Kracht VCA 0.04 User manual

Operating instructions
BVC0007EN
Gear type flow meter VCA / VCN / VCG 0,04 ... 5
BVC0007EN-D0025530002-02
Englisch
2012-03-30

Table of Content
1General points 4
1.1 About the documentation 4
1.2 Manufacturer´s address 4
1.3 Intended use 4
2Safety 6
2.1 Safety instructions and symbols 6
2.2 Personnel qualification and training 6
2.3 General safety instructions 6
2.4 Hazard statements 7
3Device description 10
3.1 Basic construction and function 10
3.2 Type key 11
3.3 Important special numbers 12
4Technical data 13
4.1 General characteristics 13
4.2 Overview nominal sizes 13
4.3 Permissible temperature of operating media 14
4.4 Overview of the series and materials 14
4.5 Dimensions and weights 16
4.5.1 Serie VCA / VCN / VCG - Type of connection R 16
4.5.2 Serie VCA / VCN /VCG - Type of connection P 18
5Transport and storage 20
5.1 Transport damage 20
5.2 Transport 20
5.3 Corrosion protection 21
6Installation 22
6.1 General points 22
6.2 Mechnical installation 22
6.2.1 Plate connection 24
6.2.2 Installation on external connection plates or valve
blocks 26

6.2.3 Pipe connection 26
6.3 Assembly with further components and devices 26
6.4 Electrical connection 27
6.4.1 Standard plug version 28
7Operation start-up 30
7.1 Preparation 30
7.2 Further operation start-up 32
7.3 Permissible limits for operation 32
8Removal 33
8.1 General points 33
8.2 Removal of the gear type flow meter 33
9Maintenance 35
9.1 General points 35
9.2 Unusual noise 37
9.3 Static seals 37
9.4 Screw joints 37
9.5 Desposits in the measuring device 37
10 Cleaning 38
11 Repairs 40
11.1 General points 40
11.2 Troubleshooting 40
11.3 Elimination of damage 40
11.4 Return 40
11.5 Disposal 41
11.6 Detecting and eliminating problems 41

1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-
nance of the gear type flow meter VCA, VCN and VCG.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter 3 “Device
description” and in the chapter 4 “Technical data”.
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Manufacturer´s address
Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: [phone] / 935-0
fax: [phone] / 935-209
email: [email protected]
web: www.kracht.eu
1.3 Intended use
The gear type flow meter is a measuring device for the continual flow me-
surement of combustible and non-combustible fluids. The different series
allow use with different viscosities and lubricating ablilities.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
Operation is only permitted within the specified enviromental and ambient
conditions.
Use in explosive areas is not permissible.
It must be guaranteed that the medium is compatible with the materials used
in the device (see "Overview of series and materials" in the chapter 4 “Tech-
nical data”). The chemical competence is necessary for this. Be careful with
ethylene oxide and/or other catalytic and/or exothermic and/or self-decom-
posing materials! Please consult the manufacturer in cases of doubt.
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The device may only be used when its materials are resistant to mechanical
and/or chemical influences or corrosion under the respective operating con-
ditions.
A filter must be installed if required to avoid the device blocking on account
of contaminants.
The device may only be operated when closed and must not be exposed to
any impermissible vibrations.
The maximum permissible operating data listed in the chapter 4 “Technical
data” must always be observed.
Deviations from the above-mentioned data and operating conditions require
express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
unlegible or unrecognisable.
In cases of noncompliance, all warranty and manufacturer responsibility shall
be void.
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2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identificationofapotentialmediumriskhazard,whichwouldlead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Personnel qualification and training
The personnel designated to install, operate and maintenace the device must
be properly qualified. This can be through training or specific instruction. Per-
sonnel must be familiar with the contents of this operating manual.
2.3 General safety instructions
The operational safety of the device delivered is only guaranteed when it is
used for the intended purpose (see chapter 1 “General points”).
The limit values given must never be exceeded (see chapter 4 “Technical
data”).
Nationalregulations concerning accident preventationand health and safe-
ty at work must be observed, as well as internal regulations laid down by
the operator, even of these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
staff responsible at all times.
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2.4 Hazard statements
DANGER
Danger due to breakage or squirting fluids!
If the device is blocked it acts like a closed gate. The pressure level that
occure in this case can result in damage to the device and to up or down-
stream plant elements. Breakage can lead to parts flying around uncon-
trolled or to fluids squirting out which can lead to accidents and severe
injuries or even result in death.
●A pressure relief valve or other kind of over-pressure safeguard must
be installed before the device.The pressure relief device must be di-
mensioned so that entire delivery volume can be conducted through
with the lowest possible pressure or pressureless.
●Do not put the device into operation without a pressure relief device.
DANGER
Danger due to pressure loaded lines.
When working on pressure loaded lines, uncontrolled or squirting fluids can
lead to accidents and severe injuries or even result in death.
●Always depressurize all lines during all work on the unit and before dis-
assembly.
DANGER
Danger due to breakage or squirting fluids!
