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Ultrasonic Flow MeterDulcoFlow® DFMa

Operating instructions

Part no. 986007 BA MAZ 014 01/11 EN

Please carefully read these operating instructions before use! · Do not discard!The operator shall be liable for any damage caused by installation or operating errors!

Technical changes reserved.

986007, 1, en_GB

© 2010

ProMinent Dosiertechnik GmbH

Im Schuhmachergewann 5-11

69123 Heidelberg

Germany

Telephone: +49 6221 842-0

Fax: +49 6221 842-617

email: [email protected]

Internet: www.prominent.com)

2

Supplementary information

Read the following supplementary informationin its entirety! Should you already know thisinformation, you have an even greater need ofthe Operating Instructions.

The following are highlighted separately in thedocument:

n Enumerated lists

Instructions

ð Outcome of the instructions

- see (reference)

Information

This provides important informationrelating to the correct operation of thesystem or is intended to make your workeasier.

Safety information

Safety information is identified by pictograms -see "Safety Chapter".

General non-discriminatory approach

In order to make it easier to read, this docu‐ment uses the male form in grammatical struc‐tures but with an implied neutral sense. It isaimed equally at both men and women. Wekindly ask female readers for their under‐standing in this simplification of the text.

Supplemental instructions

3

Table of contents1 Identity code............................................................................................................................ 6

2 About this product................................................................................................................... 8

3 Safety chapter......................................................................................................................... 9

4 Storage and transport........................................................................................................... 12

5 Device overview.................................................................................................................... 13

6 Functional description........................................................................................................... 14

7 Assembly and installation...................................................................................................... 157.1 Installation.................................................................................................................... 157.2 Hydraulic Installation.................................................................................................... 157.3 Electrical Installation..................................................................................................... 17

8 Settings ................................................................................................................................ 208.1 Operating unit............................................................................................................... 208.1.1 LCD screen............................................................................................................... 208.1.2 LEDs.......................................................................................................................... 208.1.3 Control keys.............................................................................................................. 208.2 Checking adjustable variables...................................................................................... 238.3 Operating menu overview............................................................................................ 248.4 Changing to adjustment mode..................................................................................... 258.4.1 "Mode" main menu.................................................................................................... 258.4.2 "Set-up" main menu.................................................................................................. 258.4.3 "Calibration" main menu............................................................................................ 298.4.4 "Zero set" main menu................................................................................................ 408.4.5 "Info" main menu....................................................................................................... 418.4.6 "Language" main menu............................................................................................. 41

9 Start up.................................................................................................................................. 42

10 Maintenance, repair and disposal......................................................................................... 4410.1 Maintenance............................................................................................................... 4510.2 Repairs....................................................................................................................... 4510.3 Disposal...................................................................................................................... 45

11 Troubleshooting.................................................................................................................... 4611.1 DulcoFlow® error........................................................................................................ 4711.2 Pump error................................................................................................................. 4811.3 All Other Faults........................................................................................................... 49

Table of contents

4

12 Technical data....................................................................................................................... 50

13 Dimensions sheet.................................................................................................................. 53

14 EC Declaration of Conformity................................................................................................ 54

15 Decontamination declaration................................................................................................. 55

16 Index..................................................................................................................................... 56

Table of contents

5

1 Identity code

Product range DulcoFlow® flow meter

DFMa Type For pump product ranges

05 Beta, gamma/ L: 1000 - 0413/0713; delta: 1608 - 1612

08 Beta, gamma/ L: 0220/0420 - 0232; delta: 1020 - 0280

Seal material

E EPDM

T PTFE

V FPM

Hydraulic connection

1 6/4 mm

2 8/5 mm

3 12/9 mm

Electrical connection

A 2 m European

B 2 m Swiss

C 2 m Australian

D 2 m USA

Signal output

0 No output

1 Current output

2 Counter output

Version

0 With ProMinent® Logo

2 Without ProMinent® Logo

Accessories

0 No accessories

Identity code

6

Identity code

7

2 About this productThe flow meter DulcoFlow® is intended for usein measuring pulsing volume flows in the rangefrom 0.1 to 80 l/h. All parts coming into contactwith flow media are made from PVDF. Thisensures that aggressive media can also bemeasured without problem. The device isinstalled approximately 30 cm after the pump inthe metering line. Interfering influences, suchas air bubbles, are identified and forwarded tothe analysis unit as an error message. With thedelta, it can only be used with the fast meteringstroke version.

The DulcoFlow® flow meter can not only beused for recording and measurement of volumeflows, but also for monitoring individualmetering strokes. In this case the pump is cali‐brated to the lifting volume set at the pump. Alower and upper limit can be entered, which ifexceeded or undershot, results in no feedbackto the pump. This creates an error message.The connection to the pump takes place via theinput for the "Flow Control" dosing monitor

The device is designed for wall mounting.

About this product

8

3 Safety chapter

Explanation of the safety information

The following signal words are used in theseoperating instructions to identify differentseverities of a hazard:

Signalword

Meaning

WARNING

Denotes a possibly hazardous sit‐uation. If this is disregarded, youare in a life-threatening situationand this can result in serious inju‐ries.

CAU‐TION

Denotes a possibly hazardous sit‐uation. If this is disregarded, itcould result in slight or minor inju‐ries or material damage.

Warning signs denoting different types ofdanger

The following warning signs are used in theseoperating instructions to denote different typesof danger:

Warning signs Type of danger

Warning – high-voltage.

Warning – dangerzone.

