DKM-2 Module BASICS Flow Monitor - dginstruments.com.au

DKM-2 Module BASICSFlow Monitor

Operating Instructions

Series DKM-2Type DKM-2/2 to DKM-2/7

Read the instructions prior to performing any task!

DKM-2 Module BASICS, 1, en_US

© Meister Strömungstechnik GmbH 2013

Meister Strömungstechnik GmbH

Im Gewerbegebiet 2

63831 Wiesen

Germany

Telephone: +49 6096 9720 - 0

Fax: +49 6096 9720 - 30

Email: [email protected]

Internet: www.meister-flow.com

These instructions were compiled by:

Meister Strömungstechnik GmbH

Subject to change without notice

27.10.2015DKM-2 Module BASICS Flow Monitor2

These instructions facilitate the safeand efficient handling of a flow monitor(referred to as "device" in the fol-lowing). The instructions are an inte-gral part of the device and must bekept within easy reach for the per-sonnel in the immediate vicinity of thedevice at all times. Personnel mustcarefully read and understand theseinstructions before commencing allwork. The basic requirement for safework is adherence to all safety andhandling instructions stipulated inthese instructions. The local accident-prevention regulations and generalsafety standards and regulations forthe field of application of the devicealso apply. Illustrations in theseinstructions are provided to aid generalunderstanding and might deviate fromthe actual model. No claims can bederived from any such differences.

Limitations of liability

All details and instructions in thismanual have been compiled underconsideration of the valid standardsand regulations, the current state-of-technology and our many years ofknowledge and experience. The manu-facturer does not accept any liabilityarising from:

n non-observance of any details inthese instructions

n improper use of the device, or usethat is not in accordance withthese instructions

n use of non-trained personnel

n unauthorized retrofitting or tech-nical changes that have not beenauthorized by the manufacturer

n use of non-approved spare parts

The duties and obligations agreedupon in the delivery contract apply infull, as well as the general terms andconditions, the terms of delivery by themanufacturer and the valid legal regu-lations applicable at the conclusion ofthe contract.

Copyright

These operating instructions are pro-tected by copyright.

Except for internal purposes, transferof these instructions to third-parties,copying them in any way– even in part – as well as dissemina-tion and/or communication of their con-tent is forbidden without prior writtenauthorization from Meister Strömung-stechnik ("manufacturer"). Violationsare subject to claims for indemnifica-tion. The manufacturer reserves theright to assert additional claims.

Copyright is the property of the manu-facturer.

© Meister Strömungstechnik GmbH

Im Gewerbegebiet 2

63831 Wiesen

Germany

Supplemental instructions

27.10.2015 DKM-2 Module BASICS Flow Monitor 3

Table of contents1 Overview...................................................................................................... 7

1.1 Short description.................................................................................. 71.2 Warranty and guarantee provisions..................................................... 71.3 Customer service................................................................................. 7

2 Safety........................................................................................................... 82.1 Explanation of symbols........................................................................ 82.2 Correct use in accordance with these instructions............................. 102.3 Special precautions............................................................................ 112.3.1 Hazards from electrical current....................................................... 112.3.2 Mechanical hazards........................................................................ 122.3.3 Hazards from high or low temperatures.......................................... 132.3.4 Radiation hazards........................................................................... 132.3.5 Hazards caused by media............................................................... 142.4 Personnel requirements..................................................................... 142.5 Personal safety equipment................................................................. 152.6 Protective systems............................................................................. 162.7 Replacement parts............................................................................. 162.8 Environmental protection................................................................... 172.9 Responsibility of the owner................................................................ 17

3 Design and function................................................................................. 203.1 Overview............................................................................................ 203.2 Device description.............................................................................. 203.3 Component description...................................................................... 21

4 Transport, packaging and storage.......................................................... 224.1 Safety instructions for transport......................................................... 224.2 Transport inspection........................................................................... 224.3 Packaging.......................................................................................... 224.4 Symbols on the shipping box............................................................. 234.5 Storage............................................................................................... 23

5 Installation and initial startup.................................................................. 255.1 Safety................................................................................................. 25

Table of contents


5.2 Requirements at the place of installation........................................... 255.3 Preparatory work................................................................................ 265.4 Installation in the pipe system............................................................ 295.5 Initial startup....................................................................................... 335.6 Electrical connection.......................................................................... 345.6.1 Switch contact SG-15 with connector in compliance with

EN175301-803................................................................................ 355.6.2 Plug connector M12x1.................................................................... 365.6.3 Cable............................................................................................... 375.6.4 Degree of protection (IP-Code)....................................................... 375.7 Grounding the device......................................................................... 375.8 Plug connection.................................................................................. 375.9 Contact protection measures............................................................. 40

6 Operation................................................................................................... 436.1 Switch point adjustment..................................................................... 436.2 Checking the flow............................................................................... 45

7 Troubleshooting....................................................................................... 467.1 Safety................................................................................................. 467.2 Troubleshooting guide........................................................................ 48

8 Maintenance.............................................................................................. 508.1 Safety................................................................................................. 508.2 Maintenance plan............................................................................... 508.3 Removal from the pipe system........................................................... 518.4 Disassembly....................................................................................... 528.5 Maintenance....................................................................................... 578.5.1 Cleaning.......................................................................................... 578.5.2 Parts replacement........................................................................... 588.5.3 Assembly......................................................................................... 588.5.4 Switch contact replacement............................................................ 648.6 Measures to be taken after maintenance work.................................. 65

9 Disassembly and disposal....................................................................... 669.1 Safety................................................................................................. 669.2 Disassembly....................................................................................... 66

Table of contents


9.3 Return Materials................................................................................. 679.3.1 Return Materials Authorization........................................................ 679.4 Disposal............................................................................................. 67

10 Technical data........................................................................................... 6810.1 Device data plate............................................................................. 6810.2 Switch contact data plate................................................................. 6810.3 Dimension sheet.............................................................................. 6910.4 General specifications...................................................................... 7010.5 Electrical specifications.................................................................... 7110.6 Measuring ranges............................................................................ 7210.6.1 Standard measuring ranges.......................................................... 7210.7 Operating data................................................................................. 73

11 Annex......................................................................................................... 7411.1 Tightening torque............................................................................. 7411.2 Replacement parts........................................................................... 7411.3 Tools................................................................................................ 7611.4 Sealant............................................................................................. 7611.5 Lubricants......................................................................................... 77

12 Index.......................................................................................................... 78

Table of contents


1 Overview1.1 Short description

Fig. 1: DKM-2 flow monitor

1 Switch point adjustment scale2 Switch contact with female socket

or sealed-in cable

The flow monitor DKM-2 monitors thecontinuous flow of liquids. It isdesigned for installation in pipe sys-tems.

A float inside the device is moved bythe medium flowing through it. Thedesired switch point can be set on theswitch point adjustment scale, wherebythe arrow on the switch contact isaligned to the desired volume flowvalue on the switch point adjustmentscale.

External measuring devices can beconnected at the socket.

1.2 Warranty and guar-antee provisions

Warranty and guarantee provisions arecontained in the general terms andconditions of the manufacturer.

1.3 Customer serviceFor technical information, please con-tact our customer service department(for contact details, see Page 2).

Furthermore, our staff is always inter-ested in receiving new information andexperiences gained from application ofthe device, which might be useful inimproving our products.

OverviewCustomer service


2 SafetyThis chapter provides an overview ofimportant safety aspects required foroptimum protection of personnel aswell as for safe installation and safeoperation of the device.

Non-observance of the handling andsafety instructions listed in this manualmay result in hazardous/dangerousconditions and in damage to property.

2.1 Explanation of sym-bols

Safety instructions

Safety instructions in this manual aremarked by symbols. The safety instruc-tions are preceded by signal words thatindicate the level of danger/hazard.

To prevent accidents or injuries to per-sons as well as damage to property,always observe the safety instructionsand proceed carefully.

DANGER!

This combination of symbol andsignal word indicates an imme-diate, dangerous situation thatresults in death or serious injuriesif it is not avoided.

WARNING!

This combination of symbol andsignal word indicates a possiblydangerous situation that mightresult in death or serious injury if itis not avoided.

SafetyExplanation of symbols


CAUTION!

This combination of symbol andsignal word indicates a possiblydangerous situation that mightresult in minor or slight injuries if itis not avoided.

NOTICE!

This combination of symbol andsignal word indicates a possiblydangerous situation that mightresult in damage to property and tothe environment if it is not avoided.

Tips and recommendations

This symbol emphasizes usefultips and recommendations as wellas information for efficient andfailure-free operation.

