PKP DV04 Series User manual

Instruction Manual
DV04
High precision gear wheel counter for viscous liquids
PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-65205 Wiesbaden- ordenstadt
Tel.: ++49-(0)6122-7055-0
Fax: ++49-(0)6122-7055-50
Email: [e-mail]

Contents
1 Introduction 2
2 Safety Information 2
3 Functional Description and Design 3
4 Special Conditions 4
5 Installation and Removal of the Gearwheel Flow Meter 4
6 Corrosion Protection 4
7 Mechanical Installation 5
8 Electrical Connection 6
9 Maintenance and Cleaning 7-8
10 Returning 9
11 Disposal 9
12 Troubleshooting 10
13 Dimensions 11-13
14 Specification See data sheet in the appendix
1 Introduction
Series DV04 gearwheel flow meters are noted for their reliable function and easy operation.
To obtain the greatest benefit from this device, please observe the following cautionary
statement:
Persons who are responsible for setting up or operating this device must be sure to read
the and understand the operating instructions and the safety information pertaining to
it.
2 Safety Information
2.1 General Instructions
To ensure safe operation, the device must only be operated according to the information in the
operating instructions. When the device is in use, the regulations and safety standards
applicable to the specific application must also be observed. This statement also applies to the
use of accessories.
2.2 Proper Usage
Series DV04 gearwheel flow meters are designed for the continuous measurement of the flow
of low viscous fluids.
Any application extending beyond this specific intended use does not constitute proper usage.
Series DV04 must not be employed as the sole means of avoiding hazardous conditions in
machinery and installations.
The machinery and installations must be designed in such a manner that faulty conditions and
malfunctions will not present hazardous situations for operating personnel.
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2.3 Qualified Personnel
Series DV04 must only be used by qualified, knowledgeable personnel trained in correct use
of these devices. Qualified personnel are those persons familiar with setting up and
assembling these devices, placing them in service and operating them. In addition, such
personnel must also be qualified to perform the work associated with the application for
which the device is being used.
3 Functional Description and Design
Within the DV04 there two gearwheels that are supported in low-friction bearings. During
operation, the gearwheels are driven by the flowing liquid. The movement of the gearwheels is
sensed by two non-contact sensors located in the cover and converted into electrical signals.
Between the sensor area and the measuring chamber there is a pressure-resistant antimagnetic
separator. The signals are transmitted to the connected display device.
1 Cover
2 Housing
3 Gearwheel
4 Journal
5 Bearing
6 Anti-magnetic separator
7 Sensor
8 Device connector
9 O-ring
DV04-B~2.SAM 15.09.05 Page 3

4 Special Conditions
Special conditions and/or limitations apply to the safe application of gearwheel flow meters in
the approved operating environment. These conditions and/or limitations must be met by the
customer and/or system operator by means of appropriate technical and/or organizational
measures.
Gearwheel flow meters must only be operated in the specified environment and under the
specified ambient conditions.
Gearwheel flow meters must only be used if the materials used in their construction are
resistant to mechanical and/or chemical influences or corrosion under the given service
conditions.
The fluid must at least have minimum lubricating properties (lubricity).
Gearwheel flow meters are intended for use with liquids. Dry operation is not approved.
Operation outside of the specified parameters is not allowed.
If necessary, a filter must be installed to prevent the gearwheel from being blocked by foreign
objects.
The specified installation, service and maintenance schedules must be strictly followed.
Gearwheel flow meters must only be used in closed operation and not be subject to excessive
vibration.
Only genuine spare parts must be used for service and maintenance.
5 Installation and Removal of the Gearwheel Flow Meter
This gearwheel flow meter was thoroughly tested and checked at the factory before shipment.
It will be fully functional and immediately ready for use after it has been installed in position
and the electrical lines have been connected. The space required by the installed device is
specified in the "Dimensions" section. Once installed, the measuring device should also be
accessible for safe, visual inspection at any time.
Caution: To prevent possible damage to the gearwheel flow meter, a pressure regulating
device must be present in the installation to prevent the maximum permissible pressure from
being exceeded in the volume sensor or other parts of the installation (pressure-limiting
valves). During transport and installation, the gearwheel flow meter must only be held by its
housing; must never be suspended from the plugged-in connector!
6 Corrosion Protection
All gearwheel flow meters are checked for proper function at the factory with mineral-based
hydraulic oil. Following testing, the connections are sealed with plugs so that the internal parts
are protected against corrosion for a moderate amount of time. During transport and storage,
gearwheel flow meters must not be exposed to the harmful effects of ambient weather
conditions and great variations in temperature. They must be stored under dry conditions.
If a gearwheel flow meter is to be stored for a longer period of time, both its interior and
exterior must be protected by application of a suitable anti-corrosion oil. In addition, it must
be protected from humidity by means of a desiccant material.
If high humidity or other unfavorable (aggressive, polluted) ambient conditions are expected
to be encountered during transport, appropriate steps must be taken to prevent corrosion of
the gearwheel flow meter.
DV04-B~2.SAM 15.09.05 Page 4