Correct and proper use

n The device may only be used with liquidmetering chemicals.

n The device can only be used with pulsingliquid flows with a clear zero flow.

n The device may only be used after it hasbeen correctly installed and commissionedin accordance with the technical data andspecifications contained in the operatinginstructions.

n Observe the general limitations with regardto viscosity limits, chemical resistance anddensity - see also ProMinent resistance list(In the product equipment catalogue or atwww.prominent.com)!

n Any other uses or modifications are pro‐hibited.

n The device is not suitable for measuringcontinuous liquid flows.

n The device may not be used to measuregaseous media or solids.

n The device may not be used with combus‐tible media without appropriate protectivemeasures.

n The device may not be used with explo‐sive media.

n The device may not be used with radioac‐tive media.

n The device is not intended for exteriorapplications without use of suitable protec‐tive equipment.

n The device should only be operated bytrained and authorised personnel, see thefollowing "Qualifications" table.

n You are obliged to observe the informationcontained in the operating instructions atthe different phases of the system'sservice life.

Safety chapter

9

Safety information

WARNING!

Danger of electric shockA mains voltage may exist inside thehousing.

– If the housing has been damaged,you must disconnect the device fromthe mains immediately. It may only bereturned to service after an authorisedrepair.

WARNING!

Warning of dangerous or unknown feedchemicalShould a dangerous or unknown feedchemical be used: It may escape from thehydraulic components during maintenancework.

– Take appropriate protective measuresbefore working on the device (safetyglasses, safety gloves, ...). Observethe safety data sheet for the feedchemical.

– Drain and flush the hydraulic partsbefore working on the device.

CAUTION!

Warning of feed chemical spraying aroundFeed chemical can spray out of thehydraulic components if they are manipu‐lated or opened due to pressure in thehydraulic and adjacent parts of the system.

– Disconnect the pump of the devicehydraulic system from the mainspower supply and ensure that itcannot be switched on again by unau‐thorised persons.

– Depressurise the system before com‐mencing any work on hydraulic parts.

CAUTION!

Danger of personnel injury and materialdamageThe use of untested third party parts canresult in personnel injuries and materialdamage.

– Only fit parts to the device, whichhave been tested and recommendedby ProMinent.

NOTICE!

Warning of illegal operationObserve the regulations that apply wherethe device is installed.

Information in the event of an emergency

In an emergency, disconnect the device fromthe mains!

If feed chemical escapes, also depressurise thedevice hydraulic system. Adhere to the safetydata sheet for the feed chemical.

Safety chapter

10

Qualification of personnel

Activity Qualification level

Storage, transport,unpacking

Instructed personnel

Installation, installa‐tion of hydraulicsystem

Technical personnel

Electrical installation Electrician

Operation Instructed personnel

Maintenance Technical personnel

Repairs Customer service -authorised by ProMi‐nent

Decommissioning,disposal

Technical personnel

Troubleshooting Technical personnel,electrician, instructedpersonnel

Technical personnel

A qualified employee is deemed to be a personwho is able to assess the tasks assigned to himand recognise possible hazards based on his/her technical training, knowledge and experi‐ence, as well as knowledge of pertinent regula‐tions.

Electrician

Electricians are deemed to be people, who areable to complete work on electrical systemsand recognize and avoid possible hazardsindependently based on their technical trainingand experience, as well as knowledge of perti‐nent standards and regulations. Electriciansshould be specifically trained for the workingenvironment in which the are employed andknow the relevant standards and regulations.Electricians must comply with the provisions ofthe applicable statutory directives on accidentprevention.

Instructed personnel

An instructed person is deemed to be a personwho has been instructed and, if required,trained in the tasks assigned to him/her andpossible dangers that could result fromimproper behaviour, as well as having beeninstructed in the required protective equipmentand protective measures.

Customer Service department

Customer Service refers to service technicians,who have received proven training and havebeen authorised by ProMinent® to work on thesystem.

Safety chapter

11

4 Storage and transportSafety information

WARNING!

Only return the device for repair in acleaned state and with flushed hydraulicparts - refer to the chapter "Decommis‐sioning"!

Only send the unit complete with a filled inDecontamination Declaration form. TheDecontamination Declaration constitutesan integral part of an inspection / repairorder. A unit can only be inspected orrepaired when a Decontamination Declara‐tion Form is submitted that has been com‐pleted correctly and in full by an authorisedand qualified person on behalf of the oper‐ator.

The "Decontamination Declaration Form"can be found in the Appendix or underwww.prominent.com.

NOTICE!

Danger of material damageThe device can be damaged by incorrector improper storage or transportation!

– The device should only be stored ortransported in a well packaged state -preferably in its original packaging.

– The packaged unit should also onlybe stored or transported in accord‐ance with the stipulated storage con‐ditions.

– The packaged unit should be pro‐tected from moisture and the ingressof chemicals.

Ambient conditions

Data Value Unit

Minimum storage and transport temperature -10 °C

Maximum storage and transport temperature +50 °C

Air humidity < 95 % rel.humidity*

* non-condensing

Storage and transport

12

5 Device overview

1

24

5

3

Fig. 1: Overview of equipment DulcoFlow® with arrows showing flow1 Control elements - see chapter "Settings" -

"Operating unit"2 Mains connection3 Signal output (option)

4 Feed chemical inlet5 Feed chemical outlet

Device overview

13

6 Functional descriptionThe DulcoFlow ® flow meter measures thevolume flow of pulsing flows. The ultrasonic,time of flight measurement method is used. Forthe time of flight measurement, a sound signalis alternately transmitted in and against thedirection of flow. The time difference is then ameasure of the mean flow velocity. Use of theultrasound measurement method automaticallycompensates any temperature inducedchanges in the medium. Operation withoutmoving parts guarantees a long service life andwear-free operation.

The DulcoFlow® calculates the mass flow fromthe volume flow and the density of the feedchemical.

Additionally the DulcoFlow® can measure thepressure surges of the metering pump andhence replace a dosing monitor such as theFlow Control. A metering pump such as thegamma/ L or delta® can use these signals asacknowledge pulses for its individual strokes. Ifthe acknowledge pulses are missing or if thecapacity exceeds the specified limit values, themetering pump stops after an adjustablenumber of missing pulses and goes into faultmode - see metering pump operating instruc‐tions.