Signs used in these instructions

The following signs and highlightingare used in these instructions to iden-tify handling instructions, the descrip-tion of results, lists/enumerations, ref-erences and other elements:

Designates step-by-step han-dling instructions

ð Designates a state or anautomatic sequence as aresult of a specific operatingstep

n Designates randomly ordered enu-merations and list entries

Ä “Signs used in these instructions”on page 9, designates references tochapters in these instructions

SafetyExplanation of symbols


2.2 Correct use inaccordance withthese instructions

The device is designed and con-structed exclusively for the intendeduse described herein.

Correct use in non-hazardous areas

The flow monitor serves exclusivelyto monitor the continuous flow of liq-uids within a temperature range of-20 °C to 120 °C (optional: 160 °C) ata maximum operating pressure of:300 bar (brass version) and 350 bar(stainless steel version).

Correct use in explosion-hazardzones

For employment in explosion-hazardzones, changed conditions apply forthe intended use.

The intended use in explosion-hazardzones is described in the OperatingInstructions "DKM-2 Module ATEX".

Intended use in explosion-hazardzones includes the observance of allspecifications in these OperatingInstructions, as well as those for"DKM-2 Module ATEX ".

Any additional or different application,above and beyond the correct use inaccordance with these instructions, isdeemed as incorrect use.

WARNING!

Danger due to incorrect use!Incorrect use of the flow monitormay result in dangerous situations.

– Use the flow monitor onlywithin the stipulated perform-ance limits

– Do not subject the flow mon-itor to severe temperature fluc-tuations

– Do not use the flow monitorwith quick acting valves

– Do not use the flow monitorwith solenoid valves

– Do not subject the flow mon-itor to vibrations

– Do not subject the flow mon-itor to pressure surges

– Do not use the flow monitorwith media containing solids orabrasives

– Only use the flow monitor withmedia previously approved bythe manufacturer

– Do not use the flow monitor asthe sole monitoring device toprevent dangerous conditions

– Do not install the flow monitoras a load bearing part within apipeline system

– The flow monitor must beinstalled so that it is protectedfrom damage by mechanicalforce. If necessary, install anappropriate impact protectiondevice

SafetyCorrect use in accordance with these instructions


All claims for damages due to incorrectuse are excluded.

2.3 Special precautionsThe following section lists residualrisks that might arise from the device.

To reduce health risks and preventdangerous situations, observe thesafety instructions listed here as wellas the safety instructions in the otherchapters of these operating instruc-tions.

DANGER!

Employment of the device inexplosion-hazard zonesrequires the observance of theOperating Instructions for"DKM-2 Module ATEX"including all hazard statementsand warnings, therein.

These operating instructionscannot cover all conceivable dan-gers because many dangers arise,not from the device itself, but fromthe respective media flowingthrough it. Always observe theappropriate safety data sheetswhen using hazardous media!

2.3.1 Hazards from elec-trical current

Electrical current

DANGER!

Danger to life from electricalcurrent!There is an immediate risk to lifefrom electrocution on touching liveparts. Damaged electrical insula-tion or components can beextremely dangerous.

– Only qualified electriciansshall work on the electricalsystem.

– If the insulation is damagedthen immediately switch offand have repairs carried out.

– Before commencing work onlive parts of the electrical sys-tems and operating equip-ment, disconnect the equip-ment and ensure that itremains disconnected for theduration of the work. Observethese 5 safety rules whendoing so:– Isolate (disconnect)– Secure against switching

back on– Check for absence of

voltage– Ground and short– Cover or cordon off other

live parts in the vicinity

SafetySpecial precautions > Hazards from electrical current


– Never bridge fuses or putthem out of operation. Alwaysobserve the correct currentratings when replacing fuses

– Keep moisture away from liveparts. This can result in short-circuit

2.3.2 Mechanical hazards

WARNING!

Risk of injury due to fracturedhousing and leakage!Unauthorized temperatures orexcessive pressure may cause theflow monitor body or the processconnections to burst. Injuries maybe caused by flying debris andescaping media.

– Keep within the stipulatedoperating conditions

– Wear personal protectiveequipment

– Avoid severe temperature fluc-tuations

– Avoid pressure surges

CAUTION!

Risk of injury on sharp edgesand pointed corners!Sharp edges and pointed cornerscan cause abrasions and skincuts.

– Proceed with caution whenworking near sharp edges andpointed corners

– If in doubt, wear protectivegloves

SafetySpecial precautions > Mechanical hazards


2.3.3 Hazards from highor low temperatures

Hot or cold surfaces

WARNING!

Risk of injury from hot or coldsurfaces!Surfaces of components may heatup/cool down dramatically due tothe media flowing through them.Skin contact with hot or cold sur-faces causes severe skin burning/freezing.

– Always wear temperature-resistant protective workclothing and protective gloveswhen working near hot/coldsurfaces

– Before commencing any work,make sure that all surfaceshave been cooled down orwarmed up to ambient temper-ature

2.3.4 Radiation hazardsStrong magnetic fields

WARNING!

Danger to life from strong mag-netic fields!Strong magnetic fields may causesevere injuries or even be fatal, aswell as cause considerabledamage to property.

– Persons with pacemakersmust not be located in thevicinity of the device. Thiscould impair the function of thepacemaker

– Persons with metal implantsmust not be located in thevicinity of the device. Implantscan heat up or be attractedmagnetically

– Keep ferromagnetic materialsand electromagnets awayfrom the magnetic source.These materials could beattracted and fly through theroom, thereby injuring or evenkilling persons. Minimumclearance: 3 m

– Remove and put away metalobjects before maintenancework (jewelry, watches, writingimplements, etc.)

– Do not place any electronicdevices within the vicinity ofthe magnetic source. Thesecould be damaged

SafetySpecial precautions > Radiation hazards


– Do not place any electronicstorage media, credit cards,etc. within the vicinity of themagnetic source. Data couldbe deleted

2.3.5 Hazards caused bymedia

Hazardous media

WARNING!

Risk of injury from hazardousmedia!If the flow monitor is used for toxic,corrosive or very hot/cold mediathen there is a risk of serious injuryif the media escapes.

– Observe details in the safetydata sheet of the media

– Comply with the safety, acci-dent prevention and environ-mental protection regulationsappropriate to the media used

– Wear personal protectiveequipment in accordance withthe safety data sheet

2.4 Personnel require-ments

WARNING!

Risk of injury due to insuffi-ciently trained and qualified per-sonnel!If unqualified personnel work onthe device or are located within itshazard zone, dangers arise whichmay result in serious injuries andconsiderable damage to property.

– All work must be performed byqualified personnel only.

– Keep unqualified personnelaway from hazard zones.

Authorized personnel is to be restrictedto those persons who can be expectedto carry out their work reliably. Personswhose ability to respond is influenced,e.g. by drugs, alcohol or medication,are not authorized.

Observe the age and occupational reg-ulations at the site when choosing per-sonnel.

SafetyPersonnel requirements


The following lists the personnel quali-fications for the various areas ofactivity:

Qualified electricianDue to specialized training, knowledgeand experience as well as knowledgeof the relevant standards and regula-tions, the qualified electrician is able toindependently perform work on theelectrical systems as well as to detectand avoid possible risks and dangers.

Additionally, the electrician must pro-vide proof of his/her professional quali-fication that certifies his/her ability toperform work on electrical systems.

The qualified electrician must fulfill therequirements contained in the validlegal accident-prevention regulations.

Qualified personnelDue to their specialized training, knowl-edge and experience as well as theirknowledge of the relevant standardsand regulations, qualified personnelare able to independently carry out thework assigned to them as well as todetect and avoid possible risks anddangers.

2.5 Personal safetyequipment

Personal safety equipment is used toprotect personnel from hazards/dan-gers that might impair their safety orhealth during work.

When performing the various tasks at,and with the device, personnel mustwear personal safety equipment. Spe-cial reference is made of this in theindividual chapters within these Oper-ating Instructions. The following pro-vides a description of the personalsafety equipment:

n Always wear appropriate personalsafety equipment required in thevarious chapters of these Oper-ating Instructions before com-mencing work.

n Comply with the personal safetyequipment instructions postedwithin the work area.

Description of personal safetyequipment

Goggles

The goggles are used to protect theeyes from flying debris and splashingfluid.

Protective gloves

SafetyPersonal safety equipment


Protective gloves protect the handsfrom friction, burns, grazing, abrasion,surface cuts or deeper injuries, as wellas from direct contact with hot or coldsurfaces.

