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RMU-B Module BASICSFlow Monitor
Operating Instructions
Series RMU-BType RMU-B02 thru RMU-B18
Read the instructions prior to performing any task!
RMU-B Module BASICS, 1, en_US
© Meister Strömungstechnik GmbH 2014
Meister Strömungstechnik GmbH
Im Gewerbegebiet 2
63831 Wiesen
Germany
Telephone: +49 6096 9720 - 0
Fax: +49 6096 9720 - 30
Email: [email protected]
Internet: www.meister-flow.com
These instructions were compiled by:
Meister Strömungstechnik GmbH
Subject to change without notice
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These instructions facilitate the safeand efficient handling of a flow monitor(referred to as "device" in the fol-lowing). The instructions are an inte-gral part of the device and must bekept within easy reach for the per-sonnel in the immediate vicinity of thedevice at all times. Personnel mustcarefully read and understand theseinstructions before commencing allwork. The basic requirement for safework is adherence to all safety andhandling instructions stipulated inthese instructions. The local accident-prevention regulations and generalsafety standards and regulations forthe field of application of the devicealso apply. Illustrations in theseinstructions are provided to aid generalunderstanding and might deviate fromthe actual model. No claims can bederived from any such differences.
Limitations of liability
All details and instructions in thismanual have been compiled underconsideration of the valid standardsand regulations, the current state-of-technology and our many years ofknowledge and experience. The manu-facturer does not accept any liabilityarising from:
n non-observance of any details inthese instructions
n improper use of the device, or usethat is not in accordance withthese instructions
n use of non-trained personnel
n unauthorized retrofitting or tech-nical changes that have not beenauthorized by the manufacturer
n use of non-approved spare parts
The duties and obligations agreedupon in the delivery contract apply infull, as well as the general terms andconditions, the terms of delivery by themanufacturer and the valid legal regu-lations applicable at the conclusion ofthe contract.
Copyright
These operating instructions are pro-tected by copyright.
Except for internal purposes, transferof these instructions to third-parties,copying them in any way– even in part – as well as dissemina-tion and/or communication of their con-tent is forbidden without prior writtenauthorization from Meister Strömung-stechnik ("manufacturer"). Violationsare subject to claims for indemnifica-tion. The manufacturer reserves theright to assert additional claims.
Copyright is the property of the manu-facturer.
© Meister Strömungstechnik GmbH
Im Gewerbegebiet 2
63831 Wiesen
Germany
Supplemental instructions
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Table of contents1 Overview...................................................................................................... 7
1.1 Short description.................................................................................. 71.2 Warranty and guarantee provisions..................................................... 71.3 Customer service................................................................................. 7
2 Safety........................................................................................................... 82.1 Explanation of symbols........................................................................ 82.2 Correct use in accordance with these instructions............................. 102.3 Special precautions............................................................................ 102.3.1 Hazards from electrical current....................................................... 112.3.2 Mechanical hazards........................................................................ 122.3.3 Hazards from high or low temperatures.......................................... 132.3.4 Radiation hazards........................................................................... 132.3.5 Hazards caused by media............................................................... 142.4 Personnel requirements..................................................................... 142.5 Personal safety equipment................................................................. 152.6 Protective systems............................................................................. 162.7 Replacement parts............................................................................. 162.8 Environmental protection................................................................... 172.9 Responsibility of the owner................................................................ 17
3 Design and function................................................................................. 203.1 Overview............................................................................................ 203.2 Device description.............................................................................. 203.3 Component description...................................................................... 21
4 Transport, packaging and storage.......................................................... 224.1 Safety instructions for transport......................................................... 224.2 Transport inspection........................................................................... 224.3 Packaging.......................................................................................... 224.4 Symbols on the shipping box............................................................. 234.5 Storage............................................................................................... 23
5 Installation and initial startup.................................................................. 255.1 Safety................................................................................................. 25
Table of contents
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5.2 Requirements at the place of installation........................................... 255.3 Preparatory work................................................................................ 265.4 Installation in the pipe line.................................................................. 305.5 Initial startup....................................................................................... 355.6 Electrical connection.......................................................................... 365.6.1 Plug connector EN175301-803....................................................... 365.6.2 Plug connector M12x1.................................................................... 365.6.3 Cable............................................................................................... 375.6.4 Degree of protection (IP-Code)....................................................... 375.7 Grounding the device......................................................................... 375.8 Plug connection.................................................................................. 375.9 Contact protection measures............................................................. 37
6 Operation................................................................................................... 396.1 Setting the switch point...................................................................... 396.2 Checking the flow............................................................................... 41
7 Troubleshooting....................................................................................... 427.1 Safety................................................................................................. 427.2 Troubleshooting guide........................................................................ 44
8 Maintenance.............................................................................................. 468.1 Safety................................................................................................. 468.2 Maintenance plan............................................................................... 468.3 Removal from the pipe system........................................................... 478.4 Disassembly....................................................................................... 488.5 Maintenance....................................................................................... 518.5.1 Cleaning.......................................................................................... 518.5.2 Parts replacement........................................................................... 528.5.3 Assembly......................................................................................... 528.5.4 Switch contact replacement............................................................ 568.6 Measures to be taken after maintenance work.................................. 57
9 Disassembly and disposal....................................................................... 589.1 Safety................................................................................................. 589.2 Disassembly....................................................................................... 58
Table of contents
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9.3 Return Materials................................................................................. 599.3.1 Return Materials Authorization........................................................ 599.4 Disposal............................................................................................. 59
10 Technical data........................................................................................... 6010.1 Device data plate............................................................................. 6010.2 Switch contact data plate................................................................. 6010.3 Dimension sheet.............................................................................. 6110.4 General specifications...................................................................... 6210.5 Electrical specifications.................................................................... 6210.6 Measuring ranges............................................................................ 6310.6.1 Standard measuring ranges.......................................................... 6310.7 Operating data................................................................................. 63
11 Appendix................................................................................................... 6411.1 Tightening torque............................................................................. 6411.2 Replacement parts........................................................................... 6411.3 Tools................................................................................................ 6611.4 Sealant............................................................................................. 6611.5 Lubricants......................................................................................... 67
12 Index.......................................................................................................... 68
Table of contents
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1 Overview1.1 Short description
Fig. 1: RMU-B flow monitor
1 Switch point adjustment scale2 Switch contact with connection
cable
The flow monitor RMU-B monitors thecontinuous flow of liquids. It isdesigned for installation in pipe sys-tems.
A float inside the device is moved bythe medium flowing through it. Thedesired switch point can be set on theswitch point adjustment scale, wherebythe arrow on the switch contact isaligned to the desired volume flowvalue on the switch point adjustmentscale.
The cable can be connected toexternal measuring devices.
1.2 Warranty and guar-antee provisions
Warranty and guarantee provisions arecontained in the general terms andconditions of the manufacturer.
1.3 Customer serviceFor technical information, please con-tact our customer service department(for contact details, see Page 2).
Furthermore, our staff is always inter-ested in receiving new information andexperiences gained from application ofthe device, which may be useful inimproving our products.
OverviewCustomer service
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2 SafetyThis chapter provides an overview ofimportant safety aspects required foroptimum protection of personnel aswell as for safe installation and safeoperation of the device.
Non-observance of the handling andsafety instructions listed in this manualmay result in hazardous/dangerousconditions and in damage to property.
2.1 Explanation of sym-bols
Safety instructions
Safety instructions in this manual aremarked by symbols. The safety instruc-tions are preceeded by signal wordsthat indicate the level of danger/hazard.
To prevent accidents or injury to per-sons as well as damage to property,always observe the safety instructionsand proceed carefully.
DANGER!
This combination of symbol andsignal word indicates an imme-diate, dangerous condition thatresults in death or serious injury ifit is not avoided.
WARNING!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in death or serious injury if itis not avoided.
SafetyExplanation of symbols
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CAUTION!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in minor or slight injury if it isnot avoided.
NOTICE!
This combination of symbol andsignal word indicates a possiblydangerous condition that mightresult in damage to property and tothe environment if it is not avoided.
Tips and recommendations
This symbol emphasizes usefultips and recommendations as wellas information for efficient andfailure-free operation.