Using unsuitable connections and lines can lead to breakage. Parts flying
around uncontrolled or squirting fluids can lead to accidents with severe
injuries or even lead to death.
●Use only connections and lines approved for the expected pressure
range.
●Comply with each manufacturer's regulations.
DANGER
Danger due to breakage or squirting fluids!
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, which can lead to accidents and severe
injuries or even result in death.
●Immediately replace damaged connections, pipes and hose lines.
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DANGER
Danger due to electric voltage!
Danger of death due to electric shock.
●Follow the special safety regulations during all work on electrical instal-
lations.
●Only allow electricians to work on electrical systems.
WARNING
Danger due to hazardous fluid!
Danger of death upon contact with hazardous fluids and when inhaling va-
pours from these liquids.
●Comply with the safety data sheets and regulations on handling the
hazardous liquids!
●Collect and dispose leaks of hazardous materials so that no hazards
arise for people or the environment.
●Comply with national and international rules at the place of installation.
●Wear suitable protective clothing.
WARNING
Danger due to falling and or loads falling over!
Due to the size and weight of the unit, accidents can occur resulting in se-
vere injuries or death during transport and shipping.
●Compliancewithapplicableindustrialsafetyrequirementsismandatory.
●Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
●Attach the lifting tackle in such a manner that it cannot slip.
●Secure the device so that toppling over and falling down is impossible.
●Always avoid jerks, impacts and strong vibrations during transportation.
●Never walk under suspended loads, never work under suspended
loads.
●To prevent damage to the device, be extremely cautious when shipping
or transporting.
●Wear suitable protective clothing.
CAUTION
Danger due to hot surfaces!
When operating the device with hot media, there is a danger of being
burned and scaled when touching the hot surfaces.
●At medium temperatures above 60 °C, take measures against uninten-
ded contact.
●Wear safety gloves.
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CAUTION
Danger due to hot surfaces!
When operating the device with hot media, there is a danger of being
burned and scaled when touching the hot surfaces.
●When the medium temperature is over 48 °C, let the device cool off.
●Wear safety gloves.
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3 Device description
3.1 Basic construction and function
There are two gearwheels inside the housing that are supported with low
friction. They are driven by the fluid flow during operation. This gearwheel
movement is scanned inductively by one or two sensors in the cover, and
transformedinto electrical signals.These signals areforwarded to thedisplay
unit connected.
1. O-Ring
2. Sensor
3. Device plug
4. Cover
5. Housing
6. Gear
7. Bearing pin *
8. Plain bearing bush *
* Measuring device version "B"
(Measuring device version A, C, E and F not shown)
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3.2 Type key
Ordering example VCA / VCN / VCG 0,04 ... 5
VCA 2 F A R 1 V /...
1. 2. 3. 4. 5. 6. 7. 8.
Explanation of type key VCA / VCN / VCG 0,04 ... 5
1. Product name
VCA
VCN (only nominal size 0,04 and 0,2)
VCG (only nominal size 2)
2. Nominal size 0,04 - 0,1 - 0,2 - 2 - 5
3. Seal
NNBR EEPDM
FFKM PPTFE / FEP
4. Measuring unit version
ASteel gears + Plastic friction bearings (VCA 0,2 / VCN 0,2)
BStainless steel gears + Plastic friction bearings (VCA 0,2 / VCN 0,2 / VCA
2 / VCA 5)
CSteel gears + Multi layer friction bearings (VCA 2 / VCG 2)
ESteel gears + Ball bearing (VCA 0,1 / VCA 5)
FStainless steel gears + Ball bearing (VCA 0,04 / VCN 0,04 / VCA 5)
5. Type of connection
RPipe connection PPlate structure (only VCA 2 / VCG
2)
6. Sensor
11 Sensor 22 Sensors
7. Electronics
No specification Standard VWithout pre-amplifier (for SD1)
XATEX version *
8. Special number for special versions
See section 3.3 “Important special numbers”
* .The ATEX versions are described in separate operating manuals
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3.3 Important special numbers
Special num-
ber Description
40 VC. 2 with thread connection G 1
71 Variant with Hirschmann plug with device socket according to DIN (M12x1)
74 Variant with Hirschmann plug and pre-amplifier VV12 for 12 V current supply to
pre-amplifier
77 Variant with NPT thread
79 VC 3 and VC 5 for high-pressure version (400 bar)
101 Housing and fastening screws corrosion-protected
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4 Technical data
4.1 General characteristics
General characteristics
Construction Geared motor
Material See section 4.4 “Overview of the series and materials”
Connection type Pipe thread / Plate connection
Installation position / Flow direction Arbitrary / Preferential flow direction A →B
Ambient temperature ϑ-10 ... 80 °C
4.2 Overview nominal sizes
Product name VCA VCN VCA VCA / VCN VCA VCG VCA
Nominal size * 0,04 0,1 0,2 2 5
Geom. tooth vol-
ume cm30,04 0,1 0,2 2 5,222
Resolution Imp/l 25000 10000 5000 500 191,5
Max. operating
pressure bar 200 160 200 160 160 315 80
Pressure peaks bar 240 190 240 200 200 350 100
Perm. number of load alternations
of the peak pressure - - - - 1x106
Pressure peak ** l/min 0,02 ... 4 0,08 ... 10 0,25 ... 10 1 ... 65 1 ... 200
Max. pressure
loss bar 10 16
Measuring accuracy
starting from viscosity in mm2/s ± 2%
20 ± 3% 20 ± 2,5% 20 ± 1% 20
Sound pressure
level dB(A) < 60
* See type description on the device: VCA / VCN / VCG ...
