© KROHNE 01/2006
7.02106.26.00
CMD
Installation and
operating instructions
DK 32
DK 34
All-metal
Miniature flowmeters
For explosion protected devices please refer to
Supplementary Installation an Operating Instructions:
DK3. /...
DK3. /...
Cat. II2G
Cat. II2GD
Cat. II3GD
with electr. built-in parts
Id. Nr. 710018##00
without electr. built-in parts Id. Nr. 702271##00
Electromagnetic flowmeters
Variable area flowmeters
Mass flowmeters
Ultrasonic flowmeters
Vortex flowmeters
Flow controllers
Level measuring instruments
Pressure and temperature
Heat metering
Communications technology
Switches, counters, displays and recorders
Engineering systems & solutions
Table of contents
1 General.................................................................................................................................... 4
1.1
Description code ................................................................................................................... 4
1.2
Marking................................................................................................................................. 5
1.3
Key for Pressure Equipment Directive .................................................................................. 6
1.4
Operating principle................................................................................................................ 6
2 Installation and Start-up ........................................................................................................ 7
3.1
Start-up................................................................................................................................. 7
5 Flow Table............................................................................................................................... 7
6 Materials.................................................................................................................................. 8
7 Technical Data DK 32 DK 34................................................................................................. 8
8 Product Temperature ............................................................................................................. 9
9 Dimensions and Weights..................................................................................................... 10
10
Limit Switches................................................................................................................... 10
10.1
Limit switch electrical connection .................................................................................... 10
10.2
Connecting the 2-wire limit switch (make contact) SB2-Z0 ............................................. 11
10.3
Setting the limit switches ................................................................................................. 13
10.4
Limit switch technical data .............................................................................................. 13
11
Differential pressure regulators ...................................................................................... 14
11.1
Applications..................................................................................................................... 14
11.2
Flow table - differential pressure regulators .................................................................... 14
11.3
Technical data - differential pressure regulators ............................................................. 15
11.4
Regulator characteristics................................................................................................. 15
11.5
Dimensions of differential pressure regulator .................................................................. 16
12
Spare parts list.................................................................................................................. 17
13
Maintenance ...................................................................................................................... 18
Returning a device to KROHNE
2
Installation and Operating Instructions DK 32-34
Product liability and warranty
The variable-area flowmeter is suitable for measuring the volumetric flow rate of liquids, gases
and steam. Special regulations are applicable to use in hazardous areas (see section “Scope of
supply”).
Responsibility as to suitability and intended use of these flowmeters rests solely with the
operator.
Improper installation or improper operation of the flowmeters may lead to the loss of warranty. In
addition, the “General conditions of sale” which form the basis of the purchase contract are
applicable.
The calculation of the pressurized parts is effected with allowance for corrosion, erosion through
abrasion or cavitation.
If the flowmeter needs to be returned to KROHNE Messtechnik, e.g. for repair, please follow the
instructions at the end of these installation and operating instructions.
Scope of supply
The scope of supply of the flowmeter in the version ordered includes:
•
Installation and Operating Instructions, Part No. 702106##00
For explosion protected devices refer to Supplementary Installation
and Operating Instructions:
•
DK3 . /...
Cat. II2G
with electrical components
Part No. 710018##00
•
DK3 . /...
Cat. II2GD II3GD
without electrical components
Part No. 702271##00
•
Supply without installation accessories
Special certificates (supplied to order only)
Test certificate to EN 10204:
•
•
•
Pressure test, surface crack dye penetrant inspection, leak test, ultrasonic testing, helium
leak test
Cleaning to factory specification
Calibration report
Note!
Connections which can be removed easily, such as threaded connections, screw-on reducers,
clamp connections, are not permitted in case of flammable or readily flammable media.
Installation and Operating Instructions DK 32-34
3
1
General
1.1
Description code
The description code consists of the following elements: 1)
D K
/
1
/
3
/
4
5
1:
Meter type series
32
:
Meter with needle valve and horizontal connections
34
:
Meter without needle valve and with vertical connections
2:
Differential pressure regulator
RE
:
Inlet pressure regulator
RA
:
Outlet pressure regulator
3:
Limit switch
K1
:
K2
:
one limit switch
two limit switches
4:
Types of connection
S
:
Plug connector with M16x1.5 (forerunner PG11)
L
:
Cable gland with cord grip incl. cable
5:
ATEX approval with limit switch
A
:
Limit switch EC type-tested
6:
Explosion protection (hazardous duty)
EEx
1) Places
4
/
2
:
Hazardous duty equipment to European Standard
for items not needed may be omitted from the description code
Installation and Operating Instructions DK 32-34
6
1.2
Marking
The type designation of the complete device is shown on the nameplate reproduced below (see
also Description code). Additional marking with the serial number is located inside the indicator.