Signs used in these instructions
The following signs and highlightingare used in these instructions to iden-tify handling instructions, the descrip-tion of results, lists/enumerations, ref-erences and other elements:
Designates step-by-step han-dling instructions
ð Designates a state or anautomatic sequence as aresult of a specific operatingstep
n Designates randomly ordered enu-merations and list entries
Ä “Signs used in these instructions”on page 9, designates references tochapters in these instructions
SafetyExplanation of symbols
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2.2 Correct use inaccordance withthese instructions
The device is designed and con-structed exclusively for the intendeduse described herein.
Correct use in non-hazard areas
The flow monitor serves exclusivelyto monitor the continuous flow of liq-uids within a temperature range of-20 °C to 100 °C (optional: 160 °C) ata maximum operating pressure of250 bar (brass version).
Correct use in explosion-hazardzones
Explosion-proof switch contacts arecurrently not available for the RMU-Bseries flow monitor.
Any additional or different application,above and beyond the correct use inaccordance with these instructions, isdeemed as incorrect use.
WARNING!
Danger due to incorrect use!Incorrect use of the flow monitormay result in dangerous condi-tions.
– Use the flow monitor onlywithin the stipulated perform-ance limits
– Do not subject the flow mon-itor to severe temperature fluc-tuations
– Do not use the flow monitorwith quick acting valves
– Do not use the flow monitorwith solenoid valves
– Do not subject the flow mon-itor to vibrations
– Do not subject the flow mon-itor to pressure surges
– Do not use the flow monitorwith media containing solids orabrasives
– Use the flow monitor only withmedia previously approved bythe manufacturer
– Do not use the flow monitor asthe sole monitoring device toprevent dangerous conditions
– Do not install the flow monitoras a supporting part within apipeline system
– The flow monitor must beinstalled so that it is protectedfrom damage by mechanicalforce. If necessary, install anappropriate impact protectiondevice.
All claims for damages due to incorrectuse are excluded.
2.3 Special precautionsThe following section lists residualrisks that might arise from the device.
SafetySpecial precautions
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To reduce health risks and preventdangerous conditions, observe thesafety instructions listed here as wellas the safety instruction in the otherchapters of these Operating Instruc-tions.
DANGER!
RMU-B devices are not suitablefor employment in explosionhazard zones.
These Operating Instructionscannot cover all conceivable dan-gers because many dangers arise,not from the device itself, but fromthe respective media flowingthrough it. Always observe theappropriate safety data sheetswhen using hazardous media!
2.3.1 Hazards from elec-trical current
Electrical current
DANGER!
Danger to life from electricalcurrent!There is an immediate risk to lifefrom electrocution on touching liveparts. Damaged electrical insula-tion or components can beextremely dangerous.
– Only qualified electriciansshall work on the electricalsystem.
– If the insulation is damaged,immediately switch off andhave repairs performed.
– Before commencing work onlive parts of the electrical sys-tems and operating equip-ment, disconnect the equip-ment and ensure that itremains disconnected for theduration of the work. Observethese 5 safety rules whendoing so:– Isolate (disconnect)– Secure against switching
back on– Check for absence of
voltage– Ground and short– Cover or cordon off other
live parts in the vicinity
SafetySpecial precautions > Hazards from electrical current
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– Never bridge fuses or putthem out of operation. Alwaysobserve the correct currentratings when replacing fuses
– Keep moisture away from liveparts. This can result in short-circuit
2.3.2 Mechanical hazards
WARNING!
Risk of injury due to fracturedhousing and leakage!Unauthorized temperatures orexcessive pressure may cause theflow monitor body or the processconnections to burst. Injury may becaused by flying debris andescaping media.
– Keep within the stipulatedoperating limits
– Wear personal protectiveequipment
– Avoid severe temperature fluc-tuations
– Avoid pressure surges
CAUTION!
Risk of injury on sharp edgesand pointed corners!Sharp edges and pointed cornerscan cause abrasions and skincuts.
– Proceed with caution whenworking near sharp edges andpointed corners
– If in doubt, wear protectivegloves
SafetySpecial precautions > Mechanical hazards
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2.3.3 Hazards from highor low temperatures
Hot or cold surfaces
WARNING!
Risk of injury from hot or coldsurfaces!Surfaces of components may heatup/cool down dramatically due tothe media flowing through them.Skin contact with hot or cold sur-faces may cause severe skin burnor frostbite.
– Always wear temperature-resistant protective workclothing and protective gloveswhen working near hot/coldsurfaces
– Before commencing work,make sure that all surfaceshave been cooled down orwarmed up to ambient temper-ature
2.3.4 Radiation hazardsStrong magnetic fields
WARNING!
Danger to life from strong mag-netic fields!Strong magnetic fields may causesevere injury or even be fatal, aswell as cause considerabledamage to property.
– Persons with pacemakersmust not be located in thevicinity of the device. Thiscould impair the function of thepacemaker
– Persons with metal implantsmust not be located in thevicinity of the device. Implantscan heat up or be attractedmagnetically
– Keep ferromagnetic materialsand electromagnets awayfrom the magnetic source.These materials could beattracted and fly through theroom, thereby injuring or evenkilling persons. Minimumclearance: 3 m
– Remove and put away metalobjects before maintenancework (jewelry, watches, writingimplements, etc.)
– Do not place any electronicdevices within the vicinity ofthe magnetic source. Thesecould be damaged
SafetySpecial precautions > Radiation hazards
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– Do not place any electronicstorage media, credit cards,etc. within the vicinity of themagnetic source. Data couldbe deleted
2.3.5 Hazards caused bymedia
Hazardous media
WARNING!
Risk of injury from hazardousmedia!If the flow monitor is used for toxic,corrosive or very hot/cold media,there is a risk of serious injury fromescaping media.
– Observe details in the safetydata sheet of the media
– Comply with the safety, acci-dent prevention and environ-mental protection regulationsappropriate to the media used
– Wear personal protectiveequipment in accordance withthe safety data sheet
2.4 Personnel require-ments
WARNING!
Risk of injury due to insuffi-ciently trained and qualified per-sonnel!If unqualified personnel work onthe device or are located within itshazard zone, dangers arise whichmay result in serious injury andconsiderable damage to property.
– All work must be performed byqualified personnel only.
– Keep unqualified personnelaway from hazard zones.
Authorized personnel is to be restrictedto those persons who can be expectedto perform their work reliably. Personswhose ability to respond is influenced,e.g. by drugs, alcohol or medication,are not authorized.
Observe the age and occupational reg-ulations at the site when choosing per-sonnel.
SafetyPersonnel requirements
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The following lists the personnel quali-fications for the various areas ofactivity:
Qualified electricianDue to specialized training, knowledgeand experience as well as knowledgeof the relevant standards and regula-tions, the qualified electrician is able toindependently perform work on theelectrical systems as well as to detectand avoid possible risks and dangers.
Additionally, the electrician must pro-vide proof of his/her professional quali-fication that certifies his/her ability toperform work on electrical systems.
The qualified electrician must fulfill therequirements contained in the validlegal accident-prevention regulations.
Qualified personnelDue to their specialized training, knowl-edge and experience as well as theirknowledge of the relevant standardsand regulations, qualified personnelare able to independently perform thework assigned to them as well as todetect and avoid possible risks anddangers.
2.5 Personal safetyequipment
Personal safety equipment is used toprotect personnel from hazards/dan-gers that might impair their safety orhealth during work.
When performing the various tasks at,and with the device, personnel mustwear personal safety equipment. Spe-cial reference is made of this in theindividual chapters within these Oper-ating Instructions. The following pro-vides a description of the personalsafety equipment:
n Always wear appropriate personalsafety equipment required in thevarious chapters of these Oper-ating Instructions before com-mencing work.
n Comply with the personal safetyequipment instructions postedwithin the work area.
Description of personal safetyequipment
Goggles
The goggles are used to protect theeyes from flying debris and splashingfluid.
Protective gloves
SafetyPersonal safety equipment
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Protective gloves protect the handsfrom friction, burns, grazing, abrasion,surface cuts or deeper injuries, as wellas from direct contact with hot or coldsurfaces.
