Meister DWG-3 Operating Instructions Manual

Type
Operating Instructions Manual

This manual is also suitable for

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 2018
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
03.09.2018
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.
© Meister Strömungstechnik GmbH
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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DWG Module BASICS Flow Monitor
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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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DWG Module BASICS Flow Monitor
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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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DWG Module BASICS Flow Monitor
7
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
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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
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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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DWG Module BASICS Flow Monitor
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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
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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
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DWG Module BASICS Flow Monitor
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Meister DWG-3 Operating Instructions Manual

Type
Operating Instructions Manual
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