RVO/U-4 Module BASICS Flow Monitor · 10 RVO/U-4 Module BASICS Flow Monitor 06.11.2017. All claims...

RVO/U-4 Module BASICSFlow Monitor

Operation manual

Series RVO/U-4Type RVO/U-4/01 thru RVO/U-4/5

Read this manual prior to performing any task!

RVO/U-4 Module BASICS, 1, en_US

© Meister Strömungstechnik GmbH 2013

Meister Strömungstechnik GmbH

Im Gewerbegebiet 2

63831 Wiesen

Germany

Telephone: +49 6096 9720 - 0

Fax: +49 6096 9720 - 30

E-mail: [email protected]

Internet: www.meister-flow.com

These instructions were compiled by:

Meister Strömungstechnik GmbH

Subject to change without notice

06.11.2017RVO/U-4 Module BASICS Flow Monitor2

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

Limitations of liability

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

n non-observance of any details inthese instructions

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

n use of non-trained 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

06.11.2017 RVO/U-4 Module BASICS Flow Monitor 3

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

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

2 Safety.......................................................................................................... 82.1 Explanation of symbols........................................................................ 82.2 Correct use in accordance with these instructions............................ 102.3 Special precautions............................................................................ 112.3.1 Hazards from electrical current....................................................... 112.3.2 Mechanical hazards........................................................................ 122.3.3 Hazards from high or low temperatures......................................... 122.3.4 Radiation hazards........................................................................... 132.3.5 Hazards caused by media.............................................................. 132.4 Personnel requirements.................................................................... 142.5 Personal safety equipment................................................................ 142.6 Protective systems............................................................................ 152.7 Replacement parts............................................................................ 162.8 Environmental protection................................................................... 162.9 Responsibility of the owner................................................................ 17

3 Design and function................................................................................. 193.1 Overview............................................................................................ 193.2 Device description............................................................................. 193.3 Component description...................................................................... 20

4 Transport, packaging and storage......................................................... 214.1 Safety instructions for transport......................................................... 214.2 Transport inspection.......................................................................... 214.3 Packaging.......................................................................................... 214.4 Symbols on the shipping box............................................................. 224.5 Storage.............................................................................................. 22

5 Installation and initial startup................................................................. 245.1 Safety................................................................................................ 24

Table of contents


5.2 Requirements at the place of installation........................................... 245.3 Preparatory work............................................................................... 255.4 Installation in the pipe system........................................................... 285.5 Initial startup...................................................................................... 325.6 Electrical connection.......................................................................... 335.6.1 Switch contact SG-15 with connector in compliance with

EN175301-803............................................................................... 335.6.2 Plug connector M12x1.................................................................... 345.6.3 Cable.............................................................................................. 355.6.4 Degree of protection (IP-Code)...................................................... 365.7 Grounding the device........................................................................ 365.8 Plug connection................................................................................. 365.9 Contact protection measures............................................................. 38

6 Operation.................................................................................................. 416.1 Switch point setting............................................................................ 416.2 Checking the flow.............................................................................. 43

7 Troubleshooting....................................................................................... 447.1 Safety................................................................................................ 447.2 Troubleshooting guide....................................................................... 46

8 Maintenance............................................................................................. 488.1 Safety................................................................................................ 488.2 Maintenance plan.............................................................................. 488.3 Removal from the pipe system.......................................................... 498.4 Disassembly...................................................................................... 518.5 Wartungsarbeiten.............................................................................. 548.5.1 Cleaning......................................................................................... 548.5.2 Parts replacement.......................................................................... 558.5.3 Assembly........................................................................................ 558.5.4 Switch contact replacement............................................................ 618.6 Measures to be taken after maintenance work.................................. 63

9 Disassembly and disposal...................................................................... 649.1 Safety................................................................................................ 649.2 Disassembly...................................................................................... 64

Table of contents


9.3 Return Materials................................................................................ 649.3.1 Return Materials Authorization....................................................... 649.4 Disposal............................................................................................. 65

