rvo/u-l4 module basics flow monitor...fig. 1: rvo/u-l4 flow monitor 1 sight glass with measuring...

RVO/U-L4 Module BASICSFlow Monitor

Operation manual

Series RVO/U-L4Type RVO/U-L40001 thru RVO/U-L40042

Read this manual prior to performing any task!

RVO/U-L4 Module BASICS, 1, en_US

© Meister Strömungstechnik GmbH 2014

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

08.11.2017RVO/U-L4 Module BASICS Flow Monitor2

These instructions facilitate the safeand efficient handling of a flow monitor(referred to as "device" in the fol-lowing). The instructions are an inte-gral part of the device and must bekept within easy reach for the per-sonnel in the immediate vicinity of thedevice at all times. Personnel mustcarefully read and understand theseinstructions before commencing allwork. The basic requirement for safework is adherence to all safety andhandling instructions stipulated inthese instructions. The local accident-prevention regulations and generalsafety standards and regulations forthe field of application of the devicealso apply. Illustrations in these instruc-tions 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 personneln 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

08.11.2017 RVO/U-L4 Module BASICS Flow Monitor 3

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

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

2 Safety........................................................................................................... 82.1 Explanation of symbols........................................................................ 82.2 Correct use in accordance with these instructions............................... 92.3 Special precautions............................................................................ 102.3.1 Hazards from electrical current........................................................ 112.3.2 Mechanical hazards......................................................................... 112.3.3 Hazards from high or low temperatures.......................................... 122.3.4 Radiation hazards........................................................................... 122.3.5 Hazards caused by media............................................................... 132.4 Personnel requirements..................................................................... 132.5 Personal safety equipment................................................................. 142.6 Protective systems............................................................................. 152.7 Replacement parts............................................................................. 152.8 Environmental protection................................................................... 152.9 Responsibility of the owner................................................................ 16

3 Design and function................................................................................. 183.1 Overview............................................................................................ 183.2 Device description.............................................................................. 183.3 Component description...................................................................... 19

4 Transport, packaging and storage.......................................................... 204.1 Safety instructions for transport......................................................... 204.2 Transport inspection........................................................................... 204.3 Packaging.......................................................................................... 204.4 Symbols on the shipping box............................................................. 214.5 Storage............................................................................................... 21

5 Installation and initial startup.................................................................. 225.1 Safety................................................................................................. 22

Table of contents


5.2 Requirements at the place of installation........................................... 225.3 Preparatory work................................................................................ 235.4 Installation in the pipe system............................................................ 265.5 Initial startup....................................................................................... 295.6 Electrical connection.......................................................................... 295.6.1 Switch contact SG-15 with connector in compliance with

EN175301-803................................................................................ 305.6.2 Plug connector M12x1.................................................................... 315.6.3 Cable............................................................................................... 325.6.4 Degree of protection (IP-Code)....................................................... 325.7 Grounding the device......................................................................... 325.8 Plug connection.................................................................................. 335.9 Contact protection measures............................................................. 35

6 Operation................................................................................................... 376.1 Switch point setting............................................................................ 376.2 Checking the flow............................................................................... 39

7 Troubleshooting........................................................................................ 407.1 Safety................................................................................................. 407.2 Troubleshooting guide........................................................................ 42

8 Maintenance.............................................................................................. 448.1 Safety................................................................................................. 448.2 Maintenance plan............................................................................... 448.3 Removal from the pipe system........................................................... 458.4 Disassembly....................................................................................... 468.5 Maintenance....................................................................................... 498.5.1 Cleaning.......................................................................................... 498.5.2 Parts replacement........................................................................... 508.5.3 Assembly......................................................................................... 508.5.4 Switch contact replacement............................................................ 568.6 Measures to be taken after maintenance work.................................. 57

9 Disassembly and disposal....................................................................... 589.1 Safety................................................................................................. 589.2 Disassembly....................................................................................... 58

Table of contents


9.3 Return Materials................................................................................. 589.3.1 Return Materials Authorization........................................................ 589.4 Disposal............................................................................................. 59

10 Technical data........................................................................................... 6010.1 Device data plate............................................................................. 6010.2 Switch contact rating plate............................................................... 6010.3 Dimension sheet.............................................................................. 6110.4 General specifications...................................................................... 6210.5 Electrical specifications.................................................................... 6410.6 Measuring ranges............................................................................ 6510.6.1 Standard mesuring ranges............................................................ 6510.7 Operating data................................................................................. 66

11 Appendix................................................................................................... 6711.1 Tightening torque.............................................................................. 6711.2 Replacement parts........................................................................... 6811.3 Tools................................................................................................. 6911.4 Sealant............................................................................................. 6911.5 Lubricants......................................................................................... 70

12 Index.......................................................................................................... 71

Table of contents


1 Overview1.1 Short description

Fig. 1: RVO/U-L4 flow monitor

1 Sight glass with measuring scale2 Switch contact with female socket

or connecting cable

The flow monitor RVO/U-L4 monitorsthe continuous flow of gaseous media.It is designed for installation in pipesystems.

A float inside the device is moved bythe medium flowing through it. The cur-rent rate of flow can be read-off on themeasuring scale of the sight glass. Thetop 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 the manufacturer.

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


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

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

2.1 Explanation of sym-bols

Safety instructions

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

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

L DANGER

This combination of symbol andsignal word indicates an immediate,dangerous condition that results indeath or serious injury if it is notavoided.

L WARNING

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

L CAUTION

This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in minor or slight injury if it isnot avoided.

NOTICE

Safety

Explanation of symbols


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

Tips and recommendations

This symbol emphasizes useful tipsand recommendations as well as infor-mation for efficient and failure-freeoperation.

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 9, designates references tochapters in these instructions

2.2 Correct use inaccordance withthese instructions

The device has been designed andconstructed solely for the correct use inaccordance with these instructions.

Table 1: Correct use in non-hazardareas

The flow monitor serves exclusivelyto monitor the continuous flow ofgaseous media within a temperaturerange of -20 °C to 100 °C (optional:160 °C) at a maximum operatingpressure of 16 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 "RVO/U-L4 Module ATEX".

