Operating Instructions. KRAL Flowmeter. OMG Series. OIO 14en Edition 07/2017 Original instructions.

Transcription

1 Operating Instructions KRAL Flowmeter. OMG Series OIO 14en Edition 07/2017 Original instructions

2 KRAL Flowmeter OMG Series Table of contents About this document General information 3 Target groups 3 Symbols 3 Danger levels 3 Associated documents 4 Safety Proper use 5 Safety information 5 Labelling Type code 6 Rating plate 7 Technical data Operational limits 8 Load due to pressure pulsation 8 Maximum values 8 Substitute operating data 10 Sound pressure level 10 Dimensions and weights 10 OMG with BSPP thread 10 OMG with DIN flange 11 Load-bearing capacity 12 Load-bearing capacity OMG Load-bearing capacity OMG Load-bearing capacity OMG Load-bearing capacity OMG Load-bearing capacity OMG Load-bearing capacity OMG Load-bearing capacity OMG Heating system Electric heating system 19 Fluid heating system 20 Trace heating system 20 Function description Description 21 Roller bearings 22 Signal generation 22 Linearization 22 Temperature compensation 23 Flow direction detection 23 Junction box 23 Transportation, storage and disposal Unpacking and checking the state of delivery 24 Lifting the flowmeter 24 Storage 24 Preservation 25 Preserving the flowmeter 25 Removing the preservation 25 Disposal 26 Installing the flowmeter 27 Installation types 27 Preferred installation variant 28 Recommendations for alternative installation variants 28 Protect the flowmeter against soiling 29 Connecting the flowmeter to the pipe system 29 Electrical connection 30 Safety instructions for electrical installation 30 Connection for the pick ups 30 Removing the flowmeter 30 Operation Commissioning 32 Cleaning the pipe system 32 Checking the function 32 Commissioning the flowmeter 32 Switching off the flowmeter 33 Safety instruction for switching off the flowmeter 33 Switching off the flowmeter 33 Recommissioning the flowmeter 33 Maintenance Safety instructions on maintenance 34 Required maintenance 34 Re-calibration of the flowmeters 34 Mounting instructions OMG Removing seals and bearings 35 Installing seals and bearings 36 Mounting instructions OMG 20/32 37 Removing seals and bearings 37 Installing seals and bearings 38 Mounting instructions OMG 52/68 39 Removing seals and bearings 39 Installing seals and bearings 41 Mounting instructions OMG100/ Removing seals and bearings 42 Installing seals and bearings 43 Troubleshooting Possible faults 44 Troubleshooting 44 Appendix General drawings 46 Parts list 50 Accessories 51 Junction box 51 Mounting and connecting the junction box 52 Connecting the extension cable 53 Tightening torques 53 Contents of the EC Declaration of Conformity 54 Notes 55 Installation, removal and connection Safety instructions for installation and removal 27 2 OIO 14en Edition 07/2017 Operating Instructions

3 General information About this document General information The operating instructions form part of the KRAL Flowmeter and must be kept for future reference. Furthermore please observe the associated documents. Target groups Target group Operator-owner Specialist personnel, fitters Tasks Keep these instructions available at the site of use for future reference. Ensure that employees read and observe these instructions and the associated documents, in particular the safety instructions and warnings. Observe additional system-specific directives and regulations. Read, observe and follow these instructions and the associated documents, in particular the safety instructions and warnings. About this document Symbols Symbol Meaning Warning personal injury Notice Action steps mechanical installation Action steps electrical installation Check or fault table Request for action Danger levels Warning Danger level Consequences of non-observance Danger Immediate threat of danger Serious personal injury, death Warning Possible threat of danger Serious personal injury, invalidity Caution Potentially dangerous situation Slight personal injury Caution Potentially dangerous situation Material damage Operating Instructions OIO 14en Edition 07/2017 3

