PKP DS15 User manual

Instruction Manual
DS15
Plastic Variable Area Flowmeter
PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-65205 Wiesbaden- ordenstadt
Tel.: ++49-(0)6122-7055-0
Fax: ++49-(0)6122-7055-50
Email: [email protected]

Safety Information
General Instructions
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 also aplies
to the use of accessories.
Proper Usage
The flowmeters model DS15 works according to the proven variable area principle. The float is
moved upward by the flowing medium and its upper edge indicates the flow rate by means of a
scale affixed onto the measuring tube.
By using a float with an integrated magnet optional alarm contacts or an analogue output transmitter
may be operated. All flowmeters have a male thread on the measuring tube and are additionally
equipped with PVC glue-in connectors. Also possible are connectors with female thread (BSP)
made of PVC, PP, PVDF, brass or st. steel.
Qualified Personnel
DS15 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.
DS15 Instruction manual 2017-08 page 2

Mounting
Installation Position: vertical, direction of flow from bottom to top
WAR I G:
•Ensure that in case of a break in the measuring tube, no hazards result from escaping media.
•Do not use measuring tube made of PVC for gaseous media.
•Use personal protective equipment when carrying out any work on the fitting.
To avoid unstable float conditions (fluttering of float), please include in front of the flow meter and
behind it a flow-calming section of 5 to 7 x D .
Installation:
1. Ensure that measuring tube and float are clean and free of foreign matter.
2. Remove transport lock (holds the float).
3. Ensure that the float can move freely.
4. Unscrew both union nuts. Secure float (heavy) from falling
5. Push union nuts onto spigot of process pipes. Check mounting direction.
6. Weld union end of device to spigot of process pipes
7. Check fit of O-rings
8. Connect device to the process pipework. Tighten union nuts by hand only.
Performing t e ydrostatic test:
Perform hydrostatic test using neutral medium, e.g. water.
Pressurize the device, ensuring
•Test pressure < 1.5 x P ( ominal pressure)
•Test pressure < P + 5bar
•Test pressure < permissible system pressure
Check that the device is not leaking.
DS15 Instruction manual 2017-08 page 3

Read measurement
For the measurement range 2,500-25,000, the reading edge is below the float fixture (largest dia-
meter)
1 = Reading edge
read measurement using face (1) of float
Maintanance
1. Clean device with a damp cloth as often as necessary (depends on degree of contamination
and environmental conditions)
2. Visual and function check (every 6 months):
- ormal operating conditions unchanged
- o leaks
- Measuring tube and float for deposits or changes to surface
- float is movable
3. To clean the flowmeter, in the most cases you can flush the device with clear water. In some
cases some commercial detergents can be used.
DS15 Instruction manual 2017-08 page 4

Electrical Connection of Reed contacts
Please note: we recommend to use only shielded cables.
The polarity of the connections has no influence on the function
Operating note:
•Do not exceed the current data or the switching capacity. For this reason, always fit a contact
protection relay if a power circuit is intended.
•Prior to commissioning/first start-up it is important that the float passes the switch three
times in order to cancel out any possible monostable behaviour.
•
Pin Assignment
DS15 Instruction manual 2017-08 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 con-
sidered.
one of the contact rating values printed on the switching unit must not to be exceeded, even mo-
mentarily. 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 overload
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
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.
DS15 Instruction manual 2017-08 page 6

Connecting to a PLC
There is no need for protective measures by connecting the Reed switch to a PLC. The Reed con-
tacts are plated by Tunsten, Gold, and Rhodium located in a protective atmosphere. They can be dir-
ectly 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 guar-
anteed that for specific applications more adequate Boucherot cells may exist.
For Reed switches of 10 – 40 VA
Voltage [V] Resistance [Ohm] apacitance [nF]
230 1500 330
115 470 330
48 220 330
24 100 330
For Reed switches of 40 – 100 VA
Voltage [V] Resistance [Ohm] apacitance [nF]
230 1000 330
115 470 330
48 100 330
24 47 330
DS15 Instruction manual 2017-08 page 7