Intended use in explosion-hazardzones includes the observance of allspecifications in these OperatingInstructions, as well as those for"RVO/U-L4 Module ATEX".

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

L WARNING

Danger due to incorrect use!– Use the flow monitor only within

the stipulated performancelimits

Safety

Correct use in accordance with these instructions


– Do not subject the flow monitorto severe temperature fluctua-tions

– Do not use the flow monitor withquick-acting valves

– Do not use the flow monitor withsolenoid valves

– Do not subject the flow monitorto vibrations

– Do not subject the flow monitorto pressure surges

– Do not use the flow monitor withmedia containing solids or abra-sives

– Only use the flow monitor withmedia previously approved bythe manufacturer

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

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

– The flow monitor with sightglass must be installed in sucha way as to preclude damage tothe sight glass by outside force.If necessary, install an appro-priate impact protection device

Incorrect use of the flow monitormay result in dangerous conditions.

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 situations, observe thesafety instructions listed here as wellas the safety instructions in the otherchapters of these operating instruc-tions.

L DANGER

Employment of the device in explo-sion-hazard zones requires theobservance of the OperatingInstructions for "RVO/U-L4 ModuleATEX" including all hazard state-ments and warnings, therein.

These operating instructions cannotcover all conceivable dangers becausemany dangers arise, not from thedevice itself, but from the respectivemedia flowing through it. Alwaysobserve the appropriate safety datasheets when using hazardous media!

Safety

Special precautions


2.3.1 Hazards from elec-trical current

Electrical current

L DANGER

Danger to life from electrical cur-rent!– Only qualified electricians shall

work on the electrical system.– If the insulation is damaged,

immediately switch off and haverepairs performed.

– Before commencing work onlive parts of the electrical sys-tems and operating equipment,disconnect the equipment andensure that it remains discon-nected for the duration of thework. Observe these 5 safetyrules when doing so:– Isolate (disconnect)– Secure against switching

back on– Check for absence of

voltage– Ground and short– Cover or cordon off other

live parts in the vicinity– Never bridge fuses or put them

out of operation. Alwaysobserve the correct current rat-ings when replacing fuses

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

There is an immediate risk to lifefrom electrocution on touching liveparts. Damaged electrical insulationor components can be extremelydangerous.

2.3.2 Mechanical hazards

L WARNING

Risk of injury from glass breakage!– Keep within the stipulated oper-

ating limits– Wear personal protective equip-

ment– Avoid severe temperature fluc-

tuations– Avoid pressure surges

The sight glass in the flow monitorcan burst due to excessive tempera-ture or pressure. There is a risk ofinjury from glass splinters andescaping media.

L WARNING

Risk of injury on sharp edges andpointed corners!– Proceed with caution when

working near sharp edges andpointed corners.

– If in doubt, wear protectivegloves.

Sharp edges and pointed cornerscan cause abrasions and skin cuts.

Safety

Special precautions > Mechanical hazards


2.3.3 Hazards from highor low temperatures

Hot or cold surfaces

L WARNING

Risk of injury from hot or cold sur-faces!– Always wear temperature-

resistant protective workclothing and protective gloveswhen working near hot/cold sur-faces

– Before commencing work, makesure that all surfaces have beencooled down or warmed up toambient temperature

Surfaces of components may heatup/cool down dramatically due tothe media flowing through them.Skin contact with hot or cold sur-faces may cause severe skin burnor frostbite.

2.3.4 Radiation hazardsStrong magnetic fields

L WARNING

Danger to life from strong magneticfields!– Persons with pacemakers must

not be located in the vicinity ofthe device. This could impair thefunction of the pacemaker

– Persons with metal implantsmust not be located in thevicinity of the device. Implantscan heat up or be attracted mag-netically

– Keep ferromagnetic materialsand electromagnets away fromthe magnetic source. Thesematerials could be attracted andfly through the room, therebyinjuring or even killing persons.Minimum clearance: 3 m

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

– Do not place any electronicdevices within the vicinity of themagnetic source. These couldbe damaged

– Do not place any electronicstorage media, credit cards, etc.within the vicinity of the mag-netic source. Data could bedeleted

Strong magnetic fields may causesevere injury or even be fatal, aswell as cause considerable damageto property.

Safety

Special precautions > Radiation hazards


2.3.5 Hazards caused bymedia

Hazardous media

L WARNING

Risk of injury from hazardousmedia!– Observe details in the safety

data sheet of the media– Comply with the safety, accident

prevention and environmentalprotection regulations appro-priate to the media used

– Wear personal protective equip-ment in accordance with thesafety data sheet

If the flow monitor is used for toxic,corrosive or very hot/cold media,there is a risk of serious injury fromescaping media.

2.4 Personnel require-ments

L WARNING

Risk of injury due to insufficientlytrained and qualified personnel!– All work must be performed by

qualified personnel only.– Keep unqualified personnel

away from hazard zones.

If unqualified personnel work on thedevice or are located within itshazard zone, dangers arise whichmay result in serious injury andconsiderable damage to property.

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

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

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

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

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

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

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

Safety

Personnel requirements


2.5 Personal safetyequipment

Personal safety equipment is used toprotect personnel from hazards/dangers that might impair their safetyor health during work.

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

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

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

Description of personal safetyequipment

Additional protective equipmentmust be worn when handling haz-ardous media!As specified in the Safety Data Sheetof the medium, protective equipmentmust be worn when handling haz-ardous media. In addition, the specifi-cations of the system operator must befollowed. If no protective equipment isspecified, suitable protective glovesand goggles 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.

Safety

Personal safety equipment


2.6 Protective systemsIntegration within an emergency-stop concept is required

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

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

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

The emergency-stop equipment mustalways be freely accessible.

2.7 Replacement parts

L WARNING

Risk of injury due to use of incorrectreplacement parts!– Only use original replacement

parts from the manufacturer orapproved by the manufacturer.

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

Use of incorrect or faulty replace-ment parts may result in dangers topersonnel as well as damages, mal-functions or total failure.

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

The replacement parts list is in theannex.

2.8 Environmental pro-tection

NOTICE

Risk to the environment due toimproper handling of environmen-tally hazardous substances!– Always observe the instructions

listed below on the handling anddisposal of substances harmfulto the environment.