4 About this document Associated documents Associated documents Calibration certificate Declaration of conformity according to EU Directive 2006/42/EC Manufacturer's declaration as per EU Directive 2014/34/EU ATEX supplementary instructions for operation in areas at risk of explosions Manufacturer's declaration as per EU Directive 2014/68/EU Corresponding operating instructions for pick ups Corresponding operating instructions for temperature sensor Corresponding operating instructions for electronic equipment 4 OIO 14en Edition 07/2017 Operating Instructions

5 Proper use Safety Proper use Use flowmeters of the OMG series solely for flow measurement of lubricating liquids that are chemically neutral and do not contain any gas or solids content. Flowmeters require the operation with clean liquids. If coarse soiling, solid particles in the liquid or abrasive fine particles occur during operation, the flowmeter has to be protected additionally by a correspondingly dimensioned operating filter in the pipe system, see "Cleaning the pipe system", page 32. Only use flowmeters within the operational limits specified on the rating plate and in the "Technical data" section. Deviating operating data can result in damage to the flowmeter. In the case of operating data that does not agree with the specifications on the rating plate, please contact the manufacturer. Strong changes to the flow rate (e.g. rapid shutdown, pulsations...) cause marked pressure differences on the flowmeter and can damage the measuring unit. The pressure loss of the flowmeter must not exceed the values given in the chapter "Technical data", see "Load-bearing capacity", page 12. Safety Safety information The following safety instructions must be observed: No liability is accepted for damage arising through non-observance of the operating instructions. Read the operating instructions carefully and observe them. The operator-owner is responsible for the observance of the operating instructions. Installation, removal and installation work may only be carried out by specialist personnel. Flowmeters wear to different degrees depending on the respective operating conditions (pulsations, temperature, ). Do not continue to use flowmeters that are operated contrary to specifications or after damage. Check the flowmeters regularly. Shut down damaged flowmeters and replace worn flowmeters immediately. In order for the warranty to remain valid, corrective maintenance carried out during the warranty period requires the express permission of the manufacturer. Observe the general regulations for the prevention of accidents as well as the local safety and operating instructions. Observe the valid national and international standards and specifications of the installation location. In case of systems with an increased potential of danger to humans and/or machines the failure of a flowmeter may not lead to injuries or damage to property. Always equip systems with an increased potential of danger with alarm equipment and/or bypass. Maintain and check the protective/alarm equipment regularly. The pumped liquids can be dangerous (e.g. hot, dangerous to health, poisonous, combustible). Observe the safety conditions for handling dangerous materials. Pumped liquids can be subject to pressure and can cause damage and/or personal injury should leaks occur. Operating Instructions OIO 14en Edition 07/2017 5

6 Labelling Type code Labelling Type code OMG-020.CABABA Series 2 Size 3 Sensor technology 4 Function of sensor technology 5 Material of bearing 6 Material of seal 7 Mechanical connection 8 Electrical connection 9 Version index Fig. 1 Type code Item Designation Description 1 Series OMG: Universal 2 Size Corresponds to the diameter of the measuring screw large in [mm] 3 Sensor technology B: BEG 43 4 Function of sensor technology C: BEG 44 D: BEG 45 E: BEG 45 + BEV 13 F: BEG 47 G: BEG 53 H: BEG 54 5 Material of bearing A: Steel X: Special design A: Without flow direction detection B: With flow direction detection C: Without flow direction detection, with temperature compensation D: With flow direction detection, with temperature compensation X: Special design B: Hybrid X: Special design 6 Material of seal A: FPM (FKM) 7 Mechanical connection B: FFPM C: Low temperature FPM D: EPDM X: Special design A: Pipe thread connection BSPP B: Flange connection DIN C: Pipe thread connection NPT D: Flange connection ANSI E: Flange connection JIS F: Flange connection SAE X: Special design 6 OIO 14en Edition 07/2017 Operating Instructions

7 Rating plate Item Designation Description 8 Electrical connection A: Loose cable head B: Cable gland junction box X: Special design 9 Version index For internal administration Labelling Rating plate R Serial number 2 Construction year 3 K-factor 4 Preferred flow direction 5 Maximum temperature 6 Type 7 Maximum pressure Fig. 2 Rating plate Operating Instructions OIO 14en Edition 07/2017 7