10 Technical data.......................................................................................... 6610.1 Device data plate............................................................................. 6610.2 Switch contact rating plate............................................................... 6610.3 Dimension sheet.............................................................................. 6710.4 General specifications..................................................................... 6810.5 Electrical specifications................................................................... 6910.6 Measuring ranges............................................................................ 7010.6.1 Standard measuring ranges......................................................... 7010.7 Operating data................................................................................. 71

11 Appendix................................................................................................... 7211.1 Tightening torque............................................................................. 7211.2 Replacement parts........................................................................... 7311.3 Tools................................................................................................. 7411.4 Sealant............................................................................................. 7411.5 Lubricants........................................................................................ 75

12 Index.......................................................................................................... 76

Table of contents


1 Overview1.1 Short description

Fig. 1: RVO/U-4 flow monitor

1 Sight glass with measuring scale2 Switch contact with female socket

or sealed-in cable

The flow monitor RVO/U-4 monitorsthe continuous 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 of 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 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 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.

CAUTION!

This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in minor or slight injury ifit is not avoided.

Safety

Explanation of symbols


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 9, designates references tochapters in these instructions

Safety

Explanation of symbols


2.2 Correct use inaccordance withthese instructions

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

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 of16 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-4 Module ATEX".

Intended use in explosion-hazardzones includes the observance of allspecifications in these OperatingInstructions, as well as those for"RVO/U-4 Module ATEX ".

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

WARNING!

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

within 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

– 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

– Incorrect use of the flowmonitor may result in dan-gerous situations

Safety

Correct use in accordance with these instructions


All claims for damages due to incorrectuse are excluded.

2.3 Special precautions

The following section lists residualrisks that might arise from the machineand that have been determined by arisk assessment.

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

DANGER!

Employment of the device inexplosion-hazard zonesrequires the observance ofthe Operating Instructions for"RVO/U-4 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!

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 off

other live parts in thevicinity

Safety

Special precautions > Hazards from electrical current


– 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

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


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


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/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:

Safety

Personal safety 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.

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


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


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 workconditions arising at the location at

which 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.

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.

Safety

Responsibility of the owner


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


3 Design and function3.1 Overview

Fig. 2: Front view

1 Process connection (outlet)2 Device housing3 Spring4 Sight glass with measuring scale5 Float containing magnets6 Process connection (inlet)7 Switch housing with female socket

or switch housing with cable

3.2 Device descriptionRVO/U-4 flow meters work accordingto the functional principle of the vari-able area flowmeter. The flow monitoris installed into a pipe system andmeasures the flow-rate of the mediumflowing through the pipe 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 throughthe Reed-contact (switch contact), thecurrent flow rate can also be read-offon the measuring scale on the sightglass.

RVO/U-4 flow monitors are used in,e.g. lubricating circuits: The flow mon-itor monitors the volumetric flow of thelubricating media to ensure it is highenough to ensure sufficient lubrication.If the flow through the flow monitordrops below the threshold preset bythe operator, the switch contactswitches (change-over contact) orcloses the contact (normally open con-tact).

Design and function

Device description


3.3 Component descrip-tion

Switch contact

Fig. 3: Schaltkontakt und Steckerdose

A potential-free Reed-contact is castinto the switch contact housingassembly (Fig. 3/1) The device is sup-plied 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


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 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 onlyremove the device from the shippingbox immediately before installation.

Transport, packaging and storage

Packaging


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.


Storage


Storage instructions in additionto the instructions listed heremay be listed on the packages.Follow these instructions also.


Storage


5 Installation and 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 meet thefollowing requirements:

n The device must not be underwater.

n The surrounding area must be suf-ficiently illuminated.

n There must be sufficient space toprevent accumulation of trappedheat.

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

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

Installation and initial startup

Requirements at the place of installation


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

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

n Piping, process connections orsupports made 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:

WARNING!

Danger due to incorrectinstallation!If the criteria listed above arenot observed when installingthe flow monitor, dangerous/hazardous situations may 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

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


Preparatory work


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 arcs 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.

