PKP DOZ03 User manual

Instruction Manual
DOZ03 / DOZ05 / DOZ07
Oval gear flowmeter
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

Table of Contents
Safety Information..................................................................................................................2
Requirements for use in hazardous areas:............................................................................3
Explosion and fire hazards.....................................................................................................3
Meter hazards........................................................................................................................4
Installation..............................................................................................................................5
Meter operation......................................................................................................................6
Pressure loss diagrams.........................................................................................................6
Evaluation units general.........................................................................................................9
Electrical Connection / Evaluation units..............................................................................10
Function of the on-site display.............................................................................................17
Programming of the on-site display.....................................................................................19
Linearisation.........................................................................................................................23
Additional programming of more parameters for display with pulse and analogue output
(Type B and D2)...................................................................................................................24
Cleaning...............................................................................................................................26
Safet Information
General Instructions
To ensure safe operation, the device should only be operated according to the
specifications in the instruction manual. The requisite Health & Safety regulations for a
given application must also be observed. This statement also applies to the use of
accessories.
Every person who is commissioned with the initiation or operation of this device must have
read and understood the operating instructions and in particular the safety instructions!
The work safety instructions in this manual as well as the safety, accident prevention and
environmental protection regulations generally valid for the work area must be observed.
The liability of the manufacturer expires in the event of damage due to improper use, non-
observance of this operating manual, use of insufficiently qualified personnel and
unauthorized modification of the device.
Proper Usage
The flow meters DOZ03, DOZ05 and DOZ07 are designed to monitor continuous flow
rates of liquids or gases which do not attack the device materials. All other usage is
regarded as being improper and outside the scope of the device.
In particular, applications in which shock loads occur (for example, pulsed operation)
should be discussed and checked in advance with our technical staff.
The series DOZ03, DOZ05 and DOZ07 flow meter devices should not be deployed as the
sole agents to prevent dangerous conditions occurring in plant or machinery. Machinery
and plant need to be designed in such a manner that faulty conditions and malfunctions
do not arise that could pose a safety risk for operators.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 2

Dangerous substances
For dangerous media such as e.g. Oxygen, Acetylene, flammable or toxic substances as
well as refrigeration systems, compressors, etc. must comply with the relevant regulations
beyond the general rules.
Qualified Personnel
The DOZ03, DOZ05 and DOZ07 devices may only be installed by trained, qualified
personnel who are able to mount the devices correctly. Qualified personnel are persons,
who are familiar with assembling, installation, placing in service and operating these
devices and who are suitably trained and qualified.
Inward Monitoring
Please check directly after delivery the device for any transport damages and deficiencies.
Additional with reference to the accompanying delivery note the number of parts must be
checked.
Claims for replacement or goods which relate to transport damage can only be considered
valid if the delivery company is notified without delay.
Requirements for use in hazardous areas:
Reed switch: Connection to intrinsically safe electric circuit (simple electrical equip-
ments must be operated intrinsically safe with a suitable barrier according to
E 60079-11).
Equipotential bonding has to be ensured upon the pipe system.
Meters with plastic housing: do not clean the meters with a dry cloth as this would
cause electrostatic charge.
The fluid conductivity must be higher than 1000 pico/Siemens/meter to avoid
electrostatic charges.
Explosion and fire hazards
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous
condition and result in an explosion or fire and cause serious injury.
Be sure the fluid system is properly grounded. See your pump instruction manual
for details.
If there is static sparking or if you feel an electric shock while using the meter, stop
dispensing immediately. Identify and correct the problem before continuing.
Provide fresh air ventilation. This will avoid the build-up of fumes from the fluid
being dispensed.
Do not smoke while dispensing flammable fluids.
Keep the dispensing area free of debris including solvents, rags and spilled
gasoline.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 3

Meter hazards
Equipment misuse can cause the meter to rupture or malfunction and cause serious
injury.
This equipment is for professional use only.
Read all instructions, tags and labels before operating the equipment.
Use the equipment only for its intended purpose.
Do OT modify or alter the equipment.
Do OT leave equipment unattended while dispensing.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do OT exceed the maximum working pressure level of the lowest rated system
component.
Use only extensions and nozzles that are designed for use with this equipment.
Use only fluids and solvents that are compatible with the equipment. Read all fluid
and solvent manufacturer’s warnings.
Tighten all fluid connections before operating this equipment.
Do OT stop or deflect leaks with hands, body, gloves or rags.
Do OT dispense towards any person or any part of the body.
Do OT place hands or fingers over the end of or into the dispense valve.
Comply with all local, state, and federal fire, electrical and safety regulations.
Use of this product in a manner other than specified in this manual may result in
impaired operation or damage to equipment.
These meters are designed to dispense a wide range of chemicals. Consult the factory for
chemical compatibility.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 4

