PKP DS10 Series User manual

Instruction Manual
DS10
Variable area flow meter 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] www.pkp.de

Table of Contents
Safety Information..................................................................................................................2
Functional Description............................................................................................................3
Mounting and Adjustment.......................................................................................................3
Limit Switches.........................................................................................................................4
Maintenance and Care.........................................................................................................11
Safety 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-ob-
servance of this operating manual, use of insufficiently qualified personnel and unauthorized
modification of the device.
Proper sage
Series DS10 float-type flow meters 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 im-
proper and outside the scope of the device.
Unless indicated otherwise, the scales on these devices are based on air at 1.2 bar absolute
pressure at 20°C or on water. Special applications in which shock-type loads are en-
countered (e.g. cyclic operation) should first be discussed with and examined by our engin-
eering department.
The series DS10 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 de-
signed in such a manner that faulty conditions and malfuctions 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.
DS10 Instruction manual 11/2021 page 2

Qualified Personnel
The DS10 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 assem-
bling, 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.
Functional Description
The float-type flow meter must be installed in a vertical position. The flow must proceed in the
direction from the low end to the high end of the scale.
This measuring device must be connected with fittings compatible with its design. When con-
necting the device, be sure that the pipes are run stress-free and aligned so that they are
centered with the connection ports on the device. If necessary, support the pipes to prevent
the transmission of vibrations to the device.
Mounting and Adjustment
The actual operating pressure and temperature in the installation must not exceed the max-
imum values indicated in the specifications.
1. Close the needle valve on the flow meter.
2. Open the shut-off valves upstream and downstream of the flow meter.
3. For liquids, be sure to carefully bleed the air out of the piping. For gases, allow the op-
erating pressure to slowly increase. Avoid hammering or pulsing (risk of glass break-
age).
4. Open the needle valve and set the desired flow rate.
5. The flow rate is read at the upper edge of the float.
Should the operating parameters deviate from the calibration data (flow range, flowing me-
dium, pressure, density and temperature), the flow rate displayed can be converted as per
VDI / VDE - Guideline 3513.
DS10 Instruction manual 11/2021 page 3

Limit Switches
The flowmeters can be equipped with a maximum of two limit switches.
The switching function of the limit switch can be designed as monostable or bistable.
Monostable function: Switching pulse as float passes through switching point,
independent of direction of movement.
Bistable function: Stable changeover as float passes through switching point.
Example (bistable): Above limit: switching point "High"
Below limit: switching point "Low"
For switching performance and electrical data refer to section "Technical data".
Electrical connections:
Connection of limit switch - 2-wire AMUR (standard):
1 Lower limit switch to terminal 1
2 Upper limit switch to terminal 2
The connection box includes an EMC filter unit.
DS10 Instruction manual 11/2021 page 4

Connection of limit switch - 2-wire AMUR, without connection box:
1 Limit switch (without connection box)
2 Blue cable -
3 Brown cable +
4 External EMC filter
5 Receiver device
When connecting to an EMC filter, the ground terminal must be connected to the back rail of
the flowmeter.
Connection of limit switch - 3-wire (transistor):
bn - brown: supply voltage +
bk - black: switch
bu - blue: supply voltage -
DS10 Instruction manual 11/2021 page 5

Settings of limit switches:
1 Clamping screw
2 Back rail
3 Limit switch
The following procedures are to be performed:
•Remove both clamping screws 1.
•Slide the limit switch over the measuring glass.
•Use the two clamping screws 1 to fasten the limit switch 3 to the back rail 2 of the
measuring device.
•Re-install the protective cover following installation.
For installation after the fact, the measuring glass must be removed. Refer to chapter "Main-
tenance and care”
CAUTIO !
When setting the limit switch, be careful to lay the cable so that it does not get damaged.
Avoid canting of the limit switch during installation: glass breakage
The connecting lead of the limit switch is guided through a hole in the base of the device and
sealed.
Observe the following for bistable limit switches with external EMC filters in separate DI rail
housing:
The EMC filter unit and the back rail of the meter must be galvanically connected and groun-
ded.
An isolation switching amplifier with intrinsically safe circuit controls is necessary to operate
the
AMUR limit switches.
DS10 Instruction manual 11/2021 page 6

