PKP DM08 User manual

Instruction Manual
DM08
Magnetic Inductive Flow Meter
PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-65205 Wiesbaden- ordenstadt
Tel.: ++49-(0)6122-7055-0
Fax: ++49-(0)6122-7055-50
Email: [e-mail]

Table of contents page
1 About this operating manual........................................................................................................3
2 Device description.......................................................................................................................4
2.1 Delivery, unpacking and accessories.......................................................................................
2.2 Intended use.............................................................................................................................6
2.3 Exclusion of liability...................................................................................................................6
3 Safety instructions.......................................................................................................................7
4 Construction and function............................................................................................................8
4.1 Construction..............................................................................................................................8
4.2 Measuring principle...................................................................................................................9
4.3 Functions..................................................................................................................................9
Installation of DM08.....................................................................................................................9
.1 Installation instructions display electronics.............................................................................10
.2 Instructions on potential equalisation and cathode protection...............................................11
.2.1 Potential equalisation..........................................................................................................11
.2.2 Cathodic protectives............................................................................................................13
.3 Sensor installation instructions...............................................................................................13
.4 Mounting.................................................................................................................................16
6 Electrical connection..................................................................................................................17
6.1 Mains and signal cable...........................................................................................................18
6.2 Electrode and magnetic current line.......................................................................................20
7 Commissioning..........................................................................................................................21
8 Operation...................................................................................................................................22
8.1 Functional classes (main menu).............................................................................................26
8.1.1 Measured values.................................................................................................................27
8.1.2 Password.............................................................................................................................29
8.1.3 Totalizer...............................................................................................................................31
8.1.4 Measurement processing....................................................................................................32
8.1. Flow.....................................................................................................................................33
8.1.6 Pulse output.........................................................................................................................36
8.1.7 Status output........................................................................................................................38
8.1.8 Current output......................................................................................................................39
8.1.9 Simulation............................................................................................................................40
8.1.10 Self-test..............................................................................................................................42
8.1.11 Settings Sensor.................................................................................................................44
9 Errors and returns......................................................................................................................48
9.1 System errors.........................................................................................................................48
9.2 Self-test errors........................................................................................................................49
9.3 Return shipment to the manufacturer..................................................................................... 0
10 Cleaning, maintenance, storage.............................................................................................. 1
10.1 Cleaning................................................................................................................................ 1
10.2 Maintenance......................................................................................................................... 1
10.3 Storage................................................................................................................................. 2
11 Disassembly and disposal....................................................................................................... 2
12 Technical data......................................................................................................................... 3
12.1 Characteristics of the DM08................................................................................................. 3
12.2 Materials...............................................................................................................................
12.3 Dimensions and weights....................................................................................................... 6
12.3.1 Compact device................................................................................................................. 6
Please keep this operating manual for future reference.
If the device is resold, please provide the operating manual along with it.

Instruction Manual DM08
12.3.2 Separate version (with wall bracket)................................................................................. 7
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Instruction Manual DM08
1 About this operating manual
The operating manual is aimed at specialists and semi-skilled personnel.
Before each step, read through the relevant advice carefully and keep to the specified order.
Thoroughly read and understand the information in the section "Safety instructions".
If you have any problems or questions, please contact your supplier or contact us directly at:
PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-6 20 Wiesbaden-Nordenstadt
Tel: [phone]
Fax: [phone] - 0
Hazard signs and other symbols used:
DANGER! Danger to life due to non-observance!
This sign indicates dangers which could lead to serious health defects or to death.
WARNING! / CAUTION! Risk of injury!
This sign indicates dangers that cause personal injuries that can lead to health defects or
cause considerable damage to property.
CAUTION! Electric current!
This sign indicates dangers which could arise from handling of electric current.
CAUTION! High temperature!
This sign indicates dangers resulting from high temperature that can lead to health defects or
considerable damage to property.
CAUTION! Material damage!
This sign indicates actions which could lead to possible damage to material or environmental
damage.
