Meister DWG-3 Operating Instructions Manual

DWG Module BASICS

Flow Monitor

Operating instructions

Series DWG

Type DWG-1,5 thru 50

Read this manual prior to performing any task!

DWG Modul BASICS, 2, en_US

Meister Strömungstechnik GmbH

Im Gewerbegebiet 2

63831 Wiesen

Germany

T

elephone: +49 6096 9720 - 0

Fax: +49 6096 9720 - 30

E-mail: sales@meister-flow.com

Internet: www.meister-flow.com

These instructions were compiled by:

Meister Strömungstechnik GmbH

Subject to change without notice

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DWG Module BASICS Flow Monitor

2

These instructions facilitate the safe

and ef

ficient 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 be

kept within easy reach for the per-

sonnel in the immediate vicinity of the

device at all times. Personnel must

carefully read and understand these

instructions before commencing all

work. The basic requirement for safe

work is adherence to all safety and

handling instructions stipulated in

these instructions. The local accident-

prevention regulations and general

safety standards and regulations for

the field of application of the device

also apply. Illustrations in these

instructions are provided to aid general

understanding and might deviate from

the actual model. No claims can be

derived from any such differences.

Limitations of liability

All details and instructions in this

manual have been compiled under

consideration of the valid standards

and regulations, the current state-of-

technology and our many years of

knowledge and experience. The manu-

facturer does not accept any liability

arising from:

n non-observance of any details in

these instructions

n improper use of the device, or use

that is not in accordance with

these instructions

n use of non-trained personnel

n unauthorized retrofitting or tech-

nical changes that have not been

authorized by the manufacturer

n use of non-approved replacement

parts

The duties and obligations agreed

upon in the delivery contract apply in

full, as well as the general terms and

conditions, the terms of delivery by the

manufacturer and the valid legal regu-

lations applicable at the conclusion of

the contract.

Copyright

These operating instructions are pro-

tected by copyright.

Except for internal purposes, transfer

of 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 written

authorization from Meister Strömung-

stechnik ("manufacturer"). Violations

are subject to claims for indemnifica-

tion. The manufacturer reserves the

right to assert additional claims.

Copyright is the property of the manu-

facturer.

Im Gewerbegebiet 2

63831 Wiesen

Germany

Supplemental directives

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DWG Module BASICS Flow Monitor

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Table of contents

1

Overview................................................................................................... 10

1.1 Short description................................................................................ 10

1.2 Warranty and guarantee provisions................................................... 10

1.3 Customer service............................................................................... 10

2 Safety......................................................................................................... 1

1

2.1 Explanation of symbols...................................................................... 11

2.2 Correct use in accordance with these instructions............................ 13

2.3 Special precautions........................................................................... 14

2.3.1 Hazards from electrical current....................................................... 15

2.3.2 Mechanical hazards........................................................................ 15

2.3.3 Hazards from high or low temperatures......................................... 16

2.3.4 Radiation hazards........................................................................... 17

2.3.5 Hazards caused by media.............................................................. 17

2.4 Personnel requirements.................................................................... 18

2.5 Personal safety equipment................................................................ 18

2.6 Protective systems............................................................................ 19

2.7 Replacement parts............................................................................ 20

2.8 Environmental protection................................................................... 20

2.9 Responsibility of the owner................................................................ 21

3 Design and function................................................................................. 23

3.1 Overview............................................................................................ 23

3.2 Device description............................................................................. 23

3.3 Component description...................................................................... 24

4 Transport, packaging and storage......................................................... 25

4.1 Safety instructions for transport......................................................... 25

4.2 Transport inspection.......................................................................... 25

4.3 Packaging.......................................................................................... 25

4.4 Symbols on the shipping box............................................................. 26

4.5 Storage.............................................................................................. 26

5 Installation und initial startup................................................................. 28

5.1 Safety................................................................................................ 28

Table of contents

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5.2 Requirements at the place of installation........................................... 28

5.3 Preparatory work............................................................................... 29

5.4 Installation in the pipe system........................................................... 33

5.5 Initial startup...................................................................................... 37

5.6 Electrical connection.......................................................................... 38

5.6.1 Switch contact SG-30 with connector in compliance with

EN175301-803

............................................................................... 39

