dwg module basics flow monitor
TRANSCRIPT
DWG Module BASICSFlow Monitor
Operating instructions
Series DWGType DWG-1,5 thru 50
Read this manual prior to performing any task!
DWG Modul BASICS, 2, en_US
© Meister Strömungstechnik GmbH 2018
Meister Strömungstechnik GmbH
Im Gewerbegebiet 2
63831 Wiesen
Germany
Telephone: +49 6096 9720 - 0
Fax: +49 6096 9720 - 30
E-mail: [email protected]
Internet: www.meister-flow.com
These instructions were compiled by:
Meister Strömungstechnik GmbH
Subject to change without notice
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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 replacementparts
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 directives
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Table of contents1 Overview................................................................................................... 10
1.1 Short description................................................................................ 101.2 Warranty and guarantee provisions................................................... 101.3 Customer service............................................................................... 10
2 Safety......................................................................................................... 112.1 Explanation of symbols...................................................................... 112.2 Correct use in accordance with these instructions............................ 132.3 Special precautions........................................................................... 142.3.1 Hazards from electrical current....................................................... 152.3.2 Mechanical hazards........................................................................ 152.3.3 Hazards from high or low temperatures......................................... 162.3.4 Radiation hazards........................................................................... 172.3.5 Hazards caused by media.............................................................. 172.4 Personnel requirements.................................................................... 182.5 Personal safety equipment................................................................ 182.6 Protective systems............................................................................ 192.7 Replacement parts............................................................................ 202.8 Environmental protection................................................................... 202.9 Responsibility of the owner................................................................ 21
3 Design and function................................................................................. 233.1 Overview............................................................................................ 233.2 Device description............................................................................. 233.3 Component description...................................................................... 24
4 Transport, packaging and storage......................................................... 254.1 Safety instructions for transport......................................................... 254.2 Transport inspection.......................................................................... 254.3 Packaging.......................................................................................... 254.4 Symbols on the shipping box............................................................. 264.5 Storage.............................................................................................. 26
5 Installation und initial startup................................................................. 285.1 Safety................................................................................................ 28
Table of contents
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5.2 Requirements at the place of installation........................................... 285.3 Preparatory work............................................................................... 295.4 Installation in the pipe system........................................................... 335.5 Initial startup...................................................................................... 375.6 Electrical connection.......................................................................... 385.6.1 Switch contact SG-30 with connector in compliance with
EN175301-803............................................................................... 395.6.2 Switch contact SG-30 with plug connector M12x1......................... 405.6.3 Switch contact SG-30 with cable.................................................... 415.6.4 Degree of protection (IP-Code)...................................................... 425.7 Grounding the device........................................................................ 425.8 Plug connection................................................................................. 435.9 Contact protection measures............................................................. 45
6 Operation.................................................................................................. 476.1 Setting the switch point...................................................................... 476.2 Checking the flow.............................................................................. 49
7 Troubleshooting....................................................................................... 517.1 Safety................................................................................................ 517.2 Troubleshooting guide....................................................................... 53
8 Maintenance............................................................................................. 558.1 Safety................................................................................................ 558.2 Maintenance plan.............................................................................. 558.3 Removal from the pipe system.......................................................... 568.4 Disassembly...................................................................................... 588.5 Maintenance...................................................................................... 618.5.1 Cleaning......................................................................................... 628.5.2 Parts replacement.......................................................................... 638.5.3 Assembly........................................................................................ 638.5.4 Switch contact replacement............................................................ 708.6 Measures to be taken after maintenance work.................................. 72
9 Disassembly and disposal...................................................................... 739.1 Safety................................................................................................ 739.2 Disassembly...................................................................................... 73
Table of contents
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9.3 Return Materials................................................................................ 749.3.1 Return Materials Authorization....................................................... 749.4 Disposal............................................................................................. 74
10 Technical data.......................................................................................... 7510.1 Device data plate............................................................................. 7510.2 Switch contact data plate................................................................. 7510.2.1 Switch contact data plate for UL Recognized switch contacts..... 7510.3 Dimension sheet.............................................................................. 7610.4 General specifications..................................................................... 7710.5 Electrical specifications................................................................... 7910.5.1 Electrical specifications for UL Recognized devices.................... 8010.6 Measuring ranges............................................................................ 8110.6.1 Standard measuring ranges......................................................... 8110.7 Operating data................................................................................. 82
11 Annex........................................................................................................ 8411.1 Tightening torque of screws............................................................. 8411.2 Replacement parts........................................................................... 8411.3 Tools................................................................................................. 8611.4 Sealant............................................................................................. 8611.5 Lubricants........................................................................................ 87
12 Index.......................................................................................................... 88
Table of contents
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List of figuresFig. 1: DWG flow monitor........... 10
Fig. 2: Front view........................ 23
Fig. 3: Switch contact andfemale socket.................. 24
Fig. 4: Sight glass....................... 24
Fig. 5: Installation position/direc-tion of flow....................... 29
Fig. 6: Unimpeded flow section.. 31
Fig. 7: Unimpeded outlet............ 31
Fig. 8: Strainer............................ 32
Fig. 9: Apply sealing thread........ 35
Fig. 10: Pipe connection withsealing thread.................. 35
Fig. 11: Screw in the device......... 36
Fig. 12: Screw in the device......... 36
Fig. 13: Switch position under no-flow condition.................. 39
Fig. 14: Pin assignment, plugsocket, normally-opencontact. The ground-pinis not used....................... 39
Fig. 15: Switch position under no-flow condition.................. 39
Fig. 16: Pin assignment, plugsocket, change-over con-tact. The ground-pin isnot used.......................... 39
Fig. 17: Pin-assignment, socketM12x1 (Form 30x70)....... 40
Fig. 18: Switch position under no-flow condition.................. 40
Fig. 19: Switch position under no-flow condition.................. 40
Fig. 20: Switch position under no-flow condition.................. 41
Fig. 21: Switch position under no-flow condition.................. 42
Fig. 22: Detach socket................. 43
Fig. 23: Remove socket............... 43
Fig. 24: Loosen inner section....... 43
Fig. 25: Loosen the screw con-nection............................. 44
Fig. 26: Pin assignment, plugsocket, normally-opencontact (SG-30 with con-nector in compliance withEN175301-803)............... 44
Fig. 27: Pin assignment, plugsocket, change over con-tact (SG-30 with con-nector in compliance withEN175301-803)............... 45
Fig. 28: Example 1....................... 45
Fig. 29: Example 2....................... 45
Fig. 30: Protective measureagainst capacitive loads.. 46
Fig. 31: Example 1....................... 46
Fig. 32: Example 2....................... 46
Fig. 33: Loosen set screws.......... 47
Fig. 34: Loosen set screws.......... 48
Fig. 35: Reading-off the meas-uring scale....................... 49
Fig. 36: Loosen screws................ 59
Fig. 37: Remove the process con-nection (outlet)................ 59
Fig. 38: Slot nozzle buffer O-ring.................................. 60
Fig. 39: Loosen screws................ 60
Fig. 40: Remove the inner sec-tion.................................. 61
List of figures
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Fig. 41: Remove slot nozzle......... 61
Fig. 42: O-ring (seal).................... 63
Fig. 43: O-ring (glass buffer)........ 64
Fig. 44: Position of O-rings........... 64
Fig. 45: O-ring (centering the slotnozzle)............................. 64
Fig. 46: Insert slot nozzle............. 65
Fig. 47: Centering the slotnozzle.............................. 65
Fig. 48: Float................................ 66
Fig. 49: Process connection(Inlet)............................... 66
Fig. 50: Spanner flats................... 67
Fig. 51: Insert the process con-nection into the devicehousing............................ 67
Fig. 52: Secure the process con-nection (inlet)................... 67
Fig. 53: Align slot nozzle.............. 68
Fig. 54: O-ring, slot nozzlebuffer............................... 68
Fig. 55: Position the outletprocess connection......... 69
Fig. 56: Tighten hex socketscrews............................. 69
Fig. 57: Check for free move-ment................................ 70
Fig. 58: Loosen female socket..... 70
Fig. 59: Remove the femalesocket.............................. 70
Fig. 60: Loosen set screws.......... 71
Fig. 61: Release the guide rail .... 71
Fig. 62: Rotate guide rail to theside.................................. 71
Fig. 63: Remove switch contact... 71
Fig. 64: Device data plate............ 75
Fig. 65: Switch contact ratingplate................................ 75
Fig. 66: Switch contact ratingplate with positioningarrow .............................. 75
Fig. 67: Switch contact dataplate................................ 75
Fig. 68: Adhesive label, switchcontact with positioningarrow .............................. 75
Fig. 69: Replacement partsdrawing............................ 85
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List of tablesTable 1: Correct use in non-
hazard areas................... 13Table 2: Correct use of UL Rec-
ognized Components innon-hazard areas........... 13
List of tables
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1 Overview1.1 Short description
Fig. 1: DWG flow monitor
1 Sight glass with measuring scale2 Female socket or connection
cable
The flow monitor DWG 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. Thecurrent rate of flow can be read-off onthe measuring scale on the sight glass.The top edge of the float is the read-offpoint.