With hazardous media, the protec-tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, the speci-fications of the system operatormust be followed. If no protectiveequipment is specified, suitable pro-tective gloves and goggles must beworn.The protective equipment is used toprotect against hazardous media leaksand hazardous media residue in thedevice.
2.6 Protective systemsIntegration within an emergency-stop concept is required
The device is designed for use as apart of a machine or system. It doesnot have its own controller and doesnot have an autonomous emergency-stop function.
Before starting up the device, installthe emergency-stop equipment andincorporate it into the safety chain ofthe machine or system.
Connect the emergency-stop equip-ment so that if there is an interruptionin the power supply or in the activationof the power supply after an interrup-tion, dangerous conditions areexcluded for persons and valuables.
The emergency-stop equipment mustalways be freely accessible.
2.7 Replacement parts
WARNING!
Risk of injury due to use ofincorrect replacement parts!Use of incorrect or faulty replace-ment parts may result in dangersto personnel as well as damages,malfunctions or total failure.
– Only use original replacementparts from the manufacturer orapproved by the manufacturer.
– Always contact the manufac-turer in case of doubt.
SafetyReplacement parts
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Always purchase replacement partsfrom an authorized dealer or directlyfrom the manufacturer (For contactdetails, see Page 2).
The replacement parts list is in theannex.
2.8 Environmental pro-tection
NOTICE!
Risk to the environment due toimproper handling of environ-mentally hazardous substances!Serious environmental damagemay result if substances harmful tothe environment are handled incor-rectly, especially if they are dis-posed of improperly.
– Always observe the instruc-tions listed below on the han-dling and disposal of sub-stances harmful to theenvironment.
– If harmful substances arereleased into the environment,take immediate countermeas-ures. If there is doubt, contactthe local authorities, informthem of the damage andrequest information on suit-able countermeasures to betaken.
Cleaning fluids
Solvent-based cleaning fluids containtoxic substances. They must never bereleased into the environment andmust be disposed of by a waste man-agement company.
Lubricants
Lubricants such as greases and oilscontain toxic substances. They mustnever be released into the environmentand must be disposed of by a wastemanagement company.
2.9 Responsibility of theowner
Owner
The owner is the person who operatesthe device himself for business or com-mercial purposes or who cedes suchuse/application to a third-party andwho, during operation of the device,has full legal product stewardship forprotection of the user, the personnel orthird-parties.
Duties of the owner
The device is used in the commercialsector. The owner of the device istherefore subject to legal obligationspertaining to work safety.
SafetyResponsibility of the owner
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In addition to the safety instructionscontained in these Operating Instruc-tions, the safety, accident preventionand environmental protection regula-tions applicable to the field of applica-tion of the device must be observed.
In particular, this includes:
n The owner must inform himselfregarding the valid health andsafety regulations and must per-form a risk assessment to addition-ally determine the risks resultingfrom the special work conditionsarising at the location at which thedevice is used, especially in regardto the media used. He must thenimplement these within OperatingInstructions for use of the device.
n The "Occupational Health andSafety Act" of 1970 stipulates thatit is the duty of the owner to pro-vide a safe workplace. He musthereby ensure that the device isoperated and maintained com-pliant to valid commercial, indus-trial, local, federal and state laws,standards and regulations.
n Appropriate to the working condi-tions and the media used, theowner must affix signs within theworking area that inform the userof the hazards and dangerspresent.
n During the entire period of use ofthe device, the owner must checkperiodically to ensure that theOperating Instructions correspondto the current state of regulations,and he must make adjustments asnecessary.
n The owner must clearly regulateand determine responsibilities forinstallation, operation, trouble-shooting, maintenance andcleaning.
n The owner must fit/retrofit suitablesafety equipment within the com-plete plant/system.
n The owner must ensure that allstaff/personnel have thoroughlyread and understand these instruc-tions before handling the device.Additionally, he must train the per-sonnel at regular intervals andwarn them of dangers.
n The owner must provide the per-sonnel with the required safetyequipment and must instruct themthat its wear is mandatory.
Additionally, the owner is responsiblefor ensuring that the device is alwayskept in a technically perfect condition.The following therefore applies:
n The owner must implement suit-able safety measures, appropriateto the media used.
n Different media have differentseverities of influence on thesoiling and wear of/to the device.The owner must set suitable main-tenance intervals, depending onthe media flowing through thedevice.
SafetyResponsibility of the owner
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n The owner must ensure that themaintenance intervals described inthese Operating Instructions areadhered to at all times.
n The owner must ensure that thedevice is completely free of allresidual media before disposal.Remains of corrosive or toxicmaterials must be neutralized.
SafetyResponsibility of the owner
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3 Design and function3.1 Overview
Fig. 2: Overview
1 Process connection (outlet)2 Device body3 Switch contact with cable4 Switch point adjustment scale5 Connecting thread (inlet)
3.2 Device descriptionRMU-B flow monitors work accordingto the functional principle of the vari-able area flow meter. The flow monitoris installed into a pipe line system andmeasures the flow rate of the mediumflowing through the pipe line.
A float inside the flow monitor is movedby the flowing medium. A magneticfield is generated by the magnetsinside the float. The position of the floatis detected by a switch contact. Thedesired switch point can be set on theswitch point adjustment scale bymoving the switch contact.
Applications for RMU-B flow monitorsare, for example, cooling circuits. Thedevice monitors the volume flow of thecooling media to ensure sufficientcooling. If the flow drops below thethreshold set by the operator, theswitch contact opens (Normally OpenContact).
Design and functionDevice description
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3.3 Component descrip-tion
Switch contact
Fig. 3: Switch contact with connectioncable
A potential-free Reed contact is castinto the switch contact ( Fig. 3/1). Thedevice is supplied with a connectioncable.
Switch point adjustment scale
Fig. 4: Switch point adjustment scale
A scale is applied to the device body,to which the desired switch point canbe adjusted.
Design and functionComponent description
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4 Transport, packaging and storage4.1 Safety instructions
for transport
Improper transport
NOTICE!
The device could be damaged iftransported improperly!Objects to be transported may fallor overturn if transported improp-erly. This may result in damage tothe device and/or property.
– Proceed carefully whenunloading transported pack-ages, both on delivery andwhen transporting in-house.Observe the symbols andinstructions on the shippingbox
– Remove packaging materialjust prior to assembly
4.2 Transport inspec-tion
On delivery, make an immediate checkfor completeness and check for trans-port damages.
If there are any visible external trans-port damages, proceed as follows:
n Do not accept the deliveryn Note the damage in the shipping
documents or on the delivery noteof the transporter and have thedriver confirm by signature
n Initiate a claim for damages
Make a claim for each fault assoon as it is detected. Claims fordamages can only be invokedwithin the valid claim periods.
4.3 PackagingAbout packaging
The packaging serves to protect theindividual components from transportdamages, corrosion and other dam-ages until they are installed. Do notdiscard the packaging and only removethe device from the shipping boximmediately before installation.
Transport, packaging and storagePackaging
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Handling packaging materials
Dispose of packaging material inaccordance with the valid legal regula-tions and local ordinances.
NOTICE!
Danger to the environment dueto incorrect disposal!Packaging is made of valuable rawmaterials and can be reused inmany cases or usefully processedand recycled. Improper disposal ofpackaging materials may pose adanger to the environment.
– Dispose of packaging materialin an environmentally safemanner
– Comply with the local disposalregulations. If necessary, havethe packaging disposed of byapproved specialists.
4.4 Symbols on theshipping box
Top
The arrows indicate the top side of thepackage. They must always pointupwards, otherwise the content may bedamaged.
Fragile
Designates packages with breakableor damageable contents.
Handle the package carefully and donot allow it to fall or be subjected to jar-ring or severe vibration.
4.5 StorageStoring the packages
Store the packages under the followingconditions:
n Do not store in the openn Store dry and dust-freen Do not subject to any aggressive
median Protect from direct sunlightn Avoid mechanical vibrations and
shocksn Storage temperature: 0 to 35 °Cn Relative humidity: max. 60 %n Do not stackn If storing for longer than 3 months,
regularly check the general condi-tion of all parts as well as of thepackaging.
Transport, packaging and storageStorage
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Storage instructions in addition tothe instructions listed here may belisted on the packages. Followthese instructions also.