With hazardous media, the protec-tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, the speci-fications of the system operatormust be followed. If no protectiveequipment is specified, suitable pro-tective gloves and goggles must beworn.The protective equipment is used toprotect against hazardous media leaksand hazardous media residue in thedevice.

2.6 Protective systemsIntegration within an emergency-stop concept is required

The device is designed for use as apart of a machine or system. It doesnot have its own controller and doesnot have an autonomous emergency-stop function.

Before starting up the device, installthe emergency-stop equipment andincorporate it into the safety chain ofthe machine or system.

Connect the emergency-stop equip-ment so that if there is an interruptionin the power supply or in the activationof the power supply after an interrup-tion, dangerous conditions areexcluded for persons and valuables.

The emergency-stop equipment mustalways be freely accessible.

2.7 Replacement parts

WARNING!

Risk of injury due to use ofincorrect replacement parts!Use of incorrect or faulty replace-ment parts may result in dangersto personnel as well as damages,malfunctions or total failure.

– Only use original replacementparts from the manufacturer orapproved by the manufacturer.

– Always contact the manufac-turer in case of doubt.

SafetyReplacement parts


Always purchase replacement partsfrom an authorized dealer or directlyfrom the manufacturer (For contactdetails, see Page 2).

The replacement parts list is in theannex.

2.8 Environmental pro-tection

NOTICE!

Risk to the environment due toimproper handling of environ-mentally hazardous substances!Serious environmental damagecan result if substances harmful tothe environment are handled incor-rectly, especially if they are dis-posed of improperly.

– Always observe the instruc-tions listed below on the han-dling and disposal of sub-stances harmful to theenvironment.

– If harmful substances arereleased into the environment,take immediate countermeas-ures. If there is doubt, contactthe local authorities, informthem of the damage andrequest information on suit-able countermeasures to betaken.

Cleaning fluids

Solvent-based cleaning fluids containtoxic substances. They must never bereleased into the environment andmust be disposed of by a waste man-agement company.

Lubricants

Lubricants such as greases and oilscontain toxic substances. They mustnever be released into the environmentand must be disposed of by a wastemanagement company.

2.9 Responsibility of theowner

Owner

The owner is the person who operatesthe device himself for business or com-mercial purposes or who cedes suchuse/application to a third-party andwho, during operation of the device,has full legal product stewardship forprotection of the user, the personnel orthird-parties.

Duties of the owner

The device is used in the commercialsector. The owner of the device istherefore subject to legal obligationspertaining to work safety.

SafetyResponsibility of the owner


In addition to the safety instructionscontained in these Operating Instruc-tions, the safety, accident preventionand environmental protection regula-tions applicable to the field of applica-tion of the device must be observed.

In particular, this includes:

n The owner must inform himselfregarding the valid health andsafety regulations and must carryout a risk assessment to addition-ally determine the risks resultingfrom the special work conditionsarising at the location at which thedevice is used, especially in regardto the media used. He must thenimplement these within OperatingInstructions for use of the device.

n The "Occupational Health andSafety Act" of 1970 stipulates thatit is the duty of the owner to pro-vide a safe workplace. He musthereby ensure that the device isoperated and maintained com-pliant to valid commercial, indus-trial, local, federal and state laws,standards and regulations.

n Appropriate to the working condi-tions and the media used, theowner must affix signs within theworking area that inform the userof the hazards and dangerspresent.

n During the entire period of use ofthe device, the owner must checkperiodically to ensure that theOperating Instructions correspondto the current state of regulations,and he must make adjustments asnecessary.

n The owner must clearly regulateand determine responsibilities forinstallation, operation, trouble-shooting, maintenance andcleaning.

n The owner must fit/retrofit suitablesafety equipment within the com-plete plant/system.

n The owner must ensure that allstaff/personnel have thoroughlyread and understand these instruc-tions before handling the device.Additionally, he must train the per-sonnel at regular intervals andwarn them of dangers.

n The owner must provide the per-sonnel with the required safetyequipment and must instruct themthat its wear is mandatory.

Additionally, the owner is responsiblefor ensuring that the device is alwayskept in a technically perfect condition.The following therefore applies:

n The owner must implement suit-able safety measures, appropriateto the media used.

n Different media have differentseverities of influence on thesoiling and wear of/to the device.The owner must set suitable main-tenance intervals, depending onthe media flowing through thedevice.



n The owner must ensure that themaintenance intervals described inthese Operating Instructions areadhered to at all times.

n The owner must ensure that thedevice is completely free of allresidual media before disposal.Remains of corrosive or toxicmaterials must be neutralized.



3 Design and function3.1 Overview

Fig. 2: Overview

1 Process connection (outlet)2 Device body3 Switch contact and female socket

or switch contact with cable4 Switchpoint adjustment scale5 Process connection (inlet)

3.2 Device descriptionDKM-2 flow monitors work according tothe functional principle of the variablearea flow meter. The flow monitor isinstalled into a pipe system and meas-ures the flow rate of the mediumflowing through the pipe system.

A float inside the flow monitor is movedby the flowing medium. A magneticfield is generated by the magnetsinside the float. The position of the floatis detected by a switch contact. Thedesired switch point can be set on theswitch point adjustment scale bymoving the switch contact.

Applications for DKM-2 flow monitorsare for example, lubricating circuits.The volume flow of the lubricatingmedium is monitored by the flow mon-itor to ensure it is high enough forproper lubrication. If the flow throughthe flow monitor drops below thethreshold preset by the operator, theswitch contact switches (Change-overContact) or open the contact (NormallyOpen Contact).

Design and functionDevice description


3.3 Component descrip-tion

Switch contact

Fig. 3: Switch contact and femalesocket

A potential-free Reed contact is castinto the switch contact ( Fig. 3/1). Thedevice is supplied with a connector (Fig. 3/2).

Switch point adjustment scale

Fig. 4: Switch point adjustment scaleDKM-2

A scale is applied to the device body,to which the desired switch point canbe adjusted.

Design and functionComponent description


4 Transport, packaging and storage4.1 Safety instructions

for transport

Improper transport

NOTICE!

The device could be damaged iftransported improperly!Objects to be transported may fallor overturn if transported incor-rectly. This can result in damage tothe device and/or property.

– Proceed carefully whenunloading transported pack-ages, both on delivery andwhen transporting in-house.Observe the symbols andinstructions on the shippingbox

– Only remove packaging imme-diately before assembly

4.2 Transport inspec-tion

On delivery, make an immediate checkfor completeness and check for trans-port damages.

If there are any visible external trans-port damages then proceed as follows:

n Do not accept the deliveryn Note the damage in the shipping

documents or on the delivery noteof the transporter and have thedriver confirm by signature

n Initiate a claim for damages

Make a claim for each fault assoon as it is detected. Claims fordamages can only be invokedwithin the valid claim periods.

4.3 PackagingAbout packaging

The packaging serves to protect theindividual components from transportdamages, corrosion and other dam-ages until they are installed. Do notdiscard the packaging and only removethe device from the shipping boximmediately before installation.

Transport, packaging and storagePackaging


Handling packaging materials

Dispose of packaging material inaccordance with the valid legal regula-tions and local ordinances.

NOTICE!

Danger to the environment dueto incorrect disposal!Packaging is made of valuable rawmaterials and can be reused inmany cases or usefully processedand recycled. Improper disposal ofpackaging materials may pose adanger to the environment.

– Dispose of packaging materialin an environmentally safemanner

– Comply with the local disposalregulations. If necessary, havethe packaging disposed of byapproved specialists.

4.4 Symbols on theshipping box

Top

The arrowheads indicate the top sideof the package. They must alwayspoint upwards, otherwise the contentmay be damaged.

Fragile

Designates packages with breakableor damageable contents.

Handle the package carefully and donot allow it to fall or be subjected to jar-ring or severe vibration.

4.5 StorageStoring the packages

Store the packages under the followingconditions:

n Do not store in the openn Store dry and dust-freen Do not subject to any aggressive

median Protect from direct sunlightn Avoid mechanical vibrations and

shocksn Storage temperature: 0 to 35 °Cn Relative humidity: max. 60 %n Do not stackn If storing for longer than 3 months,

regularly check the general condi-tion of all parts as well as of thepackaging.

Transport, packaging and storageStorage


Storage instructions in addition tothe instructions listed here may belisted on the packages. Followthese instructions also.

Transport, packaging and storageStorage


5 Installation and initial startup5.1 SafetyIncorrect installation and initialstartup

WARNING!