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 Meister Strömung-stechnik.
1.3 Customer serviceFor technical support, please contactour customer service department (forcontact details, see Page 2).
Furthermore, our staff is always inter-ested in receiving new information andexperiences gained from application ofthe device, which may be useful inimproving our products.
Overview
Customer service
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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 safetyinstructions are preceded by signalwords that indicate the level of danger/hazard.
To prevent accidents or injury 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 condition thatresults in death or serious injuryif it is not avoided.
WARNING!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in death or serious injuryif it is not avoided.
Safety
Explanation of symbols
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CAUTION!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in minor or slight injury ifit is not avoided.
NOTICE!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in damage to propertyand to the environment if it isnot avoided.
Tips and recommendations
This symbol emphasizes usefultips and recommendations aswell as information for efficientand failure-free operation.
Signs used in these instructions
The following signs and highlightingsare 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 12, designates references tochapters in these instructions
Safety
Explanation of symbols
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2.2 Correct use inaccordance withthese instructions
The device has been designed andconstructed solely for the correct usein accordance with these instructions.
Table 1: Correct use in non-hazardareas
The flow monitor serves exclusivelyto monitor the continuous flow of liq-uids within a temperature range of-20 °C to 100 °C (optional: 160 °C)at a maximum operating pressure of10 bar.
Table 2: Correct use of UL RecognizedComponents in non-hazard areas
The flow monitor serves exlusively tomonitor the continuous flow of liquidswithin a temperature range of -15 °Cto 100 °C at a maximum operatingpressure of 10 bar.
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 "DWG Module ATEX".
Intended use in explosion-hazardzones includes the observance of allspecifications in these OperatingInstructions, as well as those for "DWGModule ATEX"
Any additional or different application,above or beyond the correct use inaccordance with these instructions, isdeemed as incorrect use.
WARNING!
Danger due to incorrect use!Incorrect use of the flow mon-itor may result in dangerous sit-uations.
– Use the flow monitor onlywithin the stipulated per-formance limits
– Do not subject the flowmonitor to severe tempera-ture fluctuations
– Do not use the flow monitorwith quick-acting valves
– Do not use the flow monitorwith solenoid valves
– Do not subject the flowmonitor to vibrations
– Do not subject the flowmonitor to pressure surges
– Do not use the flow monitorwith media containingsolids or abrasives
– Only use the flow monitorwith media previouslyapproved by the manufac-turer
Safety
Correct use in accordance with these instructions
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– Do not use the flow monitoras the sole monitoringdevice to prevent dan-gerous conditions
– Do not install the flow mon-itor as a load bearing partwithin a pipeline system
– The flow monitor with sightglass must be installed insuch a way as to precludedamage to the sight glassby outside force. If neces-sary, install an appropriateimpact protection device
All claims for damages due to incorrectusage are excluded.
2.3 Special precautionsThe following section lists residualrisks that might arise from the device.
To reduce health risks and preventdangerous conditions, 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 ofthe Operating Instructions for"DWG Module ATEX"including all hazard state-ments and warnings, therein.
These operating instructionscannot cover all conceivabledangers because many dan-gers arise, not from the deviceitself, but from the respectivemedia flowing through it.Always observe the appropriatesafety data sheets when usinghazardous media!
Safety
Special precautions
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2.3.1 Hazards from elec-trical current
Electrical current
DANGER!
Danger to life from electricalcurrent!There is an immediate risk tolife from electrocution ontouching live parts. Damagedelectrical insulation or compo-nents can be extremely dan-gerous.
– Only qualified electriciansshall work on the electricalsystem.
– If the insulation is dam-aged, immediately switchoff and have repairs per-formed.
– Before commencing workon live parts of the elec-trical systems and oper-ating equipment, discon-nect the equipment andensure that it remains dis-connected for the durationof the work. Observe these5 safety rules when doingso:– Isolate (disconnect)– Secure against
switching back on– Check for absence of
voltage– Ground and short
– Cover or cordon offother live parts in thevicinity
– Never bridge fuses or putthem out of operation.Always observe the correctcurrent ratings whenreplacing fuses
– Keep moisture away fromlive parts. This can result inshort-circuit
2.3.2 Mechanical hazards
WARNING!
Risk of injury from glassbreakage!The sight glass in the flow mon-itor can burst due to excessivetemperature or pressure. Thereis a risk of injury from glasssplinters and escaping media.
– Keep within the stipulatedoperating limits
– Wear personal protectiveequipment
– Avoid severe temperaturefluctuations
– Avoid pressure surges
Safety
Special precautions > Mechanical hazards
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WARNING!
Risk of injury on sharp edgesand pointed corners!Sharp edges and pointed cor-ners can cause abrasions andskin cuts.
– Proceed with caution whenworking near sharp edgesand pointed corners.
– If in doubt, wear protectivegloves.
2.3.3 Hazards from highor low temperatures
Hot or cold surfaces
WARNING!
Risk of injury from hot orcold surfaces!Surfaces of components mayheat up/cool down dramaticallydue to the media flowingthrough them. Skin contact withhot or cold surfaces may causesevere skin burn or frostbite.
– Always wear temperature-resistant protective workclothing and protectivegloves when working nearhot/cold surfaces
– Before commencing work,make sure that all surfaceshave been cooled down orwarmed up to ambient tem-perature
Safety
Special precautions > Hazards from high or low temperatures
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2.3.4 Radiation hazardsStrong magnetic fields
WARNING!
Danger to life from strongmagnetic fields!Strong magnetic fields maycause severe injury or even befatal, as well as cause consider-able damage to property.
– Persons with pacemakersmust not be located in thevicinity of the device. Thiscould impair the function ofthe pacemaker
– Persons with metalimplants must not belocated in the vicinity of thedevice. Implants can heatup or be attracted magneti-cally
– Keep ferromagnetic mate-rials and electromagnetsaway from the magneticsource. These materialscould be attracted and flythrough the room, therebyinjuring or even killing per-sons. Minimum clearance:3 m
– Remove and put awaymetal objects before main-tenance work (jewelry,watches, writing imple-ments, etc.)
– Do not place any electronicdevices within the vicinity ofthe magnetic source.These could be damaged
– Do not place any electronicstorage media, creditcards, etc. within thevicinity of the magneticsource. Data could bedeleted
2.3.5 Hazards caused bymedia
Hazardous media
WARNING!
Risk of injury from hazardousmedia!If the flow monitor is used fortoxic, corrosive or very hot/coldmedia, there is a risk of seriousinjury from escaping media.
– Observe details in thesafety data sheet of themedia
– Comply with the safety,accident prevention andenvironmental protectionregulations appropriate tothe media used
– Wear personal protectiveequipment in accordancewith the safety data sheet
Safety
Special precautions > Hazards caused by media
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2.4 Personnel require-ments
WARNING!
Risk of injury due to insuffi-ciently trained and qualifiedpersonnel!If unqualified personnel work onthe device or are located withinits hazard zone, dangers arisewhich may result in seriousinjury and considerabledamage to property.
– All work must be performedby qualified personnel only.
– Keep unqualified personnelaway from hazard zones.
Authorized personnel is to berestricted to those persons who can beexpected to perform their work reliably.Persons whose ability to respond isinfluenced, e.g. by drugs, alcohol ormedication, are not authorized.
Observe the age and occupational reg-ulations at the site when choosing per-sonnel.
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,knowledge and experience as well astheir knowledge of the relevant stand-ards and regulations, qualified per-sonnel are able to independently per-form the work assigned to them as wellas to detect and avoid possible risksand dangers.
2.5 Personal safetyequipment
Personal safety equipment is used toprotect personnel from hazards or dan-gers that might impair their safety orhealth during work.
