Kobold DON-L Series User manual

Operating Instructions
for
Oval Gear Flow Meter
Model:
DON-...Lx/Hx/Rx/Dx/Gx/Kx/Bx/Zx/M4

DON
page 2 DON 01/1019
1.Contents
1. Contents........................................................................................................2
2. Note ..............................................................................................................3
3. Instrument Inspection....................................................................................5
4. Regulation Use..............................................................................................5
5. Operating Principle........................................................................................6
6. Mechanical Connection.................................................................................7
6.1General................................................................................................7
6.2Orientation...........................................................................................8
6.3Flow Conditioning and Location...........................................................9
7. Electrical Connection ..................................................................................10
7.1Connecting Cable ..............................................................................10
7.2Hazardous area wiring.......................................................................10
7.3Electrical connection for integrated electronics options .....................11
7.4Internal wiring with electronic options –Ex/Zx....................................15
7.5External wiring with electronic unit ZOK-Zx .......................................19
8. Commissioning............................................................................................21
9. Maintenance ...............................................................................................22
9.1Disassembly of DON with Pulse meter..............................................23
9.2Demounting of the electronics mounted on a DON with Zx and Ex
options...............................................................................................30
9.3Spare Parts........................................................................................30
9.4Inspection (refer Exploded View).......................................................30
9.5Re-assembly of DON.........................................................................30
10.Technical Data............................................................................................34
11.Pressure drop curves..................................................................................39
12.Order codes ................................................................................................41
13.Dimensions Electronic Options Ex/Zx.........................................................42
14.Troubleshooting ..........................................................................................43
15.ATEX Exd version.......................................................................................45
16.EU Declaration of Conformance..................................................................47
17. Manufacturers declaration – Switches for use in Explosive Atmospheres .48
18.Exd Certificate.............................................................................................49
19.IECEx Certificate.........................................................................................52
20.State of safeness ........................................................................................56
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
DON 01/1019 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
DON 1 Aluminum-Version
Model DON DN Pmax
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-105 64
art. 4, par. 3 art. 4, par. 3
DON-110 ¼ 64
DON-115 64
DON-120 ½ 64
DON-125 25 64
DON-130 40 40
DON-135 50 40
DON-140 50 16
DON-145 80 16
DON-150 80 16
DON-155 100 16
DON-160 100 16
DON 2/8 Stainless steel version
Model DON
2/8 DN Pmax [bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-05 100 art. 4, par. 3
art. 4, par. 3
DON-06 100 art. 4, par. 3
DON-10 ¼ 100 art. 4, par. 3
DON-15 100 art. 4, par. 3
DON-20 ½ 100 art. 4, par. 3
DON-25 25 100 category II
DON-30 40 50 category II
DON-35 50 50 category II
DON-40 50 16 category II
DON-45 80 16 category II
DON-50 80 16 category II
DON-55 100 16 category II
DON-60 100 16 category II

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page 4 DON 01/1019
DON-1 M4 Aluminum version with mechanical totalizer
Option M4
Model DON-1 DN Pmax [bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-05 - - -
DON-10 ¼ - - -
DON-15 - - -
DON-20 ½ 40 art. 4, par. 3
art. 4, par. 3
DON-25 1 40 art. 4, par. 3
DON-30 1½ 40 category II
DON-35 2 40 category II
DON-40 2 16 category II
DON-45 3 16 category II
DON-50 3 16 category II
DON-55 4 16 category II
DON-60 4 16 category II
DON 2/8 Stainless steel with mechanical totalizer
Option M4
Model DON
2/8 DN Pmax
[bar]
diagram 8
group 1
dangerous liquids
diagram 9
group 2
no dangerous liquids
DON-05 - - -
DON-06 - - -
DON-10 ¼ - - -
DON-15 - - -
DON-20 ½ 40 art. 4, par. 3
art. 4, par. 3
DON-25 1 40 art. 4, par. 3
DON-30 1½ 40 category II
DON-35 2 30 category II
DON-40 2 16 category II
DON-45 3 16 category II
DON-50 3 16 category II
DON-55 4 16 category II
DON-60 4 16 category II

