PKP DS03 User manual

Instruction Manual
DS03
Variable Area Flowmeter and Switch
- with Glass Measuring Tube -
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 ontents
Safety Information..................................................................................................................2
Overview................................................................................................................................3
Installation..............................................................................................................................4
Connecting devices equipped with Reed switches................................................................6
Electrical connection..............................................................................................................8
Setting the switch point........................................................................................................11
Troubleshooting guide.........................................................................................................12
Maintenance / Maintenance plan.........................................................................................13
Degree of protection (IP-Code)............................................................................................13
Returns.................................................................................................................................13
Safety Information
General Instructions
To ensure safe operation, the device should only be operated according to the specifica-
tions 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 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 unau-
thorized modification of the device.
Proper Usage
The variable area flowmeters of the DS03 series are used exclusively for monitoring and
indicating continuous flows of gaseous and liquid media that do not attack the materials
used. All other usage is regarded as being improper and outside the scope of the device.
Process conditions:
liquid media: -20...+100 °C (optional 160 °C), 10 bar
gaseous media: -20… +80 °C, 10 bar
In particular, applications in which shock loads occur (for example, pulsed operation)
should be discussed and checked in advance with our technical staff.
In particular applications in which shock loads occur (e.g. intermittent operation) should be
discussed and checked in advance with our technical staff.
Do not use flow monitors with fast-switching valves.
The series DS03 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.
DS03 Instruction manual 03/2020 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 DS03 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 suit-
ably 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.
Overview
1: Process connection (outlet)
2: Device body
3: Sight glass with measuring scale
4: Float containing magnets
6: Slot nozzle
7: Switch contact and female socket or switch contact with
cable
DS03 Instruction manual 03/2020 page 3

Checking the flow:
In addition to the electrical control by the reed contact (switching contact), the actual flow
rate can also be read off the measuring scale of the sight glass.
The top edge of the float is the read-off point. To obtain greatest reading accuracy, read-
off at eye level. The read-off value can be falsified by viewing at an angle.
Installation
Process connection:
The following requirements must be observed to avoid damage to the flow monitor or the
system:
a process connection suitable for the device must be provided by the customer
check connection size and screw-in depth
use suitable sealants (liquid sealants damage the flow monitor if they run in)
seal properly
Ambient conditions:
do not install the flow monitor as a supporting part in a pipe system
the medium must not carry solid bodies. Magnetic particles accumulate on the
magnetic float and impair its function.
Check corrosion and antifreeze agents from the application for compatibility.
DS03 Instruction manual 03/2020 page 4

Notice:
The following requirements must be observed, otherwise the function of the flow monitor is
impaired or measurement results are falsified:
external magnetic fields will influence the switch contact. Keep sufficient distance to
magnetic fields (e.g. electric motors).
piping, process connections or supports made of ferromagnetic material influence
the magnetic field of the device. Keep a space of minimum 100 mm to those
materials (e.g. steel).
changes in cross-section, branch-offs or arcs in the pipe system impair measuring
accuracy. Ensure that the unimpeded flow sections are maintained (in front of
instrument 10 x nominal diameter, behind the instrument 5 x nominal diameter).
ever reduce the pipe diameter immediately before the device.
in the case of liquid media, take appropriate steps to ensure that the device is ven-
ted.
to ensure measuring accuracy, the device must always be completely filled with
medium.
vent the pipeline. If there are air pockets in the line during the measurement, this
could result in damage to the device caused by hydraulic shock. This may cause
malfunctions.
ensure that the plant is operating without cavitation. Cavitation may result in mal-
functions and damage to the device.
ensure that the medium is flowing continuously. Pulse-like staggered loads could
destroy the device. This may result in serious injury to the user.
if the mediums is contaminated by solids, a strainer must be installed before the
device (e.g. SF00 or SF01 from PKP)
Direction of flow:
Only install the flow monitor in one of the positions displayed in the drawing. The medium
must flow in the direction of the arrow (from a low to a high scale value).
DS03 Instruction manual 03/2020 page 5