8 Technical data Operational limits Technical data Operational limits The values specified on the rating plate and the calibration certificate apply. The permissible operational limits of individual values influence each other so that every application is checked individually by the manufacturer when selecting the flowmeter. If no operating data are provided by the orderer, standardized substitute operating data are used. Load due to pressure pulsation p [bar] 30 Strong pressure pulses in the system can reduce the lifetime of the flowmeter Fig t [ms] Pressure pulses Maximum values The following table shows the respective maximum values that, however, may not occur simultaneously. In addition, the operational limits of the corresponding end connection, of the sealing material of the pick up and of the temperature sensor are to be observed. Flow rate OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Q max [l/min] Q nom Q min Pressure max. [bar] Temperature min. max. [ C] Viscosity min. max. [mm 2 /s] Measuring chamber volume [ml/u] Rotation speed n (Q max ) [min -1 ] n (Q nom ) n (Q min ) Tab. 1 Maximum values K1 OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Pole number K-factor [P/l] Milliliters/pulse [ml/p] Pulse frequency f1 (Q max ) [Hz] f1 (Q nom ) f1 (Q min ) Tab. 2 Additional maximum values when BEG 43D is used 8 OIO 14en Edition 07/2017 Operating Instructions

9 K2 OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Pole number K-factor [P/l] Milliliters/pulse [ml/p] Pulse frequency f2 (Q max ) [Hz] f2 (Q nom ) f2 (Q min ) Technical data Tab. 3 Additional maximum values when BEG 44 is used K3 OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Pole number K-factor [P/l] Milliliters/pulse [ml/p] Pulse frequency f3 (Q max ) [Hz] f3 (Q nom ) f3 (Q min ) Observe the flow range: If the value lies below Q min, refer to the operating instructions of the corresponding pick-up Tab. 4 Additional maximum values when BEG 45 is used K1 OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Pole number K-factor [P/l] Milliliters/pulse [ml/p] Pulse frequency f1 (Q max ) [Hz] f1 (Q nom ) f1 (Q min ) Tab. 5 Additional maximum values when BEG 47D is used K4 OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Pole number K-factor [P/l] Milliliters/pulse [ml/p] Pulse frequency f4 (Q max ) [Hz] f4 (Q nom ) f4 (Q min ) Tab. 6 Additional maximum values when BEG 53A or BEG 54A is used Operating Instructions OIO 14en Edition 07/2017 9

10 Technical data Sound pressure level Substitute operating data The following table shows standardized values for the flow rate, temperature and viscosity. These values can be used at the same time as maximum values without impairing the service life of the flowmeter. In addition, the operational limits of the corresponding end connection, of the sealing material of the pick up and of the temperature sensor are to be observed. Flow rate OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 Q max [l/min] Q nom Q min Pressure max. [bar] Temperature min. max. [ C] Viscosity min. max. [mm 2 /s] Tab. 7 Substitute operating data Sound pressure level The sound pressure level of the flowmeter amounts to less than 70 db(a). Dimensions and weights OMG with BSPP thread M18x1 G T G1/4" L2 L1 T D G M18x1 G1/4" D L1 L2 T Pipe thread Pick up hole Temperature sensor hole Outer diameter Total length Flowmeter length without connections Screw-in depth max. Fig. 2 Dimensioned drawing OMG with pipe thread OMG 13 OMG 20 OMG 32 OMG 52 OMG 68 OMG100 OMG140 G [inch] 1/2 3/ / Pressure stage [bar] D [mm] L1 [mm] L2 [mm] T [mm] Weight [kg] Tab. 8 Dimensions and weights pipe thread connection 10 OIO 14en Edition 07/2017 Operating Instructions

