ProMinent DulcoFlow DFMa Operating Instructions Manual
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ProMinent DulcoFlow DFMa Operating Instructions Manual

Ultrasonic flow meter
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Operating instructions
Ultrasonic flow meter
DulcoFlow
DFMa
®
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.
The latest version of the operating instructions are available on our homepage.
Part no. 986007
BA MAZ 034 04/21 EN

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  • Page 1 Operating instructions Ultrasonic flow meter DulcoFlow DFMa ® 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. The latest version of the operating instructions are available on our homepage. Part no.
  • Page 2 Supplemental directives Supplementary information Fig. 1: Please read! Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Operating instructions Outcome of the instructions...

  • Page 3: Table Of Contents

    Table of contents Table of contents Identity code..........................5 About This Product........................7 Safety Chapter........................8 Storage and transport......................11 Overview of equipment......................13 Functional description......................14 Assembly and Installation..................... 15 Assembly........................15 Installation, hydraulic....................16 Installation, electrical....................17 7.3.1 Current output......................
  • Page 4 Table of contents 11.2 Pump error in connection with DulcoFlow ® ..............62 11.3 All Other Faults......................63 Decommissioning and disposal..................... 64 Technical Data........................66 Dimensions sheet........................70 Factory settings........................71 Declaration of Conformity...................... 72 UK Declaration of Conformity....................73 Decontamination declaration....................

  • Page 5: Identity Code

    Identity code Identity code Product range Flow Meter DulcoFlow ® DFMa Type for pump product ranges Beta, gamma/ L: 1000 - 0413/0713; gamma/ X: 1000 - 0414/0715 (with the exception of 0220); delta: 1608 - 1612 Beta, gamma/ L: 1005/1605 - 0420 gamma/ X: 1604 - 0424 delta: 1020 - 0450 Sigma/ 1...
  • Page 6 Identity code Product range Flow Meter DulcoFlow ® Design with ProMinent ® logo without ProMinent ® logo Accessories no accessories...

  • Page 7: About This Product

    About This Product The Flow Meter DulcoFlow ® is intended for the measurement of pulsating volumetric flows in ProMinent ® metering pumps (recommended) and a stroke volume of approx. 0.03 ... 10 ml. The flow meter normally sits on the discharge side.

  • Page 8: Safety Chapter

    Observe the general limitations with regard operating instructions to identify different to viscosity limits, chemical resistance and severities of a hazard: density - see also ProMinent® Resistance List in the product catalogue or at www.prominent.com! All other uses or modifications are pro‐...
  • Page 9 Drain and flush the hydraulic parts before working on the device. – Only fit parts to the device that have been tested and recom‐ mended by ProMinent. NOTICE! Warning of illegal operation Observe the regulations that apply where the device is installed.
  • Page 10 Technical personnel of the hydraulic Service system Service refers to service technicians, who have Electrical Installation Electrical technician received proven training and have been author‐ ised by ProMinent to work on the device. ® Operation Instructed person Maintenance Technical personnel Repairs...

  • Page 11: Storage And Transport

    The "Decontamination Declaration Form" can be found in the Appendix or www.prominent.com . under NOTICE! Danger of material damage The device can be damaged by incor‐...
  • Page 12 Storage and transport 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...

  • Page 13: Overview Of Equipment

    Overview of equipment Overview of equipment P_DFl_0013_SW Fig. 2: Overview of equipment DulcoFlow ® with arrows showing flow Control elements - see chapter "Settings" - "Operating unit" Mains connection Signal outputs (option) Feed chemical inlet Feed chemical outlet...

  • Page 14: Functional Description

    Functional description Functional description The DulcoFlow ® flow meter measures the volume flow of pulsing flows. The ultrasonic, time of flight measurement method is used. For the time of flight measurement, a sound signal is alternately transmitted in and against the direction of flow.

  • Page 15: Assembly And Installation

    Assembly and Installation Assembly and Installation Assembly Safety information WARNING! Assemble the device prior to under‐ Install the device so that the hose taking the electrical installation. between it and the pump is approxi‐ mately 20 ... 30 cm long. This ensures it measures accurately.

  • Page 16: Installation, Hydraulic

    Assembly and Installation Installation, hydraulic CAUTION! Warning of escaping feed chemical Feed chemical can escape in the event that the hose lines are incorrectly installed. – Only use original hoses with the specified hose dimensions. – Avoid reducing the hose sizes. Direction of flow The flow direction through the device goes from the bottom to the top.

