Operating Instructions DB04 - PKP Prozessmesstechnik GmbH
Contents
1. PKP Prozessmesstechnik GmbH Borsigstrasse 24 D 65205 Wiesbaden Nordenstadt Tel 06122 7055 0 Fax 06122 7055 50 Operating Instructions DB04 Thermal mass flowmeter for gases without auxiliary power Table of Contents 01 Introduction Operator Benefits Service and Quality Guarantee 02 Mode of Operation Measurement principle CMOS Technology 03 Technical Information General Specifications of the Device Mechanical Specifications Electrical Data Display Measurement Ranges Connector Assignment Conversion Factors for other Gases Loss of Pressure Temperature Compensation Pressure Compensation 04 Mounting amp Installation General Tips Installation Position Location Mechanical Piping Electrical Connection Power Supply Gas Supply 05 Operation amp Service Warm Up Time Zero Point Check Service Cleaning in the Event of Soiling Replacement of Battery Returns 06 Alarm amp Switch Function Individual Functions in Detail Diagram of Function Settings Alarm situations 07 Totalizer General Function Reset 08 Dimensions 09 Annex Drop of Pressure 11 13 15 18 19 21 Chapter Page 00 3 01 Introduction Welcome With DBO4 you get the latest most modern CMOS sensor technology CMOSens is a technology abel and stands for a modern process in which the sensor and the signal processing are combined on a highly integrated chip This manual will2. Special steel casing electropolished PBT sensor Viton seal Options Totaliser EDPM seals 24 V DC supply for DBO4 1 and 2 Calibration protocol Medium air N2 O2 Other media PKP Prozessmesstechnik GmbH Borsigstra e 24 D 65205 Wiesbaden amp 49 0 6122 7055 0 49 0 6122 7055 50 Email info pkp de Internet www pkp de Ordering Code Order no DB04 1 01 A 0 L Thermal mass flowmeter for gases Version 1 Flowmeter 2 Flowmeter with manual regulating valve 3 Flowmeter and switch 4 Flowmeter and switch with manual regulating valve Measuring range air 01 0 004 0 2 Ni min 02 0 01 0 5 Ni min 03 0 04 2 NI min 04 0 1 5 Ni min 05 0 4 20 Ni min 06 1 50 Ni min 07 2 100 Ni min 08 4 200 Ni min Material A Aluminium casing E Stainless steel casing Options 0 without E EPDM seals V Voltage supply 24V DC for DB04 1 2 K Calibration protocol Medium L Standard medium air N Standard medium N2 O Standard medium O2 S Other media please indicate in block letters Technical data Max pressure 10 bars Medium temperature 0 50 C Measurement uncertainty 1 f s d Response time 500 ms Voltage supply Lithium battery type AA service life approx 2 years or 24V DC 10 Display LCD 4 digit Installation position up to 5 bars any position over 5 bars ho
3. Loss 5 In min Air 3 5 3 0 25 Pressure Loss mbar 2 0 15 1 0 0 5 1 2 3 4 5 Flow In min Pressure Loss 50 In min Air 3 120 WY 0 10 20 30 40 50 Flow In min Chapter Page 09 21 Pressure in mbar Pressure mbar g Annex Pressure Loss 200In min Qin Infmin Chapter Page 09 22 Flow Metering and Monitoring Systems DB04 Thermal mass flowmeter for gases without auxiliary power e Pressure and temperature independent measurement e Compact design no need for straight pipe runs e LCD display flow rate and bar graph e Needle valve switch output and totaliser as options e High degree of measuring precision e Turndown ratio up to 50 1 e Battery operated no external power supply needed Description The DB04 thermal mass flowmeter is a modular system for the measurement of the flow of gases Due to its being in dependent of any power supply because of its integrated battery and its excellent cost effectiveness the device can replace conventional variable area flowmeters in many cases The DB04 can be supplied in a number of versions as a flowmeter with an integrated regulating valve a totaliser or with an adjustable limit switch Depending on the medium the device can be made of either stainless steel or aluminium BEE PKP Process Instruments Inc 10 Brent Drive Hudson M
4. P 50 front side P 65 With battery module useful life ca 2 years 24V de 10 Floating change over contact 24 Vide 1A For present flow rate with bar graph and the corresponding unit Configuration parameters for the alarm function Chapter Page 03 8 Technical Information Measurement Ranges DB04 measurement and control devices are supplied with standard measurement ranges for air As an option the devices are available with individual measurement ranges and upon request can be calibrated with other gases Standard Measurement Ranges Meas range Unit Meas range Unit 200 minimin 20 nimin 500 minimin 50 nlmin 2000 min min 100 n min 5000 min min 200 n min Connector Assignment Instruments with the switch or external power supply are fitted with a cable 2m length with the following assignment Color Assignment Color Assignment white 24 Vdc grey ALL normal open brown 0 Vde pink not assigned grenn ALL common blue not assigned yellow AL 1 normal closed red not assigned Conversion Factors for other Gases Every instrument is fully and automatically calibrated on an ultra modern calibration system The internal conversion to the defined medium is done according to the application Should you change the mass medium this may be corrected via conversion factors For this contact your sales partner Depending on the medium these conversion factors generate an additional measurement erro