11 Dimensions and weights OMG with DIN flange M18x1 DN G1/4" L3 L2 L1 L3 TK D DN M18x1 G1/4" D L1 L2 L3 TK Nominal diameter flange Pick up hole Temperature sensor hole Outer diameter Total length Flowmeter length without connections Flange thickness Pitch circle Technical data Fig. 3 Dimensioned drawing OMG with DIN flange OMG 13 OMG 20 OMG 32 DN Pressure stage [bar] D [mm] L1 [mm] L2 [mm] L3 [mm] 25.5* 25.5* TK [mm] Weight [kg] * Screw-in depth is not equal to L3, but rather amounts to 17 mm OMG 52 OMG 68 OMG100 OMG140 DN Pressure stage [bar] D [mm] L1 [mm] L2 [mm] L3 [mm] TK [mm] Weight [kg] Tab. 9 Dimensions and weights DIN flange connection Operating Instructions OIO 14en Edition 07/

12 Technical data Load-bearing capacity Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] C 10 8 A 1000 h 500 [bar] B 5000 h h h E D [l/min] 0, C D [bar] [%] [l/min] [%] ,1 0,5 1 1,5 2 2,5 3 3,5 4 4, [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. 12 OIO 14en Edition 07/2017 Operating Instructions

13 Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] Technical data A 1000 h C [bar] B 5000 h h h E D [l/min] 0, C D [bar] [%] [l/min] [%] ,3 1,5 3 4,5 6 7,5 9 10, , [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. Operating Instructions OIO 14en Edition 07/

14 Technical data Load-bearing capacity Load-bearing capacity OMG h [mm 2 /s] A C h B h h 200 [bar] E D [l/min] C D [bar] [%] [l/min] [%] [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. 14 OIO 14en Edition 07/2017 Operating Instructions

15 Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] Technical data h C 10 8 A 5000 h 500 [bar] B h h E D [l/min] 3, C [bar] D [%] [l/min] [%] ,5 17, , , , , [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. Operating Instructions OIO 14en Edition 07/

16 Technical data Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] C A 1000 h 5000 h 500 [bar] B h h E D [l/min] C [bar] D [%] [l/min] [%] [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. 16 OIO 14en Edition 07/2017 Operating Instructions

17 Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] 1000 Technical data C 10 8 A 1000 h B 5000 h h h [bar] 0 E D [l/min] C [bar] D [%] [l/min] [%] [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. Operating Instructions OIO 14en Edition 07/

18 Technical data Load-bearing capacity Load-bearing capacity OMG [mm 2 /s] C 10 8 A 1000 h B 5000 h h h [bar] 0 E D [l/min] C D [bar] [%] [l/min] [%] [mm 2 /s] A B C D E Short-time operation Continuous operation Pressure loss Flow rate Q nom The values apply for lubricating liquids at temperatures of up to 120 C. Abrasive and aggressive liquids reduce the durability. 18 OIO 14en Edition 07/2017 Operating Instructions

19 Electric heating system Heating system Flowmeters of the OMG series can be equipped optionally with a heating system. The manufacturer recommends heating systems for high-viscosity liquids that do not flow sufficiently if not heated, because bearing damage and destruction of the device may otherwise result. Types: Electrical or fluid heating system Trace heating system by customer Electric heating system Heating system The electrical heating system for the flowmeter consists of a coiled tubing element. The coiled tubing element consists of a heating sleeve that encloses the flowmeter housing. Fig. 1 Coiled tubing element with heating sleeve Operating data: Voltage: 230 V AC Frequency: 50 Hz Wire cross-section: 3 x 0.75 mm 2 Cable length for coiled tubing element: 1 m Size [[ Heating output OMG 13 [W] 180 OMG [W] 180 OMG 52 [W] 800 OMG [W] 2000 OMG140 [W] on request If a coiled tubing element is used, the manufacturer recommends that the flowmeter and heating be insulated in order to avoid radiation losses. Operating Instructions OIO 14en Edition 07/