Safety
Personal safety equipment
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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
As specified in the Safety DataSheet of the medium, protectiveequipment must be worn when han-dling hazardous media. In addition,the specifications of the systemoperator must be followed. If noprotective equipment is specified,suitable protective gloves and gog-gles must be worn.The protective equipment is used toprotect against hazardous media leaksand hazardous media residue in thedevice.
Goggles
The goggles are used to protect theeyes from flying debris and splashingfluid.
Protective gloves
Protective gloves protect the handsfrom friction, burns, grazing, abrasion,surface cuts or deeper injuries, as wellas from direct contact with hot or coldsurfaces.
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.
Safety
Protective systems
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2.7 Replacement parts
WARNING!
Risk of injury due to use ofincorrect replacement parts!Use of incorrect or faultyreplacement parts may result indangers to personnel as well asdamages, malfunctions or totalfailure.
– Only use original replace-ment parts from the manu-facturer or approved by themanufacturer.
– Always contact the manu-facturer in case of doubt.
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 dueto improper handling of envi-ronmentally hazardous sub-stances!Serious environmental damagemay result if substancesharmful to the environment arehandled incorrectly, especially ifthey are disposed of improperly.
– Always observe the instruc-tions listed below on thehandling and disposal ofsubstances harmful to theenvironment.
– If harmful substances arereleased into the environ-ment, take immediatecountermeasures. If thereis doubt, contact the localauthorities, inform them ofthe damage and requestinformation on suitablecountermeasures 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.
Safety
Environmental protection
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Lubricants
Lubricants such as greases and oilscontain toxic substances. They mustnever be released into the environ-ment and must be disposed of by awaste management company.
2.9 Responsibility ofthe owner
Owner
The owner is the person who operatesthe device himself for business orcommercial purposes or who cedessuch use/application to a third-partyand who, during operation of thedevice, has full legal product steward-ship for protection of the user, the per-sonnel or third-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.
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 per-form a risk assessment to addi-tionally determine the risksresulting from the special work
conditions arising at the location atwhich the device is used, espe-cially in regard to the media used.He must then implement thesewithin Operating Instructions foruse of the device.
n For the USA: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 For Canada:The "Canadian Centre for Occupa-tional Health and Safety Act" of1978 stipulates that all Canadianshave “…a fundamental right to ahealthy and safe working environ-ment.” It is therefore the duty ofthe owner to provide a safe work-place. He must ensure that thedevice is operated and maintainedcompliant to valid commercial,industrial, local, provincial, territo-rial and federal laws, standardsand 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.
Safety
Responsibility of the owner
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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 theseinstructions before handling thedevice. Additionally, he must trainthe personnel at regular intervalsand warn 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.
Safety
Responsibility of the owner
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3 Design and function3.1 Overview
Fig. 2: Front view
1 Process connection (outlet)2 Device body3 Sight glass with measuring scale4 Float5 Process connection (inlet)6 Slot nozzle7 Switch contact and female socket
or switch contact with cable
3.2 Device descriptionDWG flow monitors operate on theprinciple of the variable area flow-meter. The flow monitor is installed intoa pipe system and measures the flowrate of the medium flowing through thepipe system.
A float inside the flow monitor ismoved by the flowing medium. A mag-netic field is generated by the magnetsinside the float. The position of thefloat is detected by the switch contact.In addition to electrical control by theReed-contact (switch contact), the cur-rent flow can also be read-off on themeasuring scale on the sight glass.
Applications for DWG flow monitorsare, for example, cooling circuits. Thedevice monitors the volume flow of thecooling media to ensure sufficientcooling. If the flow drops below thethreshold preset by the operator, theswitch contact (change-over contact)switches or opens (normally open con-tact).
Design and function
Device description
03.09.2018 DWG Module BASICS Flow Monitor 23
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).
Sight glass
Fig. 4: Sight glass
A measuring scale is burnt onto thesight glass, from which the current rateof flow can be read-off.
Design and function
Component description
03.09.2018DWG Module BASICS Flow Monitor24
4 Transport, packaging and storage4.1 Safety instructions
for transport
Improper transport
NOTICE!
The device could be dam-aged if transported improp-erly!Objects to be transported mayfall or overturn if transportedimproperly. This may result indamage to the device and/orproperty.
– Proceed carefully whenunloading transportedpackages, both on deliveryand when transporting in-house. Observe the sym-bols and instructions on theshipping box
– Remove packaging mate-rial just prior to 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, 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. Claimsfor damages can only beinvoked within the valid claimperiods.
4.3 PackagingPackaging
The packaging serves to protect theindividual components from transportdamages, corrosion and other dam-ages until they are installed. Do notdiscard the packaging and onlyremove the device from the shippingbox immediately before installation.
Transport, packaging and storage
Packaging
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Handling packaging materials
Dispose of packaging material inaccordance with the valid legal regula-tions and local ordinances.
NOTICE!
Danger to the environmentdue to incorrect disposal!Packaging is made of valuableraw materials and can bereused in many cases or use-fully processed and recycled.Improper disposal of packagingmaterials may pose a danger tothe environment.
– Dispose of packagingmaterial in an environmen-tally safe manner
– Comply with the local dis-posal regulations. If neces-sary, have the packagingdisposed of by approvedspecialists.
4.4 Symbols on theshipping box
Top
The arrows indicate the top side of thepackage. They must always pointupwards, otherwise the content maybe damaged.
Fragile
Designates packages with breakableor damageable contents.
Handle the package carefully and donot allow it to fall or be subjected tojarring 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 °C /
32 °F to 95 °Fn 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 storage
Storage
03.09.2018DWG Module BASICS Flow Monitor26
Storage instructions in additionto the instructions listed heremay be listed on the packages.Follow these instructions also.
Transport, packaging and storage
Storage
03.09.2018 DWG Module BASICS Flow Monitor 27
5 Installation und initial startup5.1 SafetyIncorrect installation and initialstartup
WARNING!
Risk of injury due to incorrectinstallation and initialstartup!Incorrect installation and initialstartup may result in severeinjury and considerabledamage to property.
– Ensure that the site is suffi-ciently cleared of obstruc-tions before commencingwork
– Handle open or sharpedged components care-fully
– Ensure that the assemblylocation is orderly andclean! Parts and tools lyingabout or on top of eachother are potential causesfor accidents
– Assemble componentsproperly. Observe the stipu-lated tightening torque ofscrews
– Before initial startup, makesure that all installationwork has been performedand completed in compli-ance with the specificationsand instructions in theseOperating Instructions
Safeguard against restart
WARNING!
Danger to life due to unau-thorized restart!There is a risk of severe oreven fatal injury due to unau-thorized restart of the powersupply during installation.
– Before commencing work,switch off the power supplyto the entire system/plantand secure against restart
5.2 Requirements at theplace of installation
The place of installation must meetthe following 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 und initial startup
Requirements at the place of installation
03.09.2018DWG Module BASICS Flow Monitor28
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 of ferromagneticmaterial influence the magneticfield of the device. Keep a spaceof at least 100 mm to those mate-rials (e.g. steel).
Requirements for the environmentalconditions when using UL Recog-nized Components :
n indoor usen altitude up to 2000 mn temperature -15°C to 100°Cn max. relative humidity 80 % for
temperatures up to 31 °Cdecreasing linearly to 50 % rela-tive humidity at 40 °C
n mains supply voltage fluctuationsup to +/-10 % voltage
n overvoltage category IIn pollution degree 2
5.3 Preparatory workThe following requirements must bemet during installation to ensure cor-rect functioning of the flow monitor:
WARNING!
Danger due to incorrectinstallation!If the requirements listed aboveare not observed when instal-ling the flow monitor, dan-gerous/hazardous conditionsmay arise.
– Do not install the flow mon-itor as a supporting part ina pipe system
– 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 und initial startup
Preparatory work
03.09.2018 DWG Module BASICS Flow Monitor 29
The flow monitor must only be installedin one of the positions displayedabove. The medium must flow in thedirection of the arrow (from a low to ahigh scale value).
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 pipesystem impair measuring accu-racy.
– Ensure that the unimpededflow sections are main-tained
– Never reduce the pipediameter immediatelybefore the device
We recommend unimpededflow sections, type BS-228.
Installation und initial startup
Preparatory work
03.09.2018DWG Module BASICS Flow Monitor30
Fig. 6: Unimpeded flow section
1 10 x DN2 5 x DN
n An unimpeded flow section of 10 xDN (rated width) must be main-tained before the device.
n An unimpeded flow section of 5 xDN (rated width) must be main-tained after the 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.