ADHERE TO OPERATING MANUAL! NOTICE!
This symbol indicates important notices,
tips or information.
NO DOMESTIC WASTE!
The device must not be disposed of to-
gether with domestic waste.
Pay attention to and comply with informa-
tion that is marked with this symbol.
Follow the specified instructions and steps.
Adhere to the given order.
Check the specified points or notices.
Reference to another section, document or
source.
• Item.
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Instruction Manual DM08
2 Device description
The DM08 flow meter from PKP is a flow sensor without moving parts. The measurement is per-
formed using magnetic induction.
The DM08 is used for measuring or dosing water and electrically conductive fluids. The complete
measuring instrument comprises the sensor and the related display electronics.
The display electronics is microprocessor controlled and programmable. It can be customized us-
ing a control unit.
The basic configuration settings such as display electronics calibration are realized at the factory.
Other settings are user definable.
Measurement data from sensors are processed by display electronics. It is designed for flow velo-
cities up to 10 m/s.
Components:
The most important components of the DM08 are
Display electronics.
Indication and control panel.
Sensor.
Measuring tube.
Junction box.
Process connection.
Versions:
The DM08 is available as a compact device (Fig. left) or in separate design (Fig. right).
Both designs are available in nominal widths from DN 1 to DN 200 with different features.
ype plates:
The type plates you can find at the backs of evaluation electronics and sensor.
They contain the most important technical data of DM08.
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Instruction Manual DM08
2.1 Delivery, unpacking and accessories
All units have been carefully checked for their operational reliability before shipment.
Immediately after receipt, please check the outer packaging for damages or any signs of im-
proper handling.
Report any possible damages to the forwarder and your responsible sales representative. In
such a case, state a description of the defect, the type and the serial number of the device.
Report any in-transit damage immediately. Damage reported at a later date shall not be re-
cognized.
Unpacking:
Carefully unpack the unit to prevent any damage.
Check the completeness of the delivery based on the delivery note.
Scope of delivery:
1x DM08 according to the order data.
1x operating manual.
certificates (optional)
IMPORTANT!
Use the type plate to check if the delivered unit corresponds to your order.
In particular, for devices with electrical components, check to see if the correct power supply
voltage is specified.
Accessories:
Installation supplies (gaskets/seals, screws, etc.) are not included with the delivery.
Earthing rings.
Protection rings.
Sensor cable.
You can find details on the accessories in our catalogue on the Internet.
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Instruction Manual DM08
2.2 Intended use
Magnetic inductive flow sensor DM08 is only intended to be used for measuring and dosing /
batching the flow of electric conductive, liquid media
According to the Pressure Equipment Directive 2014/68/EU, only Group 2 fluids are permitted to
be used.
Due to the magnetic field, the device can be used to measure flow rates up to 10 m/s (32.8 ft/s) and
a minimum conductivity of 0 μS/cm, when using a synchronized static field.
WARNING! No safety component!
The flow sensor of the series DM08 is not a safety component in accordance with Directive
2006/42/EC (Machine Directive).
Never use the DM08 as a safety component.
The operational safety of the device supplied is only guaranteed by intended use. The specified
limits (§ Sensor installation instructions "Sensor installation instructions") may under no circum-
stances be exceeded.
Before installing the device, check if the wetted materials of the device are compatible with the me-
dia being used (§ Materials "Materials").
CAU ION! Risk of injury due to high temperature!
Hot process media can lead to hot surfaces! Danger of burns with surface temperatures above 70
°C.
Take suitable protective measures, e.g. contact protection.
The contact protection must be devised so that the maximum ambient temperature on the
device is not exceeded.
Flow tube empty (partially filled). / Conductivity too low:
Faulty measurements can occur if the flow tube of the DM08 is empty or partially filled or if the
conductivity of the fluid being used is too low.
Make sure that the flow tube of the DM08 is always completely filled (§ Sensor "Sensor").