Minimum distance between two limit switches:
Where two limit switches are used in one device and also where meters with limit switches
are in close proximity of each other, minimum distances must be maintained in order to avoid
mutual influence of the switches.
Switching performance of limit switches
2-wire limit switch AMUR, monostable
Float outside of the limit switch: signal ≥3 mA
Float inside of the limit switch (centre): signal ≤1 mA
2-wire limit switch AMUR, bistable
Independent of the float position and passage 1: signal ≥3 mA
Prerequisite: the float is outside the limit switch.
I FORMATIO !
For the proper initialisation after power up, the bistable AMUR limit switch should pass
through each of 1 and 2 once.
3-wire limit switch, transistor
Independent of the float position and passage 2: signal ≤1 V
Prerequisite: the float is outside the limit switch.
Switching performance
DS10 Instruction manual 11/2021 page 7

Reversed function of limit switch:
The bistable limit switches can be changed from normally open switch to normally closed
switch.
The pre-fabricated connection cable must be long enough to do this.
When installing and setting, make sure the cable is not damaged when laid.
•Loosen terminal screw 1.
•Turn turnbuckle 2 counter-clockwise to loosen.
•Pull out the measuring glass along with the limit switch.
•Turn limit switch 180°.
•Install the measuring glass.
•Tighten turnbuckle 2 by hand.
•Use a 3 mm pin to tighten the turnbuckle by turning 4 to max. 5 times in 120° incre-
ments 3 in a clockwise direction.
CAUTIO !
To avoid breakage, the measuring glass must be positioned centrically between the gaskets.
Test the leak tightness by suitable measures prior to start-up.
DS10 Instruction manual 11/2021 page 8

Grounding connection:
The measuring unit is grounded on the back rail 1 (M4 thread). This connection only ensures
electrostatic grounding of the device and does not meet the requirements for equipotential
bonding.
Position of the ground terminal
DA GER!
The grounding wire may not transfer any interference voltage.
Do not use this grounding cable to ground any other electrical devices.
Ingress protection:
The limit switches with connection housing meet all requirements of ingress protection IP65.
Therefore it is essential to observe the following points:
•Use only original gaskets. They must be clean and free of any damage. Defective
gaskets must be replaced.
•The electrical cables used must be undamaged and must comply with regulations.
•The cables must be laid with a loop 3 upstream of the measuring device to prevent
water from getting into the housing.
•The cable feedthroughs 2 must be tightened.
•Close the unused cable feedthroughs with blanking plugs 1
DS10 Instruction manual 11/2021 page 9

Ingress protection
DA GER!
After all servicing and maintenance work on the measuring device, the specified protection
class
must be ensured again.
Technical data of limit switches:
1) For devices with the valve at the top in the output and devices with flow regulators for vari-
able outlet pressure, the function is inverted!
I FORMATIO !
The limit switches with ring diameters of 15 mm / 0.6" as max. contact can only be used up to
60 l/h / 15.8 GPH water or 2400 l/h / 89.3 SCFH air (outer diameter of the measuring glass).
DS10 Instruction manual 11/2021 page 10

Maintenance and Care
Due to the small number of moving parts, these devices require minimal maintenance. ev-
ertheless, regular performance tests and maintenance will not only increase the service life
and functional safety of the device but also those of the entire installation.
The frequency of maintenance depends on the following:
•The contamination of the medium
•Ambient conditions (e.g. vibrations)
•
When performing maintenance, be sure to check for the following:
•Proper function of the switching contact (on devices with limit value signal sensors)
•Leakage at the device
•Free movement of the float
The user is responsible for setting suitable maintenance intervals for the specific application.
Maintenance Notes:
•The free movement of the float can be checked by changing the flow rate and ob-
serving the float.
•In most cases, cleaning the device will only require rinsing it with clean liquid. In stub-
born cases (e.g. lime deposits), standard, commercially available cleaners can be
used as long as their ingredients will not attack the materials used in the device.
Replacing the Measuring Tube:
Caution: To avoid glass breakage, the measuring tube must be installed centered between
the seals.
1. Close the valves upstream and downstream of the device to prevent escape of the
medium being measured.
2. Close the needle valve at the device.
3. Slide the Plexiglas protective cover upward and then remove it toward the front.
4. To release the measuring tube, turn the retainer in the base of the device counter-
clockwise. The tube can now be removed.
To reinstall the tube, follow the above instructions in reverse order.
DS10 Instruction manual 11/2021 page 11