  • Page 17: Installation, Electrical

    Assembly and Installation Clarify with "Technical Support" at head office whether the flow meter can also be installed on the suction side in a special case. Installation, electrical WARNING! Danger of electric shock The use of a residual current circuit breaker drastically increases survival P_DFI_0005_SW_2 chances should persons come into con‐...

  • Page 18: Current Output

    Assembly and Installation 7.3.1 Current output Current output The following can be signalled via the current output (standard signal output (mA): Instantaneous flow Fault P_DFI_0011_SW Fig. 6 Lead Function brown white Technical data: Data Value Unit Current* 0/4 .. 20 mA Maximum load 400 Ω...
  • Page 19 Assembly and Installation To report stroke feedback on the metering pumps – such as gamma and delta ® , plug the cable from the flow meter on the pump into the "dosing monitor" terminal. The identifier for the dosing monitor ð...
  • Page 20 Assembly and Installation NPN connection information P_DFI_0009_SW Fig. 8: Wiring diagram NPN-outputs to indicating instrument or PLC Ä ‘Collector resistance Rc* Collector resistance or pull-up resistance. For more information, see , minimum level’ on page 24 .
  • Page 21 Assembly and Installation Lead DFMa V(+) = 5 … 30 V Frequency signal V(+) I < 50 mA Frequency signal Frequency / Pulse length V(+) = 5 … 30 V Fault high V(+) I < 50 mA Fault Fault P DFI 0015 SW Fig.
  • Page 22 Assembly and Installation Lead Function Value range Unit blue *** Frequency signal** 0 … 10000 black *** ** Open collector. Rectangular pulses. *** zero volt connection PNP connection information P_DFI_0010_SW Fig. 10: Wiring diagram PNP-outputs to indicating instrument or PLC Rc* Collector resistance or pull-up resistance.
  • Page 23 Assembly and Installation Lead DFMa Frequency signal V(+) = 5 … 30 V I < 50 mA V(+) Frequency signal Frequency / Pulse length Fault V(+) = 5 … 30 V high V(+) I < 50 mA Fault Fault P DFI 0016 SW Fig.
  • Page 24 Assembly and Installation Lead Function Value range Unit blue *** Frequency signal** 0 … 10000 black *** ** Open collector. Rectangular pulses. *** zero volt connection Collector resistance R , minimum level Search terms: Collector resistor Pull-up resistance CAUTION! Open-collector input or O.C. The current I through the signal leads must be limited by means of a suitably scaled collector resistor R...

  • Page 25: Current Output And Counter Output

    Assembly and Installation Collector resistance R for frequency signal Selection of collector resistor Rc lead Supply voltage of monitor = 30 V Rating for maximum frequency fmax = 10 kHz The collector resistance R (or pull-up Ä ‘Collector resistance R Use table resistance) and the cable capacity C minimum level’...

  • Page 26: Set Up

    Set up Set up Control unit Information green, lit pressure surge detected - within tolerance limits DulcoFlow ® red, lit pressure surge detected - 1145.69 mL outside tolerance limits 502.13 mL/h 8.1.3 Control keys The control keys are designated as follows: P_MAZ_0039_SW Designation Fig.
  • Page 27 Set up = set-up option main menu set-up set-up display cont. display Fig. 13: Navigation within the operating menu The control keys have different functions in the continuous display, in the operating menu, and in the sub-menus: In the continuous display Functions Functions Open the sub-menu (move to...

  • Page 28: Checking Display Variables

    Set up In a menu item of a sub-menu Functions Switch between the continuous changing of a number and changing digit by digit Raise / change the set value Lower / change the set value Apply the set value and move to the next menu item of the sub- menu.
  • Page 29 Set up [ i ] (“i” for “Information”) if the Press Continuous display Description LCD screen displays a continuous dis‐ play - i.e. does not display the operating Total volume* m and 326,05 g menu. current mass flow Q 229,21 g/h Another continuous display ð...

  • Page 30: Overview Of The Operating Menu

    Set up Overview of the operating menu Continuous display Set quantity and strokes to zero Acknowledging errors Main menu Menu Operation Operation Measured var. Measured var. Main menu Menu Settings Settings Display Display Menu * Depending on identity code Counter output* Counter output* Menu Current output*...