Caution: When applying an anti-corrosion treatment, first check to be sure that the material to
be used is compatible with the elastomers used in the construction of the gearwheel flow
meter and will not harm them. You should also check that the material used is compatible
with the fluid flowing through the flow meter.
7 Mechanical Installation
Depending on the installation, the device is connected to the system by means of a connection
plate or pipe connections in its housing.
Caution: Only piping and connections that are approved for the expected pressure range may
be used. The specifications of the respective manufacturer must be followed. The device must
be installed so that it is not subject to excessive vibration. Installation above hot parts is not
allowable since liquids that could possibly leak from the device may then be ignited. When
being placed in operation, the device must be checked for leaks under normal operating
conditions.
Connection Plate
Before installing the gearwheel flow meter, carefully clean the piping system. Then mount the
connection plate at the prescribed location in the system.
Caution: Make sure that the gaskets are seated properly! The joint surface must be free of dirt
and paint residue
Place the housing on the connection plate so that the mounting holes are in alignment.
Fasten the housing to the connection plate with the screws and tighten them down.
Caution: The mounting screws for the DV04 mountings plate must be tightened crossways.
Be sure to apply the correct amount of torque.
Installation on connection plates not supplied with the device or on valve manifolds
Be sure to observe the specified values for surface flatness and surface roughness.
Nominal size DV04.2-6 DV04.7-8
Surface roughness Rt1/ 1000 mm 0.01 0.02
Surface flatness 1/ 1000 mm 10 10
In this case, the gearwheel flow meter must also be installed as described above.
DV04-B~2.SAM 15.09.05 Page 5

Pipe Connection
Before installing the gearwheel flow meter, completely clean the piping system.
Connect the piping to the inlet and outlet of the measuring device. Be sure to observe the
specifications of the respective manufacturer.
During installation be sure than no sealant gets inside the piping system.
Caution: The gearwheel flow meter must not be subjected to excessive mechanical stress
during installation.
After the gearwheel flow meter is installed and the piping system is placed back in service,
check all connections for leakage.
8 Electrical Connection
Number of measuring channels 2
Operating voltage UB= 24 V DC +/- 20%, protected against
polarity reversal
Pulse amplitude UA>/= 0,8 UB
Pulse from with symmetric output signal Square-wave pulse, scanning ratio
/channel 1:1 +/- 15%
Pulse offset between both channels 90° +/- 30°
Power consumption Pb max = 0,9 W
Output power / channel Pa max = 0,3 W, short circuit proof
Protection type IP 65 (DIN 40500)
Prerequisite:
A 24V (DC) line (± 20 %) must be provided to supply power to the pre-amplifier.
The terminal assignment for channel 1 or 2 has an influence on the displayed direction of
rotation of the gearwheels, and thus on the preceding sign (+ or -) that is used when
displaying the measured volumetric flow rate on the evaluation device.
DV04-B~2.SAM 15.09.05 Page 6

Caution: After assembly, the mounting screw (slightly) and the cable gland nut must be tightened
9 Maintenance and Cleaning
Gearwheel flow meters are generally maintenance-free. However, if fluids that can leave
deposits flow through the device, cleaning may be necessary. Otherwise, the device can be
cleaned with the rest of the system during the standard cleaning procedure. Indications of
wear may be evident by a change in measuring accuracy. It is recommended the device be
inspected regularly.
Caution: If fluids harden in the gearwheel flow meter, it must be cleaned as quickly as
possible with suitable cleaning agents.
The mounting screws must be regularly checked for tightness. If necessary, retighten them (in
such case, observe the tightening torque specified in the section ”Installation and Removal of
the Gearwheel Flow Meter”).
Caution: Be sure to relieve the pressure in the piping before performing any work on the
gearwheel flow meter or removing it. The gaskets in the joints between the gearwheel meter
and the piping system must be checked regularly for leakage.
DV04-B~2.SAM 15.09.05 Page 7