Fig. 6: Unimpeded flow sections

1 10x DN2 5x DN

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

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


Preparatory work


Unimpeded outlet

Fig. 7: Unimpeded outlet

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

Strainer

Fig. 8: Strainer

1 min. 10x DN2 min. 5x DN

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

We recommend a Type SF,SFD or SFM strainer.


Preparatory work


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 ensurethat there are no remains ofpackaging material in the device

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

5.4 Installation in thepipe system

WARNING!

Risk of injury from pressur-ized lines!If the pipe system is underpressure when installing thedevice, severe injuries mayresult.

– Depressurize the pipesystem before installing thedevice.


Installation in the pipe system


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 may cause severeskin burning/freezing.

– 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-resistant/cold-resistant protectivework clothing and protec-tive gloves when workingnear hot/cold surfaces

WARNING!

Risk of injury from media inthe pipe system!If the pipe system contains toxicor other hazardous media,severe injuries may be causedby escaping 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 (collection 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.

Leitung abdichten

Personnel:n Qualified personnel

1. Nap the thread.

Fig. 9: Apply sealing strip

2. Apply sealing strip (Fig. 9/1) tothe napped thread in the thread-direction. Observe the quantityrecommended by the sealantmanufacturer

Fig. 10: Pipe connection with sealingstrip

ð The pipeline is now readyfor assembly (Fig. 10)




Install device in pipe system


Protective equipment:n Protective gloves

Tools:n Fixed spanner

CAUTION!

Do not hold the device by itsthreads. These are sharpedged and may cause injury.

1. GPlace 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 connectionin place to prevent slip, using asuitable spanner (Fig. 11/2)

Fig. 12: Screw in the device

3. Keep turning in the adapterunion (Fig. 12/1) while holdingthe process connection locked(Fig. 12/2) until the connection istight

4. Repeat these steps at the otherend of the device




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

1.

WARNING!

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.


Initial startup


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 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 againstswitching back on

– Check for absence ofvoltage

– 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

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. 13: Switch position under no-flowcondition


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


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

Change Over (COC):


Fig. 16: Pin assignment, plug socket,change over contact. The ground-pinis not used.

5.6.2 Plug connectorM12x1

Wiring diagram, connector M12x1


Electrical connection > Plug connector M12x1


Fig. 17: Pin assignment, connectorM12x1 (Form 15x50)

Wiring diagram

Normally Open (NOC):


Change Over (COC):


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

Wiring diagram

normally open:



Electrical connection > Cable


5.6.4 Degree of protection(IP-Code)

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

Deviceconnec-tion

Specifi-cationof con-nectionmaterial

Degree ofprotection

EN175301-803withgland

Diameterof con-nectioncable: 5–6mm

IP65

M12x1 Plugcon-nectorM12x1

IP65

Cable - IP67

5.7 Grounding thedevice

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

5.8 Plug connectionPersonnel:n Qualified electrician

Tools:n Flat-bladed screwdriver

Fig. 21: Detach socket

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

Fig. 22: Remove socket

2. Remove the socket (Fig. 22/1)


Plug connection


Fig. 23: Disconnect inner section

3. Remove the inner section fromthe socket. To do this, place aflat-bladed screwdriver into theslot (Fig. 23/1) and carefully pryout the inner section.and care-fully pry out the inner section.

Fig. 24: Disconnect the screw connec-tion

4. Unscrew the screw connection(Fig. 24/1) by turning in the leftdirection

5. Guide the connecting wirethrough the screw connection inthe socket

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

7. Place the inner section(Fig. 23/1) back into the socketand push until it locks on

8. Retighten the screw connection(Fig. 24/1) by turning it to theright


Plug connection


9. Plug the socket onto the con-nector plug and tighten the fixingscrew (Fig. 21/1).

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

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

5.9 Contact protectionmeasures

The Reed-switches used in the switchcontacts are designed to be very 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):