5. familiarize you with the installation and operation of your DBO4 Ne therefore ask you to read this manual carefully and to contact your sales partner with any questions or doubts Ne have prepared this manual very carefully in order provide you with appropriate and precise information and instructions However no liability is assumed for any errors Operator Benefits Ultimately a technology only represents a means to an end Therefore all of our efforts are aimed at the requirements and wishes of the user of this instrument and his measurement and regulation tasks Battery operated thermal mass flow meters Optional alarm function Compact easy to install measurement or regulation unit CE approved Easy maintenance and service Easy expansion of functionality 3 year guarantee Top performance in response dynamics and accuracy Matching options and accessories Service and quality Ne continuously improve the quality of our products and services Only with use does it ultimately become clear whether the right product has been selected Thus we attempt not only to propagate good service and high quality but to live it every day Guarantee The guarantee for DB04 for gasflow products extends to material defects and production flaws The guarantee maximum is the replacement of the equipment at no cost Claims are omitted in the case of inappropriate use external effects in general excessive heat or dropping We a
6. notify us and pack the device tightly H you have any further questions please contact your sales partner Chapter Page 05 14 06 Alarm amp Switch Function Alarm amp Switch Function Individual Functions in Detail Resetting the Alarm Condition AL chr In the case of alarm condition the alarm can be reset This is only possible if the manual option is selected in the corresponding menu resetting the alarm AL r ES The alarm condition is shown in the display Setting the Alarm Setpoint AL DECH The desired threshold can be set with the keys This value can be between D and the maximum possible measurement value The threshold unit corresponds to the measurement value Alarm Functions ALF Unic Measurement values greater AL h A or lower AL La than the threshold value that are considered an alarm condition can be defined In addition the alerter function can be deactivated AL FF Failsafe Mode FR iL SA H this function is activated the switching logic of the outlet is operated in such a way that alarm conditions as well as device failure and line break can be detected In the examples you will find the switching manner of the contact in the case of activated function Setting the Alarm Delay Time dE LAY An adjustable time of 0 180 sec during which the alarm condition should last until the alarm contact is appropriately activated If the upper or lower threshold is surpassed the trig
7. A 01749 amp 1 978 212 0006 1 978 568 0060 Email info pkp eu Internet www pkp eu The DBO4 measures flows of 4 200 Nml min up to 4 200 NI min The standard calibration medium is air but a number of other gases such as O2 N2 He Ar etc can be measured A 4 digit LCD display combined with a bar graph display al lows the measurements to be read off simply and quickly The device operates in any position and can be easily cleaned without the need for recalibration PKP Prozessmesstechnik GmbH 1 08 BorsigstraBe 24 D 65205 Wiesbaden amp 49 0 6122 7055 0 49 0 6122 7055 50 Email info pkp de Internet www pkp de Versions DB04 1 Mass flowmeter battery operated DB04 2 Mass flowmeter battery operated with integrated manual regulating valve DB04 3 Mass flowmeter 24V DC externally supplied with integrated limit switch DB04 4 Mass flowmeter 24V DC externally supplied with manual regulating valve and limit switch Measuring ranges and dimensions Measuring Con A B C D E range nection NL min G IG mm mm mm mm mm 0 004 0 2 1 4 114 89 44 44 25 0 01 0 5 1 4 114 89 44 44 25 0 04 2 1 4 114 89 44 44 25 0 1 5 1 4 114 89 44 44 25 0 4 20 1 4 114 89 44 44 25 1 50 1 4 114 89 44 44 25 2 100 1 2 160 89 54 54 35 4 200 1 2 160 89 54 54 35 m How A Materials DB04 x x A Aluminium casing PBT sensor Viton seal DB04 x x E