Cleaning
Devices in series 1, 2, 6, 7 and 8:
These devices must never be opened by the customer. They must only be opened by trained
service personnel because only such specialists can reassemble them properly so that they will
function correctly.
Devices in series 3, 4 and 5:
If due care is used, these devices may be opened and cleaned by the customer.
Caution: Be sure to relieve the pressure in the piping and ensure that the electrical supply is
de-energized before opening and cleaning the device. The device and the piping may still
contain the transported fluid or a cleaning agent. All guidelines governing the handling of the
fluid that was last sent through the system must be followed. Before opening the system,
make sure that containers of sufficient capacities are available to catch any escaping fluid. If
necessary, the work area must also be sufficiently ventilated.
Removing the gearwheel flow meter (see section ”Installation and Removal of the
Gearwheel Flow Meter”).
Drain the measuring device.
Loosen the screws that hold the two halves of the housing together bolts.
The 4 or 8 internal hexagon drive screws ("Allen screws) are accessible from the bottom of
the housing.
Caution: When removing the upper half of the gearwheel flow meter, do not pry the halves
apart at the joint with screwdrivers or similar tools. The gearwheels must not be removed from
the housing with pliers or similar tools.
Clean the interior of the housing, the gearwheels and the bearings with a suitable cleaning
agent.
Insert both gearwheels with the bearings in the lower housing.
Position the o-ring in the grooved seat in the housing.
Place the upper part of the housing on the bottom part (insert the locating pins).
Insert the screws and snug them down crossways. Then tighten them crossways to the
specified torque (see below).
Caution: All parts being assembled must be free of dirt and deposits. During installation of the
gearwheel flow meter, make sure that no foreign objects enter the assembly.
Nominal Size* DV04.
2DV04. 3DV04. 4DV04. 5DV04. 6DV04. 7DV04. 8DV04.
9
Tightening Torque Nm 14 14 14 35 35 120 120 290
Install the housing again in the system as described in the section ”Installation and Removal
of the Gearwheel Flow Meter”.
DV04-B~2.SAM 15.09.05 Page 8

10 Returning
If service or repair to the device is necessary or if the device needs to be inspected at the
factory, it must be suitably packed for shipment. Furthermore, the device must be
accompanied by a material safety data sheet indicating the fluid that was used in it. In the case
of common mineral oils, an exact type designation is required.
Caution: If the device was used with fluids whose residues will become hard or sticky, it must
be rinsed out before being returned.
11 Disposal
The device packing material as well as used devices and device parts must be disposed of in
accordance with applicable regulations of the country in which the device is installed.
DV04-B~2.SAM 15.09.05 Page 9

12 Troubleshooting
Error Possible cause Remedy
The two LED displays on the
isolating switch amplifier are
illuminated, but incorrect values are
displayed.
The connection between gearwheel
flow meter and evaluation device is
faulty.
Check the connection and, if
necessary, replace the cable or
plug connector.
One of the LED displays does not
illuminate during operation. The wiring between the sensor and the circuit board or individual
soldered points on the circuit board
are damaged.
Return the measuring device to
the manufacturer for repair.
The associated sensor is faulty.
The two LED displays do not
illuminate during operation. No voltage supply present Check the power cable and fuses.
Since it is unlikely that both sensors
will fail at the same time, it should
then be assumed that the measuring
mechanism has stopped for some
reason.
Immediately remove the
gearwheel flow meter from
operation!
Return devices in series 1, 2, 6,
7 and 8 to the manufacturer for
repair.
Devices in series 3, 4 and 5 may
be disassembled and cleaned
(see "Maintenance").
Leakage, fluid leak O-ring in housing defective,
allowing leakage. Return devices in series 1, 2, 6, 7 and 8 to the manufacturer for
repair and request advice on the
specific application.
Check devices in series 3, 4 and
5 for seal compatibility with the
particular fluid being
transported. If necessary contact
the manufacturer and install a
new gasket set (can be ordered
from the manufacturer).
O-ring between gearwheel flow
meter and connection plate defective,
allowing leakage.
Check seal compatibility, install
new O-rings.
Reduced measuring accuracy Device wear Check measuring device or
return to the manufacturer for
repair.
DV04-B~2.SAM 15.09.05 Page 10

13 Dimensions (series 1,2,3,4,7)
Model Weight* A C DFGS GH JKLMNP
DV04.2 1,8 85 10 60 50 101 114 -70 40 20 6,5 M6
DV04.3 2 85 9 60 56 107 120 -70 40 20 6,5 M6
DV04.4 2 85 13 60 57 108 121 -70 40 20 9 M6
DV04.5 3,7 100 17 90 63 114 127 -80 38 34 16 M8
DV04.6 5,2 120 13 95 72 123 136 15,5 84 72 35 16 M8
DV04.7 9 170 18 120 89 140 153 46,5 46 95 50 25 M12
DV04.8 13 170 22 120 105 156 169 46,5 46 95 50 25 M12
DV04.9 35,5 200 25 160 121 172 - - 64 125 70 38 M16
* in Kg
Design S and X Design H
Connection Dimensions
DV04-B~2.SAM 15.09.05 Page 11