Please observe the function "Empty pipe detection" (p. 11).
Make sure that the fluid being used has a conductivity of at least 0 μS/cm.
Before ordering and installing, check that the device is suitable for your application.
2.3 Exclusion of liability
We accept no liability for any damage or malfunctions resulting from incorrect installation, in-appro-
priate use of the device or failure to follow the instructions in this operating manual.
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Instruction Manual DM08
3 Safety instructions
Before you install the DM08 read through this operating manual carefully. If the instructions con-
tained within it are not followed, in particular the safety guidelines, this could result in danger for
people, the environment, and the device and the system it is connected to.
The DM08 corresponds to the state-of-the-art technology. This concerns the accuracy, the operat-
ing mode and the safe operation of the device.
In order to guarantee that the device operates safely, the operator must act competently and be
conscious of safety issues.
PKP provides support for the use of its products either personally or via relevant literature. The
customer verifies that our product is fit for purpose based on our technical information. The cus-
tomer performs customer- and application-specific tests to ensure that the product is suitable for
the intended use. With this verification all hazards and risks are transferred to our customers; our
warranty is not valid.
Qualified personnel:
The personnel who are charged for the installation, operation and maintenance of the DM08
must hold a relevant qualification. This can be based on training or relevant tuition.
The personnel must be aware of this operating manual and have access to it at all times.
The electrical connection should only be carried out by a fully qualified electrician.
General safety instructions:
In all work, the existing national regulations for accident prevention and safety in the workplace
must be complied with. Any internal regulations of the operator must also be complied with,
even if these are not mentioned in this manual.
Degree of protection according to EN 60 29:
Ensure that the ambient conditions at the site of use does not exceed (comply with) the require-
ments for the stated protection rating (§ Characteristics of the DM08 "Characteristics of the
DM08").
Take appropriate measures to ensure that the medium does not freeze.
Only use the DM08 if it is in perfect condition. Damaged or faulty devices must be checked
without delay and, if necessary, replaced.
When fitting, connecting and removing the DM08 use only suitable, appropriate tools.
Do not remove or obliterate type plates or other markings on the device, as otherwise the war-
ranty is rendered null and void.
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Instruction Manual DM08
Special safety instructions:
Danger! Electric current!
Particular care must be taken if the front window of the housing becomes fogged over or discol-
oured because moisture, water or product might seep through the wire sheath into the terminal
compartment in the housing!
Ingress protection IP67 is only achieved if suitable and tightly screwed down cable glands or
conduits are used. If the cable glands are only tightened manually water may leak into the ter-
minal compartment in the housing.
Electromagnetic compatibility is only achieved if the electronics housing is closed. Leaving the
enclosure open can lead to electromagnetic disturbances.
Further warnings that are specifically relevant to individual operating procedures or activities can
be found at the beginning of the relevant sections of this operating manual.
4 Construction and function
4.1 Construction
The DM08 comprises a sensor and the display electronics. The sensor is used to measure fluid
media. The display electrodes generate the coil current required for the magnetic field and pre-
pares the induced voltage applied to the electrodes.
The DM08 does not need any moving parts to make measurements. The inside of the measuring
tube is completely open, allowing the fluid to flow unhindered through the measuring tube.
Display electronics:
The display electronics has a backlit LCD.
6 buttons are used for operation. That facilitates easy configuration of the display electronics.
Furthermore the display electronics has an analogue 0/4 … 20 mA current output, a pulse or fre-
quency output and a status output.
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Instruction Manual DM08
4.2 Measuring principle
The magnetic inductive flow sensor operates on the inductive principle, i.e., a direct current is gen-
erated by the movement of a conductor in a magnetic field:
The measuring pipe of the DM08 is in a magnetic field (B).
An electrically conductive medium (Q) passes through the
pipe. During this, the positive and negative load carriers are
inversely deflected.
A voltage arises which is perpendicular to the magnetic
field, which is tapped through both electrodes.