SN:
Serial number
Example:
MD:
Year built
PS:
max. allowable operating
pressure at
max. allowable operating
temperature TS
PT max:
max. test pressure
TS:
max. operating temperature
PED:
Pressure Equipment Directive
key
Tag No.:
Metering point identification
Additional marking inside meter:
SO:
Sales order / item
KO:
KROHNE order No.
Vxxx…:
Product configurator code
AC:
Article code
Installation and Operating Instructions DK 32-34
5
1.3
Key for Pressure Equipment Directive
PED
1
/
/
2
3
1
Pressure Equipment Directive
2
Fluid
G
L
3
4
5
/
4
5
Gases, liquefied gases, gases dissolved under pressure, vapors and those
liquids whose vapor pressure at the maximum allowable temperature is more
than 0.5 bar above normal atmospheric pressure (1013 mbar).
Liquids whose vapor pressure at the maximum permissible temperature is not
more than 0.5 bar above the atmospheric pressure
Fluid group 1:
Explosive, extremely flammable, highly flammable, flammable (where
the maximum allowable temperature is above flashpoint), very toxic,
toxic, oxidizing.
Fluid group 2:
All fluids not specified in Group 1
Category
3.3
I
II
III
In accordance with Article 3.3 of Directive 97/23/EC
Category I to 97/23/EC
Category II to 97/23/EC
Category III to 97/23/EC
Conformity assessment
SEP
Solid engineering practice
A
Module A Internal production control
A1
Module A1 Internal production control with monitoring of final assessment
H
Module H Full quality assurance
The PED key is given on the nameplate.
1.4
Operating principle
The flowmeter operates on the float measuring principle. The
measuring section DK consists of a metal cone in which a float
can move freely up and down. The medium flows through the
flowmeter from bottom to top.
The float adjusts itself so that the buoyancy force A acting on it,
the form drag F and its weight G are in equilibrium (G = A + F).
The flow-dependent height of the float in the measuring section
is transmitted by means of a magnetic coupling and displayed
on a scale.
External magnetic fields can cause deviations in the measured
values.
6
Installation and Operating Instructions DK 32-34
2
Installation and Start-up
3
The variable-area flowmeter must be installed vertically (float measuring principle). The flow
direction must be from bottom to top. For installation recommendations
please refer also to VDE/VDI Code 3513, Sheet 3.
•
Before connecting, blow or flush out the pipe leading to the flowmeter.
•
Use connectors suitable for the particular version of the flowmeter. Align the pipes axially with
the connections on the flowmeter so that they are free of stresses. If necessary, the piping has
to be supported to prevent vibrations being transferred to the flowmeter.
•
Pipes for gas flow need to be dried before the flowmeter is installed.
3.1
Start-up
4
Compare the actual operating pressure and the process temperature of the system with the
figures given on the nameplate (PS and TS); these limits must not be
exceeded.
•
Make sure materials are compatible.
•
Close the needle valve on DK 32 flowmeter.
•
Slowly open the shutoff valve upstream and downstream of flowmeter.
•
In the case of liquid service: carefully vent the pipeline. In the case of
gas service: increase pressure slowly up to operating pressure. Avoid
float impact (e.g. caused by solenoid valves), as this is likely to
damage measuring section and float.
•
Open needle valve for DK 32 flowmeter and set the required flow rate.
The valve spindle is secured against unintentional disassembly (1).
5
Flow Table
Reference conditions:
Water at 20°C
Air at 20°C, 1013 bar abs.
100% flow values, turndown ratio 10:1
Cone
No.
K 005
K 010
K 015
K 040
K 080
K 125
K 200
K 300
K 340
Designation
K7
K5
K9
K4
K1
K2
K3
K6
K8
Valve spindle
diameter
mm
1.0
1.0
2.5
2.5
2.5
4.5
4.5
4.5
4.5
Water
Air
Max. pressure loss
l/h
l/h
3
5
10
25
40
60
80
100
50/16*
100
150
400
800
1250
2000
2500
3400
mbar
31
66
19
27
55
42
85
117
166
* with titanium float
Installation and Operating Instructions DK 32-34
7
6
Materials
Head and base, cone, top plug
Float
Valve
Plug gasket
Valve gasket
Housing
7
CrNi steel 1.4404 / 316 L
CrNi steel 1.4571, titanium
CrNi steel 1.4571
PTFE
PTFE
Die-cast aluminum
Technical Data DK 32 DK 34
Accuracy class
(to VDI/VDE Code 3513, Sheet 2)
Connections
Standard
Adaptors
4
1/4" NPT female thread
Ermeto 6 or 8, Serto 6 or 8,
Dilo, Gyrolok, Swagelok, G 1/4
Max. allowable operating pressure PS
Directive 97/23/EC of the Council dated 29 April 1999 concerning transportable pressure
equipment (pressure equipment directive) shall apply. The max. allowable operating pressure PS
is calculated for the max. allowable operating temperature TS. Both limit values (PS and TS) are
given on the nameplate.
