A T I O N S
Note: orient the conduit entry downward
to avoid moisture migration into the
electronic cavity.
I N C O R R E C T
C O R R E C T I N S T A L L A T I O N S

DON-H
DON-H 01/0721 page 7
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
page 8 DON-H 01/0721
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 VDC. No additional external wiring is required (e.g. pull-
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).

DON-H
DON-H 01/0721 page 9
Note!
The electronic option H0 is available with reed switch output.

DON-H
page 10 DON-H 01/0721
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.
Note: when using the reed switch output the liquid temperature
must not change at a rate greater than 10 ºC per minute (50 ºF
per minute).
Average electrical endurance of switching contact (MTTF – Mean Time To First
Failure):
Max. switching voltage (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
The individually specified maximum electrical values of the reed switch must
never be exceeded, even for a moment. Higher switching values may reduce the
service life or even destroy the contact.
For capacitive and inductive loads (e.g. via long lines), we recommend the
following protective circuits:
Lamp load with series or parallel Protection with a RC suppressor
resistance to the reed switch. For a.c. current and inductive load.
Protection with a diode Protection with an inductance or
for d.c. current and inductive load. Resistance for capacitive load.

DON-H
DON-H 01/0721 page 11
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)

DON-H
page 12 DON-H 01/0721
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).

DON-H
DON-H 01/0721 page 13
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)
b) Circuit with Reed switch

DON-H
page 14 DON-H 01/0721
7.4.2 Wiring with ZOK-ZxP
a) Circuit with Hall sensor
b) Circuit with Reed switch

DON-H
DON-H 01/0721 page 15
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”).
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
page 16 DON-H 01/0721
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 flowmeter
Confirm 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.

DON-H
DON-H 01/0721 page 17
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
1
2
3
4
6
7
8
9
10
2
Optional
Assembly alignment
dimple

DON-H
page 18 DON-H 01/0721
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
Optional

DON-H
DON-H 01/0721 page 19
9.2 Demounting of the electronics mounted on a DON with Zx
and 1A…5A options
To access the device battery, terminal connections and pulse output board, 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.
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
page 20 DON-H 01/0721
9.5.1 Re-assembly of DON-H05...DON-H10
The small flowmeters DON-H05 to DON-H10 have dimples on both housing parts
(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.
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.
5
1
2
3
4
6
7
8
9
10
2
Optional
Assembly alignment
dimple