The voltage induced during this is proportional to the aver-
age flow velocity of the fluid.
The electronics of the DM08 converts the induced voltage
into a flow-proportional frequency signal.
4.3 Functions
Empty pipe detection:
The electronic display unit has the ability for an empty pipe detection, which can be activated and
deactivated.
The operating reliability depends on the conductivity of the liquid medium and the cleanliness of
the electrodes.
As higher the conductivity is, as more reliable operates the empty pipe detection.
Insulation coatings on the electrodes surface worse the empty pipe detection.
Safety of operation:
A comprehensive self-monitoring system ensures maximum safety of operation.
Potential errors can be reported immediately via the configurable status output. The corres-
ponding error messages will also be displayed on the display of the display electronics. A
failure of the auxiliary power can also be detected via the status output.
All outputs are electrically isolated from the auxiliary power, the sensor circuit and from each
other.
5 Installation of DM08
Before installing, check that
the wetted materials of the device are suitable for the liquid being used (§ Materials "Materi-
als").
the equipment is switched off and is in a safe and de-energised state.
the equipment is depressurised and has cooled down.
Please observe in particular "Instructions of potential equalisation and cathode protection"
(§ Instructions of potential equalisation and cathode protection).
Suitable tools:
Use only suitable tools of the correct size.
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Instruction Manual DM08
5.1 Installation instructions display electronics
Compact version (standard):
For the compact version the display electronics housing is mounted on the sensor. Therefore no
cable is necessary between sensor and display electronics.
Remote version (optional):
The display electronics needs to be mounted separately from the sensor if:
the mounting area is difficult to access or there is a lack of space,
medium and ambient temperatures are extremely high,
there is strong vibration.
The display electronics has to be mounted free of vibrations!
Make sure that the cables are properly installed at high humidity and wet conditions.
The electrode cable must be fixed. If the conductivity of the medium is low, cable movements
may change the capacity considerably and thus disturb the measuring signal.
Do not lay the cables close to electrical machines and switching elements.
Equipotential bonding must be ensured between sensor and display electronics.
IMPORTANT! Pay attention to the maximum cable length!
For the separate version, the minimum permissible conductivity of the medium is determined by
the distance between the sensor and the display electronics.
The maximum cable length to ensure accuracy is 200 m (p. 19 "Connecting cables").
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Instruction Manual DM08
5.2 Instructions on potential equalisation and cathode protection
5.2.1 Potential equalisation
The signal outputs (process outputs and the mains supply of the DM08 are galvanic isolated from
each other. The housing and the interference filter of the mains supply are connected to PE.
The electrodes and measuring electronics are related to the potential of the function earth FE of
the sensor. FE is not connected to PE, but may be connected with each other in the sensor junc-
tion box. If the sensor is grounded by using ground disks (earthing rings), these must in connected
with the function earth FE.
At a separate assembly of sensor and display electronics the outer screen of the connecting cable
is connected to the housing of the display electronics and has PE potential. The inner screens of
the electrode line are connected to FE inside the junction box of the sensor and to the mass (GND)
of the display electronics.
Details of all wirings, terminals and drawing can be found in § Electrical connection "Electrical con-
nection".
IMPORTANT!
The display electronics can only process the measuring signal interference-free if this voltage is
referenced to a fixed potential (earth).
Potential equalisation on electrically conductive pipes:
The sensor is electrically connected to the pipeline in the sense of a potential equalisation.
Thus, the pipeline is earthed, and the media and therefore the signal voltage have a solid signal
common.
Potential equalisation on electrically insulated pipes:
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Instruction Manual DM08
When using pipes lined with electrical insulation, plastic tubing or concrete conduits, a separate
earthing washer is used to earth the measuring media. The earthing washer is installed between
the pipeline connection and the sensor’s flange and the ring’s inside contacts the media. Contrary
to the diagram shown below, one earthing washer on the inflow side is sufficient.
If bidirectional measurements are to be taken, one earthing washer must be installed on either
side.