The DulcoFlow® gives the flow reading, strokefeedback, or error messages via the variousoutput types.

Functional description

14

7 Assembly and installationSafety information

WARNING!

Carry out the assembly work before theelectrical installation is undertaken.

WARNING!

Observe the information in the "Technicaldata" chapter.

WARNING!

Danger of an electric shockIf the device is used outdoors without acover or weatherproof roof, water may beable to collect on the seals and penetratethe housing or direct sunlight may causethe housing to be corroded.

– Always use a cover or weatherproofroof when using the unit outdoors.

CAUTION!

Warning of illegal operationObserve the regulations that apply wherethe unit is to be installed.

The device is resistant to normal atmos‐pheres in plant rooms.

7.1 Installation

Install the device so that the hose betweenit and the pump is approximately 30 cmlong.This ensures it measures accurately.

Mount the device vertically.This ensures it measures accurately.

Mount the device vertically on the wallusing both eyes on the housing.

Do not forget the washers.

7.2 Hydraulic Installation

CAUTION!

Warning of escaping feed chemicalFeed chemicals can escape in the eventthat the hose lines are incorrectly installed.

– Only use original hoses with thespecified hose dimensions.

– Avoid reducing the hose sizes.

Assembly and installation

15

Flow direction

The flow direction through the device goesfrom the bottom to the top.

Injection valves, back pressurevalves, relief valvesInjection valves, back pressure valves orrelief valves must not have any effect onthe measurement.

Relief valves

It is best to install a relief valve before theflow meter, so that the displayed flow orflow volume actually corresponds to thevalue which is being metered into thesystem if the relief valve triggers.

Hydraulic Dampers

Hydraulic dampers, like accumulators,inline dampers or bladder accumulators /diaphragm accumulators must not haveany effect on the measurement.A zero flow must be available.The damping must not push the flow meanvalue beneath the measurement threshold.

Installing the hosing:

1. Cut off the ends of the hoses (6) so thatthey are straight.

2. Unscrew the union nut (5) and pushover the hose together with the clampring (4).

3. Push the hose end (6) up to the stopover the nozzle (3).

4. Tighten the union nut (5).

5. Pull on the hose (6) and tighten up theunion nut (5).

1

3

2

4

5

6

P_MAZ_0041_SW

Fig. 2: Installing the hose line1 Connector2 Seal3 Nozzle4 Clamp ring5 Union nut6 Hose


16

P_MAZ_0040_SW

2

PD

1

3

4

5

6

7

Fig. 3: DulcoFlow® hydraulic system1 Target use2 Pressure maintenance device3 Hydraulic Damper4 DulcoFlow®5 Overflow device6 Metering pump7 Storage tank

7.3 Electrical Installation

WARNING!

Danger of electric shockThe use of a residual current circuitbreaker drastically increases survivalchances should persons come into contactwith the mains voltage due to an electricalaccident.

– Always fit a residual current circuitbreaker on-site.

A metering pump, PLC or other devices can beconnected to the flow meter.

The following alternative electrical outputs areavailable via cable:

n Current output (identity code characteristic"signal output "1"):

n Counter output (identity code characteristic"signal output "2"):


17

Current output

The following can be signalled via the current output (standard signal output (mA)):

n Instantaneous flown Fault

Technical data:

Data Value Unit

Current* 0/4 .. 20 mA

Maximum load 400 Ω

* zero volt connection

Counter output as stroke feedback output

The counter output as stroke feedback outputcan be used to signal stroke feedback, pro‐vided it is set accordingly - see chapter "Set‐tings".

1. To report stroke feedback at themetering pump such as gamma/ L anddelta® , plug the cable from the flowmeter to the pump in the "dosing mon‐itor" terminal.

ð The identifier for the dosing monitormust appear on the LCD screen ofthe pump.

2. If it does not appear, make the neces‐sary settings at the metering pump.


18

Counter output as frequency output

The counter output as frequency output can be used to signal flow or an error, provided it is setaccordingly - see chapter "Settings".

1. Remove the connected socket.

2. Remove the insulation of the leads to match the terminals of the other device.

3. Crimp on a suitable cable end sleeve.

ð In this format, the cable can be connected to another device.

4. Connect the cable to both devices in accordance with the wiring diagram. DulcoFlow® wiringdiagram - see appendix.

Technical data:

Data Value Unit

Voltage with open contacts < 30 V

Current with closed contacts < 10 mA

Residual voltage with closed contacts < 0.7 V

Switching frequency < 10 kHz

Lead Function

brown Supply Voltage

white Error signal

blue Frequency signal

black Mass


19

8 Settings8.1 Operating unit

P_MAZ_0039_SW

V: 1145.69 mLQ: 502.13 mL/h

i

DulcoFlow ®1

2

3

4

Fig. 4: Operating unit DulcoFlow®

1 LCD display2 Status LED3 Control keys4 Stroke feedback LED

8.1.1 LCD screenThe LCD screen comprises a two-line display.

8.1.2 LEDsThe status LEDs (left) shows the followinginformation:

LED Information

green Status OK

orange Warning

red Error

The stroke feedback LED (right) shows the fol‐lowing information:

LED Information

off No pressure surge identified

green, illumi‐nated

Pressure surge detected -within tolerance

red, illumi‐nated

Pressure surge detected -outside tolerance

8.1.3 Control keysThe control keys are designated as follows:

Key Designation

i [ i ]

[DOWN]

[UP]

[P]

Settings

20

P

P 3 s

P

P 3 scont.display

main menu set-up

set-up display

= set-up option

Fig. 5: Navigation within the operating menuThe control keys have different functions in the continuous display, in the operating menu and in themenu branches.