20 Heating system Fluid heating system Fluid heating system Fluid heating systems are available for the sizes OMG The fluid heating system consists of a heating jacket with pipe thread connections. CAUTION Damage to the device if water or steam id used as a heating fluid. Use a suitable heating fluid such as heat transfer oil. Operating data: Pressure max.: 16 bars Liquid temperature max.: 200 C Trace heating system Contact the manufacturer before installing a trace heating system. 2 X Heat insulation 2 Temperature sensor with connecting cable 3 Trace heating 4 Flowmeter 5 Piping 6 Junction box 7 Pick up with connecting cable 5 7 X Area stringently without heat insulation Fig. 2 Flowmeter with trace heating system CAUTION Defective pick up, temperature sensor or cabling due to exceeding of the maximum temperature. Do not heat the pick up, temperature sensor, junction box and corresponding cables above the temperature specified in the associated operating instructions. Ensure that pick up 7, temperature sensor 2, junction box 6 and corresponding cables are not heat insulated. The area X has to be free of heat insulation, see Fig. 2, page OIO 14en Edition 07/2017 Operating Instructions

21 Description Function description Description 1 2/2a Function description Fig. 1 Structure of the flowmeter OMG series 1 Connection 2 Screw plug 2a Temperature sensor connection 3 Bearing cover 4 Measuring housing 5 Measuring screw small 6 Ball bearing, floating bearing end 7 Measuring screw large 8 Ball bearing, fixed bearing end 9 Pick up hole 10 Pole wheel As screw meters flowmeters belong to the group of rotating displacement meters. The fluid current makes the measuring unit rotate. The displacement effect results from the continuous filling, axial displacement and discharge of the volumes that are formed by the measuring housing and measuring unit. The measured liquid flows around and lubricates all the rotating parts. Thanks to the displacement principle, the flowmeter does not require inlet and smoothing sections in its supply and discharge. Depending on the customer requirements, the flowmeters can be equipped with suitable end connections for connection to various flanges. Operating Instructions OIO 14en Edition 07/

22 Function description Roller bearings Roller bearings The measuring unit is maintained without contact and with a low degree of friction in the housing of the KRAL flowmeter by means of precision roller bearings. The bearing end at the pole wheel end is realized as a fixed bearing. Depending on the respective size, the following bearings are used: Single-row deep-groove ball bearings Paired angular-contact ball bearings Four-point contact bearings The bearing point at the opposite end of the measuring unit is realized as a floating bearing with a movable deep-groove ball bearing at all sizes. Signal generation A pole wheel 10, whose pole is sampled by a pick up, is affixed at the fixed-bearing end of the measuring screw large 7. This pick up generates a specific number of pulses per flow volume unit - depending on the size and working point. This device-specific characteristic is called the K-factor (unit: Pulse/Liter) and is specified on the rating plate as well as the enclosed calibration certificate. Possible formats of the signals are: PNP Push-pull NAMUR Depending on the design of the pick up either cylindrical rotors with embedded magnets or toothed metal disks with varying tooth density can be used (higher number of poles = higher K-factor). Various types of pick ups can be used depending on the application (operating temperature, required frequencies): Inductive pick ups Pick ups based on the Hall effect Magnetic pick ups The rating plate of the flowmeter lists a preferred direction of flow at which the pick up lies on the flow-off end. This preferred direction is based on the aim to position the pick up of the low-pressure end for the case that the flowmeter is blocked. Linearization The calibration certificate contains a mean K-factor that has been determined for the flow range 10:1 and that can therefore be used across a wide flow range. However, the K-factor shows slightly different values at different flow rates. These are also documented in the enclosed calibration certificate. If highest measuring precision is required, it is therefore advisable, especially at strongly varying flow rates, to take these different values into consideration by means of a "Linearization". The K-factors are therefore fed into a suitable electronics unit across several interpolation values of the flow rate. The K- factor relevant for the flow rate being measured is then determined by means of linear interpolation between the two nearest interpolation values. The viscosity dependence of the K-factors must also be taken into account. These are determined during calibration at a viscosity of approximately 4.2 mm²/s. The influence of the flow rate on the K-factor decreases at higher viscosities so that the mean K-factor can then also be used in a considerably larger flow range without noteworthy errors. 22 OIO 14en Edition 07/2017 Operating Instructions