DON
DON 01/1019 page 5
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 Gear Flow Meter model: DON
Operating Instructions
Calibration Certificate
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 flowmeter is available as a measurement transducer with pulse output or with
other forms of evaluation electronics. Details of how to operate the electronics are
included in a separate instruction manual.
These flowmeters DON can be installed within hazardous areas when ordered
with optional Exd approval, or by using the reed switch pulse output in Intrinsically
Safe loops or installing Intrinsically Safe certified Instruments.
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.

DON
page 6 DON 01/1019
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.
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
DON 01/1019 page 7
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.

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page 8 DON 01/1019
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-x05 .. DON-x15 and on the top side
for models DON x20..DON-x60. 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

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DON 01/1019 page 9
6.3 Flow Conditioning and Location
It is highly recommended to INSTALL a filter immediately before (prior to) the
meter. Filters are available and sold separately.
Recommended Filter:
DON-x05…DON-x15: < 75 µm particle size (200 mesh)
DON-x20…DON-x35: < 150 µm particle size (100 mesh)
DON-x40…DON-x60: < 350 µm particle size (45 mesh)
Flow conditioning: Flow conditions is 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 of 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. Proper pulsating dampers are highly
recommended.

DON
page 10 DON 01/1019
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 Hazardous area wiring
The instrument can only be operated in the ATEX area as “Simple Apparatus” in
accordance with ATEX Article 1 §2 and 3 with the “Reed contact” (R0) option and
without ATEX labelling. For this purpose, intrinsically safe cabling must be laid
between the instrument, the hazardous area and an approved isolation switching
unit outside the hazardous area. (See section 17 Manufacturers declaration –
Switches for use in Explosive Atmospheres)
Alternatively, the device can be operated using option E1 to E5 with
Ex ia IIC T4 Gb approval [see separate operating instructions] or with explosion-
protected housing (Exd) option RE, BE, GE, KE, LE, HE or DE. Only Exd-certified
cable conduits and cable glands with corresponding temperature limits may be
used. Hall-effect sensor output is not possible if the DON flowmeter is operated in
an ATEX zone as simple apparatus or using the E1/E3 option.
When operating the electronic options LE, BE, GE, RE, HE and DE, suitable
operating materials must be used to ensure that the maximum operating
voltage of 28 VDC and the maximum operating current of 200 mA are not
exceeded.
The wiring methods used must be in accordance with the applicable rules,
provisions and requirements at the location where the device is installed. The
measuring devices may only be connected by qualified personnel who are
familiar with the protection classes, provisions and specifications for the device in
areas at risk of explosion.

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DON 01/1019 page 11
In accordance with the installation regulations, both, the housings and the
electronic covers must be grounded using the earthing clamps. The maximum
connection cross-section is 4 mm2.
7.3 Electrical connection for integrated electronics options
The electrical connection of the integrated electronics options always requires the
electronics cover to be dismantled. Models from size X05 to X20 incorporate the
cable inlet into the electronics cover, while models from the X25 size onwards
accommodate the cable inlet in the housing cover.
The use of an EXD-certified cable gland is imperative for explosion-protection
options HE, GE and LE etc. (M20x1.5 or ½” NPT) (not included in delivery). 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.
7.3.1 Hall-effect sensor with active pulse output
(H0/HE/B0/BE/G0/GE/HU options)
The H0/HE/B0/BE/G0/GE electronics options combine a hall-effect sensor with
an active push-pull output stage. The B0/BE options involve combining bipolar
Hall sensors with alternating polarised magnets. This option is particularly
suitable for pulsating currents, although the pulse rate is halved compared to the
H0/HE option. 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).
The hall-effect sensor pulse output is not available if a device is ordered for use in
the explosion hazard area as “Simple Apparatus” (e.g. if the “E1” option is
ordered).
The HU electronics option provides the NPN output with built-in 4.7 kpull-up
resistor. The external supply voltage is 5-30 VDC and the max. switching current
is 200 mA (short-circuit protected).
External earthing clamp
Internal earthing clamp
electronics cover

