Page 1 Profimess GmbH Twischlehe 5 D-27580 Bremerhaven Operating instructions SW-03 Air Varible Area Flowmeter and Switch Status: April 2015 Technical modifications reserved...
Page 2 Profimess GmbH Twischlehe 5 27570 Bremerhaven Germany Telephone: +49 471 98 24 - 151 Fax: +49 471 98 24 - 152 email: info@profimess.de Internet: www.profimess.com 27.04.2015...
Page 3 – even in part – as well as dissemina- tion and/or communication of their con- tent is forbidden without prior written authorization from PROFIMESS Limitations of liability ("manufacturer"). Violations All details and instructions in this...
Page 4: Table Of Contents
Table of contents Table of contents Overview...................... 7 1.1 Short description.................. 7 1.2 Warranty and guarantee provisions............. 7 1.3 Customer service................. 7 Safety......................8 2.1 Explanation of symbols................ 8 2.2 Correct use in accordance with these instructions......10 2.3 Special precautions................11 2.3.1 Hazards from electrical current............
Page 5 Table of contents 5.2 Requirements at the place of installation........... 25 5.3 Preparatory work................26 5.4 Installation in the pipe system............29 5.5 Initial startup..................33 5.6 Electrical connection................34 5.6.1 Connector DIN 43650..............35 5.6.2 Plug connector M12x1..............36 5.6.3 Cable....................
Page 6 Table of contents 9.3 Return Materials................. 69 9.3.1 Return Materials Authorization............69 9.4 Disposal..................... 69 Technical data................... 70 10.1 Device data plate................70 10.2 Switch contact data plate..............70 10.3 Dimension sheet................71 10.4 General specifications..............72 10.5 Electrical specifications..............74 10.6 Measuring ranges................
Page 7: Overview
Overview Customer service Overview 1.1 Short description 1.2 Warranty and guar- antee provisions Warranty and guarantee provisions are contained in the general terms and conditions of the manufacturer. 1.3 Customer service For technical information, please con- tact our customer service department (for contact details, see Page 2).
Page 8: Safety
Safety Explanation of symbols Safety 2.1 Explanation of sym- This chapter provides an overview of important safety aspects required for bols optimum protection of personnel as Safety instructions well as for safe installation and safe operation of the device. Safety instructions in this manual are marked by symbols.
Page 9 Safety Explanation of symbols Designates step-by-step han- dling instructions CAUTION! ð Designates a state or an This combination of symbol and automatic sequence as a signal word indicates a possibly result of a specific operating dangerous situation that might step result in minor or slight injuries if it is not avoided.
Page 10: Correct Use In Accordance With These Instructions
Do not use the flow monitor with media containing solids or The intended use in explosion-hazard abrasives zones is described in the Operating Instructions "SW-03 Air Module ATEX". – Only use the flow monitor with media previously approved by Intended use in explosion-hazard...
Page 11: Special Precautions
Operating Instructions for "SW-03 Air Module ATEX" – Before commencing work on including all hazard statements live parts of the electrical sys- and warnings, therein.
Page 12: Mechanical Hazards
Safety Special precautions > Mechanical hazards – Never bridge fuses or put CAUTION! them out of operation. Always observe the correct current Risk of injury on sharp edges ratings when replacing fuses and pointed corners! – Keep moisture away from live Sharp edges and pointed corners parts.
Page 13: Hazards From High Or Low Temperatures
Safety Special precautions > Radiation hazards 2.3.3 Hazards from high 2.3.4 Radiation hazards or low temperatures Strong magnetic fields Hot or cold surfaces WARNING! WARNING! Danger to life from strong mag- netic fields! Risk of injury from hot or cold surfaces! Strong magnetic fields may cause severe injuries or even be fatal, as...
Page 14: Hazards Caused By Media
Safety Personnel requirements 2.4 Personnel require- – Do not place any electronic ments storage media, credit cards, etc. within the vicinity of the magnetic source. Data could WARNING! be deleted Risk of injury due to use of insufficiently trained and quali- fied personnel! 2.3.5 Hazards caused by If unqualified personnel work on...
Page 15: Personal Safety Equipment
Safety Personal safety equipment The following lists the personnel quali- When performing the various tasks at, fications for the various areas of and with the device, personnel must activity: wear personal safety equipment. Spe- cial reference is made of this in the Qualified electrician individual chapters within these Oper- Due to specialized training, knowledge...
Page 16: Protective Systems
Safety Replacement parts 2.6 Protective systems Protective gloves protect the hands from friction, burns, grazing, abrasion, Integration within an emergency- surface cuts or deeper injuries, as well stop concept is required as from direct contact with hot or cold surfaces. The device is designed for use as a part of a machine or system.
Page 17: Environmental Protection
Safety Responsibility of the owner Always purchase replacement parts Cleaning fluids from an authorized dealer or directly Solvent-based cleaning fluids contain from the manufacturer (For contact toxic substances. They must never be details, see Page 2). released into the environment and The replacement parts list is in the must be disposed of by a waste man- annex.
Page 18 Safety Responsibility of the owner In addition to the safety instructions The owner must clearly regulate contained in these Operating Instruc- and determine responsibilities for tions, the safety, accident prevention installation, operation, trouble- and environmental protection regula- shooting, maintenance and tions applicable to the field of applica- cleaning.
Page 19 Safety Responsibility of the owner The owner must ensure that the maintenance intervals described in these Operating Instructions are adhered to at all times. The owner must ensure that the device is completely free of any residual media before disposal. Remains of corrosive or toxic materials must be neutralized.
Page 20: Design And Function
Design and function Device description Design and function 3.1 Overview A float inside the flow monitor is moved by the flowing medium. A magnetic field is generated by the magnets inside the float. The position of the float is detected by the switch contact. In addition to electrical control by the Reed-contact (switch contact), the cur- rent flow can also be read-off on the...
Page 21: Component Description
Design and function Component description 3.3 Component descrip- Sight glass tion Switch contact Fig. 4: Sight glass A measuring scale is burnt onto the sight glass, from which the current rate Fig. 3: Switch contact and female of flow can be read-off. socket A potential-free Reed-contact is cast into the switch contact housing...