** The measuring range may be restricted at higher pumping medium viscolity.
NOTICE
Danger of device damage due to overload
Atoohigh flow resistance Δpcancause mechanical damage onthedevice.
●The maximum pressure loss in the device may not exceed 10 bar
(nominal size 0,04 - 0,2) or 16 bar (nominal size 2 - 5).
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4.3 Permissible temperature of operating media
Seal variant VCA / VCN VCG
N = NBR -10 ... 80 °C -
F = FKM -10 ... 80 °C -15 ... 120 °C
E = EPDM -10 ... 80 °C -
P = PTFE / FEP -10 ... 80 °C -
4.4 Overview of the series and materials
Tab. 4.1: Overview of the series and materials VCA ...
Product name VCA
Nominal size 0,04 0,1 0,2 2 5
Measuring unit version F E A B B C E
Material
Housing /
cover Aluminium
Al Mg Si F30
Aluminium
Al Mg Si F30
(hard coatiert)
Measuring
unit
Stainless
steel
(1.4462)
case-hardened
steel
(1.7139)
Stainless
steel
(1.4462)
case-hardened steel
(1.7139)
Bearing Anti-friction bear-
ing steel Iglidur® X
Steel, sin-
tered
bronze,
PTFE
Anti-
friction
bearing
steel
Bearing
pin
Stainless
steel
(1.4462)
Hardened
steel Stainless steel
(1.4571) Hardened steel
Type of bearing Ball bearing Plastic friction bearings Multi layer friction
bearings
Ball
bearing
Viscosity of the operating
fluid in mm2/s 20 ... 4000 1 ...
3000
Lubricating properties of
the operating fluid good
Permissible size of con-
taminants in operating flu-
id in µm 30 20
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Tab. 4.2: Overview of the series and materials VCN / VCG ...
Product name VCN VCG
Nominal size 0,04 0,2 2
Measuring unit version F A C
Material
Housing / cover Stainless steel
(1.4404) EN-GJS-400 (GGG 40)
Measuring unit Stainless steel
(1.4462)
case-hardened
steel
(1.7139)
Bearing Anti-friction
bearing steel Iglidur® X Steel, sintered bronze, PTFE
Bearing pin Stainless steel
(1.4462) Hardened
steel Hardened steel
Type of bearing Ball bearing Plastic fric- tion bear-
ings
Multi layer fric-
tion bearings
Viscosity of the operating fluid in mm2/s 20 ... 4000 20 ... 4000
Lubricating properties of the operating fluid good
Permissible size of contaminants in operat-
ing fluid in µm 30 30
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4.5 Dimensions and weights
4.5.1 Serie VCA / VCN / VCG - Type of connection R
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Nominal size 0,04 0,1 0,2 2 5
Series avaliable VCN VCA VCA / VCN VCA VCA
Weight in kg
VCA -0,6 0,5 1,9 6
VCN - - 1,2 - -
VCG - - - - -
A55 55 55 100 170
D55 55 55 90 120
F51 70 55 73 105
G96 115 100 118 150
J22,5 7,6 9,9 16,5 25
R- - - 13 21
SG 1/4G 3/8G 3/8G 3/4G 1
T21 25 25 36 42
U11,5 14 14 22,5 30
V13 13 13 17 19
W53,6 54,4 54,4 88 118
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4.5.2 Serie VCA / VCN /VCG - Type of connection P
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Nominal size 0,04 0,1 0,2 2 5
Series avaliable - - - VCA / VCG -
Tightening torque in Nm - - - 120 -
Weight in kg
VCA - - - 2 -
VCN - - - - -
VCG - - - 5 -
A- - - 100 -
D- - - 90 -
F- - - 70 -
G- - - 115 -
J- - - 16,5 -
K- - - 84 -
L- - - 72 -
M- - - 35 -
N- - - 16 -
P- - - 9 -
R- - - 13 -
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5 Transport and storage
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
WARNING
Danger due to falling and or loads falling over!
Due to the size and weight of the unit, accidents can occur resulting in se-
vere injuries or death during transport and shipping.
●Compliancewithapplicableindustrialsafetyrequirementsismandatory.
●Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
●Attach the lifting tackle in such a manner that it cannot slip.
●Secure the device so that toppling over and falling down is impossible.
●Always avoid jerks, impacts and strong vibrations during transportation.
●Never walk under suspended loads, never work under suspended
loads.
●To prevent damage to the device, be extremely cautious when shipping
or transporting.
●Wear suitable protective clothing.
Gear type flow meter VCA / VCN / VCG 0,04 ... 5
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