Transport, packaging and storageStorage
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5 Installation and initial startup5.1 SafetyIncorrect installation and initialstartup
WARNING!
Risk of injury due to incorrectinstallation and initial startup!Incorrect installation and initialstartup may result in severe injuryand considerable damage to prop-erty.
– Ensure that the site is suffi-ciently cleared of obstructionsbefore commencing work
– Handle open or sharp edgedcomponents carefully
– Ensure that the assemblylocation is orderly and clean!Parts and tools lying about oron top of each other arepotential causes for accidents
– Assemble components prop-erly. Observe the stipulatedtightening torque of screws
– Before initial startup, makesure that all installation workhas been performed and com-pleted in compliance with thespecifications and instructionsin these Operating Instructions
Safeguard against restart
WARNING!
Danger to life due to unauthor-ized restart!There is a risk of severe or evenfatal injury due to unauthorizedrestart of the power supply duringinstallation.
– Before commencing work,switch off the power supply tothe entire system/plant andsecure against restart
5.2 Requirements at theplace of installation
The place of installation must meet thefollowing requirements
n The device must not be underwater.
n The surrounding area must be suf-ficiently illuminated.
n There must be sufficient space toprevent accumulation of trappedheat.
n The device must not be installedas a supporting part in a pipe con-struction.
n The device may not have anythingaffixed to, or suspended from it.
Installation and initial startupRequirements at the place of installation
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n The flow monitor must be installedin such a way as to precludedamage by outside force. It mustbe ensured that the flow monitorcannot be damaged. If necessary,install an appropriate impact pro-tection device.
n External magnetic fields will influ-ence the switch contact. Keep suf-ficient distance to magnetic fields(e.g. electric motors).
n Piping, process connections orsupports made from ferromagneticmaterial influence the magneticfield of the device. Keep a spaceof minimum 100mm to those mate-rials (e.g. steel).
5.3 Preparatory workThe following requirements must bemet during installation to ensure cor-rect functioning of the flow monitor:
WARNING!
Danger due to incorrect installa-tion!If the requirements are not metwhen installing the flow monitor,dangerous/hazardous conditionsmay arise.
– Do not install the flow monitoras a supporting part in a pipesystem
– Do not use the flow monitorwith quick-acting valves
– Do not use the flow monitorwith solenoid valves
Installation position/direction offlow
Fig. 5: Installation position/direction offlow
Install the flow monitor in one of thepositions displayed in the drawing,only. The medium must flow in thedirection of the arrow (from a low to ahigh scale value).
Installation and initial startupPreparatory work
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Unimpeded flow sections
NOTICE!
Measuring inaccuracy due toincorrect installation!The measuring accuracy of theflow monitor is influenced by itsposition within the pipe system.Changes in cross-section, branch-offs or bends in the pipe linesystem impair measuring accu-racy.
– Ensure that the unimpededflow sections are maintained
– Never reduce the hose diam-eter immediately before thedevice
We recommend unimpeded flowsections, type BS-228.
Fig. 6: Unimpeded flow sections
1 10x DN2 5x DN
n An unimpeded flow section of10xDN (rated width) must be main-tained before the device.
n An unimpeded flow section of5xDN (rated width) must be main-tained after the device.
Installation and initial startupPreparatory work
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Unimpeded outlet
Fig. 7: Unimpeded outlet
If the pipe line ends at an unimpededoutlet, the flow monitor must not beinstalled directly in front of the opening.The device must always be completelyfilled with media to ensure measuringaccuracy.
Strainer
Installation and initial startupPreparatory work
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Fig. 8: Strainer
1 min. 10x DN2 min. 5x DN
If the medium is contaminated bysolids, a strainer must be installedbefore the device ( Fig. 8).
We recommend a Type SF, SFDor SFM strainer.
Prepare the device
NOTICE!
Risk of damage to property dueto contamination!Contamination and deposits mayimpair the free movement of thefloat, thereby damaging thedevice.
– Ensure that there are no for-eign particles in the device
– Ensure that the device is notsoiled
– Do not use any medium con-taining solids
Due to quality assurance meas-ures, there may be some testmedium (water) residue in thedevice.
Installation and initial startupPreparatory work
16.02.2016 RMU-B Module BASICS Flow Monitor 29
1. Unpack the device and visuallyinspect the device to ensure thatit is free of packaging materials
2. Examine the device for residueof test medium and drain, if nec-essary
3. Check the device for soiling andflush with clean medium, if nec-essary.
5.4 Installation in thepipe line
WARNING!
Risk of injury from pressurizedlines!If the pipe system is under pres-sure when installing the device,severe injuries may result.
– Depressurize the pipe systembefore installing the device
WARNING!
Risk of injury from hot or coldsurfaces!Pipe lines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces maycause severe skin burn or frostbite.
– Before commencing work,ensure that the system hasbeen controlled to a tempera-ture range between 0 and 40°C
– Do not touch any parts of thesystem that are either very hotor very cold.
– Always wear heat-resistant/cold-resistant protectiveclothing and protective gloveswhen working near hot/coldsurfaces.
Installation and initial startupInstallation in the pipe line
16.02.2016RMU-B Module BASICS Flow Monitor30
WARNING!
Risk of injury from media in thepipe system!If the pipe system contains haz-ardous media, severe injuries maybe caused by escaping media.
– Before installation, ensure thatthe pipe system is empty anddoes not contain any mediaresidue
– Always wear personal protec-tive equipment during installa-tion
– Provide suitable drainingdevices (collection tanks, etc.)
NOTICE!
Risk of damage to the devicedue to contamination in the pipeline system!Dirt and foreign particles enteringthe device can damage the deviceand impair its operation.
– Ensure that the pipe system isclean before installing thedevice
– If necessary, flush the pipesystem with clean mediumbefore installation
A suitable sealant must beselected depending on the condi-tion/composition of the hose lines,the medium and the operating andenvironmental conditions. Thesealing method described here isonly an example and cannot beused in all cases.
Installation and initial startupInstallation in the pipe line
16.02.2016 RMU-B Module BASICS Flow Monitor 31
Sealing the pipe connection
Personnel:n Qualified personnel
1. Nap the connecting thread (inlet)
Fig. 9: Apply sealing thread
2. Apply sealing thread ( Fig. 9/1)to the napped area of the con-necting thread in the threadeddirection. Observe the quantityrecommended by the sealantmanufacturer.
Fig. 10: Connecting thread (inlet) withsealing thread
ð The pipe line is now readyfor assembly ( Fig. 10)
3. Nap the thread of the pipe con-nection
Fig. 11: Apply sealing thread
Installation and initial startupInstallation in the pipe line
16.02.2016RMU-B Module BASICS Flow Monitor32
4. Apply sealing thread ( Fig. 11/1)to the napped area in thethreaded direction. Observe thequantity recommended by thesealant manufacturer.
Fig. 12: Pipe connection with sealingthread
ð The pipe line is now readyfor assembly ( Fig. 12)
Install device in the pipe system
Personnel:n Qualified personnel
Protective equipment:n Protective gloves
Tools:n Fixed spanner
CAUTION!
Do not hold the device by itsthreads. These are sharp edgedand may cause injury
1. Place the threaded end of thedevice (inlet) onto the thread ofthe connecting pipe
Fig. 13: Screw in the device (inlet)
2. Fasten the adapter union of thepipe line with an appropriatespanner ( Fig. 13/2). Whendoing so, lock the process con-nection of the device in place toprevent slip, using a suitablespanner ( Fig. 13/1).
Installation and initial startupInstallation in the pipe line
16.02.2016 RMU-B Module BASICS Flow Monitor 33
Fig. 14: Screw in the device (inlet)
3. Keep turning in the adapterunion ( Fig. 14/2) while holdingthe device body locked (Fig. 14/1) until the connection istight.
Fig. 15: Screw in the device (outlet)
4. Fasten the adapter union of thepipe line with an appropriatespanner ( Fig. 13/1). Whendoing so, lock the process con-nection (outlet) of the device inplace to prevent slip, using asuitable spanner ( Fig. 13/2).
Fig. 16: Screw in the device (outlet)
5. Keep turning in the adapterunion ( Fig. 16/1) while holdingthe process connection of thedevice locked ( Fig. 16/2) untilthe connection is tight.