Page 22: Transport, Packaging And Storage
Transport, packaging and storage Packaging Transport, packaging and storage 4.1 Safety instructions 4.2 Transport inspec- for transport tion On delivery, make an immediate check for completeness and check for trans- port damages. Improper transport If there are any visible external trans- port damages then proceed as follows: NOTICE! Do not accept the delivery...
Page 23: Symbols On The Shipping Box
Transport, packaging and storage Storage Handling packaging materials Fragile Dispose of packaging material in accordance with the valid legal regula- tions and local ordinances. NOTICE! Designates packages with breakable Danger to the environment due or damageable contents. to incorrect disposal! Handle the package carefully and do Packaging is made of valuable raw not allow it to fall or be subjected to jar-...
Page 24 Transport, packaging and storage Storage Storage instructions in addition to the instructions listed here may be listed on the packages. Follow these instructions also. 27.04.2015...
Page 25: Installation And Initial Startup
Installation and initial startup Requirements at the place of installation Installation and initial startup 5.1 Safety Safeguard against restart Incorrect installation and initial startup WARNING! Danger to life due to unauthor- ized restart! WARNING! There is a risk of severe or even Risk of injury due to incorrect fatal injuries from unauthorized installation and initial startup!
Page 26: Preparatory Work
Installation and initial startup Preparatory work The flow monitor must be installed in such a way as to preclude WARNING! damage by outside force. It must be ensured that the flow monitor Danger due to incorrect installa- cannot be damaged. If necessary, tion! install an appropriate impact pro- If the criteria listed above are not...
Page 27 Installation and initial startup Preparatory work Unimpeded flow sections NOTICE! Measuring inaccuracy due to incorrect installation! The measuring accuracy of the flow monitor is influenced by its position within the pipe system. Changes in cross-section, branch- offs or arcs in the pipe system impair measuring accuracy.
Page 28 Installation and initial startup Preparatory work Unimpeded outlet Strainer If the pipe system ends at an unim- peded outlet, the flow monitor must not be installed directly in front of the opening. The device must always be completely filled with media to ensure measuring accuracy.
Page 29: Installation In The Pipe System
Installation and initial startup Installation in the pipe system 5.4 Installation in the Prepare the device pipe system NOTICE! WARNING! Risk of damage to property due to contamination! Risk of injury from pressurized Contamination and deposits may lines! impair the free movement of the If the pipe system is under pres- float, thereby damaging the sure when installing the device,...
Page 30 Installation and initial startup Installation in the pipe system WARNING! WARNING! Risk of injury from hot or cold Risk of injury from media in the surfaces! pipe system! Pipelines can heat up/cool down If the pipe system contains toxic or dramatically due to the media other hazardous media, severe flowing through them.
Page 31 Installation and initial startup Installation in the pipe system Sealing the pipe connection Personnel: Qualified personnel A suitable sealant must be selected, depending on the condi- Nap the thread tion/composition of the pipe lines, the medium and the operating and environmental conditions.
Page 32 Installation and initial startup Installation in the pipe system Apply sealing thread (Fig. 8/1) to Install device in pipe system the napped area in the threaded Personnel: direction. Observe the quantity Qualified personnel recommended by the sealant manufacturer.. Protective equipment: Protective gloves Tool: Fixed spanner...
Page 33: Initial Startup
Installation and initial startup Initial startup 5.5 Initial startup The following steps must be taken before initial startup and any subse- quent startup (e.g. after removal and installation during maintenance). WARNING! Make sure that the plant is operating vibration-free. Vibrations could destroy the Fig.
Page 34: Electrical Connection
Installation and initial startup Electrical connection 5.6 Electrical connec- – Secure against switching tion back on – Check for absence of The electrical connection of the flow voltage monitor is accomplished through the connector plug or the cast on power –...
Page 35: Connector Din 43650
Installation and initial startup Electrical connection > Connector DIN 43650 5.6.1 Connector DIN 43650 Wiring diagram of the supplied socket (DIN 43650, Form A) (Front view). Wiring diagram Fig. 14: Switch position under no-flow normally open: condition Fig. 12: Switch position under no-flow condition Fig.
Page 36: Plug Connector M12X1
Installation and initial startup Electrical connection > Cable 5.6.2 Plug connector M12x1 Wiring diagram, socket (M12x1) Fig. 18: Switch position under no-flow condition 5.6.3 Cable The individual cores of the cable are numbered according to the following connection diagrams. Wiring diagram normally open: change over: Fig.
Page 37: Degree Of Protection (Ip-Code)
Installation and initial startup Plug connection 5.6.4 Degree of protection 5.8 Plug connection (IP-Code) Personnel: The specified degree of protection (IP) Qualified electrician is only ensured if approved connection Tool: material is used (see following table). Flat-bladed screwdriver Device Specifi- Degree of connec- cation...
Page 38 Installation and initial startup Plug connection Fig. 21: Loosen inner section Remove the plug insert from the Fig. 22: Loosen the screw connection plug by placing a flat-bladed screwdriver into the slot Unscrew the screw connection (Fig. 21/1) and carefully prying (Fig.
Page 39: Contact Protection Measures
Installation and initial startup Contact protection measures Plug the female socket onto the connector plug and tighten the fixing screw (Fig. 19/1). Fig. 24: Pin assignment, plug socket, change-over contact (Form 30x70) 5.9 Contact protection Fig. 23: Pin assignment, plug socket, measures normally-open contact (Form 30x70) The Reed-switches used in the switch...
Page 40 Installation and initial startup Contact protection measures Inductive load There is danger of voltage peaks from inductive loads when switching off (up to 10 times the rated voltage). Induc- tive loads are caused by, e.g.: Contactors, relays Fig. 27: Protective measure against capacitive loads Solenoid valves Electric motors...
Page 41 Installation and initial startup Contact protection measures Protection against ohmic loads can be achieved through installation of a resistor in the circuit, or by heating the glow filament. For connection to high- impedance consumers (ex. PLC), a protective circuit is not needed. 27.04.2015...
Page 42: Operation
Operation Setting the switch point Operation 6.1 Setting the switch Personnel: point Qualified personnel Tool: Flat-bladed screwdriver Setting the switch point of an Adjust the flow to be monitored installed device and read it off at the scale on the device.