Dimensions (series 5,6,8, stainless steel version)
Model Weight* CDFGS GH JKLMNP
DV04.2 3 15 94 55 106 119 -70 40 20 6,5 M6
DV04.3 3 9 94 56 107 120 -70 40 20 6,7 M6
DV04.4 3,1 13 94 57 108 121 -70 40 20 9 M6
DV04.6 7 13 124 72 123 136 15,5 84 72 35 16 M8
DV04.7 15,9 21 170 89 140 153 46,5 46 95 50 25 M12
DV04.8 18,7 25 170 105 156 169 46,5 46 95 50 25 M12
* in Kg
Design S and X Design H
Connection Dimensions
DV04-B~2.SAM 15.09.05 Page 12

Connection flanges (cast iron)
Model Weig..* ABCEFG H JKLMNPRc d e f
DV04.2-DV04.4 1,8 85 90 35 65 76 7 11 7 70 40 20 6,5 M6 17 0,7 25 G3/8 13
DV04.5 2,7 100 110 37 86 96 7 11 7 80 38 34 16 M8 18,5 0,7 29 G1/2 15
DV04.6 2,9 100 120 37 80 106 7 11 7 84 72 35 12 M8 17,5 0,7 29 G1/2 15
DV04.7 4,9 100 120 65 80 106 7 11 8 84 72 35 13 M8 32,5 1 42 G1 19
DV04.8 14 160 165 80 140 145 9 15 9 46 95 50 25 M12 28 1 42 G1 19
DV04.9 28 200 215 100 176 191 11 18 11 64 125 70 38 M16 35 1 58 G 1 1/2 23
* in kg
View X
DV04-B~2.SAM 15.09.05 Page 13

Flow Measurement and Monitoring
DV04
High Precision Gear Wheel
Counter for Viscous Liquids
•for media with iscosities starting from 20 cSt
•excellent price / performance ratio
•cast iron or stainless steel ersion
•accuracy better than 0,3 % of m. .
•high definition
•pressure resistant up to 400 bar
•small installation dimensions
•measuring ranges: 0,008...2 l/min bis 3...700 l/min
•Pmax: 400 bar, Tmax: 220 °C
Description:
The measuring mechanism of the flow meter DV04 consists of
a pair of gears which are driven by the liquid flow according to
the operating principle of a gear pump.
The movement bearing is designed as plain bearing or ball
bearing. The movement of the gears is scanned by two
magnetoresistive sensors, which are hermetically separated
from the measuring chamber and phase-shifted by 0°.
This two-channel scanning enables a higher measured value
resolution as well as the detection of the flow direction by
means of suitable electronics. As an option, all devices are
available in explosion-proof design with separate switching
amplifier. The gearwheel flow meter DV04 is characterized by
very low flow resistance and particularly low sound pressure
level.
Typical applications:
Due to the outstanding measuring accuracy, combined with
the high resolution, these devices are particularly suitable for
use in test benches for measuring small and very small flow
rates.
Further fields of application:
• consumption measuring
• control of filling processes
• dosage of oils and chemicals
• flow measurement of paints and varnishes
• ratio control of polyol and isocyanate
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
201 0403