  • Page 31: Changing To Set Up Mode

    Set up Main menu Menu Zero set Zero set Quantity Quantity Menu Strokes Strokes Main menu Info Info Main menu Language Language B0243 Changing to set up mode ‘Mass’ is selected, then the mass density of the medium also needs to be entered. [P] for 2 seconds in a continuous If you press display, the unit moves to set up mode.
  • Page 32 Set up 8.4.2.1 “Display” menu set-up quantity unit flow unit damping flow display mL/h 30.00 s B0228 ‘display’ menu. The units can be selected for volume and flow in the The damping of the flow values displayed can also be changed (not with volume figures) if they change too quickly / too slowly in the display.
  • Page 33 Set up 8.4.2.2 “Counter output” menu (with identity code characteristic “signal output” “2” and “3”) Open-Collector settings Counter output Stroke feedback Counter output Counter output puls/freq. Open-Collector puls/freq. Open-Collector puls/freq. K factor unit signal output 1/mL K factor 5000 1/mL puls/freq.
  • Page 34 Set up ‘pulse width’ menu lets you set whether the DulcoFlow ‘Pulse width’ - ‘variable’ or ® allows ‘Pulse width’ - ‘constant’ (frequency signal) - with a pre-set value. That may be required works with if the pulses emitted are too short for your connected device (PLC, ...). Moreover, f = 10 Hz plays a role: ‘Pulse width’...
  • Page 35 Set up The DFMa always emits a frequency in accordance with the volume V that flows in 1 second. Pulse ratio : Pause = 1 : 1. A.2 - f less than 10 Hz: P_DFI_0017_SW Fig. 16: Appearance of the pulses depending on the flow volume V for: ‘Pulse width’...
  • Page 36 Set up (A.2) P_DFI_0020_SW Fig. 17: Appearance of the pulses depending on the flow volume V for: ‘Pulse width’ - ‘variable’ f less than 10 Hz (A.2) ‘Pulse width’ - ‘constant’ = 1 - “Normal mode” ‘Pulse width’ - ‘constant’ = 1.2 - with fault behaviour. Fault behaviour ‘Pulse width’...
  • Page 37 “metering monitor” terminal of the required frequency under the ‘simulation’ menu item to simulate a fre‐ metering pump for stroke feedback, for example to a Prominent metering pump - as quency signal coming from the Dulco‐ with a metering monitor Flow Control ®...
  • Page 38 Set up The operating menu does not close automatically while the ‘simulation’ menu item is open. The DulcoFlow can be used to aid ® troubleshooting or commissioning of different output signals – refer to the "Installation" - "Main Menu Settings" - "Counter Output Menu"...
  • Page 39 Set up 8.4.2.3 “Current output” menu (with identity code characteristic “signal output” “1”, “3” and “4”) settings Current output Current range flow unit Current output Signal current 4...20 mA mL/h 0/4 mA value 20 mA value 0.68 mL/h 897.65 mL/h damping 30.00 s Current output...
  • Page 40 Set up ‘controlled pump’ menu is selected, the If the DulcoFlow ® with the control module of a metering pump delta ® can control the flow - see the “Supplementary operating instructions for the metering pump delta - control module ®...