– If harmful substances arereleased into the environment,take immediate countermeas-ures. If there is doubt, contactthe local authorities, informthem of the damage and requestinformation on suitable counter-measures to be taken.

Serious environmental damage mayresult if substances harmful to theenvironment are handled incor-rectly, especially if they are dis-posed of improperly.

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


Lubricants

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

2.9 Responsibility of theowner

Owner

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

Duties of the owner

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

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 addition-ally determine the risks resultingfrom the special work conditions

arising at the location at which thedevice is used, especially in regardto the media used. He must thenimplement these within OperatingInstructions for use of the device.

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

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

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

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

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

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

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

Safety

Responsibility of the owner


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


3 Design and function3.1 Overview

Fig. 2: Front view

1 Process connection (outlet)2 Device body3 Spring4 Sight glass with measuring scale5 Float6 Process connection (inlet)7 Switch contact and female socket

or switch contact with cable

3.2 Device descriptionRVO/U-L4 flow monitors operate onthe principle 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 is movedby the flowing medium. A magneticfield is generated by the magnetsinside the float. The position of the floatis detected by the switch contact. Inaddition 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 RVO/U-L4 flow moni-tors are, for example, supply circuitstransporting gaseous media. Thedevice monitors the volume flow of thesupply medium to ensure proper oper-ation. 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


3.3 Component descrip-tion

Switch contact

Fig. 3: Switch contact and femalesocket

A potential-free Reed-contact is castinto the switch contact housing(Fig. 3/1). The device is supplied with aconnector (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


4 Transport, packaging and storage4.1 Safety instructions

for transport

Improper transport

NOTICE

The device could be damaged iftransported improperly!– Proceed carefully when

unloading transported pack-ages, both on delivery and whentransporting in-house. Observethe symbols and instructions onthe shipping box

– Remove packaging material justprior to assembly

Objects to be transported may fallor overturn if transported improp-erly. This may result in damage tothe device and/or property.

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 as soon asit is detected. Claims for damages canonly be invoked within the valid claimperiods.

4.3 PackagingAbout packaging

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

Handling packaging materials

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

Transport, packaging and storage

Packaging


NOTICE

Danger to the environment due toincorrect disposal!– Dispose of packaging material

in an environmentally safemanner

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

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

4.4 Symbols on theshipping box

Top

The arrows indicate the top side of thepackage. They must always pointupwards, otherwise the content may bedamaged.

Fragile

Designates packages with breakableor damageable contents.

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

4.5 StorageStoring the packages

Store the packages under the followingconditions:

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

median Protect from direct sunlightn Avoid mechanical vibrations and

shocksn Storage temperature: 0 to 35 °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.

Storage instructions in addition to theinstructions listed here may be listedon the packages. Follow these instruc-tions also.

Transport, packaging and storage

Storage


5 Installation and initial startup5.1 SafetyIncorrect installation and initialstartup

L WARNING

Risk of injury due to incorrect instal-lation and initial startup!– Ensure that the site is suffi-

ciently cleared of obstructionsbefore commencing work

– Handle open or sharp edgedcomponents carefully

– Ensure that the assembly loca-tion is orderly and clean! Partsand tools lying about or on topof each other are potentialcauses for accidents

– Assemble components properly.Observe the stipulated tight-ening torque of screws

– Before initial startup, make surethat all installation work hasbeen performed and completedin compliance with the specifi-cations and instructions inthese Operating Instructions

Incorrect installation and initialstartup may result in severe injuryand considerable damage to prop-erty.

Safeguard against restart

L WARNING

Danger to life due to unauthorizedrestart!– Before commencing work,

switch off the power supply tothe entire system/plant andsecure against restart

There is a risk of severe or evenfatal injury due to unauthorizedrestart of the power supply duringinstallation.

5.2 Requirements at theplace of installation

The place of installation must meet thefollowing requirements:

n The device must not be underwater.

n The surrounding area must be suf-ficiently illuminated.

n There must be sufficient space toprevent accumulation of trappedheat.

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

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

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.

Installation and initial startup

Requirements at the place of installation


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 minimum 100 mm to thosematerials (e.g. steel).

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

L WARNING

Danger due to incorrect installation!– Do not install the flow monitor

as a supporting part in a pipesystem

– Do not use the flow monitor withquick-acting valves

– Do not use the flow monitor withsolenoid valves

If the criteria listed above are notobserved when installing the flowmonitor, dangerous/hazardous con-ditions may arise.

Installation position/direction offlow

Fig. 5: Installation position/direction offlow

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).


Preparatory work


Unimpeded flow sections

NOTICE

Measuring inaccuracy due to incor-rect installation!– Ensure that the unimpeded flow

sections are maintained–– Never reduce the pipe diameter

immediately before the device

The measuring accuracy of the flowmonitor is influenced by its positionwithin the pipe system. Changes incross-section, branch-offs or bendsin the pipe system impair measuringaccuracy.

We recommend unimpeded flow sec-tions, type BS-228.

Fig. 6: Unimpeded flow section

1 10x DN2 5x DN

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

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


Preparatory work


Unimpeded outlet

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

Strainer

Fig. 7: Strainer

1 min. 10x DN2 min. 5x DN

If the medium is contaminated bysolids, a strainer must be installedbefore the device (Fig. 7).

We recommend a Type SF, SFD orSFM.

Prepare the device

NOTICE

Risk of damage to property due tocontamination!– Ensure that there are no foreign

particles in the device– Ensure that the device is not

soiled– Do not use any media con-

taining solids

Contamination and deposits mayimpair the free movement of thefloat, thereby damaging the device.

1. Remove the device from theshipping carton and visuallyinspect the device to ensure thatit is free of packaging materials

2. Check device for soiling andclean, if necessary.


Preparatory work


5.4 Installation in thepipe system

L WARNING

Risk of injury from pressurizedlines!– Depressurize the pipe system

before installing the device

f the pipe system is under pressurewhen installing the device, severeinjuries may result.

L WARNING

Risk of injury from hot or cold sur-faces!– Before commencing work,

ensure that the system has beencontrolled to a temperaturerange between 0 and 40 °C .

– Do not touch any parts of thesystem that are either very coldor very hot.