Contact protection measures


Inductive load

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

n Contactors, relaysn Solenoid valvesn Electric motors

Examples of protective measures:

Fig. 27: Example 1

Fig. 28: Example 2

Capacitive loads

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

n Long connecting cablesn Capacitive consumers

Example of protective measure:

Fig. 29: Protective measure againstcapacitive loads

Ohmic loads

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

n Filament bulbsn Motors during startup

Examples of protective measures:

Fig. 30: Example 1

Fig. 31: Example 2




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




6 Operation6.1 Switch point settingSetting 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.


Tools:n Hex 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. 32: Loosen set screw

2. Loosen the set screw of theswitch contact (Fig. 32/1) 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. 32/1) using a hexscrewdriver. When doing so,observe the correct tighteningtorque of the screw.

Ä Chapter 11.1 “Tighteningtorque” on page 72

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


1. Loosen the set screw of theswitch contact (Fig. 33/1) 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. 33/1)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. 34: 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. 34, 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

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” on page 72

– 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

Troubleshooting

Safety


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


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 con-tact is set toohigh

n Adjust the switchcontact to a lowerflow rate

n Use the device atanother measuringrange

n Increase the flowrate

Qualifiedpersonnel

Incorrect reduc-tion fitting or pipediameter is toosmall

n Correct pipe diam-eter

Qualifiedpersonnel

Float is stuck Disassemble and cleanthe device

Qualifiedpersonnel

Switch contact isdefective.

n Remedy the 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

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

RVO/U-4 type flow monitors requirevery little 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.

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 and40 °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


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


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.

WARNING!

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

media residue– Wear personal protective

equipment when workingwith dangerous media

– Improper disassembly maycause serious injuries ifdangerous 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

– To protect against haz-ardous media residue,wear personal protectiveequipment.



Maintenance

Disassembly



Protective equipment:n Gogglesn Protective gloves

Tools:n Hex screwdriver

Fig. 35: Loosen screws

1. Loosen the top 4 hex socketscrews (Fig. 35/1) using a hexscrewdriver.

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

2.

CAUTION!

Carefully pull the processconnection outlet fromthe device housing,turning slightly whendoing so (Fig. 36), do notapply undue force.

The sight glass canbreak if too much force isexerted or if the processconnection is canted

Maintenance

Disassembly


Fig. 37: Loosen screws

3. Secure the device with onehand to ensure the sight glassdoes not slip out. With the otherhand, loosen the lower 4 hexhead screws (Fig. 37/1)

Fig. 38: Remove the inner section

4. Carefully remove the inner sec-tion (Fig. 38/1) of the device(sight glass, spring and floatwith magnets) as a unit togetherwith the process connection inlet(Fig. 38/2) from the devicehousing.

Maintenance

Disassembly


Fig. 39: Remove float, magnets andspring

5. Rotate the inner section as aunit 180°and remove the springand float with magnets

6. Detach the sight glass from theprocess connection (inlet) byturning slightly

7. 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 Wartungsarbeiten

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 may lead to dan-gerous reactions withmedia residue.

– All requirements specifiedin the safety data sheetmust be observed whenhandling or otherwise usingthe medium.

– Residue of hazardousmedia inside the devicecan cause serious injury.

Maintenance

Wartungsarbeiten > Cleaning


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.



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 device.Ä Chapter 8.5.3 “Assembly”on page 55.

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

Maintenance

Wartungsarbeiten > Assembly



Tools:n Hex screwdrivern Torque screwdriver and assorted

blades

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

Fig. 40: O-ring (seal)

1. O-Ring (Dichtung) (Fig. 40/2)vorsichtig mit O-Ring Montage-werkzeug (Fig. 40/1) auf dieVerschraubung aufziehen, sodass er im oberen O-Ringsitzder Verschraubung sitzt(Fig. 42). Dabei darauf achten,dass der O-Ring nicht überdehntwird

Fig. 41: O-ring (Glass buffer)

2. O-Ring (Glaspuffer) (Fig. 41/2)vorsichtig mit O-Ring Montage-werkzeug (Fig. 41/1) auf dieVerschraubung aufziehen, sodass er im oberen O-Ringsitzder Verschraubung sitzt(Fig. 41). Dabei darauf achten,dass der O-Ring nicht überdehntwird

Maintenance



Fig. 42: Position of O-rings

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

Fig. 43: inner parts

4. Insert the spring (Fig. 43/1) andmagnets (Fig. 43/2) into the float(Fig. 43/3) observing the mag-netic polarity (north pole towardthe outlet side).