Installation and initial startupInstallation in the pipe line
16.02.2016RMU-B Module BASICS Flow Monitor34
5.5 Initial startupThe following steps must be takenbefore initial startup and any subse-quent startup (e.g. after removal andinstallation during maintenance).
1.
WARNING!
Make sure that the plant isoperating vibration-free.Vibrations could destroy thedevice. This may result in aserious risk of injury to theuser.
2.
WARNING!
Make sure that the mediumis flowing continuously.Pulse-like staggered loadscould destroy the device.This may result in a seriousrisk of injury to the user.
3.
NOTICE!
Completely fill the pipelines.Partial filling(s) may result inmalfunctions and damage tothe device.
4.
NOTICE!
Vent the pipeline. If thereare air bubbles in the lineduring the measurement,this could result in damageto the device caused byhydraulic shock. This maycause malfunctions.
5.
NOTICE!
Make sure that the plant isoperating without cavitation.Cavitation may result in mal-functions and damage to thedevice.
Installation and initial startupInitial startup
16.02.2016 RMU-B Module BASICS Flow Monitor 35
5.6 Electrical connec-tion
The electrical connection of the flowmonitor is accomplished through thecast on power cable. The switch con-tacts employed in these devices arepotential free and do not require apower source. Switch contact and flowmonitor have been optimally harmon-ized. After replacement of a switchcontact, the switch point must be read-justed.
DANGER!
Danger to life from electricalcurrent!There is an immediate risk of lifefrom electrocution on touching liveparts. Damage to the electricalinsulation or single componentscan be extremely dangerous.
– Only qualified electriciansshall work on the electricalsystem
– If the insulation is damagedthen immediately switch offand have repairs carried out
– Before commencing work onlive parts of electrical systemsand components, disconnectsthe equipment and ensure thatit remains disconnected for theduration of the work. Observethese 5 rules when doing so:– Isolate (disconnect)– secure against switching
back on
– Check for absence ofvoltage
– Ground and short– Cover or cordon off other
live parts in the vicinity– Never bridge fuses or put
them out of operation. Alwaysobserve the correct currentratings when replacing fuses
– Keep moisture away from liveparts. This can result in shortcircuit
5.6.1 Plug connectorEN175301-803
Not available for this device series
5.6.2 Plug connectorM12x1
Not available for this device series
Installation and initial startupElectrical connection > Plug connector M12x1
16.02.2016RMU-B Module BASICS Flow Monitor36
5.6.3 CableThe individual cores of the cable arenumbered according to the followingconnection diagram.
Wiring diagram
normally open:
Fig. 17: Switch position under no-flowcondition
5.6.4 Degree of protection(IP-Code)
The specified degree of protection (IP)is only ensured if approved connectionmaterial is used (see following table).
Deviceconnec-tion
Specifica-tion ofconnec-tion mate-rial
Degree ofprotection
Cable - IP67
5.7 Grounding thedevice
When installing the device in a pipesystem, ensure that the device isgrounded to the pipe system to avoid adangerous electrical potential differ-ence.
5.8 Plug connectionPersonnel:n Qualified electrician
For devices of the RMU-B series, onlyswitch contacts with sealed-in connec-tion cables are available.
5.9 Contact protectionmeasures
The Reed-switches used in the switchcontacts are designed to be very sensi-tive to overload. To prevent destructionof the switch contact, the values speci-fied on the rating plate of the switchcontact must never be exceeded (noteven temporarily).
There is a risk of overload from:
n inductive loadsn capacitive loadsn ohmic loads.
Suitable measures must be taken toprotect against overload (see followingexamples):
Inductive load
There is danger of voltage peaks frominductive loads when switching off (upto 10 times the rated voltage). Induc-tive loads are caused by, e.g.:
n Contactors, relaysn Solenoid valvesn Electric motors
Installation and initial startupContact protection measures
16.02.2016 RMU-B Module BASICS Flow Monitor 37
Examples of protective measures:
Fig. 18: Example 1
Fig. 19: Example 2
Capacitive loads
There is a danger of high currentpeaks from capacitive loads whenswitching-on the switch contact(exceeding rated current). Capacitiveloads are caused by, e.g.:
n Long connecting cablesn Capacitive consumers
Example of protective measure:
Fig. 20: Protective measure againstcapacitive loads
Ohmic loads
There is a danger of high currentpeaks from ohmic loads whenswitching-on the switch contact. Thereason for this is that the glow filamenthas a low resistance at low tempera-tures. Ohmic loads are caused by, e.g.:
n Filament bulbsn Motors during startup
Examples of protective measures:
Fig. 21: Example 1
Fig. 22: Example 2
Protection against ohmic loads can beachieved through installation of aresistor in the circuit, or by heating theglow filament. For connection to high-impedance consumers (ex. PLC), aprotective circuit is not needed.
Installation and initial startupContact protection measures
16.02.2016RMU-B Module BASICS Flow Monitor38
6 Operation6.1 Setting the switch
pointSetting the switch point of aninstalled device
The following instructions describethe procedure for a Normally OpenContact (NOC). The actual state(open or closed) can be deter-mined using a continuity meter.
Personnel:n Qualified personnel
Tools:n Hex screwdriver
Fig. 23: Loosen set screws (exampleswitch point adjustment scale)
1. Loosen the set screws of theswitch contact ( Fig. 23/1) usinga hex screwdriver.
2. Slide the switch contact to theflow value to be monitored.Make sure that the arrow on theswitch contact data plate is inexact alignment with the desiredflow rate on the switch pointadjustment scale.
3. Tighten the set screws of theswitch contact ( Fig. 23/1) usinga hex screwdriver. When doingso, observe the correct tight-ening torque of the screws.
Ä Chapter 11.1 “Tighteningtorque” on page 64
ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.
OperationSetting the switch point
16.02.2016 RMU-B Module BASICS Flow Monitor 39
Setting the switch point of a non-installed device
Fig. 24: Loosen the set screws(example switch point adjustmentscale)
1. Loosen the set screws of theswitch contact ( Fig. 24/1) usinga hex screwdriver.
2. Slide the switch contact to theflow value to be monitored.Make sure that the arrow on theswitch contact data plate is inalignment with the desired flowrate on the switch point adjust-ment scale.
3. Tighten the set screws of theswitch contact ( Fig. 24/1) usinga hex screwdriver. When doingso, observe the correct tight-ening torque.
Ä Chapter 11.1 “Tighteningtorque” on page 64
ð The set switch point corre-sponds to the switch-offpoint of the switch contactby decreasing flow.
OperationSetting the switch point
16.02.2016RMU-B Module BASICS Flow Monitor40
6.2 Checking the flowReading-off the flow value
Personnel:n Qualified personnel
Protective equipment:n Goggles
Fig. 25: Reading-off the flow value(example switch point adjustmentscale)
1. Make sure that the setting arrowand the scale mark on the switchpoint adjustment scale are inalignment ( Fig. 25).
2. Look straight on. By viewing atan angle from above or below,the reading can be falsified.(Parallax error).
3. Read-off the flow value from theswitch point adjustment scale
OperationChecking the flow
16.02.2016 RMU-B Module BASICS Flow Monitor 41
7 TroubleshootingThis chapter describes possible mal-functions of the device, their causesand repair.
If malfunctions persist or increase,shorten the maintenance interval tomeet the actual operating conditions.
For malfunctions not described in thischapter, please contact the manufac-turer (see service address on page 2).
7.1 SafetyWork performed incorrectly toremedy a malfunction
WARNING!
Risk of injury due to incorrectrepair of malfunction!Work performed incorrectly mayresult in severe injury and consid-erable damage to property.
– Ensure that the site is suffi-ciently cleared before com-mencing work
– Ensure that the repair locationis orderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes of acci-dents
– If components have beenremoved, observe correctassembly procedures. Rein-stall all fixing/fastening ele-ments and observe the pre-scribed tightening torque forthe screws
– Before placing the device backinto operation, ensure that allwork has been performed andcompleted in compliance withthe specifications and instruc-tions in these OperatingInstructions
TroubleshootingSafety
16.02.2016RMU-B Module BASICS Flow Monitor42
Conduct in case of malfunction
The complete machine or system maybe unsafe if there is a defect at the flowmonitor (e.g. fractured housing).