Max. allowable test pressure PT
The maximum allowable test pressure has been calculated in accordance with Pressure
Equipment Directive (97/23/EC) and/or AD 2000-HP30. The calculation takes account of both
max. allowable operating pressure and maximum operating temperature.
Protection category
to EN 60529/IEC 60529
IP 65
8
Installation and Operating Instructions DK 32-34
8
Product Temperature
Maximum product temperatures as function of ambient temperatures
160
150
140
TM max. [°C]
130
DK32 DK34 M0
DK32/34/K/S
120
DK32/34/K/L
110
DK32/34/K1 Reed
100
90
80
-20
0
20
40
60
80
100
120
Tamb [°C]
Maximum product temperatures TS
DK32 DK34 M0
DK32 DK34 /K1/Reed contact
+200°C
+200°C
Minimum product temperatures TS
DK32 DK34 M0
DK32 DK34 /Kx/S
DK32 DK34 /Kx/L
DK32 DK34 /K1/Reed contact
-80°C
-20°C
-20°C
-40°C
Minimum ambient temperatures -20°C
Installation and Operating Instructions DK 32-34
9
9
Dimensions and Weights
Dimensions DK (in mm)
45
55
110
90
125
35
30
25
45
42
DK 32
Weight 0.7 kg
DK 34
Weight 0.6 kg
Dimensions DK with limit switches, [mm]
CAUTION:
When using several
flowmeters side by side, pay
attention to the lateral
dimensions!
It must be possible to undo
the cover bolts to adjust the
limit switches!
46
ca. 90
10
ca. 90
1500
ca. 50
ca. 44
Limit Switches
10.1 Limit switch electrical connection
The electrical connection for limit switches SC 2-N0, SJ 2-SN (S1N), SB 2-Z0 is effected
- in the plug connector of the flowmeter or
10
Installation and Operating Instructions DK 32-34
- using a precut cable with plug.
Connecting the slot sensors on connector plug:
• Undo screw (1) of the connector plug and pull out the plug
• Remove the screw (1) completely out of the plug
• Place a screwdriver into the marked opening (2) (Lift) and
remove the terminal block
• Thread the connecting cable through the cable gland.
• Insert the cable (max. 1.5 mm2) and screw down.
The cable gland is size M16x1.5. The cable diameter is 8 to 10mm (forerunner PG11 / 6…9mm).
After threading in the power cable, tighten down union nut of the cable gland.
Color marking when using precut cable:
min.+
yellow
min.white
max.+ brown
max.green
Reed contact connection:
Version A
brown
Version B
brown
blue
blue
yellow/green
red
10.2 Connecting the 2-wire limit switch (make contact) SB2-Z0
The limit switches require auxiliary power of 5…30 V DC. They can be connected directly to a PLC
system.
Ub
Installation and Operating Instructions DK 32-34
11
Connection diagram
Output I
NAMUR
SC2 -N0
Output II Mains
LED yellow ouput
LED green power
Switch S1
Effective dir.
LED red LB/LK
Switch S2
Effective dir. II
Switch S3
LB/LK identification
LB : Line interruption
LK : Line short circuit
12
intrinsically safe *
SJ 2-SN and SJ 2-S1N
Output III
II
Output I
Mains
LED yellow
Relay output
LED red
LB/LK ident.
LED green
Power
* Intrinsicaly safe isolating switch amplifier one-channel
only
Installation and Operating Instructions DK 32-34
10.3 Setting the limit switches
•
Simply set the pointers to the required limit as min. contact
(1) and max. contact (2) using a slip coupling along the
scale.
Instrument view without housing cover
Adjusting the limit switch with reed contact:
Undo nut (1). Set reed cartridge to required value and secure
with nut (1).
The reed contact is actuated directly by the float
magnet. The required operating point can only be
established in measuring mode.
A reference to the scale and/or pointer cannot be
established.