8. Chapter Page 04 11 Mounting amp Installation Electrical Connection Power Supply With the battery operated devices mount the battery module Then the measuring device is ready for use The useful life of the battery module is about 2 years but this depends on use With constantly changing flow rates the useful life may be shorter We advise you to use only original battery modules With the external power supply and alarm options you receive a connector cable with loose ends The assignment is printed on the cable You have the option of turning the cable outlet by 180 To do this you open the cover in back by hand and turn the plastic block to the desired direction Turning the cable outlet by 180 The supply voltage must be 24 Vdc 10 and have the lowest possible residual ripple Please note that voltage drops may occur with longer connecting cables Likewise be aware of possible earth loops when you ground electrically conductive pipes Gas Supply Ne recommend that you pay close attention to the gas supply line Contamination in the form of Water oll or dust are harmful to any measurement principle Particularly in the case of air supply with compressor systems cleanliness cannot always be guaranteed In case of doubt install the appropriate filter If use related backflows are to be expected this filter should also be installed at the outlet Please monitor possible pressure loss due to t
9. ation of the manual control valve cannot be guaranteed if the pressure differential is too low or too high Chapter Page 03 10 04 Mounting amp Installation Mounting amp Installation General Tips Check the packet for external damage and contact us immediately in the case of visible damage Compare the contents of the packet with the delivery slip and check for completeness and technical compliance This product is a high precision measuring instrument We advise you to select the installation site carefully and to follow the instructions and suggestions below Before installation be sure that the data on the nameplate corresponds to the use and that the Maximum pressure occurring in the system are lower than the specified test pressure of the device Installation Position Location Ne recommend a horizontal installation position With higher pressure gt 5 bars depending on the medium an additional offset error can occur with a vertical installation position Check that no heat sources or electrical sources with strong emissions are found near the measuring device Avoid constant vibrations or other disturbing mechanical effects stress H there is a risk of fluid backflow during malfunction then you should not mount the measuring device at the lowest point of the pipe Mechanical Pipes The pipe work is very important and this is often underestimated Inlet paths dead volume of the correct amoun
10. djustable with an oFF Mo button pressed for 105 a adjustable with i NEXT Alarm Reset Mode AL res Chapter Page 06 16 Alarm amp Switch Function Alarm situations Situation 1 Parameters Function Value Function Value Function Value ALSEtP 25 DELAY 10s AL rES AUto ALFUNC ALLO HYST 05 FAILSA Off LoSUPr On A Flow 4 Hysteresis Setpoint aa Range A Alarm 50s 100s t Situation 2 Parameters Function Value Function Value Function Value ALSEtP 25 DELAY 10s AL rES MAnu ALFUNC AL HI HYST 05 FAILSA On LoSUPr OFF A Flow 4 Range 3 Setpoint Hysteresis 50s 100s t A Alarm Lo gt 50s 100s t Chapter Page 06 17 07 Totalizer Totalizer General The Totalizer function can be activated by the manufacturer Function The instrument calculates the integrated value of the gas volume The added up value is periodically displayed and stored in intervals of 15 minutes in the non volatile storage EPROM In the event of a power disruption the Totalizer therefore displays the correct total volume It is however possible that the gas volume for the past 15 minutes may be lost The added up volume of the Totalizer and the flow value are alternatively displayed The display intervals are adjusted by the manufacturer as follows Flow 5s Total 3s The unit of the Totalizer volume is ad
11. easurement functions CMOS Technology DB04 measurement and regulation units feature a new basic technology that sets standards for Maximum precision sensor systems The fusion of a semi conductor chip with sensor technology results in a highly integrated system solution that is impressive for its excellent sensor precision as Well as digital intelligence and reliability The most notable advantages to the customer are the outstanding precision of the sensor the rapid response time and a dynamic measuring range that no system has attained up until now Thanks to the compact single chip design CMOSens based sensors are extremely resistant to electromagnetic interference EMI a significant technical advantage of this ultra modern sensor technology Nith CMOSens the sensor element amplifier and A D converter form a unit on the same silicon chip Chapter Page 02 6 Mode of Operation The digital intelligence linked with the CMOSens sensor permits the emission of a fully calibrated temperature compensated output signal The CMOSens intelligence integrated onto the chip thus facilitates an extremely simple processing of the emitted measurement data CMOS is a standard technology for the manufacture of integrated circuits CMOS chips are generally known as semi conductor chips silicon chips or computer chips They are widely used in PCs mobile telephones and many other information techn