  • Page 41: Calibration" Main Menu

    Set up 8.4.2.4 “Sensitivity” menu Set-up Sensitivity Sensitivity normal B0501 The sensitivity of the unit to disturbances, like air bubbles, can be reduced in the “Sensitivity” menu. At the same time, this also reduces the measuring sensitivity. Sensitivity setting Sensitivity to air bubbles Measuring accuracy normal high...
  • Page 42 Set up back to the metering pump and the right LED is now lit as a steady red instead of green. ProMi‐ nent metering pumps, such as the gamma or the delta ® , move to fault mode after a series of defective strokes (pump set up).
  • Page 43 Set up About setpoint and tolerances calibration stroke feedback volume (stroke) volume (stroke) stroke feedback set-point 0.347 mL 0.347 mL tolerance lower tolerance upper tolerance tolerance (%) -010.00 % +020.00 % B0230 Specify the permitted range for the stroke volume V/H using the setpoint of the stroke volume V/H and tolerances in %: ‘calibration è...
  • Page 44 Set up About limit values calibration stroke feedback volume (stroke) volume (stroke) stroke feedback set-point 0.347 mL 0.347 mL tolerance tolerance (%) tolerance lower limit upper limit limits 0.312 mL 0.416 mL B0231 Alternatively, the required limits for the permitted range of the stroke volume can be entered under ‘lower limit’...
  • Page 45 Set up The required setpoint can also be entered without the need to use the stroke adjustment dial and the pump to be running, by using the [arrow keys] directly in ‘volume (stroke)’ . 8.4.3.1.2 For “mass” The permitted range for the mass per stroke m/H can be specified in this menu.
  • Page 46 Set up About setpoint and tolerances calibration stroke feedback mass (stroke) mass (stroke) stroke feedback set-point 0.347 g 0.347 g tolerance lower tolerance upper tolerance tolerance (%) -010.00 % +020.00 % B0232 Specify the permitted range for the stroke mass m/H via the setpoint of the stroke mass m/H and tolerances in %: ‘calibration è...
  • Page 47 Set up About limit values calibration stroke feedback mass (stroke) mass (stroke) stroke feedback set-point 0.347 g 0.347 g tolerance tolerance (%) tolerance lower limit upper limit limits 0.312 g 0.416 g B0233 Alternatively, the required limits for the permitted range of the stroke mass can be entered under ‘lower limit’...
  • Page 48 Set up The required setpoint can also be entered without the need to use the stroke adjustment dial or the pump to be running, by using the [arrow keys] directly in ‘mass (stroke)’ . 8.4.3.2 Calibrating “volume” Only calibrate the volume flow if the values displayed do not reach the expected accuracy.
  • Page 49 Set up 8.4.3.2.1 By input calibration stroke feedback calibration quantity corr. factor quantity corr. factor 101.23 % B0244 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 multiplying the result by 100.
  • Page 50 Set up Volume calibration stroke feedback calibration quantity quantity corr. factor quantity actual volume nominal volume meas. Value 54.72 mL 52.13 mL corr. factor 95.27 % B0226...
  • Page 51 Set up Requirements: 1 measuring cylinder which can be read sufficiently accurately The suction line of the metering pump is fed bubble-free into the measuring cylinder. Record the fluid level in the measuring cylinder. [arrow keys] to move from the ‘calibration stroke feedback’ menu item to the Use the ‘calibration quantity’...
  • Page 52 Set up Mass calibration stroke feedback calibration quantity quantity corr. factor quantity actual mass nominal mass meas. Value 54.72 g 52.13 g corr. factor 95.27 % B0227...

  • Page 53: Zero Set" Main Menu

    Set up Requirements: 1 set of scales that can be read sufficiently accurately 1 vessel with feed chemical The suction line of the metering pump is fed bubble-free into the vessel Zero the scales. [arrow keys] to move from the ‘calibration stroke feedback’ menu item to the Use the ‘calibration quantity’...

  • Page 54: Info" Main Menu

    Set up If the arrow keys are pressed simulta‐ neously, the total volume and the strokes are simultaneously set to “zero”. Simultaneously holding down [ i ] and [P] for 10 s resets the unit to its factory settings - see “Factory settings” at the end of the instructions.

  • Page 55: Start Up

    Start Up Start Up Connect the device hydraulically with the overall installation. Connect the signal cables for the device. The DulcoFlow can be used to aid ® troubleshooting or commissioning of Connect the device to the supply different output signals – refer to the voltage.
  • Page 56 Start Up If this is not the case, proceed in accord‐ Function "transmit flow value Q" ance with the handling instructions, (for identity code characteristic "signal output" which can be found after the tips. "1") Check whether the frequency signals Set up the desired values under and the mA signals of the device have ‘Settings è...
  • Page 57 Start Up (for identity code characteristic "signal output" "4") ‘Set-up è Current output’ set to Under ‘controlled pump’ . Set the control module delta ® according to the supplementary operating condi‐ tions and check whether everything functions as desired.

  • Page 58: Maintenance, Repair And Disposal

    Maintenance, repair and disposal Maintenance, repair and disposal WARNING! Danger from chemical residues There is normally chemical residue in the measurement pipe and housing after operation. This chemical residue could be hazardous to people. – It is mandatory that the safety information relating to the "Storage, transport and unpacking"...

  • Page 59: Maintenance

    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 Repairs Only ProMinent of customer service authorised by ProMinent may repair the DulcoFlow ® flow meter.

  • Page 60: Troubleshooting

    Troubleshooting Troubleshooting WARNING! Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components during main‐ tenance work. – Before maintenance work, take appropriate protective measures (safety glasses, safety gloves, ...). Adhere to the material safety data sheet for the feed chemical.