Risk of injury due to incorrectinstallation and initial startup!Incorrect installation and initialstartup may result in severe inju-ries and considerable damage toproperty.

– Ensure that the site is suffi-ciently cleared of obstructionsbefore commencing work

– Handle open or sharp edgedcomponents carefully

– Ensure that the assemblylocation is orderly and clean!Parts and tools lying about oron top of each other arepotential causes of accidents

– Assemble components prop-erly. Observe the stipulatedtightening torque of screws

– Before initial startup, makesure that all installation workhas been carried out and com-pleted in compliance with thespecifications and instructionsin these Operating Instructions

Safeguard against restart

WARNING!

Danger to life due to unauthor-ized restart!There is a risk of severe or evenfatal injuries from unauthorizedrestart of the power supply duringinstallation.

– Before commencing work,switch off the power supply tothe entire system/plant andsecure against restart

5.2 Requirements at theplace of installation

The place of installation must meet thefollowing requirements

n The device must not be underwater.

n The surrounding area must be suf-ficiently illuminated.

n There must be sufficient space toprevent accumulation of trappedheat.

n The device must not be installedas a supporting part in a pipe con-struction.

n The device may not have anythingaffixed to, or suspended from it.

Installation and initial startupRequirements at the place of installation


n The flow monitor must be installedin such a way as to precludedamage by outside force. It mustbe ensured that the flow monitorcannot be damaged. If necessary,install an appropriate impact pro-tection device.

n External magnetic fields will influ-ence the switch contact. Keep suf-ficient distance to magnetic fields(e.g. electric motors).

n Piping, process connections orsupports made from ferromagneticmaterial influence the magneticfield of the device. Keep a spaceof minimum 100mm to those mate-rials (e.g. steel).

5.3 Preparatory workThe following criteria must be metduring installation to ensure correctfunctioning of the flow monitor:

WARNING!

Danger due to incorrect installa-tion!If the criteria listed above are notmet when installing the flow mon-itor, dangerous/hazardous situa-tions may arise.

– Do not install the flow monitoras a supporting part in a pipesystem

– Do not use the flow monitorwith quick-acting valves

– Do not use the flow monitorwith solenoid valves

Installation position/direction offlow

Fig. 5: Installation position/direction offlow

Installation and initial startupPreparatory work


Only install the flow monitor in one ofthe positions displayed in the drawing.The medium must flow in the directionof the arrow (from a low to a high scalevalue).

Unimpeded flow sections

NOTICE!

Measuring inaccuracy due toincorrect installation!The measuring accuracy of theflow monitor is influenced by itsposition within the pipe system.Changes in cross-section, branch-offs or bends in the pipe systemimpair measuring accuracy.

– Ensure that the unimpededflow sections are maintained

– Never reduce the pipe diam-eter immediately before thedevice

We recommend unimpeded flowsections, type BS-228.



Fig. 6: Unimpeded flow sections

1 10x DN2 5x DN

n There must be an unimpeded flowsection of 10xDN (rated width)before the device.

n There must be an unimpeded flowsection of 5xDN (rated width) afterthe device.

Unimpeded outlet

Fig. 7: Unimpeded outlet

If the pipe system ends at an unim-peded outlet, the flow monitor must notbe installed directly in front of theopening. The device must always becompletely filled with media to ensuremeasuring accuracy.



Strainer

Fig. 8: Strainer

1 min. 10x DN2 min. 5x DN

If the medium is contaminated bysolids, a strainer must be installedbefore the device ( Fig. 8).

We recommend a Type SF, SFDor SFM.

Prepare the device

NOTICE!

Risk of damage to property dueto contamination!Contamination and deposits mayimpair the free movement of thefloat, thereby damaging thedevice.

– Ensure that there are no for-eign particles in the device

– Ensure that the device is notsoiled

– Do not use any medium con-taining solids

Due to quality assurance meas-ures, there may be some testmedium (oil) residue in the device.

1. Unpack the device and visuallyinspect the device to ensure thatit is free of packaging materials

2. Examine the device for residueof test medium and drain, if nec-essary

3. Check the device for soiling andflush with clean medium, if nec-essary

5.4 Installation in thepipe system

Installation and initial startupInstallation in the pipe system


WARNING!

Risk of injury from pressurizedpipes!If the pipe system is under pres-sure when installing the device,severe injuries may result.

– Depressurize the pipe systembefore installing the device

WARNING!

Risk of injury from hot or coldsurfaces!Pipelines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces maycause severe skin burn or frostbite.

– Before commencing work,ensure that the system hasbeen controlled to a tempera-ture range between 0 und 40°C.

– Do not touch any parts of thesystem that are either very hotor very cold.

– Always wear heat-resistant/cold-resistant protectiveclothing and protective gloveswhen working near hot/coldsurfaces.

WARNING!

Risk of injury from media in thepipe system!If the pipe system contains haz-ardous media, severe injuries maybe caused by escaping media.

– Before installation, ensure thatthe pipe system is empty anddoes not contain any mediaresidue

– Always wear personal protec-tive equipment during installa-tion

– Provide suitable drainingdevices (collection tanks, etc.)

NOTICE!

Risk of damage to the devicedue to contamination in the pipesystem!Dirt and foreign particles enteringthe device can damage the deviceand impair its operation.

– Ensure that the pipe system isclean before installing thedevice

– If necessary, flush the pipesystem with clean mediumbefore installation.



A suitable sealant must beselected depending on the condi-tion/composition of the pipe lines,the medium and the operating andenvironmental conditions. Thesealing method described here isonly an example and cannot beused in all cases.

Sealing the pipe connections

Personnel:n Qualified personnel

1. Nap the thread.

Fig. 9: Apply sealing thread



2. Apply sealing thread ( Fig. 9/1)to the napped area in thethreaded direction. Observe thequantity recommended by thesealant manufacturer.

Fig. 10: Pipe connection with sealingthread

ð The pipe line is now readyfor installation ( Fig. 10)

Install device in pipe system


Protective equipment:n Protective gloves

Tools:n Fixed spanner

CAUTION!

Do not hold the device by itsthreads. These are sharp edgedand may cause injury.

1. Start the threaded end of thedevice onto the thread of theconnecting pipe

Fig. 11: Screw in the device

2. Fasten the adapter union of thepipeline with an appropriatespanner ( Fig. 11/2). Whendoing so, lock the process con-nector in place to prevent slip,using a suitable spanner (Fig. 11/1).



Fig. 12: Screw in the device

3. Keep turning in the adapterunion ( Fig. 12/1) while holdingthe process connection of thedevice locked ( Fig. 12/2) untilthe connection is tight.

4. Repeat these steps at the otherend of the device.

5.5 Initial startupThe following steps must be takenbefore initial startup and any subse-quent startup (e.g. after removal andinstallation during maintenance).

1.

WARNING!

Make sure that the plant isoperating vibration-free.Vibrations could destroy thedevice. This could result in aserious risk of injury to theuser.

2.

WARNING!

Make sure that the mediumis flowing continuously.Pulse-like staggered loadscould destroy the device.This could result in a seriousrisk of injury to the user.

3.

NOTICE!

Completely fill the pipe lines.Partial filling(s) may result inmalfunctions and damage tothe device.

Installation and initial startupInitial startup


4.

NOTICE!

Vent the pipe line. If thereare air bubbles in the lineduring the measurementthen this could result indamage to the devicecaused by hydraulic shock.This could result in malfunc-tions.

5.

NOTICE!

Make sure that the plant isoperating without cavitation.Cavitation may result in mal-functions and damage to thedevice.

5.6 Electrical connec-tion

The electrical connection of the flowmonitor is accomplished through theconnector plug or the cast on powercable leading from the switch housing.The switch contacts employed in thesedevices are potential free and do notrequire a power source. Switch con-tacts and flow monitor have been opti-mally harmonized. After replacement ofa switch contact, the switch point mustbe readjusted.

DANGER!

Danger to life from electricalcurrentThere is an immediate risk to lifefrom electrocution on touching liveparts. Damage to the electricalinsulation or single componentscan be extremely dangerous.

– Only qualified electriciansshall work on the electricalsystem

– If the insulation is damagedthen immediately switch offand have repairs carried out

– Before commencing work onlive parts of electrical systemsand components, disconnectthe equipment and ensure thatit remains disconnected for theduration of the work. Observethese 5 safety rules whendoing so:– Isolate (disconnect)

Installation and initial startupElectrical connection


– Secure against switchingback on

– Check for absence ofvoltage

– Ground and short– Cover or cordon off other

live parts in the vicinity– Never bridge fuses or put

them out of operation. Alwaysobserve the correct currentratings when replacing fuses

– Keep moisture away from liveparts. This can result in short-circuit

5.6.1 Switch contactSG-15 with con-nector in compli-ance withEN175301-803

Wiring diagram of the suppliedsocket (EN 175301-803, Form C)front view.