5. 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 75.

Fig. 44: Process connection (inlet) insight glass

Maintenance



6.

CAUTION!

Insert the process con-nection (inlet)(Fig. 44/1)carefully into the sightglass, twisting lightly.

The sight glass canbreak if too much force isexerted or if the processconnection is canted.

Fig. 45: Spanner flats

7. Position the process connection(inlet) (Fig. 45/1) so, that thespanner flats are at a 90° angleto the sight glass scale. Thelocating bore in the process con-nection must be centered on thefront of the device housinglocating screw.

Fig. 46: Insert the process connectioninto the device housing

8. Insert the process connection(inlet) and sight glass into thedevice housing from below, asshown (Fig. 46) keeping theprocess connection axiallyaligned to the device housingand making sure that thelocating bore in the process con-nection is centered on the frontof the device housing locatingscrew.

Maintenance



Fig. 47: Secure the process connec-tion (inlet)

9. Secure the inlet process con-nection to the device housingwith 4 hex socket screws(Fig. 47/1) observing the propertorque. ( Ä Chapter 11.1 “Tight-ening torque” on page 72)

Fig. 48: Align the sight glass

10. Align the sight glass scale to thesight window of the devicehousing.

Maintenance



Fig. 49: Insert float and inner parts

11. Insert the float, magnets andspring into the device housing.

Fig. 50: Position process connection(outlet) in device housing

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

13. Insert the process connection(outlet) (Fig. 50) into the devicehousing by applying light pres-sure and twisting slightly. Whendoing so, ensure that thespanner flats (Fig. 50) are at anangle of 90° to the sight windowof the device housing.

Fig. 51: Tighten hex socket screws

14. Tighten the 4 hex head screws(Fig. 51/1) observing the propertorque ( Ä Chapter 11.1 “Tight-ening torque” on page 72)

Maintenance



Fig. 52: Check for ease of movement

15. Check the float for ease ofmovement by applying pressurewith the test rod (Fig. 52)

ð If the float moves sluggishly,then disassemble thedevice ( Ä Chapter 9.2 “Dis-assembly” on page 64)and clean the float and sightglass

If the float is still sluggish afterhaving been cleaned severaltimes, contact the manufac-turer.

8.5.4 Switch contactreplacement

Tools:n Flat-bladed screwdrivern Hex screwdriver

Fig. 53: Loosen female socket

1. Loosen the fixing screw of thefemale socket (Fig. 53/1) with aflat-bladed screwdriver.

Fig. 54: Remove female socket

2. Remove the female socket andgasket (Fig. 54/1) by pullingupwards.

Maintenance

Wartungsarbeiten > Switch contact replacement



3. Using a hex screwdriver(Fig. 55/1) remove the set screwof the switch contact

Fig. 56: Remove switch housing

4. Remove the switch contact fromthe guide surface (Fig. 56)

5. Attach the new switch contact

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

7. Insert set screw (Fig. 55/1) andtighten it slightly so that theswitch contact can still moveeasil

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

9. Retighten the set screw(Fig. 55/1) observing the propertightening torque ( Ä Chapter11.1 “Tightening torque”on page 72)

Maintenance

Wartungsarbeiten > Switch contact replacement


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 andremove all 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

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 starting the disassembly:

n Remove operating materials andpackaging and dispose of prop-erly.