The following always applies:
1. In case of malfunctions thatpresent an immediate danger topersons or valuables, proceedaccording to the valid emer-gency plans for the system
2. Determine the cause of the mal-function
3. Before repair, ensure that thereis no danger to persons fromescaping media
4. If necessary, allow the pipelineand device to cool down or towarm up before commencingwork
5. Malfunctions must be correctedby qualified personnel
The following troubleshootingguide provides an indication ofwho is qualified to repair the fault .
TroubleshootingSafety
16.02.2016 RMU-B Module BASICS Flow Monitor 43
7.2 Troubleshooting guideFault description Cause Remedy Personnel
The switch contactdoes not switch.
No mediumflowing throughflow monitor
Check that medium isflowing through the pipe-line
Qualifiedpersonnel
Flow is too low orthe switch con-tact is set toohigh
n Adjust the switchcontact to a lowerflow rate
n Use the device atanother measuringrange
n Increase the flowrate
Qualifiedpersonnel
Incorrect reduc-tion fitting or pipediameter is toosmall
n Correct pipe diam-eter
Qualifiedpersonnel
Float is stuck Disassemble and cleanthe device
Qualifiedpersonnel
Switch contact isdefective.
n Remedy the cause ofthe defect (short-cir-cuit, overload)
n Replace the switchcontact
Qualifiedpersonnel
Switch contact ispermanentlyswitched.
Flow is too highor the switchcontact is set toolow
n Reduce the flown Adjust the switch
contact to a higherflow rate
n Use the device atanother measuringrange
Qualifiedpersonnel
TroubleshootingTroubleshooting guide
16.02.2016RMU-B Module BASICS Flow Monitor44
Fault description Cause Remedy Personnel
Float is stuck Disassemble and cleanthe device
Qualifiedpersonnel
Switch contact isdefective
n Remedy the cause ofthe defect (short-cir-cuit, overload)
n Replace the switchcontact
Qualifiedpersonnel
The switch point isnot the same asthe actual flow rate.
Improper scaleinstalled formedia used
Request proper conver-sion table or scale formedia used
Qualifiedpersonnel
Incorrect reduc-tion fitting or pipediameter is toosmall
n Correct pipe diam-eter
Qualifiedpersonnel
Device is dirty Disassemble and cleanthe device
Qualifiedpersonnel
Device is defec-tive
Remove device fromsystem and contact themanufacturer
Qualifiedpersonnel
TroubleshootingTroubleshooting guide
16.02.2016 RMU-B Module BASICS Flow Monitor 45
8 Maintenance8.1 SafetyMaintenance work performed incor-rectly
WARNING!
Risk of injury due to mainte-nance work performed incor-rectly!Maintenance work performedincorrectly may result in severeinjury and considerable damage toproperty.
– Ensure that the site is suffi-ciently cleared before com-mencing work.
– Ensure that the repair locationis orderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes for acci-dents.
– If components have beenremoved, observe correctassembly procedure. Reinstallall fixing/fastening elementsand observe the prescribedtightening torque for thescrews (see Chapter 11.1).
– Before placing the device backinto operation ensure that allwork has been performed andcompleted in compliance withthe specifications and instruc-tions in these OperatingInstructions.
8.2 Maintenance planIntervals for replacement of wearparts
RMU-B type flow monitors require verylittle maintenance due to the smallnumber of moving parts. The intervalsfor the replacement of wear partsdepends significantly on the operatingconditions as well as on the composi-tion of the medium flowing through thedevice. For this reason, no intervalshave been set by the manufacturer.The operator must determine suitableintervals based on the local conditionand circumstances.
MaintenanceMaintenance plan
16.02.2016RMU-B Module BASICS Flow Monitor46
Interval Maintenance work Personnel
Visual inspection for dirt/soiling Qualified personnel
Visual inspection for free-movement of float Qualified personnel
Visual inspection for leaks from the device Qualified personnel
Check proper functioning of the switch contact Qualified personnel
8.3 Removal from thepipe system
The flow monitor must first be removedfrom the pipe system before per-forming maintenance.
WARNING!
Risk of injury from pressurizedlines!Severe injury may result if the pipesystem is under pressure whenremoving the device.
– Depressurize the systembefore removing the device
WARNING!
Risk of injury from hot or coldsurfaces!Pipelines can heat up/cool downdramatically due to the mediaflowing through them. Skin contactwith hot or cold surfaces causessevere skin burn or frostbite.
– Before removing the device,ensure that the machine orsystem and the flow monitorhave been controlled to a tem-perature range between 0 and40°C
– Do not touch any part of themachine or system that iseither very hot or very cold
– Always wear heat-resistant/cold-resistant protective workclothing and protective gloveswhen working near hot/coldsurfaces
MaintenanceRemoval from the pipe system
16.02.2016 RMU-B Module BASICS Flow Monitor 47
WARNING!
Risk of injury from media in thepipe system!If the pipe system contains haz-ardous media, severe injury maybe caused by escaping media.
– Before removing the device,ensure that the pipe system isempty and does not containmedia residue
– Always wear personal protec-tive equipment when removingthe device
WARNING!
Risk of injury from media res-idue in the device!After the pipe system has beenemptied, media residue may stillbe present inside the device. In thecase of hazardous media, thiscould result in serious injury.
– When removing (de-installingthe device from the pipesystem), always wear per-sonal protective equipment.
– All requirements specified inthe media safety data sheetmust be observed in accom-plishing the work task.
– Residue of hazardous mediain the device can result inserious injury.
Removing the device from the pipesystem
Personnel:n Qualified personnel
Protective equipment:n With hazardous media, the protec-
tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, thespecifications of the system oper-ator must be followed. If no protec-tive equipment is specified, suit-able protective gloves and gogglesmust be worn.
Tools:n Fixed spanner
1. Loosen the adapter union of thepipe line using a suitablespanner. When doing so, lockthe process connection ordevice body in place with asecond spanner.
2. Secure the device against fallingand repeat Step 1 at the otherprocess connection.
8.4 DisassemblyTo replace wear parts or to clean thedevice, the flow monitor must first bedisassembled.
MaintenanceDisassembly
16.02.2016RMU-B Module BASICS Flow Monitor48
WARNING!
Risk of injury due to incorrectdisassembly!– The device may still contain
media residue– Wear personal protective
equipment when working withhazardous media
– Improper disassembly maycause serious injuries if haz-ardous media is still presentinside the device
CAUTION!
Risk of injury due to incorrectdisassembly!Incorrect disassembly may resultin injuries.
– Before disassembling, ensurethat the flow monitor hascooled down/warmed up to atemperature range between 0and 40 °C
– Wear personal protectiveequipment to protect againsthazardous media which maystill be present inside thedevice.
Protective equipment:n With hazardous media, the protec-
tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, thespecifications of the system oper-ator must be followed. If no protec-tive equipment is specified, suit-able protective gloves and gogglesmust be worn.
Personnel:n Qualified personnel
Protective equipment:n Gogglesn Protective gloves
Tools:n Fixed spannern Socket wrench
MaintenanceDisassembly
16.02.2016 RMU-B Module BASICS Flow Monitor 49
Fig. 26: Loosen process connection(outlet)
1. Loosen the process connection(outlet) ( Fig. 26) using theproper sized fixed spannerwrench. Hold the device body inplace using a proper sizedspanner wrench..
Fig. 27: Remove process connection(outlet)
2. Unscrew the process connection(outlet) from the device body (Fig. 27). If necessary, removethe O-ring from the process con-nection.
Fig. 28: Remove inner parts
MaintenanceDisassembly
16.02.2016RMU-B Module BASICS Flow Monitor50
3. Carefully turn the device body180° and remove the inner parts(spring, magnets and float) (Fig. 28).
Fig. 29: Spring, magnets and float
4. The inner parts of the flow mon-itor consist of the spring (Fig. 29/1), magnets ( Fig. 29/2)and float( Fig. 29/3).
8.5 Maintenance
8.5.1 CleaningIt is the responsibility of the operator toestablish appropriate intervals and pro-cedures for cleaning the individualparts of the device. It must be ensuredthat the parts are not damaged during
the cleaning process. When usingcleaning agents, it must be ensuredthat these are not aggressive to theparts and that there will be no dan-gerous reactions with media residue.Damaged parts must be replaced.