12. ections On the inlet side carefully unscrew the flow rectifier together with the flow divider With this design there are no o rings in this area You can now clean the entire flow module with a mild solution e g IPA Afterwards ensure that the bored holes are absolutely clean dry and cleared Chapter Page 05 13 Operation amp Service Battery Replacement f low bat appears in the display we recommend that you change the battery or at least have a new battery module Ne recommend the following procedure with the replacement of the battery Changing the battery requires no tools at all The battery module snaps into two lateral housing clips Hold the measuring device firmly with one hand on the main body metallic part and pull the battery module out toward the back keeping it as level as possible Then place the new module in as straight as possible from the back and press in the direction of the measuring device until it snaps into the clips After the battery is changed the device goes through a self test and is then ready for use Replacement of battery module Returns With the return of a measurement or regulation device use the original packaging if possible or other appropriate packing Please inform us of the reason for the return in order to spare any unnecessary callbacks and delays Should the device come in contact with dangerous substances please clean the device carefully
13. gering of the alarm is prevented Setting the Alarm Hysteresis RASE Should the momentary flow rate and the established threshold be close to one another setting the hysteresis prevents the alarm from constantly going on and off The value can be from 0 to 10 of the maximum possible target value Setting the Low Alarm Suppression La SUP r H a minimum alarm AL Lo is configured and if the flow rate is at zero from the start this triggers the alarm immediately With the low suppression function this can be avoided Here the alerter function is only activated if the flow rate is over the threshold Alarm Reset Mode FL r E5 There are two options Auto The alarm automatically resets after the flow rate returned to normal condition Manu Manual reset with the function AL cir Chapter Page 06 15 Alarm amp Switch Function Diagram of Function Settings both button pressed for 2s Measuring m e Alarm reset NEXT Dn UI no button pressed for2s HL ce one button pressed for 2s no button pressed for 10s Y i adjustable with Alarm Setpoint P P AL SE E H a 0 max Flow Ze NEXT adjustable with Alarm Functions y NEXT adjustable with SET Failsafe Mode on F Pp oFF FALSA u y NEXT Alarm Delay Time i d E Un H 4 y NEXT adjustable with Alarm Hysteresis D 10 of full scale a
14. he filter elements The gas supply should be oversized and have the capacity of at least twice the flow rate of the attached measuring device Monitor the performance of the pressure reducing unit as well Never install the pressure regulator directly in front of the measuring device Check for possible pressure loss along the pipeline system Flow regulators especially require defined pressure ratios for proper functioning With very low flow rates pressure reduction is oversized and gas is only periodically fed on off regulation This becomes evident in the form of periodic fluctuations in the regulation or changes in the flow rate Avoid abrupt pressure buildup in the system This can lead to damage Charge the system with pressure only after establishing the electrical connections Be sure to have an inert gas e g nitrogen available for flushing in the case of dangerous abrasive or corrosive gases Chapter Page 04 12 A 05 Operation amp Service Operation amp Service Heat Up Time Right when the device is turned on it is ready for use For the most precise measurements however itis ready in 30 minutes option of external feed Before turning on please be sure that the wiring is correct and is installed according to the installation plan and that the gas connections are also mounted in accordance with the installation instructions of the manufacturer Zero Point Check Without any spec