Wiring diagram

normally open:

Fig. 13: Switch position under no-flowcondition

Fig. 14: Pin assignment, plug socket,normally-open contact. The ground-pinis not used.

change over:


Installation and initial startupElectrical connection > Switch contact SG-15 with connector in compliance with EN175301-803


Fig. 16: Pin assignment, plug socket,change-over contact. The ground-pin isnot used.

5.6.2 Plug connectorM12x1

Wiring diagram, connector M12x1Fig. 17: Pin assignment, connectorM12x1 (Form 15x50)

Wiring diagram

Normally open:


Change-over:

Installation and initial startupElectrical connection > Plug connector M12x1



5.6.3 CableThe individual cores of the cable arenumbered according to the followingconnection diagram.

Wiring diagram

normally open:


5.6.4 Degree of protection(IP-Code)

The specified degree of protection (IP)is only ensured if approved connectionmaterial is used (see following table).

Deviceconnec-tion

Specifi-cationof con-nectionmaterial

Degree ofprotection

EN175301-803withgland

Diameterof con-nectioncable: 5–6mm

IP65

M12x1 Plugcon-nectorM12x1

IP65

Cable - IP67

5.7 Grounding thedevice

When installing the device in a pipesystem, ensure that the device isgrounded to the pipe system to avoid adangerous electrical potential differ-ence.

5.8 Plug connection

Installation and initial startupPlug connection


Personnel:n Qualified electrician

Tools:n Flat-bladed screwdriver

Fig. 21: Detach socket

1. Release the fixing screw (Fig. 21) from the socket

Fig. 22: Remove socket

2. Remove socket ( Fig. 22)

Fig. 23: Disconnect inner section

3. Remove the inner section fromthe socket by inserting a flat-bladed screwdriver into the slot (Fig. 23/01) and carefully pry outthe inner section.



Fig. 24: Disconnect the screw connec-tion

4. Disconnect the screw connec-tion ( Fig. 24/01) by turning tothe left

5. Guide the connection cablethrough the screw connection inthe socket

6. Make the connections as shownin the connection diagram (Fig. 25 and Fig. 26)

7. Place the inner section ( Fig. 23)back into the socket and pushuntil it locks on

8. Retighten the screw connection (Fig. 24/01) by turning it to theright.



9. Place the socket onto the con-nection plug and tighten thefixing screw ( Fig. 21).

Fig. 25: Pin assignment, plug socket,Normally Open Contact (Form 15x50)

Fig. 26: Pin assignment, plug socket,Change-over contact (Form 15x50)

5.9 Contact protectionmeasures

The Reed-switches used in the switchcontacts are designed to be very sensi-tive to overload. To prevent destructionof the switch contact, the values speci-fied on the rating plate of the switchcontact housing must never beexceeded (not even temporarily).

There is a risk of overload from:

n inductive loadsn capacitive loadsn ohmic loads.

Suitable measures must be taken toprotect against overload (see followingexamples):

Installation and initial startupContact protection measures


Inductive load

There is danger of voltage peaks frominductive loads when switching off (upto 10 times the rated voltage). Induc-tive loads are caused by, e.g.:

n Contactors, relaysn Solenoid valvesn Electric motors

Examples of protective measures:

Fig. 27: Example 1

Fig. 28: Example 2

Capacitive loads

There is a danger of high currentpeaks from capacitive loads whenswitching-on the switch contact(exceeding rated current). Capacitiveloads are caused by, e.g.:

n Long connecting cablesn Capacitive consumers

Example of protective measure:

Fig. 29: Protective measure againstcapacitive loads

Ohmic loads

There is a danger of high currentpeaks from ohmic loads whenswitching-on the switch contact. Thereason for this is that the glow filamenthas a low resistance at low tempera-tures. Ohmic loads are caused by, e.g.:

n Filament bulbsn Motors during startup

Examples of protective measures:

Fig. 30: Example 1

Fig. 31: Example 2



Protection against ohmic loads can beachieved through installation of aresistor in the circuit, or by heating theglow filament. For connection to high-impedance consumers (ex. PLC), aprotective circuit is not needed.



6 Operation6.1 Switch point adjust-

mentSetting the switch point of aninstalled device

The following instructions describethe procedure for a Normally OpenContact (NOC). The actual state(open or closed), can be deter-mined using a continuity meter.


Tools:n Hex screwdriver

Fig. 32: Loosen set screw

1. Loosen the set screw of theswitch contact ( Fig. 32/1) usinga Hex screwdriver.

2. Slide the switch contact to theflow value to be monitored.Make sure that the arrow on theswitch contact data plate is inexact alignment with the desiredflow rate on the switchpointadjustment scale.

3. Re-tighten the set screw of theswitch contact ( Fig. 32/1) usinga Hex screwdriver. When doingso, observe the correct tight-ening torque of the screw.

Ä Chapter 11.1 “Tighteningtorque” on page 74

ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.

OperationSwitch point adjustment


Setting the switch point of a non-installed device

Fig. 33: Loosen the set screw

1. Loosen the set screw of theswitch contact ( Fig. 33/1)usinga Hex-Screwdriver screwdriver.

2. Slide the switch contact to theflow value to be monitored.Make sure that the arrow on theswitch contact data plate is inexact alignment with the desiredflow rate on the switch pointadjustment scale.

3. Re-tighten the set screw of theswitch contact ( Fig. 33/1) usinga Hex-Screwdriver. When doingso, observe the correct tight-ening torque of the screw.


ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.

OperationSwitch point adjustment


6.2 Checking the flowReading-off the switch value


Protective equipment:n Goggles

Fig. 34: Reading-off the switch pointvalue

1. Make sure that the setting arrowand the scale mark of theswitchpoint adjustment scale arein alignment ( Fig. 34).

2. To obtain the greatest readingaccuracy, read-off straight-on.The read-off value can be falsi-fied by viewing at an angle fromabove or below (parallax error).

3. Read-off the switch value fromthe adjustment scale.

OperationChecking the flow


7 TroubleshootingThis chapter describes possible mal-functions of the device, their causesand repair.

If malfunctions persist or increase,shorten the maintenance interval tomeet the actual operating conditions.

For malfunctions not described in thischapter, please contact the manufac-turer (see service address on page 2).

7.1 SafetyWork carried out incorrectly toremedy a malfunction

WARNING!

Risk of injury due to incorrectrepair of malfunction!Work carried out incorrectly mayresult in severe injuries and con-siderable damage to property.

– Ensure that the site is suffi-ciently cleared before com-mencing work

– Ensure that the repair locationis orderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes of acci-dents

– If components have beenremoved, observe correctassembly procedures. Rein-stall all fixing/fastening ele-ments and observe the pre-scribed tightening torque forthe screwsÄ Chapter 11.1 “Tighteningtorque” on page 74

– Before placing the device backinto operation, ensure that allwork has been carried out andcompleted in compliance withthe specifications and instruc-tions in these OperatingInstructions

TroubleshootingSafety


Conduct in case of malfunction

The complete machine or system maybe unsafe if there is a defect at the flowmonitor (e.g. fractured housing).

The following always applies:

1. In case of malfunctions thatpresent an immediate danger topersons or valuables, proceedaccording to the valid emer-gency plans for the system

2. Determine the cause of the mal-function

3. Before repair, ensure that thereis no danger to persons fromescaping media

4. If necessary, allow the pipelineand device to cool down or towarm up before commencingwork

5. Malfunctions must be correctedby qualified personnel

The following troubleshootingguide provides an indication ofwho is qualified to repair the fault .

TroubleshootingSafety


7.2 Troubleshooting guideFault description Cause Remedy Personnel

The switch contactdoes not switch.

No mediumflowing throughflow monitor

Check that medium isflowing through the pipe-line

Qualifiedpersonnel

Flow is too low orthe switch con-tact is set toohigh

n Adjust the switchcontact to a lowerflow rate

n Use the device atanother measuringrange

n Increase the flowrate

Qualifiedpersonnel

Incorrect reduc-tion fitting or pipediameter is toosmall

n Correct pipe diam-eter

Qualifiedpersonnel

Float is stuck Disassemble and cleanthe device

Qualifiedpersonnel

Switch contact isdefective.

n Remedy the cause ofthe defect (short-cir-cuit, overload)

n Replace the switchcontact

Qualifiedpersonnel

Switch contact ispermanentlyswitched.