Model (table. 1):
Depending on the field of applications and media properties,
the DV04 available in 8 different models:
Model Material Min.
viscosity
[mm² s]
Accuracy [%
of measured
value]
Media properties
Viscosity Lubricating
properties
1 cast iron
40/60
20 ± 0,3 low good
2 cast iron 40 50 ± 0,5 intermediate good
3 cast iron 40 100 ± 1,0 high good
4 cast iron 40 100 ± 0,5 intermediate low
5 st. steel
1.4404
100 ± 0,5
DV04.2: ± 3
intermediate low
6 st. steel
1.4404
20 ± 0,3 low good
7 cast iron 40 20 ± 1 low low
8 st. steel
1.4404
20 ± 1 low low
Process connection (table. 2):
Model 1 2 3 4 5 6 7 8
MB-Code Ball
bearing
Ball
bearing
Bronze
plain
bearing
Carbide plain
bearing
Carbide
plain
bearing
Ball
bearing
Hybrid ball
bearing
Hybrid ball
bearing
DV04.2 G 3/8 - - - G 1/8 G 1/8 G 3/8 G 1/8
DV04.3 G 3/8 - - - - G 1/4 G 3/8 G 1/4
DV04.3A G 3/8 - - G 3/8 - G 3/8 G 3/8 G 3/8
DV04.4 G 3/8 G 3/8 - G 3/8 G 3/8 G 3/8 G 3/8 G 3/8
DV04.5 G 1/2
or
G 3/4
- - G 1/2 or
G 3/4
- - - -
DV04.6 G 1/2
or
G 3/4
G 1/2
or
G 3/4
G 1/2
or
G 3/4
G 1/2 or
G 3/4
G 1/2 G 1/2 G 1/2 or
G 3/4
G 1/2
DV04.7 G 1 G 1 G 1 G 1 G 1 - -
DV04.8 G 1 G 1 G 1 G 1 G 1 G 1 - -
DV04. SAE*)- - - - - - -
DV04.10 SAE*)- - - - - - -
*)SAE flange, d = 38 mm
Measuring ranges [l/min] (Tab. 3):
MB-
Code
Model
1 2 3 4 5 6 7 8
DV04.2 0,008-2 - - - 0,02-2 0,008-2 0,008-2 0,008-2
DV04.3 0,02-4 - - - - 0,02-4 0,02-4 0,02-4
DV04.3A 0,04-8 - - 0,04-8 - 0,04-8 0,04-8 0,04-8
DV04.4 0,16-16 0,16-16 - 0,16-16 0,16-16 0,16-16 0,16-16 0,16-16
DV04.5 0,2-40 - - 0,2-30 - - - -
DV04.6 0,4-80 0,4-80 0,6-40 0,3-60 0,3-60 0,4-80 0,4-80 0,4-80
DV04.7 0,6-160 - - 0,6-100 0,6-100 0,6-160 - -
DV04.8 1-250 1-250 1,2-80 1-160 1-160 1-250 - -
DV04. 2-600 - - - - - - -
DV04.10 3-700 - - - - - - -
Parameters (Tab. 4):
MB-Code Max. pressure
[bar]
Pressure peak
[bar]
Sound
pressure level
[dB(A)]
Resolution
[Imp. l]
DV04.2 400 480 < 60 40.000
DV04.3 400 480 < 60 25.000
DV04.3A 400 480 < 60 10.000
DV04.4 400 480 < 60 4.081,63
DV04.5 400 480 < 70 2.500
DV04.6 400 480 < 70 65,25
DV04.7 315 350 < 70 333,33
DV04.8 315 350 < 72 1 1,5
DV04. 400 480 < 80 83,33
DV04.10 400 480 < 80 62,5
Order Code:
Order number: DV04.
Gear wheel counter
2. 1. F. PS. 10. S. 0. 0
Measuring ranges:
2…10 = see table 3
Model:
1…8 = see table 1
Gasket:
F = FKM (standard)
E = EPDM
P = FEP
K = FFKM
Connection type:
PS = with mounting plate, connection at side
(standard)*
PU = with mounting plate, connection bottom*
R = without mounting plate, connection at side
(models 5, 6, 8 only)
Process connection: (see table 2)
04 = G 1/8 female thread
06 = G 1/4 female thread
10 = G 3/8 female thread
15 = G 1/2 female thread
20 = G 3/4 female thread
25 = G 1 female thread
40 = SAE flange, d = 38 mm
Electronic version:
S = standard
H1 = high temperature version up to 150 °C
H2 = high temperature version up to 220 °C (FEP gasket
and terminal box)
X = intrinsically safe with separate switching amplifier
(EEx ia IIC)
Display:
0 = without display
DVA= prepared for plug-on display DVA
(date sheet on the following pages)
Options:
0 = without
1 = please specify in plain text
(*not for models 5, 6, 8)
Technical Data:
Viscosity range: 20…100.000 mm²/s
Pressure drop: depending on viscosity and
load of the devices
(exact values on request)
Medium temperature range:
standard version: −30 °C…+120 °C
high temp. version: −30 °C…+150 °C, (220 °C)
Materials:
models 1–4, 7: housing GGG 40,
GGG 60 (DV04. , DV04.10)
measuring unit 1.713
models 5, 6, 8: housing st. steel 1.4404
measuring unit st. steel 1.4462
Electronic:
standard: 2 sensors, 0° phase-shifted
Ex-version: with separate switching amplifier
Power supply: 12…30 VDC,
protected against polarity reversal
Power consumption: 0, W
Output signal: square-wave pulses, min. 0,8 x UB,
duty cycle 1:1 (± 15 %)
Protection class: IP65
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
Flow