Installation und initial startup
Preparatory work
03.09.2018 DWG Module BASICS Flow Monitor 31
Strainer
Fig. 8: Strainer
1 min. 10 x DN2 min. 5 x DN
If the medium is contaminated bysolids, a strainer must be installed atthe input side of the device (Fig. 8).
We recommend a Type SF,SFD or SFM.
Prepare the device
NOTICE!
Risk of damage to propertydue to contamination!Contamination and depositsmay impair the free movementof the float, thereby damagingthe device.
– Ensure that there are noforeign particles in thedevice
– Ensure that the device isnot soiled
– Do not use any mediumcontaining solids
Due to quality assurance meas-ures, there may be some testmedium (water) residue in thedevice.
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 device for soiling andflush with clean medium, if nec-essary
Installation und initial startup
Preparatory work
03.09.2018DWG Module BASICS Flow Monitor32
5.4 Installation in thepipe system
WARNING!
Risk of injury from pressur-ized lines!If the pipe system is underpressure when installing thedevice, severe injury mayresult.
– Depressurize the pipesystem before installing thedevice
WARNING!
Risk of injury from hot orcold surfaces!Pipelines can heat up or cooldown dramatically due to themedia flowing through them.Skin contact with hot or coldsurfaces may cause severeskin burn or frostbite.
– Before commencing work,ensure that the system hasbeen controlled to a tem-perature range between 0and 40 °C
– Do not touch any parts ofthe system that are eithervery cold or very hot
– Always wear heat-resistantor cold-resistant protectivework clothing and protec-tive gloves when workingnear hot or cold surfaces
Installation und initial startup
Installation in the pipe system
03.09.2018 DWG Module BASICS Flow Monitor 33
WARNING!
Risk of injury from media inthe pipe system!If the pipe system contains toxicor other hazardous media,severe injury may be caused byescaping media.
– Before installation, ensurethat the pipe system isempty and does not con-tain any media residue
– Always wear personal pro-tective equipment duringinstallation
– Provide suitable drainingdevices (drip pans, collec-tion tank, etc.)
NOTICE!
Risk of damage to device dueto contaminated pipe system!Dirt and foreign particlesentering the device candamage the device and impairits operation.
– Ensure that the pipesystem is clean beforeinstalling the device
– If necessary, flush the pipesystem with clean mediumbefore installation
A suitable sealant must beselected, depending on thecondition/composition of thepipe lines, the medium and theoperating and environmentalconditions. The sealing methoddescribed here is only anexample and cannot be used inall cases.
Installation und initial startup
Installation in the pipe system
03.09.2018DWG Module BASICS Flow Monitor34
Sealing the pipe connection
Personnel:n Qualified personnel
1. Nap the thread
Fig. 9: Apply sealing thread
2. Apply sealing thread (Fig. 9/1) tothe napped area in the threadeddirection. Observe the quantityrecommended by the sealantmanufacturer
Fig. 10: Pipe connection with sealingthread
ð The pipeline is now readyfor assembly (Fig. 10)
Installation und initial startup
Installation in the pipe system
03.09.2018 DWG Module BASICS Flow Monitor 35
Install device in pipe system
Personnel:n Qualified personnel
Protective equipment:n Protective gloves
Tools:n Fixed spanner
CAUTION!
Do not hold the device by itsthreads. These are sharpedged and may cause injury.
1. Place 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. 11/1). When doingso, lock the process connectionof the device in place to preventslip, using a suitable spanner(Fig. 11/2)
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
Installation und initial startup
Installation in the pipe system
03.09.2018DWG Module BASICS Flow Monitor36
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!
Ensure that the plant isoperating vibration-free.Vibrations could destroythe device. This mayresult in serious injury tothe user.
2.
WARNING!
Ensure that the mediumis flowing continuously.Pulse-like staggeredloads could destroy thedevice. This may result inserious injury to the user.
3.
NOTICE!
Completely fill the pipe-lines. Partial filling(s) mayresult in malfunctionsand damage to thedevice.
4.
NOTICE!
Vent the pipeline. If thereare air pockets in the lineduring the measurement,this could result indamage to the devicecaused by hydraulicshock. This may causemalfunctions.
5.
NOTICE!
Ensure that the plant isoperating without cavita-tion. Cavitation mayresult in malfunctionsand damage to thedevice.
Installation und initial startup
Initial startup
03.09.2018 DWG Module BASICS Flow Monitor 37
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.For UL Recognized switch contactsSG-30, with connector in compliancewith EN 175301-803, the connectioncable must be rated min. 105 °C.
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 replacementof a switch contact, the switch pointmust be readjusted.
DANGER!
Danger to life from electricalcurrentThere is an immediate risk tolife from electrocution ontouching live parts. Damage tothe electrical insulation orsingle components can beextremely dangerous.
– Only qualified electriciansshall work on the electricalsystem
– If the insulation is dam-aged, immediately switchoff and have repairs per-formed
– Before commencing workon live parts of electricalsystems and components,disconnect the equipmentand ensure that it remainsdisconnected for the dura-tion 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 thevicinity
– Never bridge fuses or putthem out of operation.Always observe the correctcurrent ratings whenreplacing fuses
– Keep moisture away fromlive parts. This may resultin short-circuit
Installation und initial startup
Electrical connection
03.09.2018DWG Module BASICS Flow Monitor38
5.6.1 Switch contactSG-30 with con-nector in compli-ance withEN175301-803
Wiring diagram of the suppliedsocket (EN 175301-803, Form A)front view.
Wiring diagram
Normally Open (NOC):
Fig. 13: Switch position under no-flowcondition
Fig. 14: Pin assignment, plug socket,normally-open contact. The ground-pinis not used.
Change Over (COC):
Fig. 15: Switch position under no-flowcondition
Fig. 16: Pin assignment, plug socket,change-over contact. The ground-pinis not used.
Installation und initial startup
Electrical connection > Switch contact SG-30 with connector in compliance with EN175301-803
03.09.2018 DWG Module BASICS Flow Monitor 39
5.6.2 Switch contactSG-30 with plugconnector M12x1
Wiring diagram, socket (M12x1)
Fig. 17: Pin-assignment, socket M12x1(Form 30x70)
Wiring diagram
Normally Open (NOC):
Fig. 18: Switch position under no-flowcondition
Change Over (COC):
Fig. 19: Switch position under no-flowcondition
Installation und initial startup
Electrical connection > Switch contact SG-30 with plug connector M12x1
03.09.2018DWG Module BASICS Flow Monitor40
5.6.3 Switch contactSG-30 with cable
The individual cores of the cable arenumbered (basic version) or colorcoded (UL-version) according to thefollowing connection diagrams.
Wiring diagram
Normally Open (NOC):
Fig. 20: Switch position under no-flowcondition
Installation und initial startup
Electrical connection > Switch contact SG-30 with cable
03.09.2018 DWG Module BASICS Flow Monitor 41
Change Over (COC):
Fig. 21: Switch position under no-flowcondition
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: 6–8 mm
IP65
M12x1 Plugcon-nectorM12x1
IP67
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.
Installation und initial startup
Grounding the device
03.09.2018DWG Module BASICS Flow Monitor42
5.8 Plug connectionPersonnel:n Qualified electrician
Tools:n Flat-bladed screwdriver
Fig. 22: Detach socket
1. Release the fixing screw(Fig. 22/1) from the socket
Fig. 23: Remove socket
2. Remove the socket (Fig. 23/1)
Fig. 24: Loosen inner section
3. Remove the plug insert from theplug by placing a flat-bladedscrewdriver into the slot(Fig. 24/1) and carefully pryingout the inner section
Installation und initial startup
Plug connection
03.09.2018 DWG Module BASICS Flow Monitor 43
Fig. 25: Loosen the screw connection
4. Unscrew the screw connection(Fig. 25/1) by turning in thedirection of the arrow
5. Guide the connecting cablethrough the screw connection inthe female socket
6. Make the connections as shownin the connection diagrams(Fig. 26 and Fig. 27)
7. Position the plug insert(Fig. 24/1) back onto the plugand push until it locks
8. Retighten the screw connection(Fig. 25/1) by turning it to theright
9. Plug the female socket onto theconnector plug and tighten thefixing screw (Fig. 22/1)
Fig. 26: Pin assignment, plug socket,normally-open contact (SG-30 withconnector in compliance withEN175301-803)
Installation und initial startup
Plug connection
03.09.2018DWG Module BASICS Flow Monitor44
Fig. 27: Pin assignment, plug socket,change over contact (SG-30 with con-nector in compliance withEN175301-803)
5.9 Contact protectionmeasures
The Reed-switches used in the switchcontacts are designed to be very sen-sitive to overload. To prevent destruc-tion of the switch contact, the valuesspecified on the rating plate of theswitch contact 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):
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. 28: Example 1
Fig. 29: 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.:
Installation und initial startup
Contact protection measures
03.09.2018 DWG Module BASICS Flow Monitor 45
n Long connecting cablesn Capacitive consumers
Example of protective measure:
Fig. 30: 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. 31: Example 1
Fig. 32: 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.