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

Pipelines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces may causesevere skin burn/freezing.

L WARNING

Risk of injury from media in the pipesystem!– Before installation, ensure that

the pipe system is empty anddoes not contain any media res-idue

– Always wear personal protectiveequipment during installation

– Provide suitable drainingdevices (collection tank, etc.)

If the pipe system contains toxic orother hazardous media, severe inju-ries may be caused by escapingmedia.

NOTICE

Risk of damage to device due tocontaminated pipe system!– Ensure that the pipe system is

clean before installing thedevice.

– If necessary, flush the pipesystem with clean mediumbefore installation

Dirt and foreign particles enteringthe device can damage the deviceand impair its operation.


Installation in the pipe system


A suitable sealant must be selected,depending on the condition/composi-tion of the pipe lines, the medium andthe operating and environmental condi-tions. The sealing method describedhere is only an example and cannot beused in all cases.

Sealing the pipe connection

Personnel:n Qualified personnel

1. Nap the thread.

Fig. 8: Apply sealing thread

2. Apply sealing thread (Fig. 8/1) tothe napped area in the threadeddirection. Observe the quantityrecommended by the sealantmanufacturer.

Fig. 9: Pipe connection with sealingthread

ð The pipeline is now readyfor assembly (Fig. 9)




Install device in pipe system


Protective equipment:n Protective gloves

Tools:n Fixed spanner

L CAUTION! Do not hold the deviceby its threads. These are sharpedged and may cause injury.

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

Fig. 10: Screw in the device

2. Fasten the adapter union of thepipeline with an appropriatespanner (Fig. 10/1). When doingso, lock the process connectionof the device in place to preventslip, using a suitable spanner(Fig. 10/2).

Fig. 11: Screw in the device

3. Keep turning in the adapterunion (Fig. 11/1) while holdingthe process connection of thedevice locked (Fig. 11/2) untilthe connection is tight

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




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

1. L WARNING! Make sure thatthe plant is operating vibra-tion-free. Vibrations coulddestroy the device. This couldresult in a serious risk ofinjury to the user.

2. L WARNING! Make sure thatthe medium is flowing contin-uously. Pulse-like staggeredloads could destroy thedevice. This could result in aserious risk of injury to theuser.

3. NOTICE! Flush the pipesystem carefully and ensurethat there are no solids orother foreign matter in thesystem. These could impairthe function, or even damagethe device.

5.6 Electrical connec-tion

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

L DANGER

Danger to life from electrical current– Only qualified electricians shall

work on the electrical system– If the insulation is damaged,

immediately switch off and haverepairs performed.

– Before commencing work onlive parts of electrical systemsand components, disconnectthe equipment and ensure that itremains disconnected for theduration of the work. Observethese 5 safety rules when doingso:– Isolate (disconnect)– Secure against switching

back on– Check for absence of

voltage– Ground and short– Cover or cordon off other

live parts in the vicinity– Never bridge fuses or put them

out of operation. Alwaysobserve the correct current rat-ings when replacing fuses


Electrical connection


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

There is an immediate risk to lifefrom electrocution on touching liveparts. Damage to the electrical insu-lation or single components can beextremely dangerous.

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

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

Wiring diagram

Normally Open (NOC):

Fig. 12: Switch position under no-flowcondition

Fig. 13: Pin assignment, plug socket,normally open contact. The ground-pinis not used.

Change Over (COC):



Electrical connection > Switch contact SG-15 with connector in compliance with EN175301-803


Fig. 15: Pin assignment, plug socket,change over contact. The ground-pin isnot used.

5.6.2 Plug connectorM12x1

Wiring diagram, connector M12x1Fig. 16: Pin assignment, connectorM12x1 (Form 15x50)

Wiring diagram

Normally Open (NOC):


Change Over (COC):


Electrical connection > Plug connector M12x1



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

Wiring diagram

normally open:


5.6.4 Degree of protection(IP-Code)

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

Deviceconnec-tion

Specifi-cationof con-nectionmaterial

Degree ofprotection

EN175301-803withgland

Diameterof con-nectioncable: 5–6mm

IP65

M12x1 Plugcon-nectorM12x1

IP65

Cable - IP67

5.7 Grounding thedevice

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


Grounding the device


5.8 Plug connectionPersonnel:n Qualified electrician

Tools:n Flat-bladed screwdriver

Fig. 20: Detach socket

1. Release the fixing screw(Fig. 20/1) from the socket

Fig. 21: Remove socket

2. Remove the socket (Fig. 21/1)

Fig. 22: Loosen inner section

3. Remove the plug insert from theplug by incerting a flat-bladedscrewdriver into the slot(Fig. 22/1) and carefully pry outthe inner section.


Plug connection


Fig. 23: Loosen the screw connection

4. Unscrew the screw connection(Fig. 23/1) by turning it to the left

5. Guide the connecting cablethrough the screw connectioninto the female socket

6. Make the connections as shownin the connection diagrams(Fig. 24 und Fig. 25).

7. Position the plug insert(Fig. 22/1) back onto the plugand push until it locks.

8. Retighten the screw connection(Fig. 23/1) by turning it to theright

9. Plug the female socket onto theconnector plug and tighten thefixing screw (Fig. 20/1).

Fig. 24: Pin assignment, plug socket,normally-open contact (Form 15x50)


Plug connection


Fig. 25: Pin assignment, plug socket,change-over contact (Form 15x50)

5.9 Contact protectionmeasures

The Reed-switches used in the switchcontacts are designed to be very sensi-tive to overload. To prevent destructionof the switch contact, the values speci-fied on the rating plate of the switchcontact must never be exceeded (noteven 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. 26: Example 1

Fig. 27: Example 2

Capacitive loads

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

n Long connecting cablesn Capacitive consumers

Example of protective measure:


Contact protection measures


Fig. 28: 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. 29: Example 1

Fig. 30: 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.


Contact protection measures


6 Operation6.1 Switch point settingSetting the switch point of aninstalled device

The following instructions describe theprocedure for a Normally Open Con-tact (NOC). The actual state (open orclosed), can be determined using acontinuity meter.


Tools:n Hex screwdriver

1. Adjust the flow to be monitoredand read it off at the scale on thedevice. The top edge of the floatis the read-off point.