5.6.2 Switch contact SG-30 with plug connector M12x1......................... 40

5.6.3 Switch contact SG-30 with cable.................................................... 41

5.6.4 Degree of protection (IP-Code)...................................................... 42

5.7 Grounding the device........................................................................ 42

5.8 Plug connection................................................................................. 43

5.9 Contact protection measures............................................................. 45

6 Operation.................................................................................................. 47

6.1 Setting the switch point...................................................................... 47

6.2 Checking the flow.............................................................................. 49

7 Troubleshooting....................................................................................... 51

7.1 Safety................................................................................................ 51

7.2 Troubleshooting guide....................................................................... 53

8 Maintenance............................................................................................. 55

8.1 Safety................................................................................................ 55

8.2 Maintenance plan.............................................................................. 55

8.3 Removal from the pipe system.......................................................... 56

8.4 Disassembly...................................................................................... 58

8.5 Maintenance...................................................................................... 61

8.5.1 Cleaning......................................................................................... 62

8.5.2 Parts replacement.......................................................................... 63

8.5.3 Assembly........................................................................................ 63

8.5.4 Switch contact replacement............................................................ 70

8.6 Measures to be taken after maintenance work.................................. 72

9 Disassembly and disposal...................................................................... 73

9.1 Safety................................................................................................ 73

9.2 Disassembly...................................................................................... 73

Table of contents

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9.3 Return Materials................................................................................ 74

9.3.1 Return Materials Authorization....................................................... 74

9.4 Disposal............................................................................................. 74

10 Technical data.......................................................................................... 75

10.1 Device data plate............................................................................. 75

10.2 Switch contact data plate................................................................. 75

10.2.1 Switch contact data plate for UL Recognized switch contacts..... 75

10.3 Dimension sheet.............................................................................. 76

10.4 General specifications..................................................................... 77

10.5 Electrical specifications................................................................... 79

10.5.1 Electrical specifications for UL Recognized devices.................... 80

10.6 Measuring ranges............................................................................ 81

10.6.1 Standard measuring ranges......................................................... 81

10.7 Operating data................................................................................. 82

11 Annex........................................................................................................ 84

11.1 Tightening torque of screws............................................................. 84

11.2 Replacement parts........................................................................... 84

11.3 Tools................................................................................................. 86

11.4 Sealant............................................................................................. 86

11.5 Lubricants........................................................................................ 87

12 Index.......................................................................................................... 88

Table of contents

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List of figures

Fig. 1:

DWG flow monitor........... 10

Fig. 2:

Front view........................ 23

Fig. 3:

Switch contact and

female socket

.................. 24

Fig. 4:

Sight glass....................... 24

Fig. 5:

Installation position/direc-

tion of flow....................... 29

Fig. 6:

Unimpeded flow section.. 31

Fig. 7:

Unimpeded outlet............ 31

Fig. 8:

Strainer............................ 32

Fig. 9:

Apply sealing thread........ 35

Fig. 10:

Pipe connection with

sealing thread.................. 35

Fig. 11:

Screw in the device......... 36

Fig. 12:

Screw in the device......... 36

Fig. 13:

Switch position under no-

flow condition.................. 39

Fig. 14:

Pin assignment, plug

socket, normally-open

contact. The ground-pin

is not used....................... 39

Fig. 15:

Switch position under no-

flow condition.................. 39

Fig. 16:

Pin assignment, plug

socket, change-over con-

tact. The ground-pin is

not used.

