PKP DS04.1 User manual

Instruction Manual
DS04
All Metal Variable Area Flowmeter and Switch
- High Pressure Version -
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 o Contents
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
Sa ety In ormation
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 DS04 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), 200 bar (brass), 300 bar (VA)
gaseous media: -20… +80 °C, 200 bar (brass), 300 bar (VA)
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.
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.
DS04 Instruction manual 03/2020 page 2

The series DS04 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.
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.
Quali ied Personnel
The DS04 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: Switch contact and female socket or switch contact
with cable
4: Switch point adjustment scale
5: Display housing with display scale and pointer
mechanism
6: Process connection (inlet)
DS04 Instruction manual 03/2020 page 3

Switch point adjustment scale:
A scale is applied to the device body, to which the
desired switch point can be adjusted.
Display scale:
On the device, a display housing is mounted with integrated
indicator scale and pointer movement. The pointer on the
scale indicates the current flow value.
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.
DS04 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 o low:
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).
DS04 Instruction manual 03/2020 page 5

Connecting 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)
Capacitive 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
DS04 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.
Connecting to a PLC
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.
RC-Circuits 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 V
Voltage [V] Resistance [Ohm] Capacitance [nF]
230 1500 330
115 470 330
48 220 330
24 100 330
For Reed switches of 40 – 100 V
Voltage [V] Resistance [Ohm] Capacitance [nF]
230 1000 330
115 470 330
48 100 330
24 47 330
DS04 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 o contacts:
Switching capacity*
Type Size Contact function ngle plug IP65 M12x1 plug IP67 cable connection (1 m) IP67
DS04.1
DS04.1A
DS04.2
DS04.3
DS04.4
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
DS04 Instruction manual 03/2020 page 8

Switching contact with connector acc. to EN 175301-803:
Normally 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
DS04 Instruction manual 03/2020 page 9

Switching contacts with plug connector M12x1 (mating connector not included in
delivery)
Normally 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:
Normally Open (NOC) Change Over (COC)
Switch position under no-flow condition Switch position under no-flow condition
DS04 Instruction manual 03/2020 page 10

Setting the switch point
The following instructions describe the procedure for a ormally Open Contact ( OC).
The actual state (open or closed), can be determined using a continuity meter.
1. Loosen the switch contact set screws (1) using a
screwdriver
2. Slide the switch contact to the flow value to be
monitored. Make sure that the arrow on the switch
contact label is in exact alignment with the desired
flow value on the body scale.
3. Re-tighten the switch contact housing set screws (1)
using a screwdriver. Observe the correct tightening
torque of 0,4 m.
The set switch point corresponds to the switch-off point of the switch contact by decreas-
ing flow.
DS04 Instruction manual 03/2020 page 11

Troubleshooting guide
Fault description Cause Remedy
The switch contact does not
switch
o medium flowing through
flow monitor
Check that medium is
flowing through the pipeline
Flow is too low or the switch
contact is set too high
Adjust the switch contact to
a lower flow rate
Use the device at another
measuring range
Increase the flow rate
Incorrect reduction fitting or
pipe diameter is too small
Correct pipe diameter
Float is stuck Disassemble and clean the
device
Switch contact is defective Remedy the cause of the
defect (short-circuit,
overload)
Replace the switch contact
Switch contact is
permanently switched
Flow is too high or the switch
contact is set too low
Reduce the flow
Adjust the switch contact to
a higher flow rate
Use the device at another
measuring range
Switch contact is
permanently switched
Float is stuck Disassemble and clean the
device
Switch contact is defective Remedy the cause of the
defect (short-circuit,
overload)
Replace the switch contact
The switch point is not the
same as the actual flow rate
Improper scale installed for
media used
Request proper conversion
table or scale for media
used
Incorrect reduction fitting or
pipe diameter is too small
Correct pipe diameter
Device is dirty Disassemble and clean the
device
Device is defective Remove device from system
and contact PKP
DS04 Instruction manual 03/2020 page 12