1
10.4 Limit switch technical data
SC 2-N0
NAMUR NC
contact
8V
SJ 2-SN *
NAMUR NC
contact
8V
Pointer shaft not read
Pointer shaft read
Continuous current
Voltage drop
≥3 mA
≤1 mA
-
≥3 mA
≤1 mA
* inverted:
SJ 2-S1N
Reed contact technical data
Type of contact
Switch reproducibility
Switch rating
max. switching voltage
max. switch current
Protection category to EN 60529/IEC
529
Bistable reed contact
<5% of full scale value
12 VA
30 VDC
0.5 A
IP 65
Switch configuration
Nominal voltage U0
SB 2-Z0 (with LED)
PNP NO contact
5…30 V
Power consumption
Installation and Operating Instructions DK 32-34
max. = 50 mA
≤ 4.9 V
13
11
Differential Pressure Regulators
Differential pressure regulators are used (DK32 only) to help maintain constant flow rates at
fluctuating inlet or outlet pressures. Minimum pressure levels are required to permit operation of
the regulators (see Regulator characteristics).
Important information!
Differential pressure regulators are not pressure reducing valves!
11.1 Applications
Inlet pressure regulators, type RE, NRE
The regulators maintain a constant flow rate at variable inlet pressure and constant outlet
pressure.
Example:
Inlet pressure regulator RE 1000:
Current flow rate:1000 Nl air
Constant outlet pressure: 1.013 bar abs.
With a variable inlet pressure greater than 0.5 bar the flow rate Qv in the device remains constant.
Outlet pressure regulators, type RA, NRA
The regulators maintain a constant flow rate at constant inlet pressure and variable outlet
pressure. In order to function, there must be a specific minimum pressure difference between inlet
and outlet pressures (please refer to section 9.2).
Inlet pressure p1 must always be greater than outlet pressure p2.
Example:
Outlet pressure regulator NRA 800
Constant inlet pressure:
Current flow rate:800 Nl air
3 bar
With a variable outlet pressure of 0...2.9 bar the flow rate Qv in the device remains constant.
11.2 Flow table - differential pressure regulators
Reference conditions
Type
Inlet pressure RE
RE-1000
RE-4000
NRE-100
NRE-800
Outlet pressure
RA
RA-1000
RA-4000
Air at 20°C, 1013 bar abs.
Water at 20°C
Max. flow
Water
Air
l/h
l/h
3…40,0
100…1000
50...80
1500...2000
100
120...160
3000...4800
1...2.5
60...100
250
250
500...800
min. pressure differential ∆p
3...40
60...100
100...1000
2000...3000
14
min. inlet pressure p1
bar
0.5
1.0
1.5
2.0
0.1
0.1
0.2
0.5
1.0
1.5
Installation and Operating Instructions DK 32-34
120...160
1
NRA-800
4800
60...250
500
800
20...25
2.0
0.1
0.2
0.,4
11.3 Technical data - differential pressure regulators
Connection
Standard
Optional
Max. operating pressure
(at 20°C)
Material
Temperature
Standard
Optional
Optional
1/4" NPT
Serto 6 or 8,
Tubing sockets 6 or 8 mm,
Ermeto 6 or 8,
Dilo, Gyrolok, Swagelok, G 1/4
64 bar
100 bar
CrNi steel 1.4404
max. 80°C
150°C
11.4 Regulator characteristics
Inlet pressure regulators, type RE and NRE
Outlet pressure regulators, type RA and NRA
l/h
l/h
Qv
Qv
Inlet pressure p1 [bar]
Outlet pressure p2 [bar]
Qv = current flow rate
Important information!
When measuring liquids, particularly water and aqueous solutions, prevent the
product from freezing, as this can destroy the regulator.
Installation and Operating Instructions DK 32-34
15
11.5 Dimensions of differential pressure regulator
Dimensions [mm]
a
approx. 230
b
approx.163
c
approx. 13
d
70
e
19
DK32 with differential pressure regulator is supplied without tube bends on the process connection
end (1) as standard.
16
Installation and Operating Instructions DK 32-34
12
Spare parts list
Description
Needle valve new version
Drive spindle
Drive spindle
Dosing unit diameter 1.0
<100 Nl/h air, <5 l/h water
Article No.
Gasket Viton / PTFE.......................... XG46030100
Gasket FFKM .................................... XG46030300
Gasket Viton ...................................... XG46030500
Gasket PTFE..................................... XG46030600
Gasket FFKM .................................... XG46030700
Gasket Viton ...................................... XG46030800
Gasket PTFE..................................... XG46030900
Gasket FFKM .................................... XG46031000
Gasket Viton ...................................... XG46031100
Gasket PTFE..................................... XG46031200
Gasket FFKM .................................... XG46031300
Dosing unit diameter 2.5
<1000 Nl/h air, <50 l/h water
Dosing unit diameter 4.5
<4000 Nl/h air, <100 l/h water
Dosing valve 1.0 mm "rigid type"
Gasket Viton ................................................