Installation
Before initial installation:
Please rinse the unit with clear water or the medium to be measured before the initial
installation.
Read the following information and have a thorough understanding before proceeding with
meter installation. Only qualified personnel should perform meter installation.
Install a strainer or Y or basket as close to the inlet side of the meter as possible.
Strainers prevent dirt and other fluid contaminants from impeding meter performance.
Strainers require periodic cleaning, as clogged strainers also impede meter
performance. Contact your local representative for specific information, per your
specific application.
Figure 1: Meter installation
Turn off any associated pumps to reduce line pressure and slowly fill the line and
meter with fluid before restarting pumps. Doing so reduces the possibility of meter
damage caused by errant air pressures in the line and meter.
Make sure all pipe conforms to the same pressure output rating as the pump.
Make sure to apply thread sealant to all pipe threads.
Make sure to install the meter as shown in figure 1.
Check for and repair leaks upon initialization of fluid flow.
Recommended filter sizes:
device size filter / ore width [mesh] filter / pore width [mm]
1/4“ 200 0,08
1/2“ 60 0,250
3/4“ 60 0,250
1“ 60 0,250
1 1/2“ 60 0,250
2“ 60 0,250
3“ 40 0,4
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 5
Strainer
Strainer

Meter operation
Fluid enters the inlet port and then passes through the metering chamber. Inside the
chamber, fluid forces the internal gears to rotate before exiting through the outlet port.
Each rotation of the gears displaces a specific volume of fluid. As the gears rotate, a
magnet on each end of the gear pass a reed switch in the top-mounted register's circuit
board. The reed switches send pulses to the microprocessor in the register to change the
LED display segments.
Pressure loss diagrams
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 6

for DOZ07 only:
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 7

DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 8

Evaluation units general
Features:
Large, six-digit LCD display
Display in litres, pints, quarts or gallons freely programmable
11-digit non-resettable totaliser and 6-digit resettable totaliser
Replaceable battery with long life
Stored calibration factor
9-point linearisation
Scalable pulse output (with output signal code B and option D2)
4-20 mA output (for output signal code B and option D2)
Protection class: IP65
Description:
The electronic evaluation unit (register) consists of a microprocessor board powered by a
lithium battery. It can be programmed in litres, pints, quarts or gallons and adds in litres or
gallons.
A calibration factor and a unit of measure are programmed during a factory test. Unlike
mechanical units, these can be electronically recalibrated in the field if necessary. A 6-digit
LC display with three decimal places shows the exact amount of liquid flowing through the
meter. The register is protected from normal wear and tear by a robust, shockproof
housing.
Operation:
The magnets integrated in oval gear counters send pulses to the register.
The register is in sleep mode until pulses arrive. The pulses are generated by the liquid
flowing through the meter.
The register shows the current flow rate, the subtotal and the total.
The resettable totaliser has a 6-digit display with three digits after the decimal point. If the
measured quantity exceeds 999.999, the display jumps over. Then only 2 digits behind the
decimal point 9999.99 are displayed and so on up to the maximum value of 999999. After
999999 is reached, the totaliser starts again with 0.000. When the reset button is pressed,
the totaliser is reset to zero. The register also has a resettable total counter. To reset this,
the total and reset keys must be pressed simultaneously ("Total" key pressed and held,
"Reset" key pressed). This can be used for several subtotals.
The non-resettable totalisers have 11 digits and count arbitrarily in either gallons or litres.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 9

Electrical Connection / Evaluation units
DOZ03, Code RH
potential free Reed contact and Hall sensor, m cable:
Connection plan:
Hall effect switch:
Rating: Power Supply: Supply input range:5-24 VDC, 3,5 mA
Output current: 30 mA, max.
Wiring: Yellow: Hall effect DC+
Brown: Hall effect ground
Green: Hall pulse output
Reed switch:
Rating: Power rating: 10 W
Switching voltage: 100 V (DC or peak AC)
Switching current: 500 mA (DC or peak AC)
Wiring: Grey: Reedswitch
White: Reedswitch
Green: Hall effect pulse output
Pulses per liter (PPL)
Meter size meas. range code measuring range pulses/L
1/8“ 06 0,017...0,83 l/min appr.4400
1/4“ 08A 0,04...1,67 l/min appr. 2170
1/4“ 08B 0,25...8,33 l/min appr. 390
Note:
Pulses per liter are shown unit-specifically on the calibration certificate supplied
and on the type plate.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 10