Page 43 Operation Setting the switch point Condition 1: The contact is now Setting the switch point of a non- closed installed device Slowly push the switch contact in the direction of flow until the contact opens Condition 2: The contact is now open Slowly push the switch contact in the direction of flow until the...
Page 44: Checking The Flow
Operation Checking the flow 6.2 Checking the flow Condition 1: The contact is now closed Reading-off the flow value Slowly push the switch contact Personnel: in the direction of flow until the Qualified personnel contact opens Protective equipment: Condition 2: The contact is now open Goggles Slowly push the switch contact...
Page 45 Operation Checking the flow To obtain greatest reading accu- racy, read-off at eye level. (Fig. 32, middle arrow). The read-off value can be falsified by viewing at an angle Read-off the flow value from the measuring scale 27.04.2015...
Page 46: Troubleshooting
Troubleshooting Safety Troubleshooting 7.1 Safety This chapter describes possible mal- functions of the device, their causes Work carried out incorrectly to and repair. remedy a malfunction If malfunctions persist or increase, shorten the maintenance interval to meet the actual operating conditions. WARNING! For malfunctions not described in this Risk of injury due to incorrect...
Page 47 Troubleshooting Safety Conduct in case of malfunction The complete machine or system may be unsafe if there is a defect at the flow monitor (e.g. broken sight glass). The following always applies: In case of malfunctions that present an immediate danger to persons or valuables, proceed according to the valid emer- gency plans for the system...
Page 48: Troubleshooting Guide
Troubleshooting Troubleshooting guide 7.2 Troubleshooting guide Fault description Cause Remedy Personnel The switch contact No medium Check that medium is Qualified does not switch. flowing through flowing through the pipe- personnel flow monitor line Flow is too low or Adjust the switch Qualified the switch con- contact to a lower...
Page 49 Troubleshooting Troubleshooting guide Fault description Cause Remedy Personnel Float is stuck Disassemble and clean Qualified the device personnel Switch contact is Remedy the cause of Qualified defective the defect (short-cir- personnel cuit, overload) Replace the switch contact The switch point is Improper scale Request proper conver- Qualified...
Page 50: Maintenance
Maintenance Maintenance plan Maintenance 8.1 Safety 8.2 Maintenance plan Maintenance work performed incor- Intervals for replacing wear parts rectly SW-03 type flow monitors require very little maintenance due to the small number of moving parts. The intervals WARNING! for the replacement of wear parts depend significantly on the operating Risk of injury due to mainte- conditions as well as on the composi-...
Page 51: Removal From The Pipe System
Maintenance Removal from the pipe system Interval Maintenance work Personnel Visual inspection for dirt/soiling Qualified personnel Visual inspection of free-movement of float Qualified personnel Visual inspection for leaks from the device Qualified personnel Check function of switch contact Qualified personnel 8.3 Removal from the pipe system WARNING!
Page 52: Disassembly
Maintenance Disassembly Removing the device from the pipe system WARNING! Personnel: Risk of injury from media in the Qualified personnel pipe system! Protective equipment: If the pipe system contains toxic or hazardous media, severe injuries With hazardous media, the protec- may be caused by escaping tive equipment specified in the media!
Page 53 Maintenance Disassembly Protective equipment: With hazardous media, the protec- WARNING! tive equipment specified in the Risk of injury due to incorrect Safety Data Sheet of the medium disassembly! must be worn. In addition, the specifications of the system oper- – The device may still contain ator must be followed.
Page 54 Maintenance Disassembly Fig. 34: Remove the process connec- Fig. 35: Slot nozzle buffer O-ring tion (outlet) Remove the slot nozzle buffer O-ring (Fig. 35/1) from the sight glass CAUTION! Carefully pull the process connection (outlet) from the device body, turning slightly when doing so (Fig.
Page 55 Maintenance Disassembly Fig. 36: Loosen screws Fig. 37: Remove the inner section Secure the device with one hand Carefully remove the inner sec- to ensure the sight glass does tion (Fig. 37/1) of the device not slip out, then loosen the (sight glass, slot nozzle and lower 3 hex head screws float) as a unit together with the...
Page 56: Maintenance
Maintenance Maintenance > Cleaning 8.5.1 Cleaning It is the responsibility of the operator to establish appropriate intervals and pro- cedures for cleaning the individual parts of the device. It must be ensured that the parts are not damaged during the cleaning process. When using cleaning agents, it must be ensured that these are not aggressive to the parts and that there will be no dan-...
Page 57: Parts Replacement
Maintenance Maintenance > Assembly Protective equipment: With hazardous media, the protec- CAUTION! tive equipment specified in the Risk of injury due to damaged Safety Data Sheet of the medium parts! must be worn. In addition, the specifications of the system oper- If parts of the device are broken or ator must be followed.
Page 58 Maintenance Maintenance > Assembly Personnel: Qualified personnel Tool: Hex screwdriver Torque screwdriver and assorted blades Special tools: Alignment tool/Test rod Fig. 40: O-ring (glass buffer) Carefully seat the O-ring (glass buffer) onto the process connec- tion (Fig. 40/1), so that it is prop- erly seated on the lower portion of the process connection (Fig.
Page 59 Maintenance Maintenance > Assembly Place the O-ring (for centering the slot nozzle) onto the slot nozzle (Fig. 42/1), so that it sits in the groove on the outlet side of the slot nozzle. Fig. 41: Position of O-rings Repeat steps 1 and 2 for the second process connection Fig.
Page 60 Maintenance Maintenance > Assembly Fig. 44: Centering the slot nozzle Fig. 45: Float Place the lower O-ring which Guide the float (Fig. 45/1) into centers the slot nozzle onto the the sight glass so that the lid of end of the slot nozzle (Fig. 44/1) the float (recognizable by the two drilled holes) points towards Using the alignment tool, center...
Page 61 Maintenance Maintenance > Assembly CAUTION! A list of suitable lubricants is Carefully insert the process contained in the annex connection (Inlet) (Fig. 46/1) Ä Chapter 11.5 “Lubricants” into the sight glass, pressing on page 80. lightly. The sight glass can break if too much force is exerted or if the process connection is canted...