Fig. 31: Loosen set screw

2. Loosen the set screw of theswitch contact (Fig. 31/1) usinga hex screwdriver.

3. Slowly push the switch contactin the opposite direction of flowup to the stop.

Condition 1: The contact is closed

4. Slowly push the switch contactin the direction of flow until thecontact opens.

Condition 2: The contact is open

5. Slowly push the switch contactin the direction of flow until thecontact closes. Keep pushingslowly in the direction of flowuntil the contact opens.

Operation

Switch point setting


6. Re-tighten the switch contact setscrew (Fig. 31/1) using a hexscrewdriver. When doing so,observe the correct tighteningtorque of the screw.

Ä Chapter 11.1 “Tighteningtorque” on page 67

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. 32: Loosen set screw

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

2. Using a non-magnetic rod ( e.g.test rod), move the float to thepoint on the measuring scalethat displays the flow rate to bemonitored. The top edge of thefloat is the read-off point.

3. Slowly push the switch contactin the opposite direction of flowup to the stop.

Condition 1: The contact is closed

4. Slowly push the switch contactin the direction of flow until thecontact opens.

Condition 2: The contact is open

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. Re-tighten the set screw of theswitch contact (Fig. 32/1)using ahex screwdriver. When doing so,observe the correct tighteningtorque of the screw.


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

Operation

Switch point setting


6.2 Checking the flowReading-off the flow value


Protective equipment:n Goggles

Fig. 33: Reading-off the measuringscale

1. The top edge of the float is theread-off point

2. To obtain greatest reading accu-racy, read-off at eye level.(Fig. 33, 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


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

L WARNING

Risk of injury due to incorrect repairof malfunction!– Ensure that the site is suffi-

ciently cleared before com-mencing work

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

– If components have beenremoved, observe correctassembly procedures. Reinstallall fixing/fastening elements andobserve the prescribed tight-ening torque for the screwsÄ Chapter 11.1 “Tighteningtorque” on page 67

– Before placing the device backinto operation, ensure that allwork has been performed andcompleted in compliance withthe specifications and instruc-tions in these Operating Instruc-tions

Work performed incorrectly mayresult in severe injury and consider-able damage to property

Troubleshooting

Safety


Conduct in case of malfunction

The complete machine or system maybe unsafe if there is a defect at the flowmonitor (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 troubleshooting guideprovides an indication of who is quali-fied to repair the fault.

Troubleshooting

Safety


7.2 Troubleshooting guide

Fault description Cause Remedy Personnel

The switch contactdoes not switch.

No mediumflowing throughflow monitor

Check that medium isflowing through the pipe-line

Qualifiedpersonnel

Flow is too low orthe switch contactis set too high

n Adjust the switchcontact to a lowerflow rate

n Use the device atanother measuringrange

n Increase the flowrate

Qualifiedpersonnel

Incorrect reduc-tion fitting or pipediameter is toosmall

n Correct pipe diam-eter

Qualifiedpersonnel

Float is stuck Disassemble and cleanthe device

Qualifiedpersonnel

Switch contact isdefective.

n Remedy the causeof the defect (short-circuit, overload)

n Replace the switchcontact

Qualifiedpersonnel

Switch contact ispermanentlyswitched.

Flow is too highor the switch con-tact is set too low

n Reduce the flown Adjust the switch

contact to a higherflow rate

n Use the device atanother measuringrange

Qualifiedpersonnel

Troubleshooting

Troubleshooting guide


Fault description Cause Remedy Personnel

Switch contact ispermanentlyswitched.

Float is stuck Disassemble and cleanthe device

Qualifiedpersonnel

Switch contact isdefective

n Remedy the causeof the defect (short-circuit, overload)

n Replace the switchcontact

Qualifiedpersonnel

The switch point isnot the same as theactual flow rate.

Improper scaleinstalled formedia used

Request proper conver-sion table or scale formedia used

Qualifiedpersonnel

Incorrect reduc-tion fitting or pipediameter is toosmall

n Correct pipe diam-eter

Qualifiedpersonnel

Device is dirty Disassemble and cleanthe device

Qualifiedpersonnel

Device is defec-tive

Remove device fromsystem and contact themanufacturer

Qualifiedpersonnel

Troubleshooting

Troubleshooting guide


8 Maintenance8.1 SafetyMaintenance work performed incor-rectly

L WARNING

Risk of injury due to maintenancework performed incorrectly!– Ensure that the site is suffi-

ciently cleared before com-mencing work.

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

– If components have beenremoved, observe correctassembly procedure. Reinstallall fixing/fastening elements andobserve the prescribed tight-ening torque for the screws (seeChapter 11.1).

– Before placing the device backinto operation ensure that allwork has been performed andcompleted in compliance withthe specifications and instruc-tions in these Operating Instruc-tions.

Maintenance work performed incor-rectly can result in severe injury andconsiderable damage to property.

8.2 Maintenance planIntervals for replacing wear parts

RVO/U-L4 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


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.

L WARNING

Risk of injury from pressurizedlines!– Depressurize the system before

removing the device

Severe injury may result if the pipesystem is under pressure whenremoving the device.

L WARNING

Risk of injury from hot or cold sur-faces!– Before removing the device,

ensure that the machine orsystem and the flow monitorhave been controlled to a tem-perature range between 0 °Cand 40 °C

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

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

Pipelines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces causessevere skin burn or frostbite.

Maintenance

Removal from the pipe system


L WARNING

Risk of injury from media in the pipesystem!– Before removing the device,

ensure that the pipe system isempty and does not contain anymedia residue

– Always wear personal protectiveequipment when removing thedevice

If the pipe system contains toxic orhazardous media, severe injury maybe caused by escaping media!

L WARNING

Risk of injury from media residue inthe device!– When removing (deinstalling the

device from the pipe system),always wear personal protectiveequipment.

– All requirements specified in themedia safety data sheet must beobserved in accomplishing thework task.

– Residue of toxic or hazardousmedia in the device can result inserious injury.

After the pipe system has beenemptied, media residue can still bepresent inside the device. In thecase of toxic or hazardous media,this could result in serious injury.

Removing the device from the pipesystem


Protective equipment:n Additional protective equipment

must be worn when handling haz-ardous media!