DOZ05 and DOZ07, Code R
potential free Reed contact, pulse output, 2,7 m cable:
Connection plan:
Pulse per unit of measure
Type Meter size pulses/L pulses/gallon
DOZ05 1/2“ ca. 100 ca. 378,5
DOZ05 3/4“ ca. 66 ca. 249,8
DOZ05 1“ ca. 66 ca. 249,8
DOZ07 1“ ca. 43 ca. 162,8
DOZ07 1 1/2“ ca. 17 ca. 64,4
DOZ07 2“ ca. 9 ca. 34,1
DOZ07 3“ ca. 3 ca. 11,4
Note:
Pulses per liter are shown unit-specifically on the calibration certificate
supplied and on the type plate.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 11
green
white

On Site Displa (mounted or seperate), Pulse output NPN,
Analoge output (4...20 mA), 3 m cable, order code B or Option D2
Connection plan:
Register wiring
External DC+ : Yellow
External ground : Brown
Pulse output : White
Analog output : Green
DC input : 8 to 24 VDC; 20 to 40 mA
Outputs:
- Analogue 4 to 20 mA output in loop powered configuration; external load of 50
ohms to 250 ohms; flow rate is linear scaled between 4 mA minimum and 20 mA
maximum set points; flow rates below programmed minimum read 4 mA.
- Pulse output with internal pull-up resistor (10 KΩ); optional open collector
output with output jumper removal; pulse output is scalable in pulses per
liter or pulses per gallon.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 12

DOZ05 and DOZ07, Code M
NAMUR Pulse output, unscaled, 2 m cabel
Technical data:
Switching function ormally open ( O)
Output type AMUR 2-wire
ominal voltage Uo 8,2 V (Ri ca. 1 kΩ)
Effective internal
inductivity
Ci ≤ 15 nF; a cable length of 10m is
considered
Effective internal
inductance
Li ≤ 35 µH; a cable length of 10m is
considered
Switch state indicator LED (yellow)
Ambient temperature -25 to 70°C (-13 to 158°F)
Cable length 2 meters (PVC)
Core cross-section 0,34 mm²
Material Stainless steel 1.4404 (316L)
Protection class IP66 / IP67
Marking:
amur CE 0102 / Ex II2G Ex ib IIC T6 Gb
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 13

Pulse per unit of measure
Type Meter size pulses/L pulses/gallon
DOZ05 1/2“ ca. 100 ca. 378,5
DOZ05 3/4“ ca. 66 ca. 249,8
DOZ05 1“ ca. 66 ca. 249,8
DOZ07 1“ ca. 43 ca. 162,8
DOZ07 1 1/2“ ca. 17 ca. 64,4
DOZ07 2“ ca. 9 ca. 34,1
DOZ07 3“ ca. 3 ca. 11,4
Note:
Pulses per liter are shown unit-specifically on the calibration certificate
supplied and on the type plate.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 14
white

DOZ05 and DOZ07, Code P or N
PNP or NPN pulse output, Open Collector, unscaled, 3 m cabel
Connection: white
red (+)
black (-)
Technical data:
Switching function Open collector
Output type P or P P 3-wire (2 versions available)
Supply voltage 5-30 VDC (I ≤ 15 mA)
Supply current 100 mA max ( Pmax = 0,66 watt)
Effective internal
inductivity
Ci ≤ 12 nF
Effective internal inductance Li ≤ 0 µH
Cable length 3 meters
Material Stainless steel 1.4404 (316L)
Protection class IP66 / IP67
Marking:
USA Intrinsically safe
Class I, II, III, Division 1
GROUP ABCDEFG T6 to T5
Class I, Zone 0, AEx ia IIC T6 to T5
Canada Intrinsically safe
Class I, Division 1
GROUP ABCD T6 to T5
Class I, Zone 0, Ex ia IIC T6 to T5
ATEX Ex II 1G Ex ia IIC T6 to T4 Ga
IIECEx Ex ia IIC T6 to T4 Ga
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 15

Pulse per unit of measure
Type Meter size pulses/L pulses/gallon
DOZ05 1/2“ ca. 100 ca. 378,5
DOZ05 3/4“ ca. 66 ca. 249,8
DOZ05 1“ ca. 66 ca. 249,8
DOZ07 1“ ca. 43 ca. 162,8
DOZ07 1 1/2“ ca. 17 ca. 64,4
DOZ07 2“ ca. 9 ca. 34,1
DOZ07 3“ ca. 3 ca. 11,4
Note:
Pulses per liter are shown unit-specifically on the calibration certificate supplied
and on the type plate.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 16