Page 62 Maintenance Maintenance > Assembly Fig. 48: Insert the process connection Fig. 49: Secure the process connection into the device housing (inlet) Insert the process connection Secure the inlet process connec- (inlet) with the inner section into tion with 3 hex socket screws the device housing (Fig.
Page 63 Maintenance Maintenance > Assembly Fig. 50: Align slot nozzle Fig. 51: O-ring, slot nozzle buffer Using the alignment tool/test rod Insert O-ring (slot nozzle buffer) (Fig. 50/1), align the slot nozzle (Fig. 51/1) and the measuring scale (Fig. 50/2) centered to the sight window of the device housing.
Page 64 Maintenance Maintenance > Assembly Fig. 52: Position the outlet process Fig. 53: Tighten hex socket screws connection Tighten the 3 hex socket screws Insert the outlet process connec- (Fig. 53/1), observing the proper tion (Fig. 52/1) into the device torque ( Ä...
Page 65: Switch Contact Replacement
Maintenance Maintenance > Switch contact replacement 8.5.4 Switch contact replacement Tool: Flat-bladed screwdriver Fig. 55: Loosen female socket Loosen the fixing screw (Fig. 55/1) of the female socket Fig. 54: Check for free movement with a flat-bladed screwdriver Check the float for ease of movement by applying light pressure with the alignment tool/ test rod (Fig.
Page 66 Maintenance Maintenance > Switch contact replacement Fig. 57: Loosen set screws Fig. 59: Rotate guide rail to the side Using a flat-bladed screwdriver, Rotate guide rail with switch loosen the set screws (Fig. 57/1) contact to the side of the switch contact until it moves freely Fig.
Page 67: Measures To Be Taken After Maintenance Work
Maintenance Measures to be taken after maintenance work Re-tighten the set screws (Fig. 57/1) observing the proper tightening torque of the screws Ä Chapter 11.1 “Tightening torque ” on page 77) Position the female socket and gasket, then tighten fixing screw 8.6 Measures to be taken after mainte- nance work...
Page 68: Disassembly And Disposal
Disassembly and disposal Disassembly Disassembly and disposal 9.2 Disassembly After its period of useful life, the device must be disassembled and disposed of Before disassembly: in an environmentally safe manner. Remove fluids and lubricants and all other packaging material and 9.1 Safety dispose of them in an environmen- tally safe manner...
Page 69: Return Materials
Profimess will apply. Return shipments which do not comply with the returns – Have electrical scrap, elec- policy may be refused by Profimess at tronic components, lubricants the expense of the consignor. and other supplies disposed of by approved specialists 9.4 Disposal...
Page 70: Technical Data
Technical data Switch contact data plate Technical data 10.1 Device data plate The data plate is on the mechanical part of the flow monitor/flow meter and contains the following information: 1. Ordering number 2. Operating range 3. Process connection 4. Serial number 5.
Page 71: Dimension Sheet
Technical data Dimension sheet 10.3 Dimension sheet 27.04.2015...
Page 72: General Specifications
Technical data General specifications 10.4 General specifications Type Overall dimensions (mm) SW-03 SW-03 SW-03 SW-03 SW-03 SW-03 SW-03 SW-03 27.04.2015...
Page 73 Technical data General specifications Type Overall dimensions (mm) weight (g) ** SW-03 ca. 96 ca. 96 ca. 96 SW-03 ca. 96 ca. 96 ca. 96 SW-03 ca. 96 ca. 96 ca. 96 SW-03 ca. 96 ca. 96 ca. 96 SW-03 ca.
Page 74: Electrical Specifications
Technical data Electrical specifications 10.5 Electrical specifications Change-Over Contact (COC) Data Value Unit Voltage 250 V Current, maximum 1,5 A Power, maximum 50 VA Minimum load 3 VA Normally Open Contact (NOC) Data Value Unit Voltage 250 V Current, maximum Power, maximum 100 VA Change-Over Contact (COC) M12x1 (-20 °C–85 °C)
Page 75: Measuring Ranges
Technical data Measuring ranges > Standard measuring ranges Normally Open Contact (NOC) M12x1 (-20 °C–85 °C) Data Value Unit Voltage 250 V Current, maximum Power, maximum 100 VA Change-Over Contact (COC), PLC Data Value Unit Voltage 250 V Current, maximum Power, maximum 60 VA 10.6...
Page 76: Operating Data
± 10 % of full scale value Operating data for devices employed in explosion hazard zones differs from the above. The operating data for devices employed in explosion hazard zones are specified in the Operating Instruc- tions for "SW-03 Air Module ATEX", Chapter 4. 27.04.2015...
Page 77: Appendix
Appendix Replacement parts Appendix 11.1 Tightening torque Component/ Designation Size Torque function Device body Hexagon M6x6 3 Nm socket screw Guide rail Countersunk M3x10 0,4 Nm screw screw Switch contact Cylinder head M3x8 0,4 Nm screw with slot 11.2 Replacement parts The following spare parts drawing provides an example of the construction of a SW-03 type flow monitor.
Page 78 Appendix Replacement parts Description Process connection, (inlet) O-ring (glass buffer) O-ring (seal) Sight glass Device body Hex socket set screw O-ring, slot nozzle buffer Pin, (slot nozzle outlet) Slot nozzle Float Process connection, (outlet) Guide rail Fixing screw, guide rail Switch contact with male connector Female socket and gasket Fixing screw, (female socket)
Page 79: Tools
Appendix Sealant 11.3 Tools The following tools are required: Tools Fixed spanner 32, 41, 50, 55 mm Hex screwdriver 3 mm Flat-bladed screwdriver, blade width 5,5 mm Torque screwdriver and assorted blades Special tools Alignment tool/test rod O-ring installation tool 11.4 Sealant Before using a sealant, ensure that...
Page 80: Lubricants
Appendix Lubricants 11.5 Lubricants Before using a lubricant, always make sure that it is compatible with the oper- ating medium. For the proper mounting of O-rings, an O-ring installation tool may be purchased from the manufacturer. The following lubricants are suitable to facilitate installing the O-rings: Lubricant O-ring material EPDM...