onnecting devices equipped with Reed switches
Reed switches are basically designed for small contact ratings. To connect a load with
higher power consumption it is indispensable to use a contact protection relay (e.g. our
series MSR01)
If you connect directly a load to a Reed contact the following recommendations should be
considered.
one of the contact rating values printed on the switching unit must not to be exceeded,
even momentarily. This is valid for each of the given values individually: voltage, current,
power. The Reed contact integrated in the switching unit is very sensible to electrical over-
load
Danger of overload is given by the following applications:
•inductive load
•capacitive load
•lamp load
Inductive Load
Inductive loads consist e.g. of relay, contactors, solenoid valves, motors, electric engines,
etc.
WAR I G: Voltage spikes at shut down (up to 10 times of nominal voltage)
Protective measures: (examples)
(Flyback diode, e.g. type 1 4007)
apacitive Load
Capacitive loads consist e.g. of long connection cables or capacitive consumers.
WAR I G: High current spikes at switching on (this will exceed the nominal current)
Protective measures: (examples)
Limitation of current by a resistor
DS03 Instruction manual 03/2020 page 6

Lamp Load
Lamp loads consist e.g. by light bulbs, starting motors .
WAR I G: High current spikes at switching on, because the glowing spiral has low
resistance at low temperature.
Protective measures: (examples)
Limitation of current by a resistor
or preheating of the glowing
spiral.
onnecting to a PL
There is no need for protective measures by connecting the Reed switch to a PLC. The
Reed contacts are plated by Tunsten, Gold, and Rhodium located in a protective atmo-
sphere. They can be directly connected to the input terminals of a PLC without problems.
R - ircuits as protective measures (Boucherot cell, Snubber)
In practice the following values of resistor/capacitor cells give good results. evertheless,
the values given in the following tables are only recommendations for general purposes.
But it cannot be guaranteed that for specific applications more adequate Boucherot cells
may exist.
For Reed switches of 10 – 40 VA
Voltage [V] Resistance [Oh ] Capacitance [nF]
230 1500 330
115 470 330
48 220 330
24 100 330
For Reed switches of 40 – 100 VA
Voltage [V] Resistance [Oh ] Capacitance [nF]
230 1000 330
115 470 330
48 100 330
24 47 330
DS03 Instruction manual 03/2020 page 7

Electrical connection
The switch contacts employed in these devices are potential free and do not require a
power source.
Note:
Switch contacts and flow monitor have been optimally harmonized. After replacement of a
switch contact, the switch point must be readjusted.
The contacts open/change when the flow rate falls below the set value.
Grounding of the device:
When installing the device in a pipeline, make sure that the device is grounded via the
pipeline. This prevents dangerous potential differences from occurring
Switching capacity of contacts:
Switching capacity
Type Size Contact function Angle plug IP65 M12x1 plug IP67 Cable connection (1 ) IP67
DS03.1
DS03.1A
DS03.2
DS03.3
DS03.4
1/4“
3/8“
1/2“
3/4“
1“
1 = /O 250 V / 3 A / 100 VA
2 = SPDT 250 V / 1,5 A / 50 VA, min. load: 3 VA
2X = SPDT for SPS 250 V / 1 A / 60 VA -/- -/-
3ST5 = Ex- /O, T5*
3ST6 = Ex- /O, T6*
-/- -/- 250 V / 2 A / 60 VA (2 m
cable)
3UT5 = Ex-SPDT, T5*
3UT6 = Ex-SPDT, T6*
-/- -/- 250 V / 1 A / 30 VA,
min load: 3 VA (2 m cable)
* Exact max. switching capacity: see ATEX documents
DS03 Instruction manual 03/2020 page 8

Switching contact with connector acc. to EN 175301-803:
Nor ally Open (NOC) Change Over (COC)
Switch position under no-flow condition Switch position under no-flow condition
The ground-pin is not used The ground-pin is not used
DS03 Instruction manual 03/2020 page 9

Switching contacts with plug connector M12x1 (mating connector not included in
delivery)
Nor ally Open (NOC) Change Over (COC)
Switch position under no-flow condition Switch position under no-flow condition
Switching contact with cable:
The individual cores of the cable are numbered according to the following connection dia -
gram:
Nor ally Open (NOC) Change Over (COC)
Switch position under no-flow condition Switch position under no-flow condition
DS03 Instruction manual 03/2020 page 10