23 Temperature compensation Temperature compensation Flowmeters of the OMG series can be equipped additionally with temperature sensors in the sizes OMG 13 to OMG100. Mounting of a temperature sensor in the piping is advisable for the size OMG140. If the flowmeter is equipped with a temperature sensor, the current density of the flowing liquid can be calculated from this measured value by means of a density table stored in the electronics unit. A normalized volume measurement is then possible at which the displayed values are converted to a reference temperature that can be selected freely. This ensures that measuring errors caused by changes in the density due to temperature variations are avoided. Flow direction detection Function description Systems with a changing flow direction as well as systems with pressure pulsations - that can also cause a reversal of the flow direction - require the use of a second pick up, see "Connection for the pick ups", page 30. This additional phase-offset signal and the incremental encoding inputs available in the KRAL electronic unit can be used to determine the direction of flow and to take it into consideration when calculating the total values. Junction box The manufacturer offers a junction box that facilitates the electrical connection of the various sensors for the flowmeters of the OMG series. Further information see "Accessories", page 51. Operating Instructions OIO 14en Edition 07/

24 Transportation, storage and disposal Unpacking and checking the state of delivery Transportation, storage and disposal Unpacking and checking the state of delivery 1. On delivery unpack the flowmeter and check for damage during transportation. 2. Report damage during transportation immediately to the manufacturer. 3. Store the supplied pick ups and temperature sensors for the installation. 4. Dispose of packing material in accordance with the locally applicable regulations. Lifting the flowmeter Fig. 1 Fastening hoisting equipment principle diagrams WARNING Risk of injury and/or damage to equipment should the flowmeter fall. Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be transported. Select the attachment points for the hoisting equipment in accordance with the center of gravity and the weight distribution. Use at least two load ropes. Do not stand under raised loads. Fasten the hoisting equipment to the flowmeter, see Fig. 1, page 24 and lift the flowmeter. Storage As a result of the calibration, the internal components of the flowmeter are wetted with calibration liquid that has a preservative effect. In addition, a special anticorrosive agent is sprayed onto the interior of the devices before being dispatched. The connections of the flowmeter are fitted with protective caps. Unless otherwise specified, the external components of the flowmeter are preserved with a single-coat PU-based two-component paint. The preservation applied at the factory will protect the flowmeter for up to six weeks, if it is stored in a dry and clean location. The manufacturer offers a long-term preservation for storage times of up to 60 months. In the case of long-term preservation the flowmeter is additionally packed in hermetically sealing anti-corrosion paper. CAUTION Damage to device through corrosion if stored improperly and during longer standstills. Protect the flowmeters against corrosion during long standstills. Observe the chapters "Storage" and "Preserving". 24 OIO 14en Edition 07/2017 Operating Instructions

25 Preservation Preservation Preservation has to be carried out additionally under the following conditions: Type of delivery Standard delivery Delivery with long-term preservation Tab. 1 Check table for preservation Preserving the flowmeter Condition Storage time exceeding six weeks Unfavorable storage conditions such as high humidity, salty air, etc. Opened or damaged packaging 1. Close a connection of the flowmeter with a blind flange. 2. Position the flowmeter vertically. 3. Fill non-corrosive and resin-free oil up to approx. 1 cm under the connection at the top, while turning the measuring unit slowly, so that the measuring unit also comes into contact with it. 4. Close the upper connection with a blind flange. 5. Apply non-corrosive and resin-free oil to all the plain and unpainted parts of the outer housing. After about six months storage check the oil level in the flowmeter and if necessary top up oil. Check the preservation of the outer housing and if necessary apply oil to the parts again. Notice: Store the preserved flowmeter cool and dry and protect it against direct sunlight. Transportation, storage and disposal Notice: After a longer storage time the manufacturer recommends that you have the flowmeter recalibrated, see "Re-calibration of the flowmeters", page 34. Removing the preservation Aids: Solvents suitable for the preservative oil Vessel to collect the preservative oil WARNING Risk of injury through emitted preservative oil. Wear protective clothing during all the work. Open the blind flange carefully in order to reduce any pressure that may exist in the flowmeter. Collect the emitted preservative oil safely and dispose of it in an environmentally compatible manner. 1. Remove one of the blind flanges. 2. Drain the flowmeter, collecting the preservative oil in a suitable vessel. 3. Remove the second blind flange. 4. Use a solvent to remove the residual oil. - or - Rinse the flowmeter with pumped liquid. Operating Instructions OIO 14en Edition 07/