1
Flow data sensor ZE 3000
micro-processor controlled for accurate flow
measurement and evaluation
330501 - 05/06
Product description
The ZE3000 emits a 4..20 mA signal according to
industrial standards, generated in the DS15 by the
precise magnet angle detection of the magnetic
float.
Existing flowmeters (with magnetic floats) can be
easily retrofitted with the ZE3000 to electrically
signal the flow and, for instance, to further process
the values in a PLC for process control or to directly
display the flow rate.
This micro-processor controlled unit is programmed
for the DS15 concerned! This guarantees accurate
flow measurement and evaluation.
IMPORTANT: The DS15 to which the ZE3000 is to be
fitted must be known in advance!
Features:
• 2-wire technology
• 4..20mA analog output
• 8..28VDC input
• Individual programming adapted to the DFM
• 11 point calibration
• non-volatile value storage
• 0 button to compensate for the surrounding
magnetic influences
• Factory setting of the lower limit value (low-cutoff)
0..99% according to customer’s specifications
• Factory settable time lag (low-pass-filter)
0.1...2.5 sec according to customer’s specifications
• Measuring accuracy better than 0.5%
Pin 1: 8..28VDC
Pin 2: GND
Installation
Screw clamps are used to fit the ZE3000 on the
dovetail guide of the flowmeter. The plug connector
is located in the upper section.
During installation, ensure that the notch of the
ZE3000 coincides with the 50% mark on the DFM
scale.
Following this, proceed with the wiring according to
the plug assignment plan.
Plug assignment
Start-up
Once installed and the voltage is applied, press the
0 button for at least 2 sec to compensate for
surrounding magnetic influences.
During this phase ensure that the float is in its
bottom position, i.e. no flow must take place!

2
Concealed 0 button
330501 - 05/06
PARAMETERS MIN. TYPE MAX. Unit
Voltage supply 8 28 Volt DC
Output current 0% -> 100%+overrange
During normal function (pin 1 – pin2) 4.0 -> 20.1 4.0 -> 21.0 4.0 -> 22.0 mA
Ambient temperature -30 (-20) 65 (150) ºC (°F)
Dimensions
Note:
Do not actuate the button during normal operation.
Electrical/mechanical parameters

Flow Measurement and Monitoring
DS15
Plastic Variable Area Flowmeter
•for liquid and gaseous media
•simple and robust construction
with high reliability
•measuring tubes in PV , PA, PSU
und PVDF
•low pressure drop, simple mounting
•scale with high resolution
•alarm contacts or analogue output
optionally
•optional special scales are available
depending on medium properties
•ranges air: 0,2...1 Nm³/h - 700...2900 Nm³/h
ranges water: 3...24 l/h – 10.000-50.000 l/h
•Pmax: 10 bar, Tmax: 110 °
Description:
The flowmeters model DS15 works according to the proven
variable area principle. The float is moved upward by the flow-
ing medium and its upper edge indicates the flow rate by
means of a scale affixed onto the measuring tube. y using a
float with an integrated magnet optional alarm contacts or an
analogue output transmitter may be operated.
All flowmeters have a male thread on the measuring tube and
are additionally equipped with PVC glue-in connectors. Also
possible are connectors with female thread ( SP) made of
PVC, PP, PVDF, brass or st. steel.
Typical applications:
The variety of different materials used and the simple to
exchange measuring scales make these meters universally
suitable for most liquid and gaseous media, also suitable for
very aggressive media. Main applications are in the water
treatment industry, in waste water applications, chemical and
food industry and many more.
PKP Prozessmesstechnik GmbH
orsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
20181120