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.

L WARNING

Risk of injury due to incorrect disas-sembly!– The device may still contain

media residue– Wear personal protective equip-

ment when working with dan-gerous media

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

Maintenance

Disassembly


L CAUTION

Risk of injury due to incorrect disas-sembly!– Before disassembling, ensure

that the flow monitor has cooleddown/warmed up to a tempera-ture range between 0 and 40° C

– Wear personal protection equip-ment to protect against haz-ardous media which may still bepresent inside the device.

Incorrect disassembly may result ininjuries.




Protective equipment:n Gogglesn Protective gloves

Tools:n Hex screwdriver

Fig. 34: Loosen screws

1. Loosen the 4 hex head screwsat the outlet side (Fig. 34/1)using a hex screwdriver.

Fig. 35: Remove the process connec-tion (outlet)

2. L CAUTION! Carefully pullthe process connection(outlet) from the device body,turning slightly when doing so(Fig. 35). Do not apply undueforce. The sight glass canbreak if too much force isexerted or if the process con-nection is canted.

Maintenance

Disassembly


Fig. 36: Loosen screws

3. Secure the device with one handto ensure the sight glass doesnot slip out, then loosen the 4hex head screws (Fig. 36/1)atthe inlet side.

Fig. 37: Remove the inner parts

4. Carefully remove the inner parts(Fig. 37/1) of the device (sightglass, spring and float) as a unittogether with the process con-nection (inlet) (Fig. 37/2) fromthe device body.

Maintenance

Disassembly


Fig. 38: Remove float and spring

5. Rotate the inner section180°and remove the spring andfloat

6. Remove the sight glass from theprocess connection (inlet) bytwisting lightly.

7. If necessary, remove the O-ringsfrom the individual parts

O-ring replacementIt is recommended that the O-rings bereplaced during maintenance.

8.5 Maintenance

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

L WARNING

Risk of injury due to impropercleaning!– To protect against hazardous

media residue in the device,wear personal protective equip-ment.

– Do not use cleaning agents thatcause dangerous reactions withmedia residue.

– All requirements specified in theSafety Data Sheet must beobserved when handling or oth-erwise using this medium.

– Residue of hazardous mediainside the device can causeserious injury.

The device may still contain mediaresidue.

Maintenance

Maintenance > Cleaning


L CAUTION

Risk of injury due to damaged parts!– Damaged parts must be

replaced– Carefully clean the parts of the

device, so as not to causedamage, this is especially so forthe sight glass.

– When cleaning, always wearappropriate personal protectiveequipment.

– Incorrect disassembly canresult in injuries

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



8.5.2 Parts replacementDepending on the operating conditions,wear parts such as O-rings, float andsight glass may have to be replaced.Steps required to replace these partscorrespond to those used whenassembling the device Ä Chapter 8.5.3“Assembly” on page 50.

8.5.3 AssemblyThe flow monitor must be reassembledafter cleaning the individual compo-nents..


Tools:n Hex screwdrivern Torque screwdriver and assorted

blades

Special tools:n O-Ring installation tooln Test rod

Fig. 39: O-ring (seal)

1. Carefully install the O-ring (seal)onto the process connection(Fig. 39/2) with the aid of the O-ring installation tool (Fig. 39/1),so that it rests in the upper O-ring groove of the process con-nection (Fig. 41). When doingso, be careful not to overstretchthe O-ring.

Maintenance

Maintenance > Assembly


Fig. 40: O-ring (glass buffer)

2. Carefully seat the O-ring (glassbuffer) on the process connec-tion (Fig. 40/2) with the aid of theO-ring installation tool(Fig. 40/1), so that it rests in thelower O-ring seat of the processconnection (Fig. 40). Whendoing so, be careful not to over-stretch the O-ring.

Fig. 41: Position of O-rings

3. Repeat steps 1 and 2 for thesecond process connection.

Fig. 42: Inner parts

4. Insert the spring into thefloat.Fig. 42

5. Lubricate the process connec-tion O-rings lightly.

A list of suitable lubricants iscontained in the annexÄ Chapter 11.5 “Lubricants”on page 70.

Maintenance



Fig. 43: Process connection (inlet) andsight glass

6. L CAUTION! Carefully insertthe process connection (inlet)(Fig. 43/1) into the sight glass,turning lightly. The sight glasscan break if too much force isexerted or if the process con-nection is canted.

Fig. 44: Spanner flats

7. Position the process connection(inlet) so that the spanner flats(Fig. 44/1) 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.

Maintenance



Fig. 45: Insert process connection intodevice housing

8. Insert the process connection(inlet) along with the sight glassinto the device housing (Fig. 45)and axially align the connectionto the housing. The locating pinhole in the process connectionmust be centered to the frontlocking screw of the devicehousing.

Fig. 46: Secure the process connection(inlet)

9. Secure the process connection(inlet) with 4 hex socket screws(Fig. 46/1) to the device housing,observing the proper torque( Ä Chapter 11.1 “Tighteningtorque” on page 67).

Maintenance



Fig. 47: Center the sight glass

10. Center the sight glass scale onthe window of the devicehousing.

Fig. 48: Insert the inner parts

11. Insert the float and spring intothe device housing

Maintenance



Fig. 49: Position the process connec-tion (outlet)

12. Insert the process connection(outlet) into the device housing

13. Insert the outlet process connec-tion (Fig. 49) into the devicehousing, turning lightly. Whendoing so, ensure that thespanner flats are at an angle of90° to the sight window of thedevice housing.

Fig. 50: Tighten hex socket screws

14. Secure the process connection(outlet) to the device body(Fig. 50/1) with the 4 hex socketscrews, observing the propertorque ( Ä Chapter 11.1 “Tight-ening torque” on page 67).

Fig. 51: Check for free movement

15. Check the float for ease ofmovement by applying lightpressure with the test rod(Fig. 51).

ð If the float moves sluggishly,disassemble the device( Ä Chapter 9.2 “Disas-sembly” on page 58) andclean the float and sightglass.

Maintenance



If the float is still sluggish after havingbeen cleaned several times, contactthe manufacturer.