......................... 39

Fig. 17:

Pin-assignment, socket

M12x1 (Form 30x70)....... 40

Fig. 18:

Switch position under no-

flow condition.................. 40

Fig. 19:

Switch position under no-

flow condition.................. 40

Fig. 20:

Switch position under no-

flow condition.................. 41

Fig. 21:

Switch position under no-

flow condition

.................. 42

Fig. 22:

Detach socket................. 43

Fig. 23:

Remove socket............... 43

Fig. 24:

Loosen inner section....... 43

Fig. 25:

Loosen the screw con-

nection............................. 44

Fig. 26:

Pin assignment, plug

socket, normally-open

contact (SG-30 with con-

nector in compliance with

EN175301-803)............... 44

Fig. 27:

Pin assignment, plug

socket, change over con-

tact (SG-30 with con-

nector in compliance with

EN175301-803)............... 45

Fig. 28:

Example 1....................... 45

Fig. 29:

Example 2....................... 45

Fig. 30:

Protective measure

against capacitive loads.. 46

Fig. 31:

Example 1....................... 46

Fig. 32:

Example 2....................... 46

Fig. 33:

Loosen set screws.......... 47

Fig. 34:

Loosen set screws.......... 48

Fig. 35:

Reading-off the meas-

uring scale....................... 49

Fig. 36:

Loosen screws................ 59

Fig. 37:

Remove the process con-

nection (outlet)................ 59

Fig. 38:

Slot nozzle buffer O-

ring.................................. 60

Fig. 39:

Loosen screws................ 60

Fig. 40:

Remove the inner sec-

tion.................................. 61

List of figures

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Fig. 41:

Remove slot nozzle......... 61

Fig. 42:

O-ring (seal).................... 63

Fig. 43:

O-ring (glass buffer)........ 64

Fig. 44:

Position of O-rings........... 64

Fig. 45:

O-ring (centering the slot

nozzle)

............................. 64

Fig. 46:

Insert slot nozzle............. 65

Fig. 47:

Centering the slot

nozzle.............................. 65

Fig. 48:

Float................................ 66

Fig. 49:

Process connection

(Inlet)............................... 66

Fig. 50:

Spanner flats................... 67

Fig. 51:

Insert the process con-

nection into the device

housing............................ 67

Fig. 52:

Secure the process con-

nection (inlet)................... 67

Fig. 53:

Align slot nozzle.............. 68

Fig. 54:

O-ring, slot nozzle

buffer............................... 68

Fig. 55:

Position the outlet

process connection......... 69

Fig. 56:

Tighten hex socket

screws............................. 69

Fig. 57:

Check for free move-

ment................................ 70

Fig. 58:

Loosen female socket..... 70

Fig. 59:

Remove the female

socket.............................. 70

Fig. 60:

Loosen set screws.......... 71

Fig. 61:

Release the guide rail .... 71

Fig. 62:

Rotate guide rail to the

side.................................. 71

Fig. 63:

Remove switch contact... 71

Fig. 64:

Device data plate............ 75

Fig. 65:

Switch contact rating

plate................................ 75

Fig. 66:

Switch contact rating

plate with positioning

arrow .............................. 75

Fig. 67:

Switch contact data

plate................................ 75

Fig. 68:

Adhesive label, switch

contact with positioning

arrow .............................. 75

Fig. 69:

Replacement parts

drawing............................ 85

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DWG Module BASICS Flow Monitor

8

List of tables

Table 1:

Correct use in non-

hazard areas

................... 13

Table 2:

Correct use of UL Rec-

ognized Components in

non-hazard areas........... 13

List of tables

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DWG Module BASICS Flow Monitor

9

1 Overview

1.1 Short description

Fig. 1: DWG flow monitor

1 Sight glass with measuring scale

2 Female socket or connection

cable

The flow monitor DWG monitors the

continuous flow of liquids. It is

designed for installation in pipe sys-

tems.

A float inside the device is moved by

the medium flowing through it. The

current rate of flow can be read-of

f on

the measuring scale on the sight glass.

The top edge of the float is the read-off

point.

External measuring devices can be

connected at the socket.

1.2

Warranty and guar-

antee provisions

Warranty and guarantee provisions are

contained in the general terms and

conditions of Meister Strömung-

stechnik.

1.3 Customer service

For technical support, please contact

our customer service department (for

contact details, see Page 2).

Furthermore, our staff is always inter-

ested in receiving new information and

experiences gained from application of

the device, which may be useful in

improving our products.

Overview

Customer service

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DWG Module BASICS Flow Monitor

10

2 Safety

This chapter provides an overview of

important safety aspects required for

optimum protection of personnel as

well as for safe installation and safe

operation of the device.

