PKP DB51 User manual

Instruction Manual
DB51
Compact mass thermal flowmeter and
counter for gases
PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-65205 Wiesbaden- ordenstadt
Tel.: ++49-(0)6122-7055-0
Fax: ++49-(0)6122-7055-50
Email: [e-mail] www.pkp.de

Foreword
DB51 EN V1.22 Page 2o 40
I. Foreword
Dear customer,
thank you very much for deciding in favour of the DB51. Please read this
installation and operation manual carefully before mounting and initiating the device
and follow our advice. A riskless operation and a correct functioning of the
DB51 are only guaranteed in case of careful observation of the described
instructions and notes
PKP Prozessmesstechnik
Borsigstraße 24
D-65205 Wiesbaden
Tel.: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.pkp.de

Table of Content
DB51 English V1.22 Page 3 of 40
II. Table of Contents
I. Foreword ....................................................................................................................... 2
1Intended use.................................................................................................................. 5
2Safety instructions........................................................................................................ 5
3Instruments description ............................................................................................... 6
4Technical data............................................................................................................... 7
5Scope of delivery.......................................................................................................... 7
6Scaling Analogue output Compressed Air............................................................... 8
7Installation Description ................................................................................................ 9
7.1 Pipe/tube requirements ......................................................................................................... 9
7.2 Inlet / outlet runs.................................................................................................................... 9
7.3 Installation of DB51.......................................................................................................... 10
7.4 Display head Position.......................................................................................................... 10
8Flow measuring ranges...............................................................................................11
8.1 Flow for different gases....................................................................................................... 11
9Dimensions ..................................................................................................................12
9.1 With measurement section and screw-in thread.............................................................. 12
9.2 With measurement section and flange (Material stainless steel 1.4404):...................... 13
10 Electrical wiring........................................................................................................14
10.1 Modbus RTU, 4…20mA, Pulse or MBus ............................................................................ 14
10.2 Ethernet (optional PoE) ...................................................................................................... 15

Table of Content
DB51 EN V1.22 Page 4o 40
11 Operation...................................................................................................................16
11.1 Initialization .......................................................................................................................... 17
11.2 Main menu ............................................................................................................................ 17
11.3 Settings................................................................................................................................. 18
11.3.1 Sensor Setup................................................................................................................... 18
11.3.1.1 Input / change tube diameter.................................................................................... 18
11.3.1.2 Input / change consumption counter ........................................................................ 19
11.3.1.3 Definition of the units for flow, velocity, temperature and pressure ......................... 19
11.3.1.4 Definition of the reference conditions....................................................................... 20
11.3.1.5 Setting of Zero point and Low-flow cut off................................................................ 22
11.3.2 Modbus settings............................................................................................................... 23
11.3.2.1 Modbus RTU Setup.................................................................................................. 23
11.3.2.2 Modbus TCP (Optional)............................................................................................ 24
11.3.2.2.1 Network Setup DHCP........................................................................................... 24
11.3.2.2.2 Network Settings static IP..................................................................................... 25
11.3.2.3 Modbus TCP Settings............................................................................................... 26
11.3.2.4 Modbus Settings (2001…2005)............................................................................. 27
11.3.2.5 Values Register (1001 …1500) ................................................................................ 27
11.3.3 Pulse /Alarm..................................................................................................................... 29
11.3.3.1 Pulse output.............................................................................................................. 29
11.3.4 User Setup....................................................................................................................... 30
11.3.4.1 Password.................................................................................................................. 30
11.3.4.2 Language.................................................................................................................. 30
11.3.4.3 Display / Touch......................................................................................................... 31
11.3.5 Advanced......................................................................................................................... 31
11.3.6 4 -20mA ........................................................................................................................... 32
11.3.7 DB51 Info...................................................................................................................... 34
11.4 MBus...................................................................................................................................... 35
11.4.1 Default Settings communication...................................................................................... 35
11.4.2 Default values transmitted ............................................................................................... 35
12 Status / Error messages...........................................................................................36
12.1 Status messages.................................................................................................................. 36
12.2 Error messages.................................................................................................................... 37
13 Maintenance..............................................................................................................38
14 Cleaning of the sensor head....................................................................................38
15 Re-Calibration...........................................................................................................38
16 Spare parts and repair..............................................................................................38
17 Calibration.................................................................................................................38
18 Warranty....................................................................................................................38