In the continuous display

Key Functions

i Changes to continuous dis‐playChanges into the operatingmenu

In the operating menu

Key Functions

Change to the previous menubranch

Change to the next menubranch

Open menu branch (switch tothe first item of the selectedmenu branch).

Settings

21

In a menu item of a menu branch

Key Functions

i Switches between the continuous changing of a number and digitby digit changingIncrease/change the set value

Reduce/change the set value

Accept the configured value and change to the next menu item ofthe menu branch.

In digit by digit changing: Within a number change to the nextfigure.

B0210

density1.3425 g/mL

density1.3425 g/mL

density1.3425 g/mL

a) b)

Fig. 6: a) Change between continuous changing of a number and digit by digit changing; b) Changesthe position within the number

Key [P] - additional generally-applicable func‐tions:

Press dura‐tion

Function

approx. 2 s Open the operating menu

approx. 3 s Quit the operating menuwithout saving the configuredvalues and return to the con‐tinuous display

A modified set value is only adopted, if ithas previously been confirmed by briefpressing of the [P] key.

Settings

22

8.2 Checking adjustable varia‐bles

Before you adjust the flow meter, you cancheck the actual settings of the adjustable vari‐ables:

Press the key [ i ] ("i" for "Info"), if theLCD screen is displaying a continuousdisplay - i.e. no display of the operatingmenu.

ð After every press on the [ i ] key,you see a different continuous dis‐play.

The number and appearance of the continuousdisplays depends on the selected measuredvariable and whether a setpoint has beenentered - see below.

The key [ i ] is used to change betweencontinuous displays.

Continuous display for the "Volume" measuredvariable

Continuous display Description

V: 243,32 mLQ: 171,05 mL/h

Total quantity* V andinstantaneous volumeflow Q

V: 243,32 mLN: 637

Total quantity* V andnumber of strokes* N

V/H: 0,382 mL%SH: 102,3 %

Volume per stroke V/H and deviation fromthe set point of thelifting volume** %SH

* since the last reset

** if a „volume (stroke)“ has been entered under„Calibration è Stroke feedback è Set-point“

Continuous displays for the "Mass" measuredvariable

(If „mass“ was set under „Modeè Measured variable“ .)

Continuous display Description

m: 326,05 gQ: 229,21 g/h

Total quantity* m andinstantaneous massflow Q

m: 326,05 gN: 527

Total quantity* m andnumber of strokes* N

m/H: 0,619 g%SH: 97,8 %

Mass per stroke m/Hand deviation from theset point of the strokemass** %SH

* since the last reset

** if a„mass (stroke)“ has been entered under„Calibration è Stroke feedback è Set-point“

Reset values

– To reset the total quantity andstrokes, press both [arrow keys]simultaneously.

– In the main menu "Zero set", the totalquantity and the strokes can be set to"zero" independently of each other.

Settings

23

8.3 Operating menu overview

B0209

P

P

P

cont.display

2 s

set to zero quantity and strokes

acknowledge error

main menumode

menumeasurandmeasurand

Pmain menucalibrationcalibrationmenu

stroke feedb.stroke feedb.

menuquantityquantity

Pmain menuzero setzero setmenu

quantityquantity

menustrokesstrokes

Pmain menuset-upset-upmenu

displaydisplay

menuserviceservice

menucounter outp.*counter outp.*

menucurrent output*current output*

* Dependent on identity code

Settings

24

main menuinfoinfo

main menulanguagelanguage

Fig. 7

8.4 Changing to adjustmentmode

If the [P] key is pressed for 2 seconds in a con‐tinuous display, the device changes to adjust‐ment mode.

The following main menus can be selected inadjustment mode:

1 - Mode

2 - Set-up

3 - Calibration

4 - Zero set

5 - Info

6 - Language

8.4.1 "Mode" main menumain menu mode

The measured variables can be selected fromthe "Operation" main menu:

n „Volume“ (-flow)n „Mass“ (-flow)The appearance of a few menus is dependenton this.

8.4.2 "Set-up" main menumain menu set-up

The following menus can be selected from the"set-up" main menu:

1 - „Display“3 - „Current output“ (identity code character‐

istic "signal output" "1")

2 - „Counter output“ (identity code character‐istic "signal output" "2")

4 - „Service“ (for customer service only)

Settings

25

8.4.2.1 "Display" menu

P P P PB0228

set-up display

flow unit mL/h

quantity unit mL

damping flow 30.00 s

In the „display“ menu, the units can be selected for the quantities and flow.Moreover, the damping of the displayed flow values can be changed (not for quantities), if theychange too quickly / slowly in the display.

The greater the set integration constant in the menu item „damping flow“, the greater the damping ofthe displayed flow values.

Non-metric units and their conversion

Unit Meaning Conversion

1 gal 1 US liquid gallon = 3.785421 l

1 lb(s) 1 Pound = 453.59237 g

8.4.2.2 "Counter output" menu(identity code characteristic "signal output" "2")

P

P

P

P P

P

P P

P P

B0235

set-up counter output

puls/freq.open-collector

counter output puls/freq.

counter output stroke feedback

open-collector NPN

K factor 5000 1/mL

puls/freq.signal output

K factor unit 1/mL

puls/freq.error output

errorbubbles

In the „counter output“ menu the counter output can be set either as a pulse/frequency output tooutput the instantaneous flow, as an error signal or as a feedback message.

Settings

26

puls/freq. (frequency output)

Firstly the type of the output („Open-Collector“)can be selected so that it is suitable for the con‐nected device (NPN / PNP).

The K factor can be set via the „signal output“menu, and is then used by the DulcoFlow® toconvert the instantaneous flow prior to outputvia the counter output to an external device.

In the „error output“ menu a setting can bemade to determine whether the DulcoFlow®outputs an error signal via the counter output toan external device. It works like a relay instatus NO.

stroke feedback

For stroke feedback, e.g. to a Prominentmetering pump, as with a Flow Control® dosingmonitor, the cable must be fed from the counteroutput to the "dosing monitor" terminal of themetering pump.