8.5.4 Switch contactreplacement

Tools:n Flat-bladed screwdrivern Hex screwdriver

Fig. 52: Loosen female socket

1. Loosen the fixing screw(Fig. 52/1) of the female socketwith a flat-bladed screwdriver.

Fig. 53: Remove the female socket

2. Remove the female socket andgasket (Fig. 53/1) by pullingupwards

Fig. 54: Remove set screw

3. Using a hex screwdriver(Fig. 54/1) remove the set screwof the switch contact

Maintenance

Maintenance > Switch contact replacement


Fig. 55: Remove switch contact

4. Remove the switch contact fromthe guide surface (Fig. 55)

5. Attach the new switch contact

6. The guide groove of the switchcontact must be slipped over thecylinder pin

7. Insert the set screw (Fig. 54/1)and tighten it slightly so that theswitch contact can still moveeasily

8. Adjust the required switch pointby moving the switch contact tothe desired position

9. Tighten the set screw(Fig. 54/1), observing the propertightening torque ( Ä Chapter11.1 “Tightening torque”on page 67)

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

8.6 Measures to betaken after mainte-nance work

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

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


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

Maintenance

Measures to be taken after maintenance work


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

9.1 Safety

L WARNING

Risk of injury if disassembled incor-rectly!– Ensure that the site is suffi-

ciently cleared before com-mencing work

– Always wear protective equip-ment when handling hazardousmedia residue

– Handle open, or sharp-edgedcomponents carefully

– Ensure that the workplace isorderly and clean! Componentsand tools that are lying about oron top of each other are poten-tial causes for accidents

– Disassemble components pro-fessionally

– Secure components so that theydo not fall or overturn

– If in doubt, contact the manufac-turer

Media residue, sharp edged compo-nents, pointed ends and corners onand in the device or on tools maycause injury.

9.2 DisassemblyBefore starting disassembly:

n Remove operating materials andpackaging and dispose of properly.


Protective equipment:n Protective glovesn Goggles

1. Remove the device from thepipeline ( Ä Chapter 8.3“Removal from the pipe system”on page 45)

2. Disassemble the device( Ä Chapter 8.4 “Disassembly”on page 46)

3. Clean components properly

4. Dispose properly

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.

Disassembly and disposal

Return Materials > Return Materials Authorization


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 environment due toincorrect disposal!– Have electrical scrap, electronic

components, lubricants andother supplies disposed of byapproved specialists

– In case of doubt, obtain informa-tion on environmentally safedisposal from the local authorityor special disposal expert

Potential risk to the environmentmay arise due to incorrect disposal.

Disassembly and disposal

Disposal


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

Fig. 56: Device data plate

10.2 Switch contactrating plate

Fig. 57: Switch contact rating plate

Fig. 58: Switch contact rating plate withpositioning 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

Technical data

Switch contact rating plate


10.3 Dimension sheet

Technical data

Dimension sheet


10.4 General specifications

Type Overall dimensions (mm)

G * DN SW L1 L2 T

RVO/U-L40001

1/4 8 17 68 90 10

RVO/U-L40002

1/4 8 17 68 90 10

RVO/U-L40003

1/4 8 17 68 90 10

RVO/U-L40005

1/4 8 17 68 90 10

RVO/U-L40008

1/4 8 17 68 90 10

RVO/U-L40012

1/4 8 17 68 90 10

RVO/U-L40014

1/4 8 17 68 90 10

RVO/U-L40020

1/4 8 17 68 90 10

RVO/U-L40024

1/4 8 17 68 90 10

RVO/U-L40035

1/4 8 17 68 90 10

RVO/U-L40042

1/4 8 17 68 90 10

Technical data

General specifications


Type Overall dimensions (mm)

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

RVO/U-L40001

1/4 19 20 - - - 60 140

RVO/U-L40002

1/4 19 20 - - - 60 140

RVO/U-L40003

1/4 19 20 - - - 60 140

RVO/U-L40005

1/4 19 20 - - - 60 140

RVO/U-L40008

1/4 19 20 - - - 60 140

RVO/U-L40012

1/4 19 20 - - - 60 140

RVO/U-L40014

1/4 19 20 - - - 60 140

RVO/U-L40020

1/4 19 20 - - - 60 140

RVO/U-L40024

1/4 19 20 - - - 60 140

RVO/U-L40035

1/4 19 20 - - - 60 140

RVO/U-L40042

1/4 19 20 - - - 60 140

* NPT thread on request

** Connecting cable weight, 2 m approx. 80g

Technical data

General specifications


10.5 Electrical specifications

Change-Over Contact (COC)

Data Value Unit

Voltage 150 V AC/DC

Current, maximum 1 A

Power, maximum 20 VA

Normally Open Contact (NOC)

Data Value Unit

Voltage 140 V AC

Voltage 200 V DC

Current, maximum (at 140 V AC) 0,7 A

Current, maximum (at 200 V DC) 1 A


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

Data Value Unit

Voltage 125 V AC/DC

Current, maximum 1 A


Technical data

Electrical specifications


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

Data Value Unit

Voltage 125 V AC/DC

Current, maximum (at 125 V AC) 0,7 A

Current, maximum (at 125 V DC) 1 A


10.6 Measuring ranges10.6.1 Standard mesuring ranges

Type Switch range for air at 1 bar abs. & 20 °C*

Nl/min SCFH SCFM

RVO/U-L40001 0,2 – 1,3 0,4 – 2,75

RVO/U-L40002 0,5 – 2 1,05 – 4,25

RVO/U-L40003 0,8 – 3 1,7 – 6,4

RVO/U-L40005 1,5 – 5 3,5 – 10,5

RVO/U-L40008 2 – 8 4,5 – 17,0

RVO/U-L40012 3 – 12 6,5 – 25,0

RVO/U-L40014 3,5 – 14 7,5 – 29,5

RVO/U-L40020 5,5 – 20 12,0 – 42,0

RVO/U-L40024 7 – 24 15,0 – 50,0

RVO/U-L40035 10 – 35 21,0 – 74,0

RVO/U-L40042 10 – 42 21,0 – 89,0

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

Technical data

Measuring ranges > Standard mesuring ranges


10.7 Operating data

Description Value Unit

Max. media temp. 100 (optional 160°C) °C

Min. media temp.