Installation und initial startup
Contact protection measures
03.09.2018DWG Module BASICS Flow Monitor46
6 Operation6.1 Setting the switch
point
Setting the switch point of aninstalled device
The following instructionsdescribe the procedure for aNormally Open Contact (NOC).The actual state (open orclosed), can be determinedusing a continuity meter.
Personnel:n Qualified personnel
Tools:n Flat-bladed screwdriver
1. Adjust the flow to be monitoredand read it off at the scale onthe device. The top edge of thefloat is the read-off point
Fig. 33: Loosen set screws
2. Loosen the set screws of theswitch contact (Fig. 33/1) usinga flat-bladed screwdriver
3. Slowly push the switch contactin the opposite direction of flowup to the stop
Operation
Setting the switch point
03.09.2018 DWG Module BASICS Flow Monitor 47
Condition 1: The contact is nowclosed
4. Slowly push the switch contactin the direction of flow until thecontact opens
Condition 2: The contact is nowopen
5. Slowly push the switch contactin the direction of flow until thecontact closes, then keeppushing slowly in the direction offlow until the contact opens
6. Tighten the set screws of theswitch contact (Fig. 33/1) usinga flat-bladed screwdriver. Whendoing so, observe the correcttightening torque of the screws.
Ä Chapter 11.1 “Tighteningtorque of screws” on page 84
ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.
Setting the switch point of a non-installed device
Fig. 34: Loosen set screws
1. Loosen the set screws of theswitch contact (Fig. 34/1) usinga flat-bladed screwdriver
2. Using a non-magnetic rod (e.g.test rod), move the float to thepoint on the measuring scalethat corresponds to the flow rateto be monitored. The top edgeof the float is the read-off point
3. Slowly push the switch contactin the opposite direction of flowup to the stop
Operation
Setting the switch point
03.09.2018DWG Module BASICS Flow Monitor48
Condition 1: The contact is nowclosed
4. Slowly push the switch contactin the direction of flow until thecontact opens
Condition 2: The contact is nowopen
5. Slowly push the switch contactin the direction of flow until thecontact closes, then keeppushing slowly in the direction offlow until the contact opens
6. Tighten the set screws of theswitch contact (Fig. 34/1) usinga flat-bladed screwdriver. Whendoing so, observe the correcttightening torque of the screws.
Ä Chapter 11.1 “Tighteningtorque of screws” on page 84
ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.
6.2 Checking the flowReading-off the flow value
Personnel:n Qualified personnel
Protective equipment:n Goggles
Fig. 35: Reading-off the measuringscale
1. The top edge of the float is theread-off point
Operation
Checking the flow
03.09.2018 DWG Module BASICS Flow Monitor 49
2. To obtain greatest reading accu-racy, read-off at eye level.(Fig. 35, middle arrow). Theread-off value can be falsified byviewing at an angle
3. Read-off the flow value from themeasuring scale
Operation
Checking the flow
03.09.2018DWG Module BASICS Flow Monitor50
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 performed incorrectly toremedy a malfunction
WARNING!
Risk of injury due to incorrectrepair of malfunction!Work performed incorrectly mayresult in severe injury and con-siderable damage to property
– Ensure that the site is suffi-ciently cleared before com-mencing work
– Ensure that the repair loca-tion is orderly and clean!Components and tools thatare lying about or on top ofeach other are potentialcauses of accidents
– If components have beenremoved, observe correctassembly procedures.Reinstall all fixing/fasteningelements and observe theprescribed tighteningtorque for the screwsÄ Chapter 11.1 “Tighteningtorque of screws”on page 84
Troubleshooting
Safety
03.09.2018 DWG Module BASICS Flow Monitor 51
– Before placing the deviceback into operation, ensurethat all work has been per-formed and completed incompliance with the specifi-cations and instructions inthese Operating Instruc-tions
Conduct in case of malfunction
The complete machine or system maybe unsafe if there is a defect at theflow monitor (e.g. broken sight glass).
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 thefault.
Troubleshooting
Safety
03.09.2018DWG Module BASICS Flow Monitor52
7.2 Troubleshooting guide
Fault description Cause Remedy Personnel
The switch contactdoes not switch
No mediumflowing throughflow monitor
n Check that medium isflowing through thepipeline
Qualifiedpersonnel
Flow is too low orthe switch con-tact is set toohigh
n Adjust the switch con-tact to a lower flowrate
n Use the device atanother measuringrange
n Increase the flow rate
Qualifiedpersonnel
Incorrect reduc-tion fitting or pipediameter is toosmall
n Correct pipe diameter Qualifiedpersonnel
Float is stuck n Disassemble andclean the 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 con-
tact to a higher flowrate
n Use the device atanother measuringrange
Qualifiedpersonnel
Float is stuck n Disassemble andclean the device
Qualifiedpersonnel
Troubleshooting
Troubleshooting guide
03.09.2018 DWG Module BASICS Flow Monitor 53
Fault description Cause Remedy Personnel
Switch contact ispermanentlyswitched
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 flowrate
Improper scaleinstalled formedia used
n Request proper con-version table or scalefor media used
Qualifiedpersonnel
Incorrect reduc-tion fitting or pipediameter is toosmall
n Correct pipe diameter Qualifiedpersonnel
Device is dirty n Disassemble andclean the device
Qualifiedpersonnel
Device is defec-tive
n Remove device fromsystem and contactthe manufacturer
Qualifiedpersonnel
Troubleshooting
Troubleshooting guide
03.09.2018DWG Module BASICS Flow Monitor54
8 Maintenance8.1 SafetyMaintenance work performed incor-rectly
WARNING!
Risk of injury due to mainte-nance work performed incor-rectly!Maintenance work performedincorrectly can result in severeinjury and considerabledamage to property.
– Ensure that the site is suffi-ciently cleared before com-mencing work.
– Ensure that the repair loca-tion is orderly and clean!Components and tools thatare lying about or on top ofeach other are potentialcauses for accidents.
– If components have beenremoved, observe correctassembly procedure. Rein-stall all fixing/fastening ele-ments and observe the pre-scribed tightening torquefor the screws (see Chapter11.1).
– Before placing the deviceback into operation ensurethat all work has been per-formed and completed incompliance with the specifi-cations and instructions inthese Operating Instruc-tions.
8.2 Maintenance planIntervals for replacing wear parts
DWG 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.
Maintenance
Maintenance plan
03.09.2018 DWG Module BASICS Flow Monitor 55
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 work.
WARNING!
Risk of injury from pressur-ized lines!Severe injury may result if thepipe system is under pressurewhen removing the device.
– Depressurize the systembefore removing the device
WARNING!
Risk of injury from hot orcold surfaces!Pipelines can heat up/cooldown dramatically due to themedia flowing through them.Skin contact with hot or coldsurfaces causes severe skinburn or frostbite.
– Before removing thedevice, ensure that themachine or system and theflow monitor have beencontrolled to a temperaturerange between 0 °C and 40°C
– Do not touch any part ofthe machine or system thatis either very cold or veryhot
– Always wear heat-resistant/cold-resistant protectivework clothing and protec-tive gloves when workingnear hot/cold surfaces
Maintenance
Removal from the pipe system
03.09.2018DWG Module BASICS Flow Monitor56
WARNING!
Risk of injury from media inthe pipe system!If the pipe system contains toxicor hazardous media, severeinjury may be caused byescaping media!
– Before removing thedevice, ensure that thepipe system is empty anddoes not contain any mediaresidue
– Always wear personal pro-tective equipment whenremoving the device
WARNING!
Risk of injury from media res-idue in the device!After the pipe system has beenemptied, media residue can stillbe present inside the device. Inthe case of toxic or hazardousmedia, this could result inserious injury.
– When removing (deinstal-ling the device from thepipe system), always wearpersonal protective equip-ment.