Page 81 Profimess GmbH Twischlehe 5 D-27580 Bremerhaven Operating instructions SW-03 Water Varible Area Flowmeter and Switch Status: February 2015 Technical modifications reserved...
Page 82 Profimess GmbH Twischlehe 5 27570 Bremerhaven Germany Telephone: +49 471 98 24 - 151 Fax: +49 471 98 24 - 152 email: info@profimess.de Internet: www.profimess.com 23.02.2015...
Page 83 – even in part – as well as dissemina- tion and/or communication of their con- tent is forbidden without prior written authorization from PROFIMESS Limitations of liability ("manufacturer"). Violations All details and instructions in this...
Page 84 Table of contents Table of contents Overview...................... 7 1.1 Short description.................. 7 1.2 Warranty and guarantee provisions............. 7 1.3 Customer service................. 7 Safety......................8 2.1 Explanation of symbols................ 8 2.2 Correct use in accordance with these instructions......10 2.3 Special precautions................11 2.3.1 Hazards from electrical current............
Page 85 Table of contents 5.2 Requirements at the place of installation........... 25 5.3 Preparatory work................26 5.4 Installation in the pipe system............29 5.5 Initial startup..................33 5.6 Electrical connection................34 5.6.1 Connector DIN 43650..............35 5.6.2 Plug connector M12x1..............36 5.6.3 Cable....................
Page 86 Table of contents 9.3 Return Materials................. 69 9.3.1 Return Materials Authorization............69 9.4 Disposal..................... 69 Technical data................... 70 10.1 Device data plate................70 10.2 Switch contact data plate..............70 10.3 Dimension sheet................71 10.4 General specifications..............72 10.5 Electrical specifications..............74 10.6 Measuring ranges................
Page 87: Overview
Overview Customer service Overview 1.1 Short description 1.2 Warranty and guar- antee provisions Warranty and guarantee provisions are contained in the general terms and conditions of the manufacturer. 1.3 Customer service For technical information, please con- tact our customer service department (for contact details, see Page 2).
Page 88: Safety
Safety Explanation of symbols Safety 2.1 Explanation of sym- This chapter provides an overview of important safety aspects required for bols optimum protection of personnel as Safety instructions well as for safe installation and safe operation of the device. Safety instructions in this manual are marked by symbols.
Page 89 Safety Explanation of symbols Designates step-by-step han- dling instructions CAUTION! ð Designates a state or an This combination of symbol and automatic sequence as a signal word indicates a possibly result of a specific operating dangerous situation that might step result in minor or slight injuries if it is not avoided.
Page 90: Correct Use In Accordance With These Instructions
Safety Correct use in accordance with these instructions 2.2 Correct use in accordance with WARNING! these instructions Danger due to incorrect use! The device has been designed and Incorrect use of the flow monitor constructed solely for the correct use in may result in dangerous situations.
Page 91: Special Precautions
Safety Special precautions > Hazards from electrical current 2.3.1 Hazards from elec- All claims for damages due to incorrect usage are excluded. trical current Electrical current 2.3 Special precautions The following section lists residual DANGER! risks that might arise from the device. Danger to life from electrical To reduce health risks and prevent current!
Page 92: Mechanical Hazards
Safety Special precautions > Mechanical hazards – Never bridge fuses or put CAUTION! them out of operation. Always observe the correct current Risk of injury on sharp edges ratings when replacing fuses and pointed corners! – Keep moisture away from live Sharp edges and pointed corners parts.
Page 93: Hazards From High Or Low Temperatures
Safety Special precautions > Radiation hazards 2.3.3 Hazards from high 2.3.4 Radiation hazards or low temperatures Strong magnetic fields Hot or cold surfaces WARNING! WARNING! Danger to life from strong mag- netic fields! Risk of injury from hot or cold surfaces! Strong magnetic fields may cause severe injuries or even be fatal, as...
Page 94: Hazards Caused By Media
Safety Personnel requirements 2.4 Personnel require- – Do not place any electronic ments storage media, credit cards, etc. within the vicinity of the magnetic source. Data could WARNING! be deleted Risk of injury due to use of insufficiently trained and quali- fied personnel! 2.3.5 Hazards caused by If unqualified personnel work on...
Page 95: Personal Safety Equipment
Safety Personal safety equipment The following lists the personnel quali- When performing the various tasks at, fications for the various areas of and with the device, personnel must activity: wear personal safety equipment. Spe- cial reference is made of this in the Qualified electrician individual chapters within these Oper- Due to specialized training, knowledge...
Page 96: Protective Systems
Safety Spare parts 2.6 Protective systems Protective gloves protect the hands from friction, burns, grazing, abrasion, Integration within an emergency- surface cuts or deeper injuries, as well stop concept is required as from direct contact with hot or cold surfaces. The device is designed for use as a part of a machine or system.
Page 97: Environmental Protection
Safety Responsibility of the owner Always purchase spare parts from an Cleaning fluids authorized dealer or directly from the Solvent-based cleaning fluids contain manufacturer (For contact details, see toxic substances. They must never be Page 2). released into the environment and The spare parts list is in the annex.
Page 98 Safety Responsibility of the owner In addition to the safety instructions The owner must clearly regulate contained in these Operating Instruc- and determine responsibilities for tions, the safety, accident prevention installation, operation, trouble- and environmental protection regula- shooting, maintenance and tions applicable to the field of applica- cleaning.
Page 99 Safety Responsibility of the owner The owner must ensure that the maintenance intervals described in these Operating Instructions are adhered to at all times. The owner must ensure that the device is completely free of any residual media before disposal. Remains of corrosive or toxic materials must be neutralized.
Page 100: Design And Function
Design and function Device description Design and function 3.1 Overview A float inside the flow monitor is moved by the flowing medium. A magnetic field is generated by the magnets inside the float. The position of the float is detected by the switch contact. In addition to electrical control by the Reed-contact (switch contact), the cur- rent flow can also be read-off on the...
Page 101: Component Description
Design and function Component description 3.3 Component descrip- Sight glass tion Switch contact Fig. 4: Sight glass A measuring scale is burnt onto the sight glass, from which the current rate Fig. 3: Switch contact and female of flow can be read-off. socket A potential-free Reed-contact is cast into the switch contact housing...