WARNING!
Risk of injury due to impropercleaning!The device may still contain mediaresidue.
– To protect against hazardousmedia residue in the device,wear personal protectiveequipment.
– Do not use cleaning agentswhich may lead to dangerousreactions with media residue.
– All requirements specified inthe safety data sheet must beobserved when handling orotherwise using the medium.
– Residue of hazardous mediainside the device can causeserious injury.
MaintenanceMaintenance > Cleaning
16.02.2016 RMU-B Module BASICS Flow Monitor 51
CAUTION!
Risk of injury due to damagedparts!If parts of the device are broken ordamaged, they may cause injurydue to sharp edges or splintersduring the cleaning process.
– Damaged parts must bereplaced
– Carefully clean the parts of thedevice, so as not to causedamage.
– When cleaning, always wearappropriate personal protec-tive equipment.
– Incorrect disassembly canresult in injuries.
Protective equipment:n With hazardous media, the protec-
tive equipment specified in theSafety Data Sheet of the mediummust be worn. In addition, thespecifications of the system oper-ator must be followed. If no protec-tive equipment is specified, suit-able protective gloves and gogglesmust be worn.
8.5.2 Parts replacementDepending on the operating conditions,wear parts such as float or magnetsmay have to be replaced. Stepsrequired to replace these parts corre-spond to those used to assemble thedevice Ä Chapter 8.5.3 “Assembly”on page 52.
8.5.3 AssemblyAfter cleaning the individual compo-nents, the flow monitor must be reas-sembled.
MaintenanceMaintenance > Assembly
16.02.2016RMU-B Module BASICS Flow Monitor52
Personnel:n Qualified personnel
Tools:n Fixed spannern Socket wrenchn Torque wrench
Special tools:n Test rodn O-Ring installation tooln Magnetic pole indicator
Fig. 30: O-ring (seal)
1. Carefully install the O-ring (Fig. 30/2) with the aid of the O-ring installation tool ( Fig. 30/1)onto the process connection(outlet), so that it is properly
seated in the O-ring groove ofthe process connection (Fig. 31). When doing so, takecare not to overstretch the O-ring.
Fig. 31: Properly positioned O-ring
2. Position the O-ring properly onthe process connection (outlet) (Fig. 31/1)
3. Lubricate the O-ring lightly.
A list of suitable lubricants iscontained in the annexÄ Chapter 11.5 “Lubricants”on page 67.
MaintenanceMaintenance > Assembly
16.02.2016 RMU-B Module BASICS Flow Monitor 53
Fig. 32: Inner parts
4. Insert spring ( Fig. 32/1) withmagnets ( Fig. 32/2) into thefloat ( Fig. 32/3), ensuring propermagnetic pole orientation (northpole toward device outlet).
Fig. 33: Insert inner parts
5. Insert float with magnets andspring into the device body (Fig. 33)
MaintenanceMaintenance > Assembly
16.02.2016RMU-B Module BASICS Flow Monitor54
Fig. 34: Insert process connection(outlet)
6. Insert the process connection(outlet) into the device body(outlet) ( Fig. 34)
Fig. 35: Tighten process connection(outlet)
7. Using a proper sized fixedspanner, tighten the processconnection (outlet). Hold thedevice body in place using aproper sized fixed spanner (Fig. 35), and observe the propertorque ( Ä Chapter 11.1 “Tight-ening torque” on page 64).
MaintenanceMaintenance > Assembly
16.02.2016 RMU-B Module BASICS Flow Monitor 55
Fig. 36: Check for smooth operation
8. Check the float for ease ofmovement ( Fig. 36) by applyinglight pressure with the test rod
ð If the float moves sluggishly,then disassemble the deviceÄ Chapter 9.2 “Disas-sembly” on page 58 andclean the float and devicebody bore
If the float is still sluggish afterhaving been cleaned severaltimes, contact the manufacturer.
8.5.4 Switch contactreplacement
Tools:n Hex screwdriver
Fig. 37: Loosen set screws
1. Loosen the set screws ( Fig. 37)of the switch contact using anappropriate sized hex screw-driver until the switch contactcan be removed.
Fig. 38: Remove switch contact
2. Remove the switch contact (Fig. 38) from the device
3. Position the new switch contact
MaintenanceMaintenance > Switch contact replacement
16.02.2016RMU-B Module BASICS Flow Monitor56
4. Insert and lightly tighten the setscrews so that the switch con-tact can slide easily.
5. Connect a continuity meter: ForNormally Open Contact (NOC),pin 1 and pin 2 are assigned
6. Slide the switch contact in theopposite direction of flow up tothe stop. The switch contactmust now be closed.
7. Slowly push the switch contactin the direction of flow, until thecontact opens. This switch pointshould be set as accurately aspossible because it affects theaccuracy of the switch pointadjustment scale values (ifneeded, repeat steps 6 and 7).
8. Tighten the set screws ( Fig. 37)observing the proper tighteningtorque ( Ä Chapter 11.1 “Tight-ening torque” on page 64)
9. Affix the enclosed data plate tothe side of the switch contact sothat the reference arrow is inalignment with the lowest scalemark. If a reference tick mark ison the data plate (recognizableas a thinner line), it is to be usedas the alignment mark. Theadhesive surface must be dryand free of oil and grease.
10. Adjust the desired flow rate (cut-off point) on the switch pointadjustment scale, then tightenthe set screws, observing theproper torque ( Ä Chapter 11.1“Tightening torque” on page 64).
8.6 Measures to betaken after mainte-nance work
Take the following steps after comple-tion of maintenance work and beforeswitching on the device:
1. Check all previously loosened/released screw connections fortightness.
Ä Chapter 11.1 “Tighteningtorque” on page 64
2. Clean the work area and removeall residual materials, packaging,substances or spills.
MaintenanceMeasures to be taken after maintenance work
16.02.2016 RMU-B Module BASICS Flow Monitor 57
9 Disassembly and disposalAfter its period of useful life, the devicemust be disassembled and disposed ofin an environmentally safe manner.
9.1 Safety
WARNING!
Risk of injury if disassembledincorrectly!Media residue, sharp edged com-ponents, pointed ends and cornerson and in the device or on toolsmay cause injury.
– Ensure that the site is suffi-ciently cleared before com-mencing work
– Always wear protective equip-ment when handling haz-ardous media residue
– Handle open, or sharp-edgedcomponents carefully
– Ensure that the workplace isorderly and clean! Compo-nents and tools that are lyingabout or on top of each otherare potential causes of acci-dents
– Disassemble components pro-fessionally
– Secure components so thatthey do not fall or overturn
– If in doubt, contact the manu-facturer
9.2 Disassembly
Before starting disassembly:
n Remove operating materials andpackaging and dispose of properly.
Personnel:n Qualified personnel
Protective equipment:n Protective glovesn Goggles
1. Remove the device from thepipe line ( Ä Chapter 8.3“Removal from the pipe system”on page 47)
2. Disassemble the device (Ä Chapter 9.2 “Disassembly”on page 58)
3. Clean components properly andremove media residue
4. Dispose in an environmentallysafe manner
Disassembly and disposalDisassembly
16.02.2016RMU-B Module BASICS Flow Monitor58
9.3 Return Materials9.3.1 Return Materials
AuthorizationFor products being returned, regard-less of the reason, the currently validprovisions of the returns policy set byMEISTER will apply. Return shipmentswhich do not comply with the returnspolicy may be refused by MEISTER atthe expense of the consignor.
9.4 DisposalIf no return or disposal agreement hasbeen made, recycle disassembledcomponents:
n Scrap metalsn Recycle plastic elementsn Dispose of the remaining compo-
nents according to their materialproperties
NOTICE!
Danger to the environment dueto incorrect disposal!Potential risk to the environmentmay arise due to incorrect dis-posal.