Protection washers or protection rings can also be used as earthing component; or special earth-
ing electrodes, incorporated in the sensor, may be installed.
Earthing electrodes are more economical than earthing washers. However, it must be ensured that
noticeable differences in potential within the equipment are eliminated, otherwise the earthing elec-
trodes will electrolyze and be destroyed.
Potential-free installation of the sensor:
If the pipelines cannot be earthed, due to operational reasons, the sensor must be installed voltage
free. To do this, a separate cable must be used to electrically connect these segments of the
pipeline (min. 6mm²).
An electrical connection occurring between the sensor and any material used for the installation
must be avoided. Insulating segments must be installed between the sensor and the pipeline (e.g.
PVC pipes or similar).
Subsequently, earthing washers are used to electrically connect the media with the display elec-
tronics. The display electronics must not be connected with the protective earth conductor. This
may only be done, if the auxiliary power is 24 VDC.
Potential equalisation in separate design:
Create the potential equalisation in the separate design the same as described in the above sec-
tions. For the potential equalisation, the display electronics and the sensor are connected to each
other through Pin 7 of the connecting cable.
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Instruction Manual DM08
5.2.2 Cathodic protectives
Using a cathodic protective unit to avoid corrosion, which put a voltage to the tube wall, it must be
connected to terminal FE. The boards, control panel and internal switches of the display electron-
ics are on the same potential as FE.
CAU ION! Electric current - comply with limits!
According to EN 61010-1:2012 all electrical circuits with „protective safety isolation without any
protection against contacts” must observe the following maximum voltages:
Maximum AC voltage (Veff) 33 V
Maximum DC voltage 60 V.
 Make sure that no higher potential is connected to FE.
5.3 Sensor installation instructions
CAU ION! Risk of malfunction due to external magnetic fields!
Magnetic fields close to the device can cause malfunctions and should be avoided.
 Ensure that no external magnetic fields are present at the installation site of the DM08.
Please observe § Delivery, unpacking and accessories "Delivery, unpacking and accessories" and
the following installation instructions:
General:
The DM08 can always be installed at any point on the pipeline in the horizontal as well as in
vertical sections.
Ideally, the sensor should be installed in a pipeline with a sufficient straight run, both before
and after the measuring point.
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Instruction Manual DM08
Basically, the measuring principle does not depend on the flow profile. You should use
straight inlet and outlet sections according to the nominal width (DN). An inflow path of x
DN and an outflow zone of at least 2 to 3 x DN is required.
The flow sensor is only suitable for application in completely filled pipe systems. With a free
pipe outlet, the sensor should not be installed in pipe sections that could run empty (e.g.,
downpipes).
If the sensor must be installed in a down pipe, ensure that portion of the pipeline is always
filled 100% with the media.
Due to possible accumulation of gases, the sensor should not be installed at the highest
point of a pipeline.
It must be ensured, that the axes of the electrodes are running horizontally to avoid erro-
neous measurements due to deposits or air bubbles on the electrodes.
Also, note that in case of deviations from horizontal, the functioning of the Empty pipe de-
tection (p. 9) is limited.
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Instruction Manual DM08
Installation in unfilled pipeline:
If a pipeline is not always filled, or in case of an open channel (drainage), the sensor must
be installed in a siphon. That means the flow tube cannot run dry and is always filled with
measured medium.
Installation between tees, valves and pumps:
Always maintain the distance of the pipe's straight run (Fig. ). If these distances cannot be main-
tained, flow conditioners must be installed or pipes with smaller diameter must be used.
If several sensors are installed in series, the distance between each sensor must be equal to the
length of one sensor. If two or more sensors are to be installed in parallel, the distance between
sensors must be at least 1 m.
Measures during malfunctions:
In case of malfunctions in the inflow section due to vortexing (e.g. after pipe elbows, at tangential
inclusions or with a half-open gate before the sensor), measures for normalisation of the flow pro-
file are necessary.