Then the „stroke feedback“ must be calibratedunder „calibration“, see chapter "Calibration".

Settings

27

8.4.2.3 "Current output" menu(identity code characteristic "signal output" "1")

P P P P

P P

P PB0234

set-up current output

current range 4...20 mA

current output signal current

flow unit mL/h

0/4 mA value 0.68 mL/h

20 mA value 897.65 mL/h

current outputerror current

error currentbubbles

In the „current output“ menu the standard signal output (mA) can be set either to output the instanta‐neous flow or as a feedback message.

In the „signal current“ menu a setting can bemade to determine how the DulcoFlow® outputsthe instantaneous flow via the current output toan external device.

In the „error output“ menu a setting can bemade to determine whether the DulcoFlow®outputs an error signal via the current output toan external device (23 / 3.6 mA).

Settings

28

8.4.2.4 "service" menu

P PB0229

set-up service

service code 0000

The "service" menu is password protected and only for customer service.

8.4.3 "Calibration" main menumain menu calibration

From the "calibration" menu either the flowmeasurement can be calibrated or the strokefeedback set up.

8.4.3.1 Calibrate "stroke feedback"8.4.3.1.1 For "volume"The permitted range for the lifting volume V/Hcan be specified in this menu. If the liftingvolume moves outside of this range, e.g. due toa changed back pressure, the DulcoFlow® nolonger gives any stroke feedback to themetering pump and the right LED now illumi‐nates as a steady red instead of green. ProMi‐nent metering pumps such as the gamma/ L ordelta® go into fault mode after a series of defec‐tive strokes (pump set up).

Settings

29

About setpoint and tolerances

P P P P

P P PB0230

calibration stroke feedback

volume (stroke) 0.347 mL

stroke feedback set-point


lower tolerance -010.00 %

tolerance tolerance (%)

upper tolerance +020.00 %

Specify the allowed range for the lifting volume V/H via the setpoint of the lifting volume V/H andtolerances in %:

1. Follow the menu path „calibration è stroke feedback è set-point“ and press the key [P] .

ð The menu item „volume (stroke)“ displays the currently stored setpoint.

2. Start the metering pump.

ð The actual measured value is displayed.

3. Turn the stroke length adjustment knob until the desired setpoint is displayed.

4. Press key [P] .

ð The displayed measured value is saved as a setpoint and the menu item „tolerancetolerances“ appears.

The setpoint is valid as 100%.

5. Stop the metering pump.

6. Press key [P] .7. Set the „lower tolerance“ with the [arrow keys] and press the [P] .8. Set the „upper tolerance“ with the [arrow keys] and press the [P] .

ð The continuous display appears again.

The desired setpoint can also be entered, without having to use the stroke adjustment dial orthe pump having to be running, directly under „volume (stroke)“ using the [arrow keys] .

Settings

30

Upper limit values

B0231



stroke feedback set-pointP P P P


tolerance tolerance (%) P

lower limit 0.312 mL

tolerance limits P P P

upper limit 0.416 mL

Alternatively, the desired limits for the allowed range of the lifting volume can be entered under„lower limit“ and „upper limit“:1. Follow the menu path „calibration è stroke feedback è set-point“ and press the key [P] .





4. Press key [P] .



5. Using the [arrow keys] change to the menu item „limits“ and press key [P] .6. Turn the stroke length adjustment dial down until the desired lower limit is reached and press

key [P] .7. Proceed analogously for the upper limit.



Settings

31

The desired setpoint can also be entered, without having to use the stroke adjustment dial orthe pump having to be running, directly under „volume (stroke)“ using the [arrow keys] .

8.4.3.1.2 For "mass"The permitted range for the mass per stroke m/H can be specified in this menu. If the mass perstroke moves outside of this range, e.g. due toa changed back pressure, the DulcoFlow® nolonger gives any stroke feedback to themetering pump and the right LED now illumi‐nates as a steady red instead of green. ProMi‐nent metering pumps such as the gamma/ L ordelta® go into fault mode after a series of defec‐tive strokes (pump set up).

Settings

32

About setpoint and tolerances

B0232

P P P P

P P P


mass (stroke) 0.347 g



lower tolerance -010.00 %


upper tolerance +020.00 %

Specify the allowed range for the mass per stroke m/H via the setpoint of the lifting volume m/H andtolerances in %:

1. Follow the menu path „calibration è stroke feedback è set-point“ and press the key [P] .





4. Press key [P] .



5. Press key [P] .6. Set the „lower tolerance“ with the [arrow keys] and press the [P] .7. Set the „upper tolerance“ with the [arrow keys] and press the [P] .



The desired setpoint can also be entered, without having to use the stroke adjustment dial orthe pump having to be running, directly under „mass (stroke)“ using the [arrow keys] .

Settings

33

Upper limit values

B0233

P P P P

P

P P P






lower limit 0.312 g

tolerance limits

upper limit 0.416 g

Alternatively, the desired limits for the allowed range of the stroke mass can be entered under „lowerlimit“ and „upper limit“:1. Follow the menu path „calibration è stroke feedback è set-point“ and press the key [P] .





4. Press key [P] .



5. Using the [arrow keys] change to the menu item „limits“ and press key [P] .6. Turn the stroke length adjustment dial down until the desired lower limit is reached and press

key [P] .7. Analogously, proceed in the same way for the upper limit.



Settings

34

The desired setpoint can also be entered, without having to use the stroke adjustment dial orthe pump having to be running, directly under „mass (stroke)“ using the [arrow keys] .

8.4.3.2 Calibrate "quantity"

Only calibrate the quantity flow if the dis‐played values do not attain the expectedaccuracy.