Maintenance / Maintenance plan
Intervals for replacing wear parts
DS04 type flow monitors require very little maintenance due to the small number of mov-
ing parts. The intervals for the replacement of wear parts depend significantly on the oper -
ating conditions as well as on the composition of the medium flowing through the device.
For this reason, no intervals have been set by the manufacturer. The operator must
determine suitable intervals based on the local conditions and circumstances.
Maintenance work:
Visual inspection for dirt/soiling
Visual inspection for free movement of float
Visual inspection for leaks from the device
Check function of switch contact
For detailed information on maintenance and cleaning of the device, please refer to
a separate manual. Please ask for them if required.
Degree o protection (IP-Code)
Process connection Specification of
connection material
Degree of protection
E 175301-803 with gland Ø of connection cable:
6-8 mm
IP65
M12x1 Plug connector M12x1 IP67
Cable -- IP67
Returns
For returns please contact us:
PKP Prozessmesstechnik GmbH
[e-mail]
[phone]
DS04 Instruction manual 03/2020 page 13

Flow Measurement and Monitoring
DS04
Variable Area Flowmeter
and Switch for High Pressure
Applications
•applicable for low viscosit liquids and gases
•small mounting dimensions
•brass (nickel plated) or stainless steel version
•high switching accurac
•robust design without a measuring glass tube
•for process pressure up to 300 bar
• optional Ex- version acc. to ATEX
•analogue transmitter 4...20 mA available
Description:
The flowmeter and switch model DS04 works according to a
modified variable area principle.
The float is guided in an upward tapered measuring tube. The
flowing medium moves the float in the flow direction. An
externally mounted pointer indicator is magnetically coupled
to the float and thus following the float position indicates the
flow rate on a scale.
A Reed contact is mounted outside the meter in a sealed
housing. When the float reaches the position of the Reed
contact the switch will close. With higher flows the float
moves further upward until it reaches a built-in float stop still
keeping the switch closed. This ensures a bistable switch
function at any time. The Reed contact is adjustable over the
full measuring and switching range of the meter.
Typical application:
The variable area flowmeters and monitors DS02 are used to
measure and monitor continuous flow rates of low-viscosity
liquids or gaseous media.
Areas of applications are:
•cooling systems
•engineering
•medical technology
•pharmaceutical and chemical industries
•research and development
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
20200302