The appropriate steps are:
increasing the inflow and outflow zones
using flow conditioners
reducing the inner diameter of the pipe
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Instruction Manual DM08
5.4 Mounting
As a compact device, the DM08 is installed directly into the pipeline. With the separate design, the
sensor is installed in the pipeline. The display electronics can be attached to the wall with the
bracket.
IMPORTANT NOTICES:
Only use suitable gaskets for installation.
Observe the flow direction indicated on the type plate and on the back site of the sensor.
Observe the mounting dimensions (§ Dimensions and weights "Dimensions and weights").
Select an appropriate location for installation (§ Sensor "Sensor installation instructions").
To ensure the best possible measuring accuracy, a vertical installation position with increasing
flow is preferable (no collecting of dirt deposits).
Install the appropriate screwed connections at the installation location.
Insert the DM08 together with the gaskets.
Connect the flange connections corresponding to the requirements of their use.
WARNING! Risk of injury or material damage!
Incorrect gaskets and connection materials plus improper assembly can lead to injuries or material
damage.
During installation, comply with the requirements that result from your application.
Maintain the required tightening torques.
IMPORTANT! Weather protection required
In the case of an outdoor installation, the device must be protected against direct solar irradiation
with a weather shield.
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Instruction Manual DM08
6 Electrical connection
CAU ION! Electric current!
The electrical connection of the DM08 should only be carried out by a fully qualified electrician.
De-energize the electrical system before connecting the DM08.
Make the electrical connection of the DM08 through the terminal strips in the interior of the display
electronics.
For the separate design, the sensor cable for the electrodes and the magnetic current are required
in addition. They are connected through the terminal strips in the junction boxes of the display
electronics and the sensor.
Connecting cables:
When connecting the DM08, use the following cable depending on the cable lengths:
Cable
length
Wire cross-sec-
tion
Example Cable ends dimension:
≤ 10 m ≥ 0.2 mm2LIYCY-CY TP 2x2x0.2
mm2
> 10 m ≥ 0.7 mm2LIY-TPC-Y 2x2x0.7 mm2
The cables are each twisted in pairs and shielded. In order to protect the cable from external inter-
ference, the pair wires are covered by an additional, overall shield.
The outer shield is grounded by means of special EMC-compliant cable glands at both ends of the
cable.
IMPORTANT! Potential equalisation required!
Comply with the instructions on Potential equalisation (§ Potential equalisation).
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Instruction Manual DM08
6.1 Mains and signal cable
The connection of the mains and signal cable are the same in both versions.
The terminal strips are located behind the rear housing cover.
Screw the rear cover from the housing counter clockwise.
Only use signal cables as specified in chapter "Connecting cables“.
Lay the signal cables separately from cables with voltages >60 V.
Avoid laying signal cables close to large electrical installations.
IMPORTANT! Pay attention to the clamping area of the cable gland!
To guarantee the protection class as per DIN EN 60 29, the connection cable being used must
have a sheathing diameter that matches the cable gland.
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Instruction Manual DM08
erminal assignment:
erminal Label Function
115 / 230 VAC 24 VAC
1 PE Protective con-
ductor -/-
2 N Neutral conductor 0 V
3 L Phase 24 V
4 Pulse - Pulse output (passive)
Pulse +
6 Status - Status output (passive)
7 Status +
8 Current - Current output
(active / passive)*
9 Current +
* permanently configured in factory.
Wiring pulse / status output (passive):
The external wiring for the pulse output and the status output is the same.
The wiring for the pulse output is done via terminals 4 and and for the status output via terminals
6 and 7.
Pull-up wiring: Pull-down wiring: Switching values:
UN: 24 V
Umax: 30 V
Imax: 60 mA
Pmax: 1.8 W
Recommendation Pull-Up / Pull-Down resistance ~ kΩ.
Wiring current output (passive):
An external voltage supply is required when connecting the passive current output.
Technical changes reserved - 19 -