It must be ensured thatthe medium does notfreeze.

-20 °C

Max. operating pressure 16 bar

Pressure loss 0,02 – 0,2 bar

Measuring accuracy ± 10 % of full scale value

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

The operating data for devicesemployed in explosion hazard zonesare specified in the Operating Instruc-tions for "RVO/U-L2 Module ATEX",Chapter 4.

Technical data

Operating data


11 Appendix11.1 Tightening torque

Component/function

Description Size Torque Qty

Devicehousing screw

Hexagonsocket screw

M4x4 1,0 Nm 8

Switch contacthousingassemblyscrew

Cylinder headscrew

M3x10 0,4 Nm 1

Appendix

Tightening torque


11.2 Replacement partsThe following replacement parts drawing provides an example of the constructionof an RVO/U-L4 type flow monitor. The actual configuration may vary dependingon the model.

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 housing

6 8 Hex socket screw

7 1 Spring

8 1 Float

9 1 Process connection (outlet)

10 1 Cylinder pin (switch contact)

11 1 Switch contact with male connector

12 1 Female socket and gasket

Appendix

Replacement parts


Item Qty Description

13 1 Fixing screw (female socket)

14 1 Set screw (switch contact)

11.3 ToolsThe following tools are required:

Tools

n Fixed spanner 17 mmn Flat-bladed screwdriver, blade

width 5,5mmn Hex screwdriver 2 mmn Hex screwdriver 2,5 mmn Torque screwdriver and assorted

blades

Special tools

n Test rod RVO/U-L4n O-ring installation tool RVO/U-L4

11.4 Sealant

Before using a sealant, ensure that it iscompatible with the media used andthat it can be employed under thegiven operating conditions.

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

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

facturer's instructions

Appendix

Sealant


11.5 Lubricants

Before using a lubricant, always make sure that it is compatible with the operatingmedium.

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

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

Appendix

Lubricants


12 IndexAApplication . . . . . . . . . . . . . . . . . . 9Assembly . . . . . . . . . . . . . . . . . . 50

CCable . . . . . . . . . . . . . . . . . . . . . 32Component groups . . . . . . . . . . . 19Connected loads

NOC . . . . . . . . . . . . . . . . . . . 64

ConnectorM12x1 . . . . . . . . . . . . . . . . . . 31

Contact . . . . . . . . . . . . . . . . . . . . 7Contact protection measures . . . . . 35Copyright . . . . . . . . . . . . . . . . . . . 3Correct use in accordance withthese instructions . . . . . . . . . . . . . 9Customer service . . . . . . . . . . . . . 7

DDegree of protection

IP-Code . . . . . . . . . . . . . . . . . 32

Device data plate . . . . . . . . . . . . . 60Device description . . . . . . . . . . . . 18Dimension sheet . . . . . . . . . . . . . 61Disassembly

maintenance . . . . . . . . . . . . . 46

DisasssemblyDisposal . . . . . . . . . . . . . . . . 58

Disposal . . . . . . . . . . . . . . . . . . . 59

EElectrical connection . . . . . . . . . . 29Environmental protection . . . . . . . 15

cleaning fluids . . . . . . . . . . . . 15

lubricants . . . . . . . . . . . . . . . . 16

FFault table . . . . . . . . . . . . . . . . . . 42flow value . . . . . . . . . . . . . . . . . . 39

GGeneral

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

HHazard

electrical current . . . . . . . . . . . 11

Hazardsmechanical . . . . . . . . . . . . . . . 11

media . . . . . . . . . . . . . . . . . . 13

radiation . . . . . . . . . . . . . . . . 12

temperature . . . . . . . . . . . . . . 12

IInitial startup . . . . . . . . . . . . . . . . 29Installation

pipe system . . . . . . . . . . . . . . 26

preparation . . . . . . . . . . . . . . 23

LLimitation of liability . . . . . . . . . . . . 3

Index


Lubricant . . . . . . . . . . . . . . . . . . 70

MMaintenance . . . . . . . . . . . . . . . . 49Maintenance plan . . . . . . . . . . . . 45Measuring range . . . . . . . . . . . . . 65

OOperating conditions . . . . . . . . . . 66Overview . . . . . . . . . . . . . . . . . . 18Owner . . . . . . . . . . . . . . . . . . . . 16

PPackaging . . . . . . . . . . . . . . . . . . 20Parts replacement . . . . . . . . . . . . 50Plug connection . . . . . . . . . . . . . . 33Plug connector

EN175301-803 . . . . . . . . . . . . 30

Precautionsgeneral . . . . . . . . . . . . . . . . . 10

PreparationDevice . . . . . . . . . . . . . . . . . . 25

RRead-off . . . . . . . . . . . . . . . . . . . 39Replacement parts . . . . . . . . . 15, 68Return Materials Authorization . . . . 58

SSafety

disassembly . . . . . . . . . . . . . . 58

Safety equipment . . . . . . . . . . 14, 15

Safety instructionstransport . . . . . . . . . . . . . . . . 20

Sealant . . . . . . . . . . . . . . . . . . . . 69Service . . . . . . . . . . . . . . . . . . . . . 7Sight glass . . . . . . . . . . . . . . . . . 19Specifications

Change-Over Contact (COC) . . 64

Storage . . . . . . . . . . . . . . . . . . . 21Strainer . . . . . . . . . . . . . . . . . . . 25Switch contact . . . . . . . . . . . . . . . 19

replacement . . . . . . . . . . . . . . 56

Switch contact rating plate . . . . . . 60Switch point . . . . . . . . . . . . . . . . 37Symbols

packaging . . . . . . . . . . . . . . . 21

Symbols usedin the instructions . . . . . . . . . . . 8

TTechnical data

general specifications . . . . . . . 62

Tightening torque . . . . . . . . . . . . . 67Tightening torque of screws . . . . . 67Tools . . . . . . . . . . . . . . . . . . . . . 69Transport inspection . . . . . . . . . . . 20

UUnimpeded flow sections . . . . . . . 24

WWarranty and guarantee provisions . 7

Index


rvo/u-l4 module basics flow monitor...fig. 1: rvo/u-l4 flow monitor 1 sight glass with measuring...

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