Flow is too highor the switchcontact is set toolow

n Reduce the flown Adjust the switch

contact to a higherflow rate

n Use the device atanother measuringrange

Qualifiedpersonnel

TroubleshootingTroubleshooting guide


Fault description Cause Remedy Personnel

Float is stuck Disassemble and cleanthe device

Qualifiedpersonnel

Switch contact isdefective

n Remedy the cause ofthe defect (short-cir-cuit, overload)

n Replace the switchcontact

Qualifiedpersonnel

The switch point isnot the same asthe actual flow rate.

Improper scaleinstalled formedia used

Request proper conver-sion table or scale formedia used

Qualifiedpersonnel

Incorrect reduc-tion fitting or pipediameter is toosmall

n Correct pipe diam-eter

Qualifiedpersonnel

Device is dirty Disassemble and cleanthe device

Qualifiedpersonnel

Device is defec-tive

Remove device fromsystem and contact themanufacturer

Qualifiedpersonnel

TroubleshootingTroubleshooting guide


8 Maintenance8.1 SafetyMaintenance work performed incor-rectly

WARNING!

Risk of injury due to mainte-nance work performed incor-rectly!Maintenance work performedincorrectly may result in severeinjuries and considerable damageto property.

– Ensure that the site is suffi-ciently cleared before com-mencing work.

– Ensure that the repair locationis orderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes of acci-dents.

– If components have beenremoved, observe correctassembly procedure. Reinstallall fixing/fastening elementsand observe the prescribedtightening torque for thescrews (see Chapter 11.1).

– Before placing the device backinto operation ensure that allwork has been carried out andcompleted in compliance withthe specifications and instruc-tions in these OperatingInstructions.

8.2 Maintenance planIntervals for replacing wear parts

DKM-2 type flow monitors require verylittle maintenance due to the smallnumber of moving parts. The intervalsfor the replacement of wear partsdepend significantly on the operatingconditions as well as on the composi-tion of the medium flowing through thedevice. For this reason, no intervalshave been set by the manufacturer.The operator must determine suitableintervals based on the local conditionsand circumstances.

MaintenanceMaintenance plan


Interval Maintenance work Personnel

Visual inspection for dirt/soiling Qualified personnel

Visual inspection for free-movement of float Qualified personnel

Visual inspection for leaks from the device Qualified personnel

Check function of switch contact Qualified personnel

8.3 Removal from thepipe system

The flow monitor must first be removedfrom the pipe system before per-forming maintenance.

WARNING!

Risk of injury from pressurizedlines!Severe injuries may result if thepipe system is under pressurewhen removing the device.

– Depressurize the systembefore removing the device

WARNING!

Risk of injury from hot or coldsurfaces!Pipelines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces causessevere skin burns or frost bite.

– Before removing the device,ensure that the machine orsystem and the flow monitorhave been controlled to a tem-perature range between 0 and40°C

– Do not touch any part of themachine or system that iseither very hot or very cold

– Always wear heat-resistant/cold-resistant protective workclothing and protective gloveswhen working near hot/coldsurfaces

MaintenanceRemoval from the pipe system


WARNING!

Risk of injury from media in thepipe system!If the pipe system contains haz-ardous media, severe injuries maybe caused by escaping media.

– Before removing the device,ensure that the pipe system isempty and does not containmedia residue

– Always wear personal protec-tive equipment when removingthe device

WARNING!

Risk of injury from media res-idue in the device!After the pipe system has beenemptied, media residue can still bepresent inside the device. In thecase of hazardous media, thiscould result in serious injuries.

– When removing (de-installingthe device from the pipesystem), always wear per-sonal protective equipment.

– All requirements specified inthe media safety data sheetmust be observed in accom-plishing the work task.

– Residue of hazardous mediain the device can result inserious injuries.

Removing the device from the pipesystem


Protective equipment:n With hazardous media, the protec-

tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, thespecifications of the system oper-ator must be followed. If no protec-tive equipment is specified, suit-able protective gloves and gogglesmust be worn.

Tools:n Fixed spanner

1. Loosen the adapter union of thepipe line using a suitablespanner. When doing so, lockthe process connection ordevice body in place with asecond spanner.

2. Secure the device against fallingand repeat Step 1 at the otherprocess connection.

8.4 DisassemblyTo replace wear parts or to clean thedevice, the flow monitor must first bedisassembled.

MaintenanceDisassembly


WARNING!

Risk of injury due to incorrectdisassembly!– The device may still contain

media residue– Wear personal protective

equipment when working withdangerous media residue

– Improper disassembly maycause serious injuries if dan-gerous media is still presentinside the device

CAUTION!

Risk of injury due to incorrectdisassembly!Incorrect disassembly may resultin injuries.

– Before disassembling, ensurethat the flow monitor hascooled down/warmed up to atemperature range between 0and 40° C.

– Wear personal protectiveequipment to protect againsthazardous media which maystill be present inside thedevice.




Protective equipment:n Gogglesn Protective gloves

Tools:n Fixed spannern Socket wrench

Special tools:n Threaded ring insertion tool



Fig. 35: Loosen process connection(outlet)

1. Loosen the process connection(outlet) ( Fig. 35) using theproper sized fixed spannerwrench. Hold the device body inplace using a proper sizedspanner wrench.

Fig. 36: Remove the process connec-tion (outlet)

2. Unscrew the process connection(outlet) from the device body (Fig. 36). If necessary, removethe O-ring from the process con-nection.



Fig. 37: Insert threaded ring insertiontool (outlet)

3. Insert the threaded ring insertiontool into the device outlet (Fig. 37) and turn until it rests inthe keyway of the threaded ring

Fig. 38: Loosen threaded ring (outlet)

4. Insert socket wrench into thethreaded ring insertion tool andloosen the threaded ring (Fig. 38). Hold the device body inplace using a proper sizedspanner wrench.

Fig. 39: Remove threaded ring (outlet)

5. Unscrew the threaded ring(outlet) from the device body (Fig. 39)



Fig. 40: Remove inner parts

6. Carefully turn the device body180° and remove the inner parts(float, magnets and spring) (Fig. 40)

Fig. 41: Spring, magnets and float

7. The inner parts of the flow mon-itor consist of the spring (Fig. 41/1), magnets ( Fig. 41/2)and float ( Fig. 41/3).

Fig. 42: Loosen process connection(inlet)

8. Loosen the process connection(inlet) ( Fig. 42) using the propersized fixed spanner wrench.Hold the device body in placeusing a proper sized spannerwrench



Fig. 43: Remove the process connec-tion (inlet)

9. Unscrew the process connection(inlet) from the device body (Fig. 43). If necessary, removethe O-ring from the process con-nection.

O-ring replacement

It is recommended that the O-ringsbe replaced during maintenance.

8.5 Maintenance

8.5.1 CleaningIt is the responsibility of the operator toestablish appropriate intervals and pro-cedures for cleaning the individualparts of the device. It must be ensuredthat the parts are not damaged duringthe cleaning process. When usingcleaning agents, it must be ensuredthat these are not aggressive to theparts and that there will be no dan-gerous reactions with media residue.Damaged parts must be replaced.

WARNING!

Risk of injury due to impropercleaning!The device may still contain mediaresidue.

– To protect against hazardousmedia residue in the device,wear personal protectiveequipment.

– Do not use cleaning agentswhich may lead to dangerousreactions with media residue.

– All requirements specified inthe safety data sheet must beobserved when handling orotherwise using the medium.

– Residue of hazardous mediainside the device can causeserious injury.

MaintenanceMaintenance > Cleaning


CAUTION!

Risk of injury due to damagedparts!If parts of the device are broken ordamaged, they may cause injurydue to sharp edges or splintersduring the cleaning process.

– Damaged parts must bereplaced

– Carefully clean the parts of thedevice, so as not to causedamage.

– When cleaning, always wearappropriate personal protec-tive equipment.

– Incorrect disassembly canresult in injuries.



8.5.2 Parts replacementDepending on the operating conditions,wear parts such as O-rings, float ormagnets may have to be replaced.Steps required to replace these partscorrespond to those used whenassembling the device Ä Chapter 8.5.3“Assembly” on page 58.