26 Transportation, storage and disposal Disposal Disposal Aids: Solvents or industrial cleaners suitable for the pumped liquid WARNING Danger of poisoning and environmental damage from the pumped liquid. Wear protective clothing during all the work. Before disposing of the flowmeter collect the discharging pumped liquid and dispose of in accordance with the locally applicable regulations. Before disposing of the flowmeter neutralize the residues of the pumped liquid in the flowmeter. 1. Disassemble the flowmeter. 2. Clean residues of the pumped liquid from the individual parts. 3. Separate sealing elements made of elastomer from the flowmeter and dispose of them in the residual waste. 4. Recycle cast-iron and steel parts. 26 OIO 14en Edition 07/2017 Operating Instructions

27 Safety instructions for installation and removal Installation, removal and connection Safety instructions for installation and removal The following safety instructions must be observed: Flowmeters are precision measuring devices. Ensure cleanliness and take care during installation and removal. Do not take apart the flowmeter. Do not remove the protective caps from the dry sleeves during installation. Put the protective caps on the dry sleeves during removal. During installation only remove the screw plugs in order to insert the temperature sensors. Screw in the screw plugs again after the temperature sensors have been removed. If installing a trace heating system, pick up, temperature sensor, junction box and corresponding cables have to be free of heat insulation, see "Trace heating system", page 20. Installing the flowmeter Flowmeters of the OMG series can be operated in any installation position. Notice: Both directions of flow are possible. The preferred flow direction is indicated on the rating plate by means of a bright arrow, see Fig. 2, page 7. Installation types Installation, removal and connection Fig. 1 OMG installation types The arrow with dashed line identifies the preferred flow direction when an operating filter is used. Tab. 1 Installation type 1 Without bypass With or without operating filter 2 Manual bypass With or without operating filter 3 Bypass with 3 stop valves for flange connection With or without operating filter 4 Bypass with 3 stop valves for pipe thread connection With or without operating filter OMG installation types Properties Small space requirements Dismantling of the flowmeter only with interruption of operation Bypass is opened manually Dismantling of the flowmeter only with interruption of operation Dismantling of the flowmeter without interruption of operation Dismantling of the flowmeter without interruption of operation Minimally higher pressure loss Operating Instructions OIO 14en Edition 07/

28 Installation, removal and connection Installing the flowmeter Preferred installation variant X X X Recommendations for alternative installation variants Flow vertically from bottom to top Preferred installation variant. X Flow vertically from top to bottom Ensure that the liquid does not flow freely out of the flowmeter, for example by routing the piping upwards. No vertical installation with open outlet Measuring error through free flowing of the liquid out of the flowmeter. Horizontal flow Ensure that the liquid does not flow freely out of the flowmeter, for example by routing the piping upwards. No horizontal installation at the highest point in the pipe system Avoid measuring error through formation of an air pocket in the flowmeter. X No air bubbles in the pipe system Measuring error through air bubbles in the pipe system. Vent the complete pipe system thoroughly during commissioning. 28 OIO 14en Edition 07/2017 Operating Instructions

29 Installing the flowmeter CAUTION Measuring error through air in the pipe system and/or incorrect installation of the flowmeter. In the case of horizontal installation of the flowmeter