– All requirements specifiedin the media safety datasheet must be observed inaccomplishing the worktask.
– Residue of toxic or haz-ardous media in the devicecan result in serious injury.
Maintenance
Removal from the pipe system
03.09.2018 DWG Module BASICS Flow Monitor 57
Removing the device from the pipesystem
Personnel:n Qualified personnel
Protective equipment:n As specified in the Safety Data
Sheet of the medium, protectiveequipment must be worn whenhandling hazardous media. Inaddition, the specifications of thesystem operator must be followed.If no protective equipment isspecified, suitable protectivegloves and goggles must be worn.
Tools:n Fixed spanner
1. Loosen the adapter union of thepipeline using a suitablespanner. When doing so, lockthe process connection in placewith a second spanner.
2. Secure the device against fallingand repeat Step 1 at the otherend of the device
8.4 DisassemblyTo replace wear parts or to clean thedevice, the flow monitor must first bedisassembled.
WARNING!
Risk of injury due to incorrectdisassembly!– The device may still contain
media residue– Wear personal protective
equipment when workingwith hazardous media
– Improper disassembly maycause serious injuries ifhazardous media is stillpresent inside the device
CAUTION!
Risk of injury due to incorrectdisassembly!Incorrect disassembly mayresult in injury.
– Before disassembling,ensure that the flow mon-itor has cooled down/warmed up to a tempera-ture range between 0 and40° C
– Wear personal protectionequipment to protectagainst hazardous mediawhich may still be presentinside the device
Maintenance
Disassembly
03.09.2018DWG Module BASICS Flow Monitor58
Protective equipment:n As specified in the Safety Data
Sheet of the medium, protectiveequipment must be worn whenhandling hazardous media. Inaddition, the specifications of thesystem operator must be followed.If no protective equipment isspecified, suitable protectivegloves and goggles must be worn.
Personnel:n Qualified personnel
Protective equipment:n Gogglesn Protective gloves
Tools:n Hex screwdriver
Special tools:n Alignment tool/Test rod
Fig. 36: Loosen screws
1. Loosen the top 3 hex headscrews (Fig. 36/1) using a hexscrewdriver
Fig. 37: Remove the process connec-tion (outlet)
2.
CAUTION!
Carefully pull the processconnection (outlet) fromthe device housing,turning slightly whendoing so (Fig. 37). Do notapply undue force.
The sight glass canbreak if too much force isexerted or if the processconnection is canted.
Maintenance
Disassembly
03.09.2018 DWG Module BASICS Flow Monitor 59
Fig. 38: Slot nozzle buffer O-ring
3. Remove the slot nozzle bufferO-ring (Fig. 38/1) from the sightglass
Fig. 39: Loosen screws
4. Loosen the lower 3 hex headscrews (Fig. 39/1)
Maintenance
Disassembly
03.09.2018DWG Module BASICS Flow Monitor60
Fig. 40: Remove the inner section
5. Carefully remove the inner sec-tion (Fig. 40/1) of the device(sight glass, slot nozzle andfloat) as a unit together with theprocess connection (inlet)(Fig. 40/2) from the devicehousing
6. Rotate the inner section 180°and remove the process con-nection (inlet)
7. Slightly tilt the sight glass withslot nozzle and remove the float
Fig. 41: Remove slot nozzle
8. Using the alignment tool, pushthe slot nozzle out of the sightglass until it can be pulled out byhand (Fig. 41)
9. If necessary, remove the O-ringsfrom the individual parts
O-ring replacement
It is recommended that the O-rings be replaced during main-tenance.
8.5 Maintenance
Maintenance
Maintenance
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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 toimproper cleaning!The device may still containmedia residue.
– To protect against haz-ardous media residue inthe device, wear personalprotective equipment
– Do not use cleaning agentswhich lead to reactions withmedia residue
– All requirements specifiedin the Safety Data Sheetmust be observed whenhandling or otherwise usingthis medium
– Residue of hazardousmedia inside the devicecan cause serious injury
CAUTION!
Risk of injury due to dam-aged parts!If parts of the device are brokenor damaged, they may causeinjury due to sharp edges orsplinters during the cleaningprocess.
– Damaged parts must bereplaced
– Carefully clean the parts ofthe device, so as not tocause damage, this isespecially so for the sightglass
– When cleaning, alwayswear appropriate personalprotective equipment
– Incorrect disassembly canresult in injuries
Protective equipment:n As specified in the Safety Data
Sheet of the medium, protectiveequipment must be worn whenhandling hazardous media. Inaddition, the specifications of thesystem operator must be followed.If no protective equipment isspecified, suitable protectivegloves and goggles must be worn.
Maintenance
Maintenance > Cleaning
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8.5.2 Parts replacementDepending on the operating condi-tions, wear parts such as O-rings, floatand sight glass may have to bereplaced. Steps required to replacethese parts correspond to those usedwhen assembling the deviceÄ Chapter 8.5.3 “Assembly”on page 63.
8.5.3 AssemblyThe flow monitor must be reassembledafter cleaning the individual compo-nents.
Personnel:n Qualified personnel
Tools:n Hex screwdrivern Torque screwdriver and assorted
blades
Special tools:n Alignment tool/Test rod
Fig. 42: O-ring (seal)
1. Carefully install the O-ring (seal)onto the process connection(Fig. 42) so that it rests in theupper O-ring groove of theprocess connection (Fig. 44).When doing so, be careful not tooverstretch the O-ring.
Maintenance
Maintenance > Assembly
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Fig. 43: O-ring (glass buffer)
2. Carefully seat the O-ring (glassbuffer) onto the process connec-tion (Fig. 43)so that it is properlyseated on the lower portion ofthe process connection(Fig. 44). When doing so, becareful not to overstretch the O-ring.
Fig. 44: Position of O-rings
3. Repeat steps 1 and 2 for thesecond process connection
Fig. 45: O-ring (centering the slotnozzle)
4. Place the O-ring (for centeringthe slot nozzle) onto the slotnozzle (Fig. 45/1) so that it sitsin the groove on the outlet sideof the slot nozzle.
Maintenance
Maintenance > Assembly
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Fig. 46: Insert slot nozzle
5. Using the alignment tool, insertthe slot nozzle through the sightglass until the lower groove pro-trudes from the sight glass(Fig. 46/1) (/2)
Fig. 47: Centering the slot nozzle
6. Place the lower O-ring whichcenters the slot nozzle onto theend of the slot nozzle (Fig. 47/1)
7. Using the alignment tool, centerthe slot nozzle on the scale inthe sight glass
Maintenance
Maintenance > Assembly
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Fig. 48: Float
8. Guide the float (Fig. 48/1) intothe sight glass so that the lid ofthe float (recognizable by thetwo drill holes) points towardsthe slot nozzle
9. Lubricate the process connec-tion O-rings lightly
A list of suitable lubri-cants is contained in theannex Ä Chapter 11.5“Lubricants”on page 87.
Fig. 49: Process connection (Inlet)
10.
CAUTION!
Carefully insert theprocess connection(Inlet) (Fig. 49/1) into thesight glass, pressinglightly.
The sight glass canbreak if too much force isexerted or if the processconnection is canted
Maintenance
Maintenance > Assembly
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Fig. 50: Spanner flats
11. Position the process connection(inlet) so that the spanner flats(Fig. 50/1) are at a 90° angle tothe sight glass scale. Thelocating pin hole on the processconnection must be centered onthe front of the device housinglocating screw.
Fig. 51: Insert the process connectioninto the device housing
12. Insert the process connection(inlet) with the inner section intothe device housing (Fig. 51) andaxially align the connection tothe housing. The locating pinhole in the process connectionmust be centered to the frontlocking screw of the devicehousing
Fig. 52: Secure the process connec-tion (inlet)
13. Secure the inlet process con-nection with 3 hex socketscrews (Fig. 52/1) to the devicehousing, observing the propertorque
14. Rotate the device 180°
Maintenance
Maintenance > Assembly
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Fig. 53: Align slot nozzle
15. Using the alignment tool/test rod(Fig. 53/1), align the slot nozzleand the measuring scale(Fig. 53/2) centered to the sightwindow of the device housing.Secure the sight glass againstturning when doing so.