Safety instructions
DB51 English V1.22 Page 5 of 40
1 Intended use
The DB51 consumption sensor is used for continuous flow measurements.
The DB51 consumption sensor is designed and constructed exclusively for the intended purpose
described here and may only be used accordingly.
The user must check whether the instrument is suitable for the selected application. It must be
ensured that the medium is compatible with the wetted parts. The technical data listed in the data
sheet are binding.
Improper handling or operation outside the technical specifications is not permitted. Claims of any kind
based on improper use are excluded.
2Safety instructions
Please read carefully before starting the device!
Warning: Do not exceed the pressure range of 16 bar!
Observe the measuring range of the sensor!
Always observe the direction of flow when positioning the sensor!
The screwed fixture must be pressure tight.
It is absolutely necessary to avoid condensation on the sensor element or water drops in the
measuring air as they may cause faulty measuring results.
The manufacturer cannot be held liable for any damage which occurs as a result of non-observance or
non-compliance with these instructions. Should the device be tampered with in any manner other than
a procedure which is described and specified in the manual, the warranty is cancelled and the
manufacturer is exempt from liability.
The device is destined exclusively for the described application.
We offer no guarantee for the suitability for any other purpose and are not liable for errors which may
have slipped into this operation manual. We are also not liable for consequential damage resulting
from the delivery, capability or use of this device.
We offer you to take back the instruments of the instruments family DB51 which you would like to
dispose of.
Qualified employees from the measurement and control technology branch should only carry out
adjustments and calibrations.
The consumption sensor DB51 works according to the calorimetric measuring procedure.
Flammable gases
If this consumption sensor is used for measurement of flammable gases (e. g. natural gas and so on)
we expressly would like to point out that the sensor has no DVGW admission, however, it can be used
for measurements in natural gas. A DVGW admission is not mandatory.
The consumption sensor corresponds with the current state of technology and basically it can be used
in any flammable and non-flammable gases.
If the sensor is used e.g. in the medium natural gas, the sensor will be adjusted for natural gas. The
calibration protocol (inspection certificate) will be included in the scope of delivery.
The area outside the pipeline (ambient area of the sensor) must not be an explosive area.
The installation has to be carried out by authorized professionals.

Instruments decription
DB51 English V1.22 Page 6 of 40
3Instruments description
The DB51 is a compact consumption counter for compressed air and gases.
Special features:
- Optimum accuracy due to compact design
- Integrated Display showing Flow, consumption, velocity and temperature
- Input inner tube diameter via display keys
- Units free selectable. m³/h, m³/min, l/min, l/s, kg/h, kg/min, kg/s, cfm
- Modbus RTU (RS485) Interface
- Analogue output 4..20mA
- Pulse output galv. isolated.

Technische Daten
DB51 English V1.22 Page 7 of 40
4Technical data
Measurement: Flow and consumption
Reference Standard: Standard settings ex works:
DIN 1945, ISO 1217 at 20°C and 1000 mbar
Selectable Units m³/h (Standard settings ex works)
m³/min, l/min, l/s, ft/min, cfm, m/s, kg/h, kg/min, kg/s
Measuring principle: calorimetric measurement
Sensor: Pt45, Pt1000
Measuring medium: Air, gases
Operating temperature: -30 ... 80°C probe tube
-20 ... 70°C housing
Rel. humidity of the
measuring medium: < 95 % r.H. (no condensation allowed on the sensor element)
Operating pressure: up to 16 bar, special version PN 40 (40 bar)
Power supply: 18 to 36 VDC
Power consumption: max. 5W
Digital output: RS 485 (Modbus RTU)
Analog output: 4...20 mA (see chapter 4), max. burden < 500 Ohm
Pulse output: pulse output potential free (dry contact)
passive: max. 48Vdc, 150mA
1 pulse pro m³ resp. pro l,
Valency adjustable with the display keys
Accuracy: ± 1,5 % m.v., ± 0,3 % f. s.*
Display: TFT 1.8 Resolution 220 x 176
Mounting thread: R 1/4", R1/2", R3/4", R1", R 1 1/4" R1 1/2", R 2” DIN EN
10226 (ISO 7-1)
Material: Stainless steel 1.4301 / 1.4404
Version with flange DIN EN 1092-1: Stainless steel 1.4404
Protection class: IP65
* m.v. = measured values
f.s. = full scale
5 Scope of delivery
1x Flow sensor DB51 with measuring section
1x Calibration certificate
1x Instruction manual