Settings

35

8.4.3.2.1 By corr. factor

B0244

P P Pcalibration quantitycorr. factor 101.23 %

quantity corr. factor


If the new correction factor is know in %, it can be entered directly here.

It is obtained by dividing a value you have measured yourself by the displayed value and multiplyingthe result by 100.

1. Follow the menu path „calibration è stroke feedback“.2. Using the [arrow keys] change to the menu item „calibration quantity“ and press key [P] 2x.3. Using the [arrow keys] Enter the „corr. factor“ and press the key [P] .


8.4.3.2.2 By meas. Value

CAUTION!

Danger with dangerous feed chemicalsProvided the following handling instruc‐tions are followed, contact with the feedchemical is possible.

– If the feed chemical is dangerous,take appropriate safety precautionswhen carrying out the following han‐dling instructions.

– Observe the feed chemical safetydata sheet.

Depending on the set measured variable, a cal‐ibration menu appears for:

n Volumen Mass

Settings

36

Volume

B0226

P P

P P P

P

calibration quantity


actual volume 54.72 mL

quantity meas. Value

corr. factor 95.27 %

nominal volume 52.13 mL


Settings

37

Requirements:

n 1 measuring cylinder which can be read sufficiently accuratelyn The metering pump suction line is fed, bubble-free into the measuring cylinder.

1. Record the fluid level in the measuring cylinder.

2. Change from the menu item „calibration stroke feedback“ using the [arrow keys] to the menuitem „calibration quantity“ and press key [P].

ð The menu item „quantity corr. factor“ appears.

3. Change from the menu item „quantity corr. factor“ using the [arrow keys] to the menu item„quantity meas. Value“ and press key [P].

ð The menu item „actual volume“ appears.


Select the number of strokes so that the reading error at the measuring cylinder (half ofthe smallest readable volume graduation divided by the metered total volume) is smallerthan the Dulcoflow measurement error.


6. Record the fluid level in the measuring cylinder and calculate the difference.

7. Press key [P] .

ð The menu item „nominal volume“ appears.

8. Adjust the value in the menu item „nominal volume“ using the [arrow keys] based on this dif‐ference and press the [P] key.

ð The menu item „corr. factor“ appears. It shows the calculated correction factor.

9. Press key [P] , to return to the continuous display.

It is also possible to manually calculate the correction factor and enter it directly under „entry“ - „corr.factor“.

Settings

38

Mass

B0227

P P

P P P

P

calibration quantity


actual mass 54.72 g

quantity meas. Value

corr. factor 95.27 %

nominal mass 52.13 g


Settings

39

Requirements:

n 1 weighing instrument which can be read sufficiently accuratelyn 1 vessel with feed chemicaln the suction line is fed, bubble-free into the measuring vessel.

1. Zero the weighing instrument.

2. Change from the menu item „calibration stroke feedback“ using the [arrow keys] to the menuitem „calibration quantity“ and press key [P].

ð The menu item „quantity corr. factor“ appears.

3. Change from the menu item „quantity corr. factor“ using the [arrow keys] to the menu item„quantity meas. Value“ and press key [P].

ð The menu item „actual mass“ appears.


Select the number of strokes so that the reading error at the weighing instrument (half ofthe smallest readable mass graduation divided by the metered total mass) is smallerthan the Dulcoflow measurement error.


6. Read off the weight from the weighing instrument.

7. Press key [P] .

ð The menu item „nominal mass“ appears.

8. Adjust the value in the menu item „nominal mass“ using the [arrow keys] to the read-offweight and press the key [P] .

ð The menu item „corr. factor“ appears. It shows the calculated correction factor.

9. Press key [P] , to return to the continuous display.

It is also possible to manually calculate the correction factor and enter it directly under „entry“ -„correction factor“.

8.4.4 "Zero set" main menumain menu zero set

In the main menu "Zero set", the total quantityand the strokes, which are displayed in the con‐tinuous display, can be set to "zero" independ‐ently of each other.

Settings

40

8.4.5 "Info" main menumain menu info

This information can be read-off in the "info"main menu:

Code Meaning

ID Identity code

SN Serial number

HW Hardware version

SW Software version

BL Bootloader

8.4.6 "Language" main menumain menu language

The operating language can be selected fromthe "language" main menu.

Settings

41

9 Start up1. Connect the device hydraulically to the

installation.

2. Connect the device to the supplyvoltage.

3. If necessary set:

n the language - see Ä Chapter 8.4.6„"Language" mainmenu“ on page 41

n the measured variable to "mass"and density of the feed chemical -see Ä on page 25

n the units - see Ä Chapter 8.4.2.1„"Display" menu“ on page 26

n the current output - see Ä Chapter8.4.2.3 „"Current output"menu“ on page 28

n the counter output - see Ä Chapter8.4.2.2 „"Counter output"menu“ on page 26

4. Allow the metering pump to prime -press both [arrow keys] simultaneouslyat the pump control unit.

5. At the device acknowledge the error„bubbles“ by pressing the key [P] .

6. Allow the metering pump to run.

7. Check whether the displayed values areplausible.

8. Check whether the stroke feedback tothe metering pump is plausible.

9. Check whether the frequency signalsand the mA signals of the device havethe expected effect if these signals arebeing used.

If the metering pump goes into fault modeduring start up, press the [P] key toacknowledge.

Use with the metering pump delta® is onlypossible if the pump is set to "dosing" -"set-up" (discharge stroke)" - "fast".