Dosing valve 2.5 mm "rigid type"
Gasket Viton ................................................
Dosing valve 4.5 mm "rigid type"
Gasket Viton ................................................
Dosing valve PEEK 2.5 mm “rigid type” Gasket Viton ................................................
XG46032100
XG46032200
XG46032300
XG46033100
Indicator housing complete, without scale
Housing cover, painted
........................................................... XG46010100
........................................................... XG46011100
Housing gasket (silicone)
Viewing window
........................................................... XG46011300
........................................................... XG46011500
Connector plug complete with PG11 cable gland
XG46022100
Gasket sealing plug PTFE
Gasket sealing plug FFKM
........................................................... XG46041100
........................................................... XG46041200
Inlet pressure regulator
Regulator RE 1000 R, stainless steel
Regulator RE 4000 R, stainless steel
........................................................... XG30091100
........................................................... XG30091300
Outlet pressure regulator
Regulator RA 1000 R, stainless steel
Regulator RA 2500 R, stainless steel
........................................................... XG30092100
........................................................... XG30092300
Inlet pressure regulator
Regulator NRE 100 R, stainless steel
Regulator NRE 800 R, stainless steel
........................................................... XG30093100
........................................................... XG30093300
Outlet pressure regulator
Regulator NRA 800 R, stainless steel
........................................................... XG30094100
Installation and Operating Instructions DK 32-34
17
13
Maintenance
Within the scope of routine maintenance of the system and pipelines, the flowmeter should also be
inspected for signs of fouling, corrosion, mechanical wear and leaks, as well as damage to the
measuring tube and indicator. We advise that inspections be carried out at least once a year. The
device must be removed from the piping before cleaning.
Caution!
Pressurized pipes are to be depressurized before removing the
device.
In the case of flowmeters used for measuring aggressive or
hazardous products, appropriate safety precautions must be taken
regarding of residual liquid in the measuring section.
Always use new gaskets when reinstalling the flowmeter in the
pipeline.
Open needle valve for DK 32 flowmeter and set the required flow
rate. The valve spindle is secured against unintentional
disassembly (1).
Press on this security pin (against internal spring) to allow the
valve spindle to be removed.
Caution
The valve packing gland may have to be adjusted under certain circumstances
during its service life. To do so, the union nut has to be retightened, applying a
maximum tightening torque of 5 Nm.
Caution
Valves that have not been actuated for a longer period of time may exhibit a higher
initial actuation torque.
18
Installation and Operating Instructions DK 32-34
Returning a device for testing or repair to KROHNE
This device has been carefully manufactured and tested. If installed and operated in accordance with these instructions,
it will rarely present any problems. Should you nevertheless need to return a device for inspection or repair, please pay
strict attention to the following points:
Due to statutory regulations concerning protection of the environment and the health and safety of our personnel,
KROHNE may only handle, test and repair returned flowmeters that have been in contact with liquids if it is possible to
do so without risk to personnel and environment.
This means that KROHNE can only service this device if it is accompanied by the following certificate confirming that
the device is safe to handle.
If the device has been operated with toxic, caustic, flammable or water-endangering products, you are kindly requested:
• to check and ensure, if necessary by rinsing out or neutralizing, that all cavities are free from such dangerous
substances.
• to enclose a certificate with the device confirming that is safe to handle and stating the product used.
KROHNE regret that they cannot service your device unless accompanied by such a certificate. Thank you for your
understanding.
F O R M S H E E T (for copying)
Company:
………………………………………………………….
Address: ………………………………………………………….
Department:
……………………………………………………..
Name: …………………………………………………………….
Tel. No. ……………………………………………………….
Fax No. …………………………………………………………..
The enclosed flowmeter,
Type:
……………………………………………………………………………………………………………………………………..
KROHNE Commission or Series No.: ………………………………………………………………………………………….
has been operated with the following liquid: ……………………………………………………………………
Because this liquid is:
c water-endangering
c toxic
c caustic
c flammable
we have:
c checked that all cavities in the device are free of such substances
c flushed out and neutralized all cavities in the device
We confirm that there is no risk to man or environment through any residual liquid contained in this flowmeter.
Date: ……………………………………
Signature: …………………………………………………………………………
Company stamp:
Installation and Operating Instructions DK 32-34
19
20
Installation and Operating Instructions DK 32-34