Function of the on-site displa
The register display consists of two rows
of seven-segment digits, status, unit of
measures, flow rate, and battery
indicators.
Operating function settings and
programming are provided using the
TOTAL and RESET buttons.
Normal operation
To enter normal operation mode - when the screen is blank after exiting programming
mode, or upon initial use, press either the TOTAL or RESET button once.
Status
The status indicators are RESET and TOTAL
Totalizers
The top row of indicators is the batch totalizer. This totalizer displays the cumulative
volume of flow through the meter with six digits. The batch totalizer totalizes in selected
units of measure.
To reset the batch totalizer, after 2 seconds of no flow, press and release the RESET
button.
The bottom row of indicators display the resettable totalizer with five digits or the five least
significant digits of the non-resettable totalizer. RESET and TOTAL is indicated when the
resettable total is displayed in the five-digit lower row. Only TOTAL is indicated when the
non-resettable total is displayed.
To toggle between the non-resettable totalizer and the resettable totalizer, press and
release the TOTAL button.
To reset the resettable totalizer, press and hold the TOTAL button and then press and
release the RESET button.
To display 11-digit non-resettable totalizer, while the non-resettable total is displayed,
press and hold the TOTAL button for seconds. The top row displays the 6 most significant
digits; the bottom row displays five least-significant digits.
NOTE: The non-resettable totalizer normally displays 5 least-significant digits.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 17

Flow rate
PER MI is displayed in conjunction with the unit of measure. All flow rates are calculated
in volume unit per minute.
Battery
The "LBat" indicator will indicate when the battery is approaching end of life. When the
indicator is illuminated, the CR123A, 3.0 VDC lithium battery is drained to 10% of its total
capacity and should be changed. ormal battery life is five years.
Checksum
To display the firmware checksum, press and hold the RESET button for three seconds.
To return to normal display, release the RESET button.
Display scale factor
To display the scale factor:
At the same time, press and hold the TOTAL and RESET buttons for two seconds to
display the programmed scale factor. To return to the normal display, release both
buttons.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 18

Programming of the on-site displa
In programming mode only, pressing and releasing the TOTAL button advances to the
next parameter on the current screen. Pressing and releasing the RESET button changes
the current flashing selection to another selection (such as “L” to “GAL”).
To enter the programming mode, press the TOTAL button three times and then press the
RESET button three times (the time lag between pressing both buttons six times must be
within two seconds).
Changing the unit of measure and scale factor:
Unit of measure:
1. Press and release the RESET button to change the unit of measure (L, GAL, QT,
PT).
2. Press and release the TOTAL button to select desired the unit of measure
(theselected unit of measure will flash).
3. When the appropriate unit of measure is selected, press the TOTAL button to
advance to the scale factor programming.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 19

Scale factor
The register collects input pulses from the oval gear meter and then determines the
appropriate display output using the scale factor. This scale factor varies depending upon
the viscosity of the liquid being measured, therefore calibrating the meter and register in
the appropriate liquid will affect the scale factor. The scale factor is displayed as 5 digits
(on the top row) next to the unit of measure. The scale factor consists of 1 integer digit
and 4 decimal digits (see figure 5).
1. Press the TOTAL button to select a digit (selected digits flash). After cycling
through all 5 digits of the scale factor, the register will return to the unit of measure
selection.
2. Press RESET to change the selected digit. The scale factor must fall between the
values of 0.5000 and 2.0000. The Badger Meter factory preset is set between those
values at 1.0000.
3. When finished adjusting the unit of measure and scale factor, press and hold the
TOTAL button for one second to advance to the Pulse Rate section.
NOTE: Error checking will not allow the user to advance to the next screen.
Changing the meter pulse rate
The meter pulse rate (screen is indicated by the “I” on the top row, on the left side) is the
number of pulses per unit of measure as detected by the register. The pulse rate varies
according to the type of attached meter. The bottom row consists of the 5-digit integer
value of the meter pulse rate, whereas the top row consists of the 2-digit decimal value of
the meter pulse rate.
The meter pulse rate is entered in pulses per liter if the selected unit of measure is liters.
The meter pulse rate is entered in pulses per gallon if the selected unit of measure is
gallons, quarts or pints.
1. Press the TOTAL button to select a digit (selected digits flash). Press RESET to
change the selected digit. The pulse rate can be any value between 00000.01 and
99999.99 on the top row; integer values are displayed on the bottom row. Example:
10.45 would display .45 on the top row and 10 would be displayed on the bottom
row.
2. When finished adjusting the pulse rate, press and hold the TOTAL button for one
second to advance to the “register orientation” section.
NOTE: Error checking will not allow the user to advance to the next screen.
DOZ03 / DOZ05 / DOZ07 Instruction manual 02/2021 page 20