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page 12 DON 01/1019
Note!
The electronic options H0/HE/HU are available with reed switch
output while options B0/BE are not equipped with reed switch.
7.3.2 Reed Switch Pulse Output
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. The output may also be used with an
appropriate intrinsically safe barrier for use in hazardous locations. If the intention
is to operate the dry-reed contact impulse output in ATEX areas as simple
apparatus, only the R0 option may be used. 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 (100 V/10 mA) 5x105switching cycles
Max. current load (20 V/500 mA) 5x106switching cycles
Min. load (<5 V/10 mA) 5x108switching cycles
Switching capacity: Max. 30 VDC, max. 200 mA
Hall sensor output connection for H0/HE/B0/BE/G0/GE/HU options

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DON 01/1019 page 13
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
page 14 DON 01/1019
7.3.3 Quadrature Pulse Output (QUAD, Option D0/DE)
For the D0/DE option, the DON devices come with 2 independent hall-sensor
elements. The hall-effect sensors are arranged so that they emit separate phase-
shifted signals to one another.
The QUAD output is best-suited for verified use with a redundant signal or for
counting bidirectional currents (detecting the current direction).
Max. output current per channel (power source or sink): 100 mA (short-circuit
protected).
The current direction of the medium is defined as follows:
a.) Hx signal leading over Dx signal: Current flowing in the direction of the
marked arrow (positive)
b.) Hx signal lagging behind Dx signal: Current flowing against the direction of the
marked arrow (negative)

DON
DON 01/1019 page 15
7.4 Internal wiring with electronic options –Ex/Zx
The Ex/Zx electronic options are pre-configured ex works in connection with the
sensor boards. Reconfiguration is available on request.
7.4.1 For Z1/Z3 electronic options (reed switch and Hall sensor)
a) Wiring diagram with reed switch (ex works standard)

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page 16 DON 01/1019
b) Wiring diagram with Hall sensor (recommended in connection
with external supply)
7.4.2 For Z6/Z7 electronics options (bipolar Hall sensor)
The circuitry corresponds to 7.4.1 b.)
7.4.3 For E1...E5 electronics options
Refer operating instructions supplement ZOK-Ex wiring options E1...E5

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DON 01/1019 page 17
7.4.4 For Z2/Z8/Z9 electronics options (2 Hall sensors for direction
detection)

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page 18 DON 01/1019
7.4.5 Analog output 4-20 mA, 2-line (L0/LE option)
The L0 and LE (explosion hazard) options include a loop-powered 4-20 mA
output. The loop is powered by an external voltage source 16 – 32 VDC. The
maximum working resistance of loads connected in series (PLC-analogue input /
electronic displays) depends on the supply voltage level, namely:
Max. working resistance (ohms) = (+Vs – 9 VDC) / 0.02 A [ohms]
Example: +Vs = 32 VDC => max. working resistance = 1150 ohms
+Vs = 16 VDC => max. working resistance = 350 ohms
The load can be coupled at any point of the current loop, provided the polarity is
correct.
All DON devices with L0/LE options are factory-calibrated to the respective
measurement range end value. This setting should only be modified by the
manufacturer.
7.4.6 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.
Please reference the appropriate digital display manual for programming details.

DON
DON 01/1019 page 19
7.5 External wiring with electronic unit ZOK-Zx
7.5.1 Wiring with ZOK-ZxK
a) Circuit with Hall sensor (not for battery operation)
b) Circuit with Reed switch

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page 20 DON 01/1019
7.5.2 Wiring with ZOK-ZxP
a) Circuit with Hall sensor
b) Circuit with Reed switch