Operation as a flow meter

1. In the menu „calibration“ calibrate the„quantity“ - see Ä Chapter 8.4.3.2 „Cali‐brate "quantity"“ on page 35

2. Check whether the displayed values areplausible.

Operation as a dosing monitor

1. Under „set-up è set counter output“ to„stroke feedback“.

2. Connect the device cable with the"dosing monitor" terminal of the pump.

3. In the menu „calibration“ set the „strokefeedback“ - see Ä Chapter 8.4.3.1 „Cali‐brate "stroke feedback"“ on page 29

Function "transmit error signal"

(for identity code characteristic "signal output""1")

1. Under „set-up è current outputè error current“ set the desired errorresult and set the „error current“.

2. Cause the error to occur and checkwhether everything functions as desired.

Start up

42

(for identity code characteristic "signal output""2")

1. Under „set-up è counter outputè puls/freq. è error output“ set thedesired error result.

2. Cause the error to occur and checkwhether everything functions as desired.

Start up

43

10 Maintenance, repair and disposal

WARNING!

Danger from chemical residuesThere is normally chemical residue in themeasurement pipe and housing after ope‐ration. This chemical residue could be haz‐ardous to people.

– It is mandatory that the safety infor‐mation relating to the "Storage, trans‐port and unpacking" chapter is readbefore shipping or transporting theunit.

– Thoroughly clean the measurementpipe and the housing to removechemicals and dirt. Adhere to thesafety data sheet for the feed chem‐ical.

Maintenance, repair and disposal

44

10.1 Maintenance

Interval Maintenance work

Regularly Check whether the correct flow value is displayed.

If this is not the case, recalibrate the flow - see chapter "calibrate".

If stroke feedback is used: Adjust the stroke length with the metering pump run‐ning and set just above the programmed upper limit - the flow identifier at thepump should no longer flash.

Adjust the stroke length with the metering pump running and set just below theprogrammed lower limit - the flow identifier at the pump should no longer flash.

If this is not the case, check for the cause and as necessary readjust the Dulco‐Flow® - see Ä Chapter 8.4.3.1 „Calibrate "stroke feedback"“ on page 29

If stroke feedback is used: Check whether the stroke feedback LED (right-handside of the device) illuminates in time with the strokes.

If this is not the case, check for the cause and rectify as necessary.

Check whether feed chemical is coming out.

If necessary, carefully wipe the device with a soft cloth and soapy water.

10.2 RepairsOnly ProMinent of customer service authorisedby ProMinent may repair the DulcoFlow® flowmeter.

10.3 Disposal

CAUTION!

Environmental hazard due to electronicwasteThere are electronic components in thedevice, which can have a toxic effect onthe environment.

– Separate the electronic componentsfrom the remaining parts.

– Observe the current applicable regu‐lations in your country.

Maintenance, repair and disposal

45

11 Troubleshooting

WARNING!

Warning of dangerous or unknown feedchemicalShould a dangerous or unknown feedchemical be used: It may escape from thehydraulic components during maintenancework.

– Before maintenance work, takeappropriate protective measures(safety glasses, safety gloves, ...).Observe the safety data sheet for thefeed chemical.

– Drain and flush the liquid end of themetering pump before working on it.

Troubleshooting

46

11.1 DulcoFlow® errorFaults with error messages

The left device LED lights up red if an error exists.

Fault description Cause Remedy

Bubbles detected There are too many bubbles or particlesin the feed chemical.

Avoid bubbles or particles in thefeed chemical.

Warning with error message

The left device LED lights up orange if awarning exists.

LED signals

For further information about LED signals,see the "Settings" chapter.

Troubleshooting

47

11.2 Pump error

To return the pump to operating status after one of the following errors, press the key [P] .

In the event of an error an LED lights up red and the flow identifier flashes.


The pump stopsduring priming.

Due to air in the liquid end,the DulcoFlow® has notoutput an acknowledgepulse.

During priming pull the cable to the DulcoFlow®out - the function "Flow" is disabled which thecable is out.

The pump stopduring Dulco‐Flow® set-up.

The DulcoFlow® has givenout too few sequentialacknowledge pulses.

Press key [P] .

The pump stopswhile running.

There is air in the liquid end,gaseous feed chemical.

n Pull out the cable to the DulcoFlow® fromthe pump.

n Bleed the liquid end.n Plug the cable to the DulcoFlow® into the

socket on the pump.n Increase the number of acknowledge

pulses in the pump's menu.

Troubleshooting

48


There is air in the liquid end,the chemical feed containeris empty.

n Fill the metering tank.n Pull out the cable to the DulcoFlow® from

the pump.n Bleed the liquid end.n Plug the cable to the DulcoFlow® into the

socket on the pump.

There is gas in the dosinghead - leaks in the pathbetween the chemical feedcontainer and the Dulco‐Flow®.

n Repair the leak.n Pull out the cable to the DulcoFlow® from


socket on the pump.

Blockage between Dulco‐Flow® and metering tank

n Clear the blockage.n Pull out the cable to the DulcoFlow® from


socket on the pump.

The stroke adjustment dialis mis-set

- see metering pump operating instructions

The feed chemical is tooviscous

- see metering pump operating instructions

11.3 All Other FaultsAll other faults:

Inform your customer service department oryour ProMinent branch.