Page 102: Transport, Packaging And Storage
Transport, packaging and storage Packaging Transport, packaging and storage 4.1 Safety instructions 4.2 Transport inspec- for transport tion On delivery, make an immediate check for completeness and check for trans- port damages. Improper transport If there are any visible external trans- port damages then proceed as follows: NOTICE! Do not accept the delivery...
Page 103: Symbols On The Shipping Box
Transport, packaging and storage Storage Handling packaging materials Fragile Dispose of packaging material in accordance with the valid legal regula- tions and local ordinances. NOTICE! Designates packages with breakable Danger to the environment due or damageable contents. to incorrect disposal! Handle the package carefully and do Packaging is made of valuable raw not allow it to fall or be subjected to jar-...
Page 104 Transport, packaging and storage Storage Storage instructions in addition to the instructions listed here may be listed on the packages. Follow these instructions also. 23.02.2015...
Page 105: Installation And Initial Startup
Installation and initial startup Requirements at the place of installation Installation and initial startup 5.1 Safety Safeguard against restart Incorrect installation and initial startup WARNING! Danger to life due to unauthor- ized restart! WARNING! There is a risk of severe or even Risk of injury due to incorrect fatal injuries from unauthorized installation and initial startup!
Page 106: Preparatory Work
Installation and initial startup Preparatory work The flow monitor must be installed in such a way as to preclude WARNING! damage by outside force. It must be ensured that the flow monitor Danger due to incorrect installa- cannot be damaged. If necessary, tion! install an appropriate impact pro- If the criteria listed above are not...
Page 107 Installation and initial startup Preparatory work Unimpeded flow sections NOTICE! Measuring inaccuracy due to incorrect installation! The measuring accuracy of the flow monitor is influenced by its position within the pipe system. Changes in cross-section, branch- offs or arcs in the pipe system impair measuring accuracy.
Page 108 Installation and initial startup Preparatory work Unimpeded outlet Strainer Fig. 7: Unimpeded outlet If the pipe system ends at an unim- Fig. 8: Strainer peded outlet, the flow monitor must not min. 10x DN be installed directly in front of the min.
Page 109: Installation In The Pipe System
Installation and initial startup Installation in the pipe system 5.4 Installation in the Prepare the device pipe system NOTICE! WARNING! Risk of damage to property due to contamination! Risk of injury from pressurized Contamination and deposits may lines! impair the free movement of the If the pipe system is under pres- float, thereby damaging the sure when installing the device,...
Page 110 Installation and initial startup Installation in the pipe system WARNING! WARNING! Risk of injury from hot or cold Risk of injury from media in the surfaces! pipe system! Pipelines can heat up/cool down If the pipe system contains toxic or dramatically due to the media other hazardous media, severe flowing through them.
Page 111 Installation and initial startup Installation in the pipe system Sealing the pipe connection Personnel: Qualified personnel A suitable sealant must be selected, depending on the condi- Nap the thread tion/composition of the pipe lines, the medium and the operating and environmental conditions.
Page 112 Installation and initial startup Installation in the pipe system Apply sealing thread (Fig. 9/1) to Install device in pipe system the napped area in the thread Personnel: direction. Observe the quantity Qualified personnel recommended by the sealant manufacturer. Protective equipment: Protective gloves Tool: Fixed spanner...
Page 113: Initial Startup
Installation and initial startup Initial startup 5.5 Initial startup The following steps must be carried out before initial startup and any subse- quent startup (e.g. after removal and installation during maintenance). WARNING! Make sure that the plant is operating vibration-free. Vibrations could destroy the Fig.
Page 114: Electrical Connection
Installation and initial startup Electrical connection 5.6 Electrical connec- tion NOTICE! The electrical connection of the flow Vent the pipe line. If there monitor is accomplished through the are air bubbles in the line connector plug or the cast on power during the measurement cable leading from the switch housing.
Page 115: Connector Din 43650
Installation and initial startup Electrical connection > Connector DIN 43650 5.6.1 Connector DIN – Secure against switching 43650 back on – Check for absence of Wiring diagram of the supplied voltage socket (DIN 43650, Form A) (Front view). – Ground and short –...
Page 116: Plug Connector M12X1
Installation and initial startup Electrical connection > Plug connector M12x1 5.6.2 Plug connector M12x1 Wiring diagram, socket (M12x1) Fig. 15: Switch position under no-flow condition Fig. 17: Pin-assignment, socket M12x1 Form 30x70) Fig. 16: Pin assignment, plug socket, change-over contact. The ground-pin is Wiring diagram not used.
Page 117: Cable
Installation and initial startup Grounding the device 5.6.4 Degree of protection (IP-Code) The specified degree of protection (IP) is only ensured if approved connection material is used (see following table). Fig. 19: Switch position under no-flow Device Specifi- Degree of condition connec- cation...
Page 118: Plug Connection
Installation and initial startup Plug connection 5.8 Plug connection Personnel: Qualified electrician Tool: Flat-bladed screwdriver Fig. 20: Detach socket Fig. 22: Loosen inner section Remove the plug insert from the Release the fixing screw plug by placing a flat-bladed (Fig. 20/1) from the socket screwdriver into the slot (Fig.
Page 119 Installation and initial startup Plug connection Plug the female socket onto the connector plug and tighten the fixing screw (Fig. 20/1) Fig. 23: Loosen the screw connection Unscrew the screw connection Fig. 24: Pin assignment, plug socket, (Fig. 23/1) by turning in the normally-open contact (Form 30x70) direction of the arrow Guide the connecting cable...
Page 120: Contact Protection Measures
Installation and initial startup Contact protection measures Inductive load There is danger of voltage peaks from inductive loads when switching off (up to 10 times the rated voltage). Induc- tive loads are caused by, e.g.: Contactors, relays Solenoid valves Electric motors Examples of protective measures: Fig.
Page 121 Installation and initial startup Contact protection measures Protection against ohmic loads can be achieved through installation of a resistor in the circuit, or by heating the glow filament. For connection to high- impedance consumers (ex. PLC), a protective circuit is not needed. Fig.