Models:
Measuring tube: PVC-U transparent, Polyamid,
Polysulfon, or PVDF semi transparent
Float: PVDF or
PVDF with integrated magnet
Gaskets: EPDM or FPM
Tube connections: PVC, optionally PP, PVDF, brass
GTW, stainless steel
Technical Data:
Max. pressure: PN 10 at 20 °C
Max. me ia-temperature:
Without threa e connection:
PVC: 60 °C
Polyamid: 75 °C
Polysulfon: 100 °C
PVDF: 110 °C
with threa e connection ma e of:
PVC: 60 °C
PP: acc. to the temperature ranges for
the particular measuring tube, but
max. 80 °C
PVDF, brass,
stainless steel: acc. to the temperature ranges for
the particular measuring tube
Mounting position: vertical, flow from bottom to top
Mounting: inlet and outlet pipe 5-7 x DN
Accuracy: class 4 (VDI/VDE 3513, page. 2)
Output Signals:
Limit switch:
N/O, N/C 230 V, 0,5 A, 10 VA, bistable with plug
acc. to DIN EN 175301-803
Ambient temperature 0 °C... +55 °C
Protection class IP65
Transmitter type 50 - Hall sensor:
Analogue output 4...20 mA, 2 wire
11 point calibration is factory set
Power supply 8...28 VDC
Ambient temperature: -20 °C...+65 °C
Protection class IP 67
Transmitter type 51 - Ree chain:
Analogue output 4...20 mA, 2 wire, for measuring ranges 101 to
404 (corresponds to the height of the float)
not linearized
Power supply 18...30 VDC
Ambient temperature: -20 °C...+70 °C
Protection class IP 65
Note:
Limit switches or transmitters only work in conjunction with a
float with integrated magnet.
Order ode:
Or er number:
DS15.
Plastic Variable Area
Flowmeter
2. 1. 202. 102. 1. 0. E
Material (measuring tube):
1 = PVC-U (only with scales for
water)
2 = Polyamide
3 = Polysulfon
4 = PVDF
Scales:
1 = Water
2 = Air (0 bar g)
3 = Air (1 bar g)
4 = Air (2 bar g)
5 = Air (3 bar g)
9 = Special scale
Measuring ranges:
101 … 612 = acc. to table 1
Process connection:
acc. to table 2
Float:
1 = PVDF (without magnet for devices without contacts)
2 = PVDF (with magnet for devices with contacts)
Options:
00 = None
11 = 1 limit switch (N/C)
21 = 2 limit switch (N/C)
12 = 1 limit switch (N/O)
22 = 2 limit switch (N/O)
50 = transmitter, 4 – 20 mA – Hall sensor
51 = transmitter, 4 – 20 mA – Reed chain (non linear)
Gaskets:
0 = EPDM (standard at DS15.1, -2. or -3.)
F = FPM (standard at DS15.4)
Scales:
Water scales (in l/h) and air scales (in Nm³/h) referenced to
0, 1, 2 and 3 bar are standard.
For other media, i.e, gases with higher pressures, HCl (30 %),
NaOH (30 %), as well as other units of measurement (m³/h,
l/sec., l/min, USGPM or IGPM) special scales may be supplied.
Also special scales for other media and operating conditions
may be calculated if the following data are known:
- Me ium
- Operating pressure
- Operating temperature
- Operating ensity
- Operating viscosity
PKP Prozessmesstechnik GmbH
orsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de