8.5.3 AssemblyAfter cleaning the individual compo-nents, the flow monitor must be reas-sembled.

MaintenanceMaintenance > Assembly



Tools:n Flat-bladed screwdrivern Torque screwdriver and assorted

bladesn Fixed spannern Socket wrenchn Torque wrench

Special tools:n Threaded ring insertion tooln Test rodn O-Ring installation tooln Magnetic pole indicator

Fig. 44: O-ring (seal)

1. Carefully install the O-rings (Fig. 44) with the aid of the O-ringinstallation tool ( Fig. 44) ontoboth process connections (inletand outlet), so that they areproperly seated in the O-ringgrooves of the process connec-tion ( Fig. 45). When doing so,be careful not to overstretch theO-rings.

Fig. 45: Properly positioned O-ring

2. Position the O-ring properly onthe process connection ( Fig. 45)

3. Lubricate the O-rings lightly.

A list of suitable lubricants iscontained in the annexÄ Chapter 11.5 “Lubricants”on page 77.



Fig. 46: Insert process connection(inlet)

4. Insert the process connection(inlet) into the device body (inlet)( Fig. 46)

Fig. 47: Tighten process connection(inlet)

5. Using a proper sized fixedspanner tighten the process con-nection (inlet). Hold the devicebody in place using a suitablefixed spanner ( Fig. 47), andobserve the proper torque (Ä Chapter 11.1 “Tighteningtorque” on page 74)



Fig. 48: Inner parts

6. Insert spring ( Fig. 48/1) withmagnets ( Fig. 48/2) into thefloat ( Fig. 48/3) ensuring propermagnetic pole orientation (northpole toward device outlet)

Fig. 49: Insert inner parts

7. Insert float with magnets andspring into the device body (Fig. 49)



Fig. 50: Insert threaded ring (outlet)

8. Insert the threaded ring (outlet)into the device body (outlet) (Fig. 50)

Fig. 51: Seat threaded ring (outlet)

9. Lightly seat the threaded ring(outlet) with the aid of thethreaded ring insertion tool andtighten with a torque wrench (Fig. 51), observing the propertorque ( Ä Chapter 11.1 “Tight-ening torque” on page 74)

Fig. 52: Insert process connection(outlet)

10. Insert the process connection(outlet) into the device body(outlet) ( Fig. 52)



Fig. 53: Tighten process connection(outlet)

11. Using a proper sized fixedspanner tighten the process con-nection (outlet). Hold the devicebody in place using a suitablefixed spanner( Fig. 53), andobserve the proper torque (Ä Chapter 11.1 “Tighteningtorque” on page 74)

Fig. 54: Check for smooth operation

12. Check the float for ease ofmovement ( Fig. 54) by applyinglight pressure with the test rod

ð If the float moves sluggishly,then disassemble the deviceÄ Chapter 9.2 “Disas-sembly” on page 66 andclean the float and devicebody bore

If the float is still sluggish afterhaving been cleaned severaltimes, contact the manufacturer.



8.5.4 Switch contactreplacement

Tools:n Flat-bladed screwdrivern Hex screwdriver

Fig. 55: Loosen female socket

1. Loosen the fixing screw of thefemale socket ( Fig. 55) with aflat-bladed screwdriver.

Fig. 56: Remove the female socket

2. Remove the female socket andgasket ( Fig. 56) by pullingupwards.

Fig. 57: Loosen set screw

3. Using a Hex screwdriver (Fig. 57)loosen the set screwuntil the switch contact can beremoved

Fig. 58: Remove switch contact

4. Remove the switch contact fromthe device ( Fig. 58).

5. Attach the new switch contact,making sure that the cylinder pinslides into the guide.

6. Insert the set screw and tightenjust enough to still allow theswitch contact to move easily.

MaintenanceMaintenance > Switch contact replacement


7. Connect a continuity meter. ForNormally Open Contact (NOC),connect pin 1 and pin 2. ForChange-Over Contact (COC),connect pin 1 and pin 3.

8. Slide the switch contact in theopposite direction of flow up tothe stop. The switch contactmust now be closed.

9. Slowly slide the switch contact inthe direction of flow until thecontact opens. This switch pointshould be set as accurately aspossible because it affects theaccuracy of the switchpointadjustment scale values. (If nec-essary, repeat steps 9 and 10).

10. Tighten the set screw (Fig. 57/1), observing the correcttightening torque of the screw (Ä Chapter 11.1 “Tighteningtorque” on page 74)

11. Bond the enclosed rating platewith setting arrow onto theswitch contact so that the settingarrow is in alignment with thelowest scale mark. If a referencemark is present on the scale,(recognizable due to a thinnerline width), then this is to beused as the reference mark. Thebonding surface must be dry andfree of grease

12. Set the desired flow rate (cut-offpoint) using the switchpointadjustment scale

13. Position the female socket andgasket, then tighten the fixingscrew

8.6 Measures to betaken after mainte-nance work

Take the following steps after comple-tion of maintenance work and beforeswitching on the device:

1. Check all previously loosened/released screw connections fortightness.


2. Clean the work area and removeall residual materials, packaging,substances or spills.

MaintenanceMeasures to be taken after maintenance work


9 Disassembly and disposalAfter its period of useful life, the devicemust be disassembled and disposed ofin an environmentally safe manner.

9.1 Safety

WARNING!

Risk of injury if disassembledincorrectly!Media residue, sharp edged com-ponents, pointed ends and cornerson and in the device or on toolsmay cause injuries.

– Ensure that the site is suffi-ciently cleared before com-mencing work

– Always wear protective equip-ment when handling dan-gerous media residue

– Handle open, or sharp-edgedcomponents carefully

– Ensure that the workplace isorderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes of acci-dents

– Disassemble components pro-fessionally

– Secure components so thatthey do not fall or overturn

– In case of doubt, contact themanufacturer

9.2 Disassembly

Before starting disassembly:

n Remove operating materials andpackaging and dispose of properly.


Protective equipment:n Protective glovesn Goggles

1. Remove the device from thepipeline ( Ä Chapter 8.3“Removal from the pipe system”on page 51)

2. Disassemble the device (Ä Chapter 9.2 “Disassembly”on page 66)

3. Clean components properly andremove media residue

4. Dispose properly

Disassembly and disposalDisassembly


9.3 Return Materials9.3.1 Return Materials

AuthorizationFor products being returned, regard-less of the reason, the currently validprovisions of the returns policy set byMEISTER will apply. Return shipmentswhich do not comply with the returnspolicy may be refused by MEISTER atthe expense of the consignor.

9.4 DisposalIf no return or disposal agreement hasbeen made then recycle disassembledcomponents:

n Scrap metalsn Recycle plastic elementsn Dispose of the remaining compo-

nents according to their materialproperties

NOTICE!

Danger to the environment dueto incorrect disposal!Potential risk to the environmentmay arise due to incorrect dis-posal.

– Have electrical scrap, elec-tronic components, lubricantsand other supplies disposed ofby approved specialists

– In case of doubt, get informa-tion on environmentally safedisposal from the localauthority or special disposalexpert

Disassembly and disposalDisposal


10 Technical data10.1 Device data plateThe data plate is on the mechanicalpart of the flow monitor/flow meter andcontains the following information:

Fig. 59: Device data plate

10.2 Switch contactdata plate

Fig. 60: Switch contact data plate

Fig. 61: Switch contact data plate withpositioning arrow

The data plate is on the switch contacthousing and may provide the followinginformation:

n maximum voltagen maximum currentn maximum powern positioning arrow for cut-off point

Technical dataSwitch contact data plate


10.3 Dimension sheet

Technical dataDimension sheet


10.4 General specificationsType Overall dimensions (mm)

G * DN SW L1 L2 T

DKM-2/2 1/4 8 24 90 98 10

3/8 10 24 90 118,6 11

1/2 15 27 90 - 14

DKM-2/3 1/4 8 24 90 98 10

3/8 10 24 90 118,6 11

1/2 15 27 90 - 14

DKM-2/7 1/4 8 24 90 98 10

3/8 10 24 90 118,6 11

1/2 15 27 90 - 14

Type Overall dimensions (mm)

G * D1 D2 A1 A2 A3 A4 weight(g) **

DKM-2/2 1/4 27,7 31,2 38,9 - - ca. 85 350

3/8 27,7 31,2 38,9 - - ca. 85 350

1/2 - 31,2 38,9 - - ca. 85 350

DKM-2/3 1/4 27,7 31,2 38,9 - - ca. 85 350

3/8 27,7 31,2 38,9 - - ca. 85 350

1/2 - 31,2 38,9 - - ca. 85 350

DKM-2/7 1/4 27,7 31,2 38,9 - - ca. 85 350

3/8 27,7 31,2 38,9 - - ca. 85 350

1/2 - 31,2 38,9 - - ca. 85 350

Technical dataGeneral specifications


Type Overall dimensions (mm)