Flow Measurement and Monitoring
DS10
Variable Area Flowmeter
with Glass Measuring Tube
•for low viscous liquids and gases
•fittings of brass
or stainless steel
•with integrated needle valve
•limit switch o tionally
•accuracy class 4, 2,5 or 1,0
•max. ressure 10 bar,
max. tem erature 100 °C
•measuring ranges: 0,04...160 l/h water
0,5...5000 Nl/h air
Description:
The flowmeters DS10 operate according to the proven vari-
able area principle. The flowing media moves a float upwards
against gravity in a conical measuring tube. The height of the
float indicates the flow rate and may be read off a burnt-in
scale on the measuring tube.
Optional inductive contacts, which are mounted on the meas-
uring tube, may be used for flow rate limit detection. ll
meters are equipped with an integrated needle valve for
exactly regulating the flow rate.
Typical applications:
Variable area flowmeters model DS10 are mainly used for
measuring and monitoring the flow rate of low- viscous liquid
and gaseous media.
Scales for water or air at standard operating conditions have
already been defined. For other media or different process
conditions special scales are available.
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
20181113

Models:
DS10.1: miniature version, installation high 111 mm
accuracy class 4
DS10.2: standard version, installation high 146 mm
accuracy class 2,5
DS10.3: maxi version, installation high 196 mm
accuracy class 2,5
DS10. : precision version, installation high 346 mm
accuracy class 1,0
Measuring Ranges:
The measuring ranges given below serve as orientation. Please indicate medium,
pressure and temperature, we will calculate an individual scale for you.
Measuring
range-
No
Measuring
range
[Nl/h] air, 20°C,
1,2 bar abs.
Contact-
version
Models
DS10.1 DS10.2 DS10.3 DS10.
01 0,5...5 x x - -
02 0,8...8 x x - -
03 1,6...16 x x x x
04 4...40 x x x x
05 6...60 x x x x
06 10...100 B x x x x
07 25...250 B x x x x
08 50...500 B x x x x
09 80...800 B x x x x
09 120...1200 B x - - x
10 100...1000 B - x - x
11 180...1800 B - x - x
12 240...2400 B - x - x
13 300...3000 B (min) - x - x
14 400...4000 B (min) - x - -
15 500...5000 B (min) - x - -
[l/h] water
40 0,04...0,4 - - - - x
41 0,063...0,63 - - - - x
42 0,1...1 - - - - x
43 0,16...1,6 - - - x
16 0,25...2,5 x x - x
17 0,5...5 B x x x x
18 1,2...12 B x x x x
19 2,5...25 B x x x x
20 4...40 B x x x x
21 6...60 B x x x x
22 10...100 B (min) x x x x
23 12...120 B (min) x x - -
24 16...160 B (min) x x - -
x = available - = not available
Contacts: The contact version is determinated by the measuring range.
(min) = Contact available for minimum monitoring only.
Dimensions:
The upper edge of the float is the reading edge.
Models a [mm] b [mm] c [mm]
DS10.1 45 90 111
DS10.2 80 125 146
DS10.3 130 175 196
DS10.4 280 325 346
Order Code:
Order number: DS10.
Variable area flowmeter
with glass measuring tube
2. 1. 1. 1. 06. 1. 1. 0
Models:
1 = miniature version
2 = standard version
3 = maxi version
4 = precision version
Process connection:
1 = G 1/4 female on back
2 = 1/4“ NPT on back
Material:
1 = brass
2 = stainless steel
Gasket:
1 = FKM (standard)
2 = PTFE / FFKM
3 = EPDM
Measuring ranges:
01...24 = according to table
99 = special ranges
Valve:
0 = without
1 = valve at inlet (standard)
2 = valve at outlet
Limit switches:
0 = without
1 = 1 contact (contact model )
2 = 2 contacts (contact model )
3 = 1 contact (contact model B)
4 = 2 contacts (contact model B)
Options (multiple answers possible):
0 = without
1 = panel mounting kit
2 = cable connector housing for devices with contact
Special connections like hose connectors, SW GELOK,
ERMETO or others on request.
To operate the limit switches, switch amplifiers of type P+F are required.
See data sheet P+F.
Technical Data:
Max. pressure: 10 bar
Max. medium
temperature: 100 °C (65 °C with contact)
Materials:
fitting and valve: brass or stainless steel,
float: stainless steel
gaskets: FKM / EPDM or PTFE / FFKM,
measuring tube: borosilicate glass
Accuracy: DS10.1: class 4
DS10.2: class 2,5
DS10.3: class 2,5
DS10.4: class 1,0
Switch contacts: acc. to N MUR (bistable)
1 m passage from top to bottom
3 m passage from bottom to top
(monostabile or 3-wire contacts on
request)
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
Flow