Non-observance of the handling and

safety instructions listed in this manual

may result in hazardous/dangerous

conditions and in damage to property

.

2.1 Explanation of sym-

bols

Safety instructions

Safety instructions in this manual are

marked by symbols. The safety

instructions are preceded by signal

words 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 instructions

and proceed carefully.

DANGER!

This combination of symbol and

signal word indicates an imme-

diate, dangerous condition that

results in death or serious injury

if it is not avoided.

WARNING!

This combination of symbol and

signal word indicates a possibly

dangerous condition that might

result in death or serious injury

if it is not avoided.

Safety

Explanation of symbols

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CAUTION!

This combination of symbol and

signal word indicates a possibly

dangerous condition that might

result in minor or slight injury if

it is not avoided.

NOTICE!

This combination of symbol and

signal word indicates a possibly

dangerous condition that might

result in damage to property

and to the environment if it is

not avoided.

Tips and recommendations

This symbol emphasizes useful

tips and recommendations as

well as information for efficient

and failure-free operation.

Signs used in these instructions

The following signs and highlightings

are 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 an

automatic sequence as a

result of a specific operating

step

n Designates randomly ordered enu-

merations and list entries

Ä

“Signs used in these instructions”

on page 12, designates references to

chapters in these instructions

Safety

Explanation of symbols

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DWG Module BASICS Flow Monitor

12

2.2 Correct use in

accordance with

these instructions

The device has been designed and

constructed solely for the correct use

in accordance with these instructions.

Table 1: Correct use in non-hazard

areas

The flow monitor serves exclusively

to 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 of

10 bar

.

Table 2: Correct use of UL Recognized

Components in non-hazard areas

The flow monitor serves exlusively to

monitor the continuous flow of liquids

within a temperature range of -15 °C

to 100 °C at a maximum operating

pressure of 10 bar

.

Correct use in explosion-hazard

zones

For employment in explosion-hazard

zones, changed conditions apply for

the intended use.

The intended use in explosion-hazard

zones is described in the Operating

Instructions "DWG Module A

TEX".

Intended use in explosion-hazard

zones includes the observance of all

specifications in these Operating

Instructions, as well as those for "DWG

Module A

TEX"

Any additional or different application,

above or beyond the correct use in

accordance with these instructions, is

deemed as incorrect use.

WARNING!

Danger due to incorrect use!

Incorrect use of the flow mon-

itor may result in dangerous sit-

uations.

– Use the flow monitor only

within the stipulated per-

formance limits

–

Do not subject the flow

monitor to severe tempera-

ture fluctuations

– Do not use the flow monitor

with quick-acting valves

– Do not use the flow monitor

with solenoid valves

– Do not subject the flow

monitor to vibrations

– Do not subject the flow

monitor to pressure surges

– Do not use the flow monitor

with media containing

solids or abrasives

– Only use the flow monitor

with media previously

approved by the manufac-

turer

Safety

Correct use in accordance with these instructions

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DWG Module BASICS Flow Monitor

13

– Do not use the flow monitor

as the sole monitoring

device to prevent dan-

gerous conditions

–

Do not install the flow mon-

itor as a load bearing part

within a pipeline system

– The flow monitor with sight

glass must be installed in

such a way as to preclude

damage to the sight glass

by outside force. If neces-

sary, install an appropriate

impact protection device

All claims for damages due to incorrect

usage are excluded.

2.3 Special precautions

The following section lists residual

risks that might arise from the device.

To reduce health risks and prevent

dangerous conditions, observe the

safety instructions listed here as well

as the safety instructions in the other

chapters of these operating instruc-

tions.

DANGER!

Employment of the device in

explosion-hazard zones

requires the observance of

the Operating Instructions for

"DWG Module A

TEX"

including all hazard state-

ments and warnings, therein.

These operating instructions

cannot cover all conceivable

dangers because many dan-

gers arise, not from the device

itself, but from the respective

media flowing through it.

Always observe the appropriate

safety data sheets when using

hazardous media!

Safety

Special precautions

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DWG Module BASICS Flow Monitor

14

2.3.1 Hazards from elec-

trical current

Electrical current

DANGER!

Danger to life from electrical

current!