  • Page 61: Dulcoflow ® Errors

    Troubleshooting 11.1 DulcoFlow Errors ® Faults 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 particles Avoid bubbles or particles in the in the feed chemical. feed chemical.

  • Page 62: Pump Error In Connection With Dulcoflow

    Troubleshooting 11.2 Pump error in connection with DulcoFlow ® Press [P] to return the pump to its operating status after one of the following errors. In the event of an error an LED lights up red and the flow identifier flashes. Fault description Cause Remedy...

  • Page 63: All Other Faults

    - see metering pump operating instructions while running. is incorrectly adjusted The feed chemical viscosity - see metering pump operating instructions is too high 11.3 All Other Faults All other faults: Inform your customer service department or your ProMinent branch.

  • Page 64: Decommissioning And Disposal

    Decommissioning and disposal Decommissioning and disposal Decommissioning CAUTION! WARNING! Warning of dangerous or unknown feed chemical Danger of electric shock Should a dangerous or unknown feed A mains voltage may exist inside the chemical be used: it may escape from device.
  • Page 65 Decommissioning and disposal Disposal CAUTION! Environmental hazard due to incorrect disposal There are components in the pump, which can have a toxic effect on the environment. – Observe the current applicable regulations in your country.

  • Page 66: Technical Data

    Technical Data Technical Data Performance data Data Value Unit Smallest measurable stroke volume, pulsing approx. 0.03 ml/stroke Largest measurable stroke volume, pulsing approx. 10.00 ml/stroke Precision over at least 100 strokes: ± 2 %* * relative to the measured value Electrical data Data Value Unit...
  • Page 67 Technical Data Data Value Unit Medium temperature: -10...+45 °C Sound pressure level: 1000 ... 2500 m/s CAUTION! Measuring capability of feed chemicals – All liquids that conduct ultrasound waves can be measured. – Any liquids that poorly conduct ultrasound waves cannot be measured, such as sodium hydroxide solution (NaOH) at concentrations above 20%.
  • Page 68 Technical Data Nominal widths of hose connector - see "Identity code"...
  • Page 69 Technical Data Compatibility for flow measurement Type Pumps Beta, gamma/ L: 1000 - 0413/0713 gamma/ X: 1000 - 0414/0715 (with the exception of 0220) delta: 1608 - 1612 Beta, gamma/ L: 1005/1605 - 0420 gamma/ X: 1604 - 0224 delta: 1020 - 0450 Sigma/ 1...

  • Page 70: Dimensions Sheet

    Dimensions sheet Dimensions sheet 121.6 35.5 M20x1,5 P_DFI_0003 Fig. 20: Dimensional drawing DulcoFlow - dimensions in mm ®...

  • Page 71: Factory Settings

    Factory settings Factory settings Tab. 8: DulcoFlow DFMa factory settings ® parameters Value parameters Value Pump type Solenoid Metering Pump settings Calibration Measured variable Volume Correction factor 100% Unit of density g/mL Stroke volume 1 ml Density Plus tolerance 100% Volume unit Minus tolerance -100 %...

  • Page 72: Declaration Of Conformity

    Harmonised standards EN 61010-1: 2010 applied, in particular: EN 61326-1: 2013 EN 61000-6-2: 2005 + AC: 2005 EN 61000-6-3: 2007 + A1: 2011 + AC: 2012 EN 50581: 2012 Date: 20/04/2016 You can download the Declaration of Conformity at www.prominent.com.

  • Page 73: Declaration Of Conformity

    UK Declaration of Conformity UK Declaration of Conformity ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety require‐ ments of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
  • Page 74 Electronic Equipment Regulations 2012 Applied standards, espe‐ BS EN 61010-1:2010 cially: BS EN 61326-1:2013 BS EN 61000-6-2:2005 BS EN 61000-6-3:2007 / A1:2011 BS EN IEC 63000:2018 Date: 23.02.2021 You can find the UK Declaration of Conformity to download at www.prominent.com.

  • Page 75: Decontamination Declaration

    Decontamination declaration Decontamination declaration...

  • Page 76: Index

    Index Index Density ..... . . 31 Designation of the product ... 72 About This Product .
  • Page 77 Index Installation ..... 15 Intended Use ....8 Performance data .
  • Page 78 Index Stroke feedback ... . . 18, 37, 41 Supplementary information ... 2 Units ......32 SW .
  • Page 80 ProMinent GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com 986007, 11, en_GB © 2010...

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