15. ial specifications for the installation position of the device the zero point is aligned at operating temperature and horizontal installation position before delivery If the device is installed vertically a value can be read out at a zero flow rate according to operating pressure During the check be completely sure that no gas is flowing In the case of a shift in the zero point please contact your sales partner Service With proper operation DBO4 does not require any routine service at all lf the measurement value is in a quality relevant range e g ISO 9001 we recommend a periodic check of calibration The interval depends strongly on use Cleaning in the Case of Contamination Should there be suspicion of contamination sudden deviation of measurement value in familiar processes visible traces in the piping etc try flushing the device with a dry inert gas Depending on the contamination it may be necessary to dismantle the device Tips Use only designated tools Handle the device and individual components with extreme care Ensure that the dismantling area is clean The guarantee lapses at all events with the dismantling of the device Never loosen a torx screw Do not touch the electronic circuit board or electronic components under any circumstances After the cleaning you should have the device checked by your sales partner at the first opportunity Dismantling Flow Module Disconnect the gas and electrical conn
16. justed by the manufacturer Reset The Totalizer function can be activated by the manufacturer in two different modes 1 Totalizer without reset In the event of a power disruption the most recently registered value from the non volatile storage EEPROM is loaded and added up further 2 Totalizer with reset n the event of a power disruption the Totalizer volume is set to zero and from then on resumes adding up Chapter Page 07 18 43 3 08 Dimensions Dimensions G1 4 15 23 5 w Chapter Page 08 19 Dimensions G1 2 Dimensions 53 3 35 47 2 non G 2xX15 52 7 p 88 6 SL 160 Befestigungsgewinde Mounting threads Filets de fixation Ansicht A View A Vue A 130 130 Chapter Page 08 20 Annex 09 Annex Pressure Loss Pressure Loss 500 min min Air a a N Pressure Loss nbar m Pr rm oO 0 6 0 4 0 2 0 100 200 300 400 500 Flow min min Pressure
17. measurement depends on the type of gas in addition to the specific heat the standard density 0 C 1 01325 bar a for the conversion to standard volume ts also used With all design options of the measuring principle there is always a heater and one or more temperature measurement points and the gasflow draws heat from the heater With the mass flow meter a constant heating power ensures a temperature difference that is directly proportional to the gas flow rate In the flume a temperature measurement e followed by a heater and then a temperature measurement again The figure below illustrates this process If the flow rate 0 the heater H uniformly distributes the heat for which the temperature difference T1 T2 equals zero Two effects occur with the flow rate that lead to a temperature difference First the temperature sensor TL at the entrance detects a lower temperature This happens because of the cooling of the entering gas which theoretically drops to the ambient temperature respective of gas Secondly the gas flowing over the heater carries heat to the temperature sensor T2 located after the heater and thus increases this temperature The temperature difference is in direct proportion to the mass flow AT2 wr KT Pa AT H nn mr gt flow T1 2 I lg an A AA A aa AT le i Lt environment si vn Figure 2 Schematic illustration of how thermal mass m
18. ology devices Battery ae Power Supply Alarm contact or SPI LCD uP EEPROM Push buttons f Wang Sensor uP Control E s Vale Sensor Esc E Flow rectifier Figure 2 Block diagram of the hardware Chapter Page 02 7 03 Technical Information Technical Information General Specifications of the Device Accuracy Dynamics Standard measurement range Repeatability Long term stability Temperature coefficient Pressure coefficient Operating pressure Temperature range Leak rate Heat up period Mechanical specifications Materials Design Code A Alu Design Code E high grade steel Sensor Sealing material Process connection Protection category Electrical data Supply voltage Battery operation External feed Alarm contact switch and all in Function Max voltage Max current Display LC Display l 1 of full scale 2 100 within the specification Signal suppression less than 2 of full scale 1 from measurement value lt 1 from measurement value year lt 0 2 bar typical N2 up to 10 bar g Q 50 C 1x 10 mbars Ve He 30 minutes for maximum accuracy Aluminum nickelized brass stainless steel Stainless steel PBT epoxy FKM optional EPDM or PTFE Inside thread G1 4 G1 2 on both sides optional with compression fittings see accessory annex