Protective equipment:n Protective glovesn Goggles

1. Remove the device from thepipeline ( Ä Chapter 8.3“Removal from the pipe system”on page 49)

2. Disassemble the device( Ä Chapter 8.4 “Disassembly”on page 51)

3. Clean components properly andremove medium residue

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 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


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

Fig. 57: Device data plate

10.2 Switch contactrating plate

Fig. 58: Switch contact rating plate

Fig. 59: 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

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-4/01 1/4 8 17 68 90 10

RVO/U-4/02 1/4 8 17 68 90 10

RVO/U-4/03 1/4 8 17 68 90 10

RVO/U-4/06 1/4 8 17 68 90 10

RVO/U-4/1 1/4 8 17 68 90 10

RVO/U-4/2 1/4 8 17 68 90 10

RVO/U-4/3 1/4 8 17 68 90 10

RVO/U-4/5 1/4 8 17 68 90 10

Type Overall dimensions (mm)

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

RVO/U-4/01 1/4 19 20 - - - 60 140

RVO/U-4/02 1/4 19 20 - - - 60 140

RVO/U-4/03 1/4 19 20 - - - 60 140

RVO/U-4/06 1/4 19 20 - - - 60 140

RVO/U-4/1 1/4 19 20 - - - 60 140

RVO/U-4/2 1/4 19 20 - - - 60 140

RVO/U-4/3 1/4 19 20 - - - 60 140

RVO/U-4/5 1/4 19 20 - - - 60 140

* NPT threads on request

** Sealed in cable weight, 2m 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 measuring ranges

Type Switch range für H2O at 20 °C*

l/min gph gpm

RVO/U-4/01 0,005 – 0,06 0,08 – 0,95

RVO/U-4/02 0,025 – 0,13 0,4 – 2,0

RVO/U-4/03 0,06 – 0,3 1,0 – 4,8

RVO/U-4/06 0,1 – 0,6 1,6 – 9,5

RVO/U-4/1 0,2 – 1,2 3,0 – 19,0

RVO/U-4/2 0,4 – 2,0 0,1 – 0,5

RVO/U-4/3 0,5 – 3,0 0,13 – 0,8

RVO/U-4/5 1,0 – 5,0 0,25 – 1,3

* The specified data are switch-off points. Other switch ranges are available onrequest.

Technical data

Measuring ranges > Standard measuring ranges


10.7 Operating data

Description Value Unit

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

Min. media temp.

It must be ensured thatthe medium does notfreeze.

-20 °C

Max. operating pressure 16 bar

Pressure loss 0,02 – 0,3 bar

Measuring accuracy ± 10 % of full scale value

Operating data for devices employedin explosion hazard zones differs fromthe above and are specified in theOperating Instructions for " RVO/U-4Module ATEX", Chapter 4.

Technical data

Operating data


11 Appendix11.1 Tightening torque

Component/function

Description Size Torque Number

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-4 type flow monitor. The actual configuration may vary depending onthe model.

Item

Nr. ofpieces

Description

1 1 process connection (outlet)

2 1 process connection (inlet)

3 2 O-Ring (glass buffer)

4 2 O-Ring (seal)

5 1 sight glass

6 1 device housing

7 6 hex socket screw

8 1 spring

9 2 magnet

10 1 float

11 1 Cylinder pin (switch contact)

Appendix

Replacement parts


Item

Nr. ofpieces

Description

12 1 switch contact with male connector

13 1 fixing screw, hex.

14 1 female socket and gasket

15 1 fixing screw (female socket)

11.3 ToolsThe following tools are required:

Werkzeug

n Fixed spanner 17 mmn Flat-bladed screwdriver, blade

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

sponding blades

Special tool

n Test rod RVO/U-4n Magnetic pole tester

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

Appendix

Sealant


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

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

Appendix

Lubricants


12 IndexAApplication . . . . . . . . . . . . . . . . . 10Assembly . . . . . . . . . . . . . . . . . . 55

BBasic

dangers . . . . . . . . . . . . . . . . . 11

CCable . . . . . . . . . . . . . . . . . . . . . 35Component groups . . . . . . . . . . . 20Connected loads