Page 122: Operation
Operation Setting the switch point Operation 6.1 Setting the switch Personnel: point Qualified personnel Tool: Flat-bladed screwdriver Setting the switch point of an Adjust the flow to be monitored installed device and read it off at the scale on the device.
Page 123 Operation Setting the switch point Condition 1: The contact is now Setting the switch point of a non- closed installed device Slowly push the switch contact in the direction of flow until the contact opens Condition 1: The contact is now open Slowly push the switch contact in the direction of flow until the...
Page 124: Checking The Flow
Operation Checking the flow 6.2 Checking the flow Condition 1: The contact is now closed Reading-off the flow value Slowly push the switch contact Personnel: in the direction of flow until the Qualified personnel contact opens Protective equipment: Condition 2: The contact is now open Goggles Slowly push the switch contact...
Page 125 Operation Checking the flow To obtain greatest reading accu- racy, read-off at eye level. (Fig. 33, middle arrow). The read-off value can be falsified by viewing at an angle Read-off the flow value from the measuring scale 23.02.2015...
Page 126: Troubleshooting
Troubleshooting Safety Troubleshooting 7.1 Safety This chapter describes possible mal- functions of the device, their causes Work carried out incorrectly to and repair. remedy a malfunction If malfunctions persist or increase, shorten the maintenance interval to meet the actual operating conditions. WARNING! For malfunctions not described in this Risk of injury due to incorrect...
Page 127 Troubleshooting Safety Conduct in case of malfunction The complete machine or system may be unsafe if there is a defect at the flow monitor (e.g. broken sight glass). The following always applies: In case of malfunctions that present an immediate danger to persons or valuables, proceed according to the valid emer- gency plans for the system...
Page 128: Troubleshooting Guide
Troubleshooting Troubleshooting guide 7.2 Troubleshooting guide Fault description Cause Remedy Personnel The switch contact No medium Check that medium is Qualified does not switch. flowing through flowing through the pipe- personnel flow monitor line Flow is too low or Adjust the switch Qualified the switch con- contact to a lower...
Page 129 Troubleshooting Troubleshooting guide Fault description Cause Remedy Personnel Float is stuck Disassemble and clean Qualified the device personnel Switch contact is Remedy the cause of Qualified defective the defect (short-cir- personnel cuit, overload) Replace the switch contact The switch point is Improper scale Request proper conver- Qualified...
Page 130: Maintenance
Maintenance Maintenance plan Maintenance 8.1 Safety 8.2 Maintenance plan Maintenance work performed incor- Intervals for replacing wear parts rectly SW-03 type flow monitors require very little maintenance due to the small number of moving parts. The intervals WARNING! for the replacement of wear parts depend significantly on the operating Risk of injury due to mainte- conditions as well as on the composi-...
Page 131: Removal From The Pipe System
Maintenance Removal from the pipe system Interval Maintenance work Personnel Visual inspection for dirt/soiling Qualified personnel Visual inspection of free-movement of float Qualified personnel Visual inspection for leaks from the device Qualified personnel Check function of switch contact Qualified personnel 8.3 Removal from the pipe system WARNING!
Page 132: Disassembly
Maintenance Disassembly Removing the device from the pipe system WARNING! Personnel: Risk of injury from media in the Qualified personnel pipe system! Protective equipment: If the pipe system contains toxic or hazardous media, severe injuries With hazardous media, the protec- may be caused by escaping tive equipment specified in the media!
Page 133 Maintenance Disassembly Protective equipment: With hazardous media, the protec- WARNING! tive equipment specified in the Risk of injury due to incorrect Safety Data Sheet of the medium disassembly! must be worn. In addition, the specifications of the system oper- – The device may still contain ator must be followed.
Page 134 Maintenance Disassembly Fig. 35: Remove the process connec- Fig. 36: Slot nozzle buffer O-ring tion (outlet) Remove the slot nozzle buffer O-ring (Fig. 36/1) from the sight glass CAUTION! Carefully pull the process connection (outlet) from the device housing, turning slightly when doing so (Fig.
Page 135 Maintenance Disassembly Fig. 37: Loosen screws Fig. 38: Remove the inner section Loosen the lower 3 hex head Carefully remove the inner sec- screws (Fig. 37/1) tion (Fig. 38/1) of the device (sight glass, slot nozzle and float) as a unit together with the process connection (inlet) (Fig.
Page 136: Maintenance
Maintenance Maintenance > Cleaning 8.5.1 Cleaning It is the responsibility of the operator to establish appropriate intervals and pro- cedures for cleaning the individual parts of the device. It must be ensured that the parts are not damaged during the cleaning process. When using cleaning agents, it must be ensured that these are not aggressive to the parts and that there will be no dan-...
Page 137: Parts Replacement
Maintenance Maintenance > Assembly Protective equipment: With hazardous media, the protec- CAUTION! tive equipment specified in the Risk of injury due to damaged Safety Data Sheet of the medium parts! must be worn. In addition, the specifications of the system oper- If parts of the device are broken or ator must be followed.
Page 138 Maintenance Maintenance > Assembly Personnel: Qualified personnel Tool: Hex screwdriver Torque screwdriver and assorted blades Special tools: Alignment tool/Test rod Fig. 41: O-ring (glass buffer) Carefully seat the O-ring (glass buffer) onto the process connec- tion (Fig. 41)so that it is properly seated on the lower portion of the process connection (Fig.
Page 139 Maintenance Maintenance > Assembly Repeat steps 1 and 2 for the second process connection Fig. 44: Insert slot nozzle Using the alignment tool, insert Fig. 43: O-ring (centering the slot the slot nozzle through the sight nozzle) glass until the lower groove pro- trudes from the sight glass Place the O-ring (for centering (Fig.
Page 140 Maintenance Maintenance > Assembly Fig. 45: Centering the slot nozzle Fig. 46: Float Place the lower O-ring which Guide the float (Fig. 46/1) into centers the slot nozzle onto the the sight glass so that the lid of end of the slot nozzle (Fig. 45/1) the float (recognizable by the two drill holes) points towards Using the alignment tool, center...