There is an immediate risk to

life from electrocution on

touching live parts. Damaged

electrical insulation or compo-

nents can be extremely dan-

gerous.

– Only qualified electricians

shall work on the electrical

system.

–

If the insulation is dam-

aged, immediately switch

off and have repairs per-

formed.

– Before commencing work

on live parts of the elec-

trical systems and oper-

ating equipment, discon-

nect the equipment and

ensure that it remains dis-

connected for the duration

of the work. Observe these

5 safety rules when doing

so:

– Isolate (disconnect)

– Secure against

switching back on

– Check for absence of

voltage

– Ground and short

– Cover or cordon off

other live parts in the

vicinity

– Never bridge fuses or put

them out of operation.

Always observe the correct

current ratings when

replacing fuses

– Keep moisture away from

live parts. This can result in

short-circuit

2.3.2 Mechanical hazards

WARNING!

Risk of injury from glass

breakage!

The sight glass in the flow mon-

itor can burst due to excessive

temperature or pressure. There

is a risk of injury from glass

splinters and escaping media.

– Keep within the stipulated

operating limits

–

Wear personal protective

equipment

– Avoid severe temperature

fluctuations

– Avoid pressure surges

Safety

Special precautions > Mechanical hazards

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DWG Module BASICS Flow Monitor

15

WARNING!

Risk of injury on sharp edges

and pointed corners!

Sharp edges and pointed cor-

ners can cause abrasions and

skin cuts.

– Proceed with caution when

working near sharp edges

and pointed corners.

–

If in doubt, wear protective

gloves.

2.3.3 Hazards from high

or low temperatures

Hot or cold surfaces

WARNING!

Risk of injury from hot or

cold surfaces!

Surfaces of components may

heat up/cool down dramatically

due to the media flowing

through them. Skin contact with

hot or cold surfaces may cause

severe skin burn or frostbite.

– Always wear temperature-

resistant protective work

clothing and protective

gloves when working near

hot/cold surfaces

–

Before commencing work,

make sure that all surfaces

have been cooled down or

warmed up to ambient tem-

perature

Safety

Special precautions > Hazards from high or low temperatures

03.09.2018

DWG Module BASICS Flow Monitor

16

2.3.4 Radiation hazards

Strong magnetic fields

WARNING!

Danger to life from strong

magnetic fields!

Strong magnetic fields may

cause severe injury or even be

fatal, as well as cause consider-

able damage to property

.

– Persons with pacemakers

must not be located in the

vicinity of the device. This

could impair the function of

the pacemaker

–

Persons with metal

implants must not be

located in the vicinity of the

device. Implants can heat

up or be attracted magneti-

cally

– Keep ferromagnetic mate-

rials and electromagnets

away from the magnetic

source. These materials

could be attracted and fly

through the room, thereby

injuring or even killing per-

sons. Minimum clearance:

3 m

– Remove and put away

metal objects before main-

tenance work (jewelry,

watches, writing imple-

ments, etc.)

– Do not place any electronic

devices within the vicinity of

the magnetic source.

These could be damaged

– Do not place any electronic

storage media, credit

cards, etc. within the

vicinity of the magnetic

source. Data could be

deleted

2.3.5 Hazards caused by

media

Hazardous media

WARNING!

Risk of injury from hazardous

media!

If the flow monitor is used for

toxic, corrosive or very hot/cold

media, there is a risk of serious

injury from escaping media.

– Observe details in the

safety data sheet of the

media

–

Comply with the safety,

accident prevention and

environmental protection

regulations appropriate to

the media used

– Wear personal protective

equipment in accordance

with the safety data sheet

Safety

Special precautions > Hazards caused by media

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DWG Module BASICS Flow Monitor

17

2.4 Personnel require-

ments

WARNING!

Risk of injury due to insuffi-

ciently trained and qualified

personnel!

If unqualified personnel work on

the device or are located within

its hazard zone, dangers arise

which may result in serious

injury and considerable

damage to property

.

– All work must be performed

by qualified personnel only.

– Keep unqualified personnel

away from hazard zones.

Authorized personnel is to be

restricted to those persons who can be

expected to perform their work reliably.