NOC . . . . . . . . . . . . . . . . . . . 69

ConnectorM12x1 . . . . . . . . . . . . . . . . . . 34

Contact . . . . . . . . . . . . . . . . . . . . 7Contact protection measures . . . . 38Copyright . . . . . . . . . . . . . . . . . . . 3Correct use in accordance withthese instructions . . . . . . . . . . . . 10Customer service . . . . . . . . . . . . . 7

DDegree of protection

IP-Code . . . . . . . . . . . . . . . . 36

Device data plate . . . . . . . . . . . . . 66Device description . . . . . . . . . . . . 19Dimension sheet . . . . . . . . . . . . . 67Disassembly

Maintenance . . . . . . . . . . . . . 51

DisasssemblyDisposal . . . . . . . . . . . . . . . . 64

Disposal . . . . . . . . . . . . . . . . . . . 65

EElectrical connection . . . . . . . . . . 33Environmental protection . . . . . . . 16

cleaning fluids . . . . . . . . . . . . 16

lubricants . . . . . . . . . . . . . . . 17

FFault table . . . . . . . . . . . . . . . . . 46flow value . . . . . . . . . . . . . . . . . . 43

GGeneral

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

HHazard

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

Hazardsmechanical . . . . . . . . . . . . . . 12

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

radiation . . . . . . . . . . . . . . . . 13

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

IInitial startup . . . . . . . . . . . . . . . . 32Installation

Pipeline . . . . . . . . . . . . . . . . . 28

Index


Preparations . . . . . . . . . . . . . 25

Sealing . . . . . . . . . . . . . . . . . 30

LLimitation of liability . . . . . . . . . . . . 3Lubricant . . . . . . . . . . . . . . . . . . 75

MMaintenance work . . . . . . . . . . . . 49Measuring ranges . . . . . . . . . . . . 70

OOperating conditions . . . . . . . . . . 71Overview . . . . . . . . . . . . . . . . . . 19Owner . . . . . . . . . . . . . . . . . . . . 17

PPackaging . . . . . . . . . . . . . . . . . 21Parts replacement . . . . . . . . . . . . 55Plug connection . . . . . . . . . . . . . 36Plug connector

EN175301-803 . . . . . . . . . . . . 33

PreparationDevice . . . . . . . . . . . . . . . . . 28

RRead-off . . . . . . . . . . . . . . . . . . . 43Replacement parts . . . . . . . . . 16, 73Return Materials Authorization . . . 64

SSafety

disassembly . . . . . . . . . . . . . . 64

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

Safety instructionstransport . . . . . . . . . . . . . . . . 21

Sealant . . . . . . . . . . . . . . . . . . . 74Service . . . . . . . . . . . . . . . . . . . . 7Sight glass . . . . . . . . . . . . . . . . . 20Specifications

Change-Over Contact (COC) . . 69

Storage . . . . . . . . . . . . . . . . . . . 22Strainer . . . . . . . . . . . . . . . . . . . 27Switch contact . . . . . . . . . . . . . . . 20Switch contact housing

replacement . . . . . . . . . . . . . . 61

Switch contact rating plate . . . . . . 66Switch point . . . . . . . . . . . . . . . . 41Symbols

packaging . . . . . . . . . . . . . . . 22

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

TTechnical data

General specifications . . . . . . . 68

Tightening torque . . . . . . . . . . . . 72Tightening torque of screws . . . . . 72Tools

Special tools . . . . . . . . . . . . . 74

Transport inspection . . . . . . . . . . 21

UUnimpeded flow sections . . . . . . . 26

Index


WWarranty and guarantee provisions 7

Wartungsarbeiten . . . . . . . . . . . . 54

Index


RVO/U-4 Module BASICS Flow Monitor · 10 RVO/U-4 Module BASICS Flow Monitor 06.11.2017. All claims...

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Transcript of RVO/U-4 Module BASICS Flow Monitor · 10 RVO/U-4 Module BASICS Flow Monitor 06.11.2017. All claims...