– Have electrical scrap, elec-tronic components, lubricantsand other supplies disposed ofby approved specialists
– In case of doubt, obtain infor-mation on environmentallysafe disposal from the localauthority or special disposalexpert
Disassembly and disposalDisposal
16.02.2016 RMU-B Module BASICS Flow Monitor 59
10 Technical data10.1 Device data plateThe data plate is on the mechanicalpart of the flow monitor/flow meter andcontains the following information:
Fig. 39: Device data plate
10.2 Switch contactdata plate
Fig. 40: Switch contact data plate
Fig. 41: Switch contact data plate withpositioning arrow
The data plate is on the switch contactand may provide the following informa-tion:
n maximum voltagen maximum currentn maximum powern positioning arrow for cut-off point
Technical dataSwitch contact data plate
16.02.2016RMU-B Module BASICS Flow Monitor60
10.3 Dimension sheet
Technical dataDimension sheet
16.02.2016 RMU-B Module BASICS Flow Monitor 61
10.4 General specificationsType Overall dimensions (mm)
G*(AG)
G* (IG) DN SW 1 SW 2 L1 L2
RMU-B02 3/8 3/8 10 24 27 63 77,3
RMU-B12 3/8 3/8 10 24 27 63 77,3
RMU-B18 3/8 3/8 10 24 27 63 77,3
Type Overall dimensions (mm)
G*(AG)
G*(IG)
D1 D2 A1 A2 A3 A4 Weight(g) **
RMU-B02 3/8 3/8 - 31,2 - - - ca.37,5
320
RMU-B12 3/8 3/8 - 31,2 - - - ca.37,5
320
RMU-B18 3/8 3/8 - 31,2 - - - ca.37,5
320
* NPT thread on request
**Connecting cable weight, 2m approx. 80g
10.5 Electrical specificationsNormally Open Contact (NOC)
Data Value Unit
Voltage 230 V
Current, maximum 3 A
Power, maximum 60 VA
Technical dataElectrical specifications
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10.6 Measuring ranges10.6.1 Standard measuring rangesType Switch range for H2O at 20 °C*
l/min gph gpm
RMU-B02 0,4 – 1,7 6,5 – 27
RMU-B12 5,5 – 10,0 87,0 – 159,0
RMU-B18 8,5 - 15,5 135,0 – 245,0
* The specified data are switch-off points (other switch ranges are available onrequest).
10.7 Operating dataDescription Value Unit
Max. media temperature 100 (optional 160°C) °C
Min. media temperature
It must be ensured thatthe medium does notfreeze.
-20 °C
Max. operating pressure 250 bar
Pressure loss 0,025 – 0,3 bar
Measuring accuracy ± 10 % of full scale value
RMU-B devices are not suitable foremployment in explosion-hazardzones.
Technical dataOperating data
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11 Appendix11.1 Tightening torqueComponent/function
Description Size
Torque Qty
Connection fit-ting
Connection fitting (outlet) G1/2"
5 Nm 1
Switch contact Cylinder head screw, hex M3x10
0,4 Nm 2
11.2 Replacement partsThe following replacement parts drawing provides an example of the constructionof an RMU-B type flow monitor. The actual configuration may vary depending onthe model.
AppendixReplacement parts
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Item Qty Description
1 1 Device body
2 2 Float
3 2 Magnet
4 1 Spring
5 1 O-ring (seal)
6 1 Threaded connection (outlet)
7 1 Switch contact with connecting cable
AppendixReplacement parts
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Item Qty Description
8 2 Washer
9 2 Set screw (switch contact)
11.3 ToolsThe following tools are required:
Tools
n Fixed spanner 24, 27 mmn Hex screwdriver 2,5 mmn Torque screwdriver and assorted
bladesn Socket wrench 1/2" and assorted
socketsn Torque wrench 1/2"
Special tools
n Test rod RMU-Bn O-ring installation tool RMU-Bn Magnetic pole indicator
11.4 Sealant
Before using a sealant, ensure thatit is compatible with the mediaused and that it can be employedunder the given operating condi-tions.
n Ensure proper sealn Use a suitable sealant. Liquid seal-
ants will damage the flow monitorn Always follow the sealant manu-
facturer's instructions
AppendixSealant
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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, device-specific O-ring installation tools may bepurchased from the manufacturer.
The following lubricants are suitable to facilitate installing the O-rings:
Lubricant O-ring material
NBR EPDM FKM
Glycerine* suitable suitable suitable
Soapy water suitable suitable suitable
* Glycerine must not be used if the device is used for sulfuric acid and/or nitricacid.
AppendixLubricants
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12 IndexAAssembly . . . . . . . . . . . . . . . . . . 52
CCable . . . . . . . . . . . . . . . . . . . . . 37Component groups . . . . . . . . . . . 21Connected loads
Normally Open Contact (NOC) . 62Contact . . . . . . . . . . . . . . . . . . . . 7Contact protection measures . . . . . 37Copyright . . . . . . . . . . . . . . . . . . . 3Correct use . . . . . . . . . . . . . . . . . 10Customer service . . . . . . . . . . . . . 7
DDegree of protection
IP-Code . . . . . . . . . . . . . . . . . 37Device data plate . . . . . . . . . . . . . 60Device description . . . . . . . . . . . . 20Dimension sheet . . . . . . . . . . . . . 61Disassembly
disposal . . . . . . . . . . . . . . . . . 58Maintenance . . . . . . . . . . . . . 48
Disposal . . . . . . . . . . . . . . . . . . . 59
EElectrical connection . . . . . . . . . . 36employment . . . . . . . . . . . . . . . . 10Environmental protection . . . . . . . 17
cleaning fluids . . . . . . . . . . . . 17lubricants . . . . . . . . . . . . . . . . 17
FFault table . . . . . . . . . . . . . . . . . . 44flow value . . . . . . . . . . . . . . . . . . 41
GGeneral
safety . . . . . . . . . . . . . . . . . . . 8
HHazard
electrical current . . . . . . . . . . . 11Hazards
mechanical . . . . . . . . . . . . . . 12media . . . . . . . . . . . . . . . . . . 14radiation . . . . . . . . . . . . . . . . 13temperature . . . . . . . . . . . . . . 13
IInitial startup . . . . . . . . . . . . . . . . 35Installation
pipe line . . . . . . . . . . . . . . . . . 30preparatory work . . . . . . . . . . . 26
LLimitation of liability . . . . . . . . . . . . 3Lubricant . . . . . . . . . . . . . . . . . . 67
MMaintenance . . . . . . . . . . . . . . . . 51Maintenance plan . . . . . . . . . . . . 47Measuring range . . . . . . . . . . . . . 63
OOperating conditions . . . . . . . . . . 63Overview . . . . . . . . . . . . . . . . . . 20Owner . . . . . . . . . . . . . . . . . . . . 17
PPackaging . . . . . . . . . . . . . . . . . . 22Parts replacement . . . . . . . . . . . . 52Plug connection . . . . . . . . . . . . . . 37Precautions
general . . . . . . . . . . . . . . . . . 10Preparation
device . . . . . . . . . . . . . . . . . . 29
Index
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RRead-off . . . . . . . . . . . . . . . . . . . 41Replacement parts . . . . . . . . . 16, 64Return Materials Authorization . . . . 59
SSafety
disassembly . . . . . . . . . . . . . . 58Safety equipment . . . . . . . . . . 15, 16Safety instructions
transport . . . . . . . . . . . . . . . . 22Sealant . . . . . . . . . . . . . . . . . . . . 66Service . . . . . . . . . . . . . . . . . . . . . 7Special tools . . . . . . . . . . . . . . . . 66Storage . . . . . . . . . . . . . . . . . . . 23Strainer . . . . . . . . . . . . . . . . . . . 28Switch contact . . . . . . . . . . . . . . . 21
replacement . . . . . . . . . . . . . . 56Switch contact data plate . . . . . . . 60Switch point . . . . . . . . . . . . . . . . 39
Switch point adjustment scale . . . . 21Symbols
packaging . . . . . . . . . . . . . . . 23Symbols used
in the instructions . . . . . . . . . . . 8
TTechnical data
general specifications . . . . . . . 62Tightening torque . . . . . . . . . . . . . 64Tightening torque of screws . . . . . 64Tools . . . . . . . . . . . . . . . . . . . . . 66Transport inspection . . . . . . . . . . . 22
UUnimpeded flow section . . . . . . . . 27
WWarranty and guarantee provisions . 7
Index
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