Persons whose ability to respond is

influenced, e.g. by drugs, alcohol or

medication, are not authorized.

Observe the age and occupational reg-

ulations at the site when choosing per-

sonnel.

The following lists the personnel quali-

fications for the various areas of

activity:

Qualified electrician

Due to specialized training, knowledge

and experience as well as knowledge

of the relevant standards and regula-

tions, the qualified electrician is able to

independently perform work on the

electrical systems as well as to detect

and avoid possible risks and dangers.

Additionally

, the electrician must pro-

vide proof of his/her professional quali-

fication that certifies his/her ability to

perform work on electrical systems.

The qualified electrician must fulfill the

requirements contained in the valid

legal accident-prevention regulations.

Qualified personnel

Due to their specialized training,

knowledge and experience as well as

their knowledge of the relevant stand-

ards and regulations, qualified per-

sonnel are able to independently per-

form the work assigned to them as well

as to detect and avoid possible risks

and dangers.

2.5 Personal safety

equipment

Personal safety equipment is used to

protect personnel from hazards or dan-

gers that might impair their safety or

health during work.

Safety

Personal safety equipment

03.09.2018

DWG Module BASICS Flow Monitor

18

When performing the various tasks at,

and with the device, personnel must

wear personal safety equipment. Spe-

cial reference is made of this in the

individual chapters within these Oper-

ating Instructions. The following pro-

vides a description of the personal

safety equipment:

n Always wear appropriate personal

safety equipment required in the

various chapters of these Oper-

ating Instructions before com-

mencing work.

n Comply with the personal safety

equipment instructions posted

within the work area.

Description of personal safety

equipment

As specified in the Safety Data

Sheet of the medium,

protective

equipment must be worn when han-

dling hazardous media. In addition,

the specifications of the system

operator must be followed. If no

protective equipment is specified,

suitable protective gloves and gog-

gles must be worn.

The protective equipment is used to

protect against hazardous media leaks

and hazardous media residue in the

device.

Goggles

The goggles are used to protect the

eyes from flying debris and splashing

fluid.

Protective gloves

Protective gloves protect the hands

from friction, burns, grazing, abrasion,

surface cuts or deeper injuries, as well

as from direct contact with hot or cold

surfaces.

2.6 Protective systems

Integration within an emergency-

stop concept is required

The device is designed for use as a

part of a machine or system. It does

not have its own controller and does

not have an autonomous emergency-

stop function.

Before starting up the device, install

the emergency-stop equipment and

incorporate it into the safety chain of

the machine or system.

Connect the emergency-stop equip-

ment so that if there is an interruption

in the power supply or in the activation

of the power supply after an interrup-

tion, dangerous conditions are

excluded for persons and valuables.

The emergency-stop equipment must

always be freely accessible.

Safety

Protective systems

03.09.2018

DWG Module BASICS Flow Monitor

19

2.7 Replacement parts

WARNING!

Risk of injury due to use of

incorrect replacement parts!

Use of incorrect or faulty

replacement parts may result in

dangers to personnel as well as

damages, malfunctions or total

failure.

– Only use original replace-

ment parts from the manu-

facturer or approved by the

manufacturer

.

– Always contact the manu-

facturer in case of doubt.

Always purchase replacement parts

from an authorized dealer or directly

from the manufacturer (For contact

details, see Page 2).

The replacement parts list is in the

annex.

2.8 Environmental pro-

tection

NOTICE!

Risk to the environment due

to improper handling of envi-

ronmentally hazardous sub-

stances!

Serious environmental damage

may result if substances

harmful to the environment are

handled incorrectly

, especially if

they are disposed of improperly.

– Always observe the instruc-

tions listed below on the

handling and disposal of

substances harmful to the

environment.

– If harmful substances are

released into the environ-

ment, take immediate

countermeasures. If there

is doubt, contact the local

authorities, inform them of

the damage and request

information on suitable

countermeasures to be

taken.

Cleaning fluids

Solvent-based cleaning fluids contain

toxic substances. They must never be

released into the environment and

must be disposed of by a waste man-

agement company.

Safety

Environmental protection

03.09.2018

DWG Module BASICS Flow Monitor

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