Troubleshooting

49

12 Technical dataPerformance data

Data Value Unit

Measuring range, pulsing, type 05: 0.1... 13 L/h

Measuring range, pulsing, type 08: 0.6... 80 L/h

Smallest measurable lifting volume, pulsing approx. 0.03 mL/stroke

Accuracy over at least 100 strokes: ± 2 %*

* relative to the measured value

Electrical data

Data Value Unit

Stroke feedback, output**: 1 Contact/stroke

Frequency output**: < 10 kHz

Current output, max. load: 400 Ω

Protective system: IP 65

Supply voltage: 100...230 V AC

Mains supply frequency: 50/60 Hz

** open collector

Media requirements

Material compatibility with: PVDF, sealing material

Data Value Unit

Medium pressure: 0...16 bar

Medium temperature: -10...+45 °C

Dynamic viscosity (η): 0.5...2000 mPas

Sound pressure level: 1000 ... 2500 m/s

Technical data

50

Ambient conditions

Data Value Unit

Minimum storage and transport temperature -10 °C

Maximum storage and transport temperature +50 °C

Ambient temperature in operation, min. -10 °C

Ambient temperature in operation, max. +50 °C

Maximum air humidity * 95 % rel. humidity

* non-condensing

Material

Component Material

Measurement pipe PVDF

Seals, hydraulic - see identity code

Housing PPE+GF20

Screws, etc. A2

Electronics Electronic components

Dimensions

Data Value Unit

Hose connection - nominal widths: 6/4, 8/5, 12/9 mm

Dimensions (HxBxD): 183.6 x 121 x 122.7 mm

Technical data

51

Compatibility

Type Pumps

05 Beta, gala: 1000 - 0413/0713

delta: 1608 - 1612

08 Beta, gala: 0220/0420 - 0232

delta: 1020 - 0280

Technical data

52

13 Dimensions sheet

107

183.6

35.5121.6

160.5

80.4

18

5.4

10

121

91.9

M20x1,5

Fig. 8: Dimensional drawing DulcoFlow® - dimensions sheet in mm

Dimensions sheet

53

14 EC Declaration of Conformity

- Original -

EC Declaration of Conformity

We, ProMinent Dosiertechnik GmbH

Im Schuhmachergewann 5 - 11 DE - 69123 Heidelberg

hereby declare that, the product specified in the following complies with the relevant basic health and safety

rules of the EC Directive, on the basis of its functional concept and design and in the version marketed by us.

This declaration loses its validity in the event of a modification to the product not agreed with us.

Description of the product: DulcoFlow ultrasonic flow meter

Product type: DFMa...

Serial no.: Please refer to type plate on the device

Relevant EC

Directives:

EC Low Voltage Directive (2006/95/EC)

EC EMC Directive (2004/108/EC)

Harmonised standards applied, in

particular:

EN 60335-1, EN 61010-1 EN 55011, EN 61000-6-3, EN 61326-1

Other applicable national

standards and specifications:

EN 60529, EN 61000-4-2/3/4/5/6/11

Technical documents have been

compiled by documentation

specialists:

Norbert Berger

Im Schuhmachergewann 5-11

DE-69123 Heidelberg

Date / manufacturer's signature:

Details of the signatory:

09.12.2010

Dr. Johannes Hartfiel, Assistance Development Director

EC Declaration of Conformity

54

15 Decontamination declaration

Decontamination declaration

55

16 IndexAAbout this product.......................................... 8BBL................................................................. 41bubbles......................................................... 28CCalibration.................................................... 29Checking...................................................... 23Checking adjustable variables..................... 23Control keys................................................. 20corr. factor.................................................... 36Correct and proper use.................................. 9Correction factor............................... 36, 37, 39Counter output....................................... 18, 26Current output........................................ 18, 28Ddamping....................................................... 26Display......................................................... 26Disposal....................................................... 44dosing monitor.............................................. 27Dosing monitor....................................... 18, 42EEmergency................................................... 10error output............................................. 27, 28Error signal................................................... 42Explanation of the safety information ............ 9FFault............................................................. 18Flow.............................................................. 18Flow meter................................................... 42frequency output.......................................... 27Frequency output......................................... 19Functional description.................................. 14

HHW............................................................... 41Hydraulic system.......................................... 17IID.................................................................. 41Identity code................................................... 6Info............................................................... 41Information in the event of an emergency.... 10Installation.................................................... 15LLanguage..................................................... 41LCD screen.................................................. 20Leads........................................................... 19LEDs............................................................ 20Limit values............................................ 31, 34MMain menu................................................... 25Maintenance................................................. 44Mass................................................. 25, 32, 39Mass flow..................................................... 25meas. Value................................................. 36Mode............................................................ 25OOperating unit............................................... 20Ppuls/freq....................................................... 27QQualification of personnel............................. 11RRepair........................................................... 44SSafety chapter................................................ 9Service......................................................... 29Setpoint.................................................. 30, 33Set-up........................................................... 25

Index

56

SN................................................................ 41Standard signal output (mA)........................ 18Start up......................................................... 42Storage......................................................... 12stroke feedback...................................... 27, 29Stroke feedback........................................... 18Supplementary information............................ 3SW............................................................... 41TTechnical data.............................................. 50Tolerances............................................. 30, 33

Transport...................................................... 12Troubleshooting........................................... 46UUnits............................................................. 26VVolume....................................... 25, 29, 35, 37Volume flow.................................................. 25WWarning sign.................................................. 9ZZero set........................................................ 40

Index

57

Table of contents1 Identity code2 About this product3 Safety chapter4 Storage and transport5 Device overview6 Functional description7 Assembly and installation7.1 Installation7.2 Hydraulic Installation7.3 Electrical Installation

8 Settings8.1 Operating unit8.1.1 LCD screen8.1.2 LEDs8.1.3 Control keys

8.2 Checking adjustable variables8.3 Operating menu overview8.4 Changing to adjustment mode8.4.1 "Mode" main menu8.4.2 "Set-up" main menu8.4.2.1 "Display" menu8.4.2.2 "Counter output" menu8.4.2.3 "Current output" menu8.4.2.4 "service" menu

8.4.3 "Calibration" main menu8.4.3.1 Calibrate "stroke feedback"8.4.3.1.1 For "volume"8.4.3.1.2 For "mass"

8.4.3.2 Calibrate "quantity"8.4.3.2.1 By corr. factor8.4.3.2.2 By meas. ValueVolumeMass

8.4.4 "Zero set" main menu8.4.5 "Info" main menu8.4.6 "Language" main menu

9 Start up10 Maintenance, repair and disposal10.1 Maintenance10.2 Repairs10.3 Disposal

11 Troubleshooting11.1 DulcoFlow® error11.2 Pump error11.3 All Other Faults

12 Technical data13 Dimensions sheet14 EC Declaration of Conformity15 Decontamination declaration16 Index

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