Fig. 54: O-ring, slot nozzle buffer
16. Insert O-ring (slot nozzle buffer)(Fig. 54/1)
Maintenance
Maintenance > Assembly
03.09.2018DWG Module BASICS Flow Monitor68
Fig. 55: Position the outlet processconnection
17. Insert the outlet process con-nection (Fig. 55/1) into thedevice housing, pressing lightly.When doing so, ensure that thespanner flats are at an angle of90° to the sight window of thedevice housing
Fig. 56: Tighten hex socket screws
18. Tighten the 3 hex socket screws(Fig. 56/1), observing the propertorque ( Ä Chapter 11.1 “Tight-ening torque of screws”on page 84)
Maintenance
Maintenance > Assembly
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Fig. 57: Check for free movement
19. Check the float for ease ofmovement by applying lightpressure with the alignment tool/test rod (Fig. 57).
ð If the float is sluggish, disas-semble the deviceÄ Chapter 8.4 “Disas-sembly” on page 58 andclean the float.
If the float is still sluggish afterhaving been cleaned severaltimes, contact the manufac-turer.
8.5.4 Switch contactreplacement
Tools:n Flat-bladed screwdriver
Fig. 58: Loosen female socket
1. Loosen the fixing screw(Fig. 58/1) of the female socketwith a flat-bladed screwdriver
Fig. 59: Remove the female socket
2. Remove the female socket andgasket (Fig. 59/1) by pullingupwards
Maintenance
Maintenance > Switch contact replacement
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Fig. 60: Loosen set screws
3. Using a flat-bladed screwdriver,loosen the set screws Fig. 60/1)of the switch contact until itmoves freely
Fig. 61: Release the guide rail
4. Loosen one of the two screws(Fig. 61/1) of the guide rail
Fig. 62: Rotate guide rail to the side
5. Rotate guide rail with switchcontact to the side
Fig. 63: Remove switch contact
6. Remove the switch contact fromthe guide rail (Fig. 63)
7. Attach a new switch contact
8. Rotate the guide rail back ontothe device
9. Fasten the guide rail Fig. 61/1)
10. Adjust the required switchingpoint by moving the switch con-tact to the desired position.
Maintenance
Maintenance > Switch contact replacement
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11. Tighten the set screws(Fig. 60/1) observing the propertightening torque of the screws( Ä Chapter 11.1 “Tighteningtorque of screws” on page 84)
12. Position the female socket andgasket, then tighten fixing screw
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.
Ä Chapter 11.1 “Tighteningtorque of screws” on page 84
2. Clean the work area andremove all residual materials,packaging, substances or spills.
Maintenance
Measures to be taken after maintenance work
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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 edgedcomponents, pointed ends andcorners on and in the device oron tools may cause injury.
– Ensure that the site is suffi-ciently cleared before com-mencing work
– Always wear protectiveequipment when handlinghazardous media residue
– Handle open, or sharp-edged components care-fully
– Ensure that the workplaceis orderly and clean! Com-ponents and tools that arelying about or on top ofeach other are potentialcauses for accidents
– Disassemble componentsprofessionally
– Secure components so thatthey do not fall or overturn
– If in doubt, contact themanufacturer
9.2 DisassemblyBefore disassembly:
n Remove fluids and lubricants andall other packaging material anddispose of them in an environmen-tally safe manner
Personnel:n Qualified personnel
Protective equipment:n Protective glovesn Goggles
1. Remove the device from thepipe system ( Ä Chapter 8.3“Removal from the pipe system”on page 56)
2. Disassemble the device( Ä Chapter 8.4 “Disassembly”on page 58)
3. Clean the components andremove media residue
4. Dispose in an environmentallysafe manner
Disassembly and disposal
Disassembly
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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, recycle disassembledcomponents:
n Scrap metalsn Recycle plastic elementsn Dispose of the remaining compo-
nents according to their materialproperties
NOTICE!
Danger to the environmentdue to incorrect disposal!Potential risk to the environ-ment may arise due to incorrectdisposal.
– Have electrical scrap, elec-tronic components, lubri-cants and other suppliesdisposed of by approvedspecialists
– In case of doubt, obtaininformation on environmen-tally safe disposal from thelocal authority or specialdisposal expert
Disassembly and disposal
Disposal
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10 Technical data10.1 Device data plateThe data plate is on the mechanicalpart of the flow monitor/flowmeter andcontains the following information:
Fig. 64: Device data plate
10.2 Switch contactdata plate
Fig. 65: Switch contact rating plate
Fig. 66: Switch contact rating platewith positioning arrow
The rating plate is on the switch con-tact and may provide the followinginformation:
n maximum voltagen maximum currentn maximum powern positioning arrow for cut-off point
10.2.1 Switch contactdata plate for ULRecognizedswitch contacts
Fig. 67: Switch contact data plate
Fig. 68: Adhesive label, switch contactwith positioning arrow
The data plate is on the switch contactand may provide the following informa-tion:
n Type of current (AC or DC)n Maximum voltagen Maximum currentn Maximum powern Frequency
For UL Recognized switch contactsSG-30, with connector in compliancewith EN 175301-803:
n temperature rating for the connec-tion cable
Technical data
Switch contact data plate > Switch contact data plate for UL Recognized switch contacts
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10.3 Dimension sheet
Technical data
Dimension sheet
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10.4 General specifications
Type Overall dimensions (mm)
G DN SW L1 L2 T
DWG-1,5
1/4" 8 32 121 132 10
3/8" 10 32 121 135 15
1/2" 15 32 121 135 14
DWG-3
1/4" 8 32 121 132 10
3/8" 10 32 121 135 15
1/2" 15 32 121 135 14
DWG-8
1/4" 8 32 121 132 10
3/8" 10 32 121 135 15
1/2" 15 32 121 135 14
DWG-12
1/4" 8 32 121 132 10
3/8" 10 32 121 135 15
1/2" 15 32 121 135 14
DWG-181/2" 15 32 143 161 14
3/4" 20 32 143 166 15
DWG-353/4" 20 41 143 163 15
1" 25 41 143 181 17
DWG-503/4" 20 41 143 163 15
1" 25 41 143 181 17
Technical data
General specifications
03.09.2018 DWG Module BASICS Flow Monitor 77
Type Overall dimensions (mm)
G D1 D2 A1 A2 A3 A4 Weight(g)
DWG-1,5
1/4" 35 43 – – – ca. 96 800
3/8" 35 43 – – – ca. 96 800
1/2" 35 43 – – – ca. 96 800
DWG-3
1/4" 35 43 – – – ca. 96 800
3/8" 35 43 – – – ca. 96 800
1/2" 35 43 – – – ca. 96 800
DWG-8
1/4" 35 43 – – – ca. 96 800
3/8" 35 43 – – – ca. 96 800
1/2" 35 43 – – – ca. 96 800
DWG-12
1/4" 35 43 – – – ca. 96 800
3/8" 35 43 – – – ca. 96 800
1/2" 35 43 – – – ca. 96 800
DWG-181/2" 35 43 – – – ca. 96 800
3/4" 35 43 – – – ca. 96 960
DWG-353/4" 45 50 – – – ca. 104 1450
1" 45 50 – – – ca. 104 1450
DWG-503/4" 45 50 – – – ca. 104 1450
1" 45 50 – – – ca. 104 1450
NPT threads are available on request.
The weight of the connection cable at a length of 2m is approx. 80 g
Technical data
General specifications
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10.5 Electrical specifications
Change-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 250 V
Current, maximum 3 A
Power, maximum 100 VA
Change-Over Contact (COC) M12x1 (-20 °C–85 °C)
Data Value Unit
Voltage 250 V
Current, maximum 1,5 A
Power, maximum 50 VA
Minimum load 3 VA
Technical data
Electrical specifications
03.09.2018 DWG Module BASICS Flow Monitor 79
Normally Open contact (NOC) M12x1 (-20 °C–85 °C)
Data Value Unit
Voltage 250 V
Current, maximum 3 A
Power, maximum 100 VA
Change-Over Contact (COC), PLC
Data Value Unit
Voltage 250 V
Current, maximum 1 A
Power, maximum 60 VA
10.5.1 Electrical specifications for UL Recognizeddevices
Change-Over Contact (COC)
Data Value Unit
Voltage 240 V AC/DC
Current, maximum 1,5 A
Power, maximum 50 VA
Minimum load 3 VA
Frequency 50/60 Hz
Technical data
Electrical specifications > Electrical specifications for UL Recognized devices
03.09.2018DWG Module BASICS Flow Monitor80
Normally Open Contact (NOC)
Data Value Unit
Voltage 250 V AC/DC
Current, maximum 3 A
Power, maximum 100 VA
Frequency 50/60 Hz
10.6 Measuring ranges10.6.1 Standard measuring ranges
Type Switch range for H2O at 20 °C
l/min gph gpm
DWG-1,5 0,1 – 1,5 1,6 – 23,8 –
DWG-3 0,2 – 3 3,2 – 47,5 –
DWG-8 0,3 – 8 5,0 – 127,0 –
DWG-12 1 – 12 16,0 – 190,0 –
DWG-18 2 – 18 32,0 – 285,0 –
DWG-35 3 – 35 48,0 – 550,0 –
DWG-50 4 – 50 60,0 – 790,0 –
The specified data are switch-off points. Other switch ranges are availableon request.