Measuring Range (Table 1):
Tube
L
[mm]
Range
No.
Measuring range
Water
[l/h]
Air at 20 °C [Nm³/h]
not for PVC-measuring tubes
0 bar
rel.
1 bar
rel.
2 bar
rel.
3 bar
rel.
1
(165)
101 3-24 0,2-1 0,2-1,2 0,25-1,55 0,3-1,75
102 5-60 0,2-2,5 0,4-3,2 0,2-3,8 0,3-4,4
103 10-100 0,6-3,6 0,6-5,0 0,75-6,0 0,8-7,0
104 25-250 0,5-9,0 1,0-13,0 1,0-16,0 1,5-19,5
2
(170)
201 5-50 0,4-2,8 0,2-3,2 0,4-3,6 0,3-4,0
202 15-150 0,8-6,2 1,0-9,0 1,0-11,0 1,5-12,0
203 25-250 0,9-9,5 1,0-13,0 1,0-16,0 2,0-20,0
204 40-400 2,0-15,0 2,0-20,0 3,0-26,0 3,0-30,0
3
(185)
301 15-150 0,5-5,5 1,0-9,0 1,0-11,0 1,0-10,5
302 40-400 2,0-14,0 2,0-20,0 3,0-26,0 3,0-30,0
303 60-600 2,5-22,0 4,0-31,0 4,0-38,0 5,0-45,0
304 100-1000 4,0-34,0 5,0-45,0 6,0-58,0 7,5-67,5
4
(200)
401 25-250 1,0-8,0 1,5-13,0 1,5-16,0 1,5-19,5
402 40-400 2,0-14,0 2,0-20,0 3,0-26,0 3,0-30,0
403 100-1000 4,0-34,0 5,0-45,0 5,0-55,0 6,0-66,0
404 150-1500 5,0-50,0 6,0-70,0 7,5-86,0 7,5-98,0
6
(350)
603 60-600 2,5-20 3,5-28 4-35 5-40
604 100-1000 4-34 5-50 8-60 8-70
605 150-1500 5-50 7,5-67 9,5-83 11-96
606 250-2500 8,5-76 10-115 14-131 17-152
607 400-4000 14-125 10-170 24-210 28-245
608 600-6000 22-190 30-260 40-380 40-400
609 1000-10000 35-300 50-420 60-510 70-600
610 1500-15000 50-500 80-700 85-760 102-880
611 2500-25000 80-720 115-1050 140-1240 166-1400
612 10000-50000 400-1500 500-2100 600-2500 700-2900
*Reference standard: ISO 1217 (20 °C, 1 bar abs.)
Other scales on special request.
Pressure- Temperature- Diagram:
Limit Switch:
Mo el: reed contact, bistable
Contact function: N/O or N/C with increasing flow
Mounting: adjustable on measuring tube
Contact rating: max. 220 VAC, max. 0,5 A,
max. 10 A / 10 VA
Operating temperature: 0...+55 °C
Hysteresis: 3 mm of float height
Electrical connection: 2-wire, independent of polarity
Analogue output transmitter:
The optional analogue output transmitter mounted on to the
measuring tube of the DS15 flowmeter and registers the height
of the float by means of an analogue Hall sensor. The integrated
electronic converts this signal to a 4-20 mA output.
To operate the analogue output transmitter, the standard float
must be exchanged with a float with an integrated magnet.
The transmitter is equipped with an EPROM which is pro-
grammed especially for the application. Therefore it is not
possible to change the transmitter without consulting the
manufacturer.
Features:
• 4...20 mA analogue output, 2-wire, 8..28 VDC
• programmed individually to DS15
• 11 point calibration, non volatile storage of
parameters
• 0-push button for compensation of environmental
magnetic influences
• factory set low-cutoff value 0-99 % custom specific
• factory set low-pass-filter 0,1...2,5 s custom specific
• accuracy better than 0,5 % F.S.
Low Cost version with Ree chain
Also a low cost version equipped with a Reed chain is available
for the measuring ranges 101 – 404. Output is non linear acc. to
flowrate but proportional to height of float.
Resolution: 3,5 mm
PKP Prozessmesstechnik GmbH
orsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de

Process onnections (table 2):
Tube
L
[mm]
Range
No.
Male
(G)
Process connection Connec.
No.
(Weight)
[kg]
**
Pressure loss
PVC-
Glue in
fitting
Stan ar
[mm]
Female threa
(G)
PVDF
wel in
fitting
(at PVDF
tube
only)
Water
20°C
Air
20°C
P
V
C
P
P
M*
S
V*
A
Material No:
[mbar]
1 2 3 5 6 8
1
(165)
101
102
103
104
3/4
d: 16
DN: 10
L1: 171
3/8
DN: 10
01
0,8 3,3 4,8
2
(170)
201
202
203
204
1
d: 20
DN: 15
L1: 171
1/2
DN: 15
02
0,10 2,5 4,3
3
(185)
301
302
303
304
1 1/4
d: 25
DN: 20
L1: 191
3/4
DN: 20
03
0,13 6,1 8,3
4
(200)
401
402
403
404
1 1/2
d: 32
DN: 25
L1: 206
1
DN: 25
04
0,25 6,1 8,3
6
(350)
603
604 1 1/2
d: 32
DN: 25
L1: 356
1
DN: 25
09
0,48 12,3 15,9
605
606
2 d: 40
DN: 32
L1: 356
1 1/4
DN: 32
10
0,71 12,3 15,9
691A
692A 2 1/4
d: 50
DN: 40
L1: 356
1 1/2
DN: 40
10A
1,05 12,3 15,9
607
608
609
609A
2 3/4
d: 63
DN: 50
L1: 356
2
DN: 50
11
1,53 22,2 27,1
610
611
612 3 1/2
d: 75
DN: 65
L1: 356
2 1/2
nicht in PP
DN: 65
12
2,10 33,7 40,0
PVDF measuring tubes have different dimensions L and L1.
*For process connection with female thread made of brass or st. st., the union nut is
made of malleable cast iron.
**Weight with PVC glue in fitting
The connection code is build from material number and connection number
Example:
PCV-female thread G1 for measuring tube no. 6:
Material-No.: 2, Connection-No.: 09
Connection code: 209
Dimensions Measuring Tube:
PKP Prozessmesstechnik GmbH
orsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de