G * D1 D2 A1 A2 A3 A4 weight(g) **

* NPT thread on request

**Sealed-in cable weight 2m ca. 80g

10.5 Electrical specificationsChange-Over Contact (COC)

Data Value Unit

Voltage 250 V

Current, maximum 1,5 A

Power, maximum 50 VA

Minimum load 3 VA

Normally Open Contact (NOC)

Data Value Unit

Voltage 230 V

Current, maximum 3 A


Technical dataElectrical specifications


Change-Over Contact (COC) M12x1 (-20 °C–85 °C)

Data Value Unit

Voltage 125 V

Current, maximum 1,5 A


Minimum load 3 VA

Normally Open Contact (NOC) M12x1 (-20 °C–85 °C)

Data Value Unit

Voltage 125 V



Change-Over Contact (COC) PLC

Data Value Unit

Voltage 250 V



10.6 Measuring ranges10.6.1 Standard measuring rangesType Switch range for oil, density 0,9 kg/dm3*

l/min gph gpm

DKM-2/2 0,5 – 1,6 8–25,5

Technical dataMeasuring ranges > Standard measuring ranges


Type Switch range for oil, density 0,9 kg/dm3*

DKM-2/3 0,8–3 13–48

DKM-2/7 2–7 32–111

* The specified data are switch-off points (other switch ranges are available onrequest).

10.7 Operating dataDescription Value Unit

Max operating pressure 300 (brass) / 350 (stain-less steel)

bar

Pressure loss 0,02 – 0,2 bar

Viscosity range 30 - 600 cSt

Max. media temp. 120 (optional: 160) °C

Measuring accuracy ± 10 % of full scale value

Min. media temp.

It must be ensured thatthe medium does notfreeze.

-20 °C

Operating data for devices employed inexplosion hazard zones differs fromthe above.

The operating data for devicesemployed in explosion hazard zonesare specified in Chapter 4 of the Oper-ating Instructions for "DKM-2 ModuleATEX".

Technical dataOperating data


11 Annex11.1 Tightening torqueComponent/function

Description Size Torque Qty

Threaded ring Threaded ring(outlet)

G1/2" 5 Nm 1

Connection fit-ting

Process con-nection (inlet/outlet)

G1/2" 40 Nm 2

Switch contactfixing screw

slotted cyl-inder headscrew

M3x10 0,4 Nm 1

11.2 Replacementparts

AnnexReplacement parts


The following replacement parts drawing provides an example of the constructionof a DKM-2 type flow monitor. The actual configuration may vary depending on themodel.

Item Qty Description

1 1 Process connection (inlet)

2 2 O-Ring (seal)

3 1 Device body

4 1 Float

5 3 Magnet

6 1 Spring

7 1 Threaded ring (outlet)

AnnexReplacement parts


Item Qty Description

8 1 Process connection (outlet)

9 1 Cylinder pin (switch contact)

10 1 Switch contact with male connector

11 1 Female socket and gasket

12 1 Fixing screw (female socket)

13 1 Set screw (switch contact)

11.3 ToolsThe following tools are required:

Tools

n Fixed spanner 24, 27 mmn Flat-bladed screwdriver, width of

blade 5,5 mmn Hex-screwdriver 2,5 mmn Torque screwdriver and corre-

sponding bladesn Socket wrench 1/2" and corre-

sponding socketsn Torque wrench 1/2"

Special tools

n Threadet ring insertion tool DKM-2n Test rod DKM-2n O-Ring installation tool DKM-2n Magnetic pole tester

11.4 Sealant

Before using a sealant, ensure thatit is compatible with the mediaused and that it can be employedunder the given operating condi-tions.

n Ensure proper sealn Use a suitable sealant. Liquid seal-

ants will damage the flow monitorn Always follow the sealant manu-

facturer's instructions

AnnexSealant


11.5 Lubricants

Before using a lubricant, always make sure that it is compatible with the oper-ating medium.

For the proper mounting of O-rings, an O-ring installation tool may be purchasedfrom the manufacturer.

The following lubricants are suitable to facilitate installing the O-rings:

Lubricant O-ring material

NBR EPDM FKM

Glycerine* suitable suitable suitable

Soapy water suitable suitable suitable

* Glycerine must not be used if the device is used for sulfuric acid and/or nitricacid.

AnnexLubricants


12 IndexAAssembly . . . . . . . . . . . . . . . . . . 58

CCable . . . . . . . . . . . . . . . . . . . . . 37Component groups . . . . . . . . . . . 21Connector

M12x1 . . . . . . . . . . . . . . . . . . 36Contact . . . . . . . . . . . . . . . . . . . . 7Contact protection measures . . . . . 40Copyright . . . . . . . . . . . . . . . . . . . 3Correct use . . . . . . . . . . . . . . . . . 10Customer service . . . . . . . . . . . . . 7

DDegree of protection

IP-Code . . . . . . . . . . . . . . . . . 37Device data plate . . . . . . . . . . . . . 68Device description . . . . . . . . . . . . 20Dimension sheet . . . . . . . . . . . . . 69Disassembly

disposal . . . . . . . . . . . . . . . . . 66Maintenance . . . . . . . . . . . . . 52

Disposal . . . . . . . . . . . . . . . . . . . 67

EElectrical connection . . . . . . . . . . 34Environmental protection . . . . . . . 17

Cleaning fluids . . . . . . . . . . . . 17Lubricants . . . . . . . . . . . . . . . 17

FFault table . . . . . . . . . . . . . . . . . . 48

GGeneral

safety . . . . . . . . . . . . . . . . . . . 8

HHazard

Electrical current . . . . . . . . . . . 11Hazards

mechanical . . . . . . . . . . . . . . 12Media . . . . . . . . . . . . . . . . . . 14Radiation . . . . . . . . . . . . . . . . 13Temperature . . . . . . . . . . . . . 13

IInitial startup . . . . . . . . . . . . . . . . 33Installation

pipe system . . . . . . . . . . . . . . 30preparation . . . . . . . . . . . . . . 26

Intended use . . . . . . . . . . . . . . . . 10

LLimitation of liability . . . . . . . . . . . . 3Lubricant . . . . . . . . . . . . . . . . . . 77

MMaintenance . . . . . . . . . . . . . . . . 57Maintenance plan . . . . . . . . . . . . 51Measuring range . . . . . . . . . . . . . 72

OOperating conditions . . . . . . . . . . 73Overview . . . . . . . . . . . . . . . . . . 20Owner . . . . . . . . . . . . . . . . . . . . 17

PPackaging . . . . . . . . . . . . . . . . . . 22Parts replacement . . . . . . . . . . . . 58Plug connection . . . . . . . . . . . . . . 38Plug connector

EN175301-803 . . . . . . . . . . . . 35Precautions

general . . . . . . . . . . . . . . . . . 11

Index


Preparationdevice . . . . . . . . . . . . . . . . . . 29

RRead-off . . . . . . . . . . . . . . . . . . . 45Replacement parts . . . . . . . . . 16, 74Return Materials Authorization . . . . 67

SSafety

Disassembly . . . . . . . . . . . . . 66Safety equipment . . . . . . . . . . 15, 16Safety instructions

Transport . . . . . . . . . . . . . . . . 22Sealant . . . . . . . . . . . . . . . . . . . . 76Service . . . . . . . . . . . . . . . . . . . . . 7Special tools . . . . . . . . . . . . . . . . 76Specifications

Change-Over Contact (COC) . . 71Normally Open Contact (NOC) . 71

Storage . . . . . . . . . . . . . . . . . . . 23Strainer . . . . . . . . . . . . . . . . . . . 29Switch contact . . . . . . . . . . . . . . . 21

replacement . . . . . . . . . . . . . . 64

Switch contact data plate . . . . . . . 68Switch point adjustment scale . . . . 21Switch point setting . . . . . . . . . . . 43Switch value . . . . . . . . . . . . . . . . 45Symbols

Packaging . . . . . . . . . . . . . . . 23Symbols used

in the instructions . . . . . . . . . . . 8

TTechnical data

General specifications . . . . . . 70Tightening torque . . . . . . . . . . . . . 74Tightening torque of screws . . . . . 74Tools . . . . . . . . . . . . . . . . . . . . . 76Transport inspection . . . . . . . . . . . 22

UUnimpeded flow section . . . . . . . . 27

WWarranty and guarantee provisions . 7

Index


Documents

DKM-2 Module BASICS Flow Monitor - dginstruments.com.au