Technical data
Measuring ranges > Standard measuring ranges
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10.7 Operating data
Description Value Unit
Max. operating pressure 10 bar
Pressure loss 0,01 – 0,2 bar
Max. media temp. 100 (optional: 160) °C
Max. media temp. for ULRecognized Components
100 °C
Measuring accuracy ± 5 % of full scale value
Min. media temp. -20 °C
Min. media temp. for ULRecognized Compo-nents.
-15 °C
Operating conditions for UL Recognized Components
Description Value Unit
Indoor use
Altitude Up to 2 000 m
Temperature -15 to 100 °C
Max.relative humidity 80 % for temperatures up to 31 °C
decreasing linearly to 50 % relative humidity at 40 °C
Mains supply voltagefluctuations
Up to +/-10 % voltage
Overvoltage category II
Pollution degree 2
Technical data
Operating data
03.09.2018DWG Module BASICS Flow Monitor82
NOTICE!
It must be ensured that themedium does not freeze.
Operating data for devicesemployed in explosion hazardzones differs from the aboveand are specified in the Oper-ating Instructions for "DWGModule ATEX, Chapter 4.
Technical data
Operating data
03.09.2018 DWG Module BASICS Flow Monitor 83
11 Annex11.1 Tightening torque of screws
Component/function
Designation Size Torque Qty
Devicehousing screw
Hexagonsocket screw
M6x6 3 Nm 6
Guide railscrew
Countersunkscrew
M3x10 0,4 Nm 4
Switch contacthousingassemblyscrew
Cylinder headscrew withslot
M3x10 0,4 Nm 2
11.2 Replacementparts
Annex
Replacement parts
03.09.2018DWG Module BASICS Flow Monitor84
The following replacement parts drawing provides an example of the constructionof a DWG Type flow monitor. The actual configuration may vary depending on themodel.
Fig. 69: Replacement parts drawing
Item
Qty Description
1 1 Process connection, (inlet)
2 2 O-ring (glass buffer)
3 2 O-ring (seal)
4 1 Sight glass
5 1 Device body
6 6 Hex socket set screw
7 2 O-ring, slot nozzle buffer
8 1 Pin, (slot nozzle outlet)
Annex
Replacement parts
03.09.2018 DWG Module BASICS Flow Monitor 85
Item
Qty Description
9 1 Slot nozzle
10 1 Float with magnets
11 1 Process connection, (outlet)
12 2 Guide rail
13 4 Fixing screw, guide rail
14 1 Switch contact with male connector
15 1 Female socket and gasket
16 1 Fixing screw, (female socket)
17 2 Washer
18 2 Fixing screw, (switch contact)
11.3 ToolsThe following tools are required:
Tools
n Fixed spanner 32, 41, mmn Hex screwdriver 3 mmn Flat-bladed screwdriver, blade
width 5,5 mmn Torque screwdriver and assorted
blades
Special tools
n Alignment tool/test rod DWG
11.4 Sealant
Before using a sealant, ensurethat it is compatible with themedia used and that it can beemployed under the given oper-ating conditions.
n Ensure proper sealn Use a suitable sealant. Liquid
sealants will damage the flowmonitor
n Always follow the sealant manu-facturer's instructions
Annex
Sealant
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11.5 Lubricants
Before using a lubricant, always make sure that it is compatible with theoperating medium.
For the proper mounting of O-rings, device-specific O-ring installation tools may bepurchased from 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
NOTICE!
Glycerine must not be used if the device is used for sulfuric acid and/ornitric acid.
Annex
Lubricants
03.09.2018 DWG Module BASICS Flow Monitor 87
12 IndexAApplication . . . . . . . . . . . . . . . . . 13Assemblies . . . . . . . . . . . . . . . . . 24Assembly . . . . . . . . . . . . . . . . . . 63
CCable . . . . . . . . . . . . . . . . . . . . . 41Connector
EN175301-803 . . . . . . . . . . . . 39
Contact . . . . . . . . . . . . . . . . . . . 10Contact protection measures . . . . 45Copyright . . . . . . . . . . . . . . . . . . . 3Correct use in accordance withthese instructions . . . . . . . . . . . . 13Customer service . . . . . . . . . . . . 10
DDegree of protection
IP-Code . . . . . . . . . . . . . . . . 42
Device data plate . . . . . . . . . . . . . 75Device description . . . . . . . . . . . . 23Dimension sheet . . . . . . . . . . . . . 76Disassembly
Disposal . . . . . . . . . . . . . . . . 73
Maintenance . . . . . . . . . . . . . 58
Disposal . . . . . . . . . . . . . . . . . . . 74
EElectrical connection . . . . . . . . . . 38Electrical specifications
UL Recognized . . . . . . . . . . . 80
Environmental protection . . . . . . . 20cleaning fluids . . . . . . . . . . . . 20
lubricants . . . . . . . . . . . . . . . 21
FFault table . . . . . . . . . . . . . . . . . 53
GGeneral
safety . . . . . . . . . . . . . . . . . . 11
HHazard
electrical current . . . . . . . . . . . 15
Hazardsmechanical . . . . . . . . . . . . . . 15
media . . . . . . . . . . . . . . . . . . 17
radiation . . . . . . . . . . . . . . . . 17
temperature . . . . . . . . . . . . . . 16
IInitial startup . . . . . . . . . . . . . . . . 37Installation
Pipeline . . . . . . . . . . . . . . . . . 33
Preparations . . . . . . . . . . . . . 29
Sealing . . . . . . . . . . . . . . . . . 34
LLimitation of liability . . . . . . . . . . . . 3Lubricant . . . . . . . . . . . . . . . . . . 87
Index
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MMaintenance . . . . . . . . . . . . . . . 61Maintenance plan . . . . . . . . . . . . 56Measuring range . . . . . . . . . . . . . 81
OOperating conditions . . . . . . . . . . 82Overview . . . . . . . . . . . . . . . . . . 23Owner . . . . . . . . . . . . . . . . . . . . 21
PPackaging . . . . . . . . . . . . . . . . . 25Parts replacement . . . . . . . . . . . . 63Plug connection . . . . . . . . . . . . . 43Plug connector
M12x1 . . . . . . . . . . . . . . . . . . 40
Precautionsgeneral . . . . . . . . . . . . . . . . . 14
PreparationDevice . . . . . . . . . . . . . . . . . 32
RRead-off
flow value . . . . . . . . . . . . . . . 49
Replacement parts . . . . . . . . . 20, 84Return Materials Authorization . . . 74
SSafety
disassembly . . . . . . . . . . . . . . 73
Safety equipment . . . . . . . . . . 18, 19Safety instructions
transport . . . . . . . . . . . . . . . . 25
Sealant . . . . . . . . . . . . . . . . . . . 86Service . . . . . . . . . . . . . . . . . . . 10Sight glass . . . . . . . . . . . . . . . . . 24Special tools . . . . . . . . . . . . . . . . 86Storage . . . . . . . . . . . . . . . . . . . 26Strainer . . . . . . . . . . . . . . . . . . . 32Switch contact . . . . . . . . . . . . . . . 24
replacement . . . . . . . . . . . . . . 70
Switch contact data plateUL Recognized . . . . . . . . . . . 75
Switch contact rating plate . . . . . . 75Switch point . . . . . . . . . . . . . . . . 47
setting . . . . . . . . . . . . . . . . . . 47
Symbolspackaging . . . . . . . . . . . . . . . 26
Symbols usedin the instructions . . . . . . . . . . 11
TTechnical data
General specifications . . . . . . . 77
Tightening torque . . . . . . . . . . . . 84Tools . . . . . . . . . . . . . . . . . . . . . 86Transport inspection . . . . . . . . . . 25
UUnimpeded flow sections . . . . . . . 30
WWarranty and guarantee provisions 10
Index
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