Scaling Analogue output
DB51 English V1.22 Page 8 of 40
6Scaling Analogue output Compressed Air
Reference DIN1945/ ISO 1217: 20°C, 1000 mbar (Reference during calibration)
Description
Version
Analogue output
DB51 with integrated 1/4" meas. section
Low Speed
4… 20 mA =
0...25 l/min
Standard
0...50 l/min
Max
0...105 l/min
High Speed
0...130 l/min
DB51 with integrated 1/2" meas. section
Low Speed
4… 20 mA =
0...20 m³/h
Standard
0...45 m³/h
Max
0...90 m³/h
High Speed
0...110 m³/h
DB51 with integrated 3/4" meas. section
Low Speed
4… 20 mA =
0...45 m³/h
Standard
0...85 m³/h
Max
0...175 m³/h
High Speed
0...215 m³/h
DB51 with integrated 1" meas. section
Low Speed
4… 20 mA =
0...75 m³/h
Standard
0...145 m³/h
Max
0...290 m³/h
High Speed
0...355 m³/h
DB51 with integrated 1 1/4" meas.
section
Low Speed
4… 20 mA =
0...140 m³/h
Standard
0...265 m³/h
Max
0...530 m³/h
High Speed
0...640 m³/h
DB51 with integrated 1 1/2" meas.
section
Low Speed
4… 20 mA =
0...195 m³/h
Standard
0...365 m³/h
Max
0...730 m³/h
High Speed
0...885 m³/h
DB51 with integrated 2" meas. section
Low Speed
4… 20 mA =
0...320 m³/h
Standard
0...600 m³/h
Max
0…1195m³/h
High Speed
0...1450 m³/h
DB51 with integrated 2 1/2" meas.
section
Low Speed
4… 20 mA =
0...550 m³/h
Standard
0...1025 m³/h
Max
0…2050m³/h
High Speed
0...2480 m³/h
DB51 with integrated 3" meas. section
Low Speed
4… 20 mA =
0...765 m³/h
Standard
0...1420 m³/h
Max
0…2840m³/h
High Speed
0...3440 m³/h

Installation
DB51 English V1.22 Page 9 of 40
7Installation Description
7.1 Pipe/tube requirements
•Correctly sized gaskets
•Correct aligned flanges and gaskets
•Diameter mismatch at the pipe junctions should be avoided but must be less than 1mm. For
further information see ISO 14511
•Ensure clean pipes after installation
7.2 Inlet / outlet runs
The principle of thermal Mass flow measurement is very sensitive against disturbances. Therefore, it is
necessary to ensure the recommended inlet and outlet runs.
Table of additionally required inlet sections
Flow obstruction in front of the
measuring section
Minimum length inlet
section (L1)
Minimum length
outlet section (L2)
Slight curve
(bend < 90°)
12 x D
5 x D
Reduction
(pipe narrows towards the meas. section)
15 x D
5 x D
Expansion
(pipe expands towards the meas. section)
15 x D
5 x D
90° bend
or T-piece
15 x D
5 x D
2 bends á 90°
on one level
20 x D
5 x D
2 bends á 90°
3-dimensional change of direction
35 x D
5 x D
Shut-off valve
45 x D
5 x D
15 x D 5 x D
15 x D 5 x D15 x D
15 x D 5 x D
20 x D 5 x D
35 x D 5 x D
5 x D45 x D
The respective minimum values required are indicated here. If it is not possible to observe the
stipulated equalising sections, considerable deviations in the measuring results must be expected.
Attention:
The dimensions of the DB51 consumption counter measuring sections do not fullfill the required
minimum lengths of the input and outlet runs.
Please ensure recommended in - and outlet distances, dimensions for measuring sections see page
12 and 13.

Installation
DB51 EN V1.22 Page 10 o 40
7.3 Installation of DB51
The sensor DB51 is pre-supplied with the measuring section.
•An installation at customer site is only allowed in the unpressurized state of
the system
•It has to be checked whether the VA520 is correctly installed in the
measuring section, the flow direction arrows must point in the same
direction.
>>> Flow >>> >>> Flow >>>
•The connecting nut is tightened to a torque of 25 -30 Nm.
•Tightness of the connection must be checked and ensured
7.4 Display head Position
Fastening screws
The Position of the Display head is twistable by 180 e.g. in
case of reverse flow direction.
For this purpose the 6 fastening screws are to be released
and the display head rotated 180°.
Caution:
It must be ensured that the connection plugs are still plugged
and the gasket is installed correctly.