Models:
Measuring ranges:
water: 0 1–1 5 l/min ... 4–50 l/min
air: 1–28 Nl/min ... 200–1450 Nl/min
(referenced to 1 bar abs 20°C)
Materials: brass (nickel plated) or
stainless steel versions
Technical Data:
Max. pressure: brass version: 200 bar
stainless steel version: 300 bar
Pressure loss: 0 02–0 2 bar (for liquids)
0 02 – 0 4 bar (for gases)
Max. media
temperature: 100 °C for liquids (optional 160 °C)
80 °C for gases
Ex-devices acc. to. ATEX-marking
Operating temp.: 70 °C with analogue transmitter AZ06
Electr. Con.: angle plug acc. to EN 155301-803
Form A (DIN 43650)
Ex-contact with 2 m cable
optional: cable connection
round plug M12 x 1 acc. to EN 50044
angle plug with LED or glow lamp
Accuracy: ± 5 % of full scale for liquids
± 10 % of full scale for air
Mounting position: vertical
Materials:
Brass version (nickel plated):
Wetted parts:
float: brass nickel plated (for liquids)
POM (for gases)
threaded rings: brass
gaskets: NBR (optional FKM EPDM)
all other wetted parts: brass nickel plated
Stainless steel version 1.4571:
Wetted parts:
float: stainless steel 1.4571 (for liquids)
POM (for gases)
gaskets: FKM
(optional NBR EPDM)
all other wetted parts: stainless steel 1.4571
Order Code:
Order Number: DS04.
variable area flow meter
and switch
3. 1. 1. WA06. 1. 1. 1. 0
Connection female thread:
1 = G 1/4 1N = 1/4“ NPT
1A = G 3/8 1AN = 3/8“ NPT
2 = G 1/2 2N = 1/2“ NPT
3 = G 3/4 3N = 3/4“ NPT
4 = G 1 4N = 1“ NPT
Material:
1 = brass nickel plated
2 = stainless steel 1.4571
Scale:
1 = for water
2 = for air (at 1 bar abs. 20 °C)
Measuring ranges:
Water Air
DS04.1, DS04.1A and DS04.2:
WA01 = 0 1–1 5 l/min LA01 = 1–28 Nl/min
WA02 = 0 2 –3 l/min LA02 = 4–60 Nl/min
WA03 = 0 3–8 l/min LA03 = 6–160 Nl/min
WA04 = 1–12 l/min LA04 = 20 –240 Nl/min
DS04.2 and DS04.3:
WA05 = 2 –18 l/min LA05 = 40 –360 Nl/min
DS04.3 or DS04.4:
WA06 = 3–35 l/min
WA07 = 4–50 l/min LA07 = 60–700 Nl/min
only DS04.4:
LA08 = 200 –1450 Nl/min
Addition S...= special scale
Flow indicator:
0 = switch only without flow indicator
1 = flow meter and -switch with flow indicator
Number of contacts:
0 = without contact (only for devices with indication and/or AZ06)
1 = 1 contact
2 = 2 contacts
Contact function / Analogue output:
(contact or analogue transmitter available)
0 = without
1 = N/O
2 = SPDT
2X = SPDT for SPS application
3ST5 = Ex-N/O T5 (100 °C) with 2 m cable
3ST6 = Ex-N/O T6 (80 °C) with 2 m cable
3UT5 = Ex-SPDT T5 (100 °C) with 2 m cable
3UT6 = Ex-SPDT T6 (80 °C) with 2 m cable
AZ06.1.I = analogue transmitter 4...20 mA
AZ06.1.V = analogue transmitter 0...10 V
Options:
0 = without
1 = please specify in plain text
HT = high temperature version 160 °C (for liquids only)
M12 = round plug M12 x 1 acc. to EN 50044 (Tmax. 85 °C)
Kx = cable version 1 m 2 m 5 m or 10 m
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
Flow

Dimensions:
DS04 with flow indicator
Contacts:
The contact opens/changes if the flow level has fallen under the
adjusted value
* Exact max. switching capacity: see ATEX documents
ATEX designations:
Contacts 3ST5, 3ST6, 3UT5, 3UT6:
ATEX II 2 G Ex mb II T6 & ATEX II 2 D Ex tD A21 IP67 T80 °C
ATEX II 2 G Ex mb II T5 & ATEX II 2 D Ex tD A21 IP67 T100 °C
(with cable connection Standard 2 m only)
Dimensions:
Type
Dimensions [mm] Weight
appr. [g]
SW D D1 B. G T L
01 - 04 27 30 47 71
1/4
3/8
1/2
14
19
19
131 800/900
05 27
32
30
35
47
47
71
71
1/2
3/4
19
17
146
174
800/850
960/1010
06
07
08
34
40
50
40
40
40
57
57
67
76
76
81
3/4
1
1
18
19
20
152
156
200
1350/1400
1050/1100
2750/2800
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
Switching capacity
Type Size Contact function Angle plug IP65 M12x1 plug IP67 cable connection (1 m) IP67
DS04.1
DS04.1A
DS04.2
DS04.3
DS04.4
1/4“
3/8“
1/2“
3/4“
1“
1 = N/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-N/O T5*
3ST6 = Ex-N/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)

Accessories (see separate data sheets):
• Needle valves SNV01, SNV02
• Ball valves SKG01, SKG02
• Dirt traps SF00, SF01
• Protection relay MSR01
• M12 Plug connector PVC cable SM12
Notes:
The specified measuring/switching ranges apply when the
instrument is installed vertically and the flow rate is from bottom
to top.
Other installation positions or operating densities deviating from
the specified specifications increase the specified measuring
error.
Special scales for different media and operating conditions are
available on request.
The specified switching points are shut-off points at falling flow
rates. Please note that the switch-on points are higher due to
the hysteresis.
For applications where pressure surges are to be expected
please contact PKP!
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de