19. r Note In the case of plant calibration with a gas other than air an increased zero offset may be displayed when the device is not operated with the calibrated gas Pressure Loss The thermal mass flow meters feature little pressure loss This essentially depends upon the medium operating pressure and the flow rate In the annex chapter 08 page 19 you will find a table that shows the typical course of pressure loss in air 20 C 1 013 bar a for the three Measurement devices The pressure loss for other gases can be calculated using the formula AP uired AP x Za 1 250 Please note that pipes that are two small and unsuitable fittings are often the cause of excessive pressure loss in the system For trouble free operation devices with manual control valve require a certain pressure differential which is specified on the nameplate Chapter Page 03 9 Technical Information Temperature Compensation Thermal mass flow meters measure the flow of gases to a large extent independent on pressure and temperature Varying temperatures are automatically compensated by the measurement device The sensor measures gas temperature and automatically calculates a correction value using a three dimensional value table Pressure Compensation With the calibration the operating pressure specified with the order is also taken into consideration With pressure changes an additional error can occur Please note that the oper
20. re always grateful for information on existing defects for suggestions for improvements and for critiques Chapter Page 01 4 Introduction Tips and Warnings Before putting the instrument into use these operating instructions should be read thoroughly mproper use errors for lack of understanding and the consequences arising from this can lead to the destruction of the instrument or even the endangerment of personnel The equipment should be put into operation and serviced by appropriately qualified personnel only The proper handling of the products is an absolute requirement for its trouble free operation Electrostatic discharges can destroy the electronic components of this measurement and regulation unit Chapter Page 01 5 02 Mode of Operation A bit of theory Measuring principle The measuring principle of thermal flow measurement is perfectly suited for the measurement of gas flows One of the significant advantages is that the measurement is largely independent of pressure and temperature By contrast to volumetric principles pressure and temperature do not have to be additionally measured Although the principle yields mass as a measurement result e g g min most devices are calibrated to standard volumes e g In min One possible explanation is the fact that the comparability of the measurement results with other principles ts given with this Since the thermal flow
21. rizontal Limit value output Potential free change over contact 24 V 1 A MIN or MAX alarm switching point delay hy Function steresis programmable PKP Process Instruments Inc 10 Brent Drive Hudson MA 01749 amp 1 978 212 0006 1 978 568 0060 Email info pkp eu Internet www pkp eu
22. t proper grounding clean pipes and leak free connections have a decisive effect on the quality of the measurement Be sure that the piping used is absolutely clean Use suitable pipe materials compressive strength durability With permanent pipes it is also recommended that the device be fixed with the mounting holes provided for this Avoid when possible a 90 angle directly at the inlet If there is no other possibility consult your sales partner Use appropriate fittings which are preferably sealed with o rings on the front side against the body of the device Please do not hold on the housing while tightening the fittings Never use liquid sealant If it has not hardened it can spread all through the measuring device during flow Optimize the pipe length between pressure reducing unit and flow meter A certain dead volume must be available with high flow rates in particular The pipe diameter must likewise be adapted to the flow rate Pipe sections that are too small cause high pressure loss and can impair the operation of the device Check the piping for any leaks The measuring devices have a flow rectifier Nevertheless with high flow rates gt 50 In min we recommend that you install an inlet path 10 times pipe diameter With critical applications e g consumption metering with gas supply we recommend the installation of a bypass system with which you can continue to draw gas in the case of service or repairs
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