Page 141 Maintenance Maintenance > Assembly Fig. 48: Spanner flats Position the process connection (inlet) so that the spanner flats (Fig. 48/1) are at a 90° angle to the sight glass scale. The locating pin hole on the process connection must be centered on the front of the device housing Fig.
Page 142 Maintenance Maintenance > Assembly Fig. 49: Insert the process connection Fig. 50: Secure the process connection into the device housing (inlet) Insert the process connection Secure the inlet process connec- (inlet) with the inner section into tion with 3 hex socket screws the device housing (Fig.
Page 143 Maintenance Maintenance > Assembly Fig. 51: Align slot nozzle Fig. 52: Slot nozzle buffer Using the alignment tool Insert O-ring (slot nozzle buffer) (Fig. 51/1), align the slot nozzle (Fig. 52/1) and the measuring scale (Fig. 51/2) centered to the sight window of the device housing.
Page 144 Maintenance Maintenance > Assembly Fig. 53: Position the outlet process Fig. 54: Tighten hex socket screws connection Tighten the 3 hex socket screws Insert the outlet process connec- (Fig. 54/1), observing the proper tion (Fig. 53/1) into the device torque ( Ä...
Page 145: Switch Contact Replacement
Maintenance Maintenance > Switch contact replacement 8.5.4 Switch contact replacement Tool: Flat-bladed screwdriver Fig. 56: Loosen female socket Loosen the fixing screw (Fig. 56/1) of the female socket Fig. 55: Check for free movement with a flat-bladed screwdriver Check the float for ease of movement by applying light pressure with the alignment tool (Fig.
Page 146 Maintenance Maintenance > Switch contact replacement Fig. 58: Loosen set screws Fig. 60: Rotate guide rail to the side Using a flat-bladed screwdriver, Rotate guide rail with switch loosen the set screws Fig. 58/1) contact to the side of the switch contact until it moves freely Fig.
Page 147: Measures To Be Taken After Maintenance Work
Maintenance Measures to be taken after maintenance work Re-tighten the set screws (Fig. 58/1) observing the proper tightening torque of the screws Ä Chapter 11.1 “Tightening torque of screws” on page 77) Position the female socket and gasket, then tighten fixing screw 8.6 Measures to be taken after mainte- nance work...
Page 148: Disassembly And Disposal
Disassembly and disposal Disassembly Disassembly and disposal 9.2 Disassembly After its period of useful life, the device must be disassembled and disposed of Before disassembly: in an environmentally safe manner. Remove fluids and lubricants and all other packaging material and 9.1 Safety dispose of them in an environmen- tally safe manner...
Page 149: Return Materials
Profimess will apply. Return shipments which do not comply with the returns – Have electrical scrap, elec- policy may be refused by Profimess at tronic components, lubricants the expense of the consignor. and other supplies disposed of by approved specialists 9.4 Disposal...
Page 150: Technical Data
Technical data Switch contact data plate Technical data 10.1 Device data plate The data plate is on the mechanical part of the flow monitor/flow meter and contains the following information: 1. Ordering number 2. Operating range 3. Process connection 4. Serial number 5.
Page 151: Dimension Sheet
Technical data Dimension sheet 10.3 Dimension sheet 23.02.2015...
Page 152: General Specifications
Technical data General specifications 10.4 General specifications Type Overall dimensions (mm) SW-03 ½ SW-03 ½ SW-03 ½ SW-03 ½ SW-03 ½ SW-03 SW-03 23.02.2015...
Page 153 Technical data General specifications Type Overall dimensions (mm) weight (g) ** SW-03 ca. 96 ca. 96 ½ ca. 96 SW-03 ca. 96 ca. 96 ½ ca. 96 SW-03 ca. 96 ca. 96 ½ ca. 96 SW-03 ca. 96 ca. 96 ½...
Page 154: Electrical Specifications
Technical data Electrical specifications 10.5 Electrical specifications Change-Over Contact (COC) Data Value Unit Voltage 250 V Current, maximum 1,5 A Power, maximum 50 VA Minimum load 3 VA Normally Open Contact (NOC) Data Value Unit Voltage 250 V Current, maximum Power, maximum 100 VA Change-Over Contact (COC) M12x1 (-20 °C–85 °C)
Page 155: Measuring Ranges
Technical data Measuring ranges > Standard measuring ranges Normally Open Contact (NOC) M12x1 (-20 °C–85 °C) Data Value Unit Voltage 250 V Current, maximum Power, maximum 100 VA Change-Over Contact (COC), PLC Data Value Unit Voltage 250 V Current, maximum Power, maximum 60 VA 10.6...
Page 156: Operating Conditions
Technical data Operating conditions 10.7 Operating conditions Description Value Unit Max media temp 100 (optional: 160) °C Min media temp °C It must be ensured that the medium does not freeze. Max Operating pressure Pressure loss 0,01 – 0,2 Measuring accuracy ±...
Page 157: Annex
Annex Spare parts Annex 11.1 Tightening torque of screws Component/ Designation Size Torque function Device Hexagon M6x6 3 Nm housing screw socket screw Guide rail Countersunk M3x10 0,4 Nm screw screw Switch contact Cylinder head M3x10 0,4 Nm housing screw with assembly slot screw...
Page 158 Annex Spare parts The following spare parts drawing provides an example of the construction of a SW-03 Type flow monitor. The actual configuration may vary depending on the model. Fig. 65: Spare parts drawing Description Process connection, (inlet) O-ring (glass buffer) O-ring (seal) Sight glass Device body...
Page 159: Tools
Annex Sealant Description Float with magnets Process connection, (outlet) Guide rail Fixing screw, guide rail Switch contact with male connector Female socket and gasket Fixing screw, (female socket) Washer Fixing screw, (switch contact) 11.3 Tools 11.4 Sealant The following tools are required: Tools Before using a sealant, ensure that Fixed spanner 32, 41, mm...
Page 160: Lubricants
Annex Lubricants 11.5 Lubricants Before using a lubricant, always make sure that it is compatible with the oper- ating medium. For the proper mounting of O-rings, an O-ring installation tool may be purchased from the manufacturer. The following lubricants are suitable to facilitate installing the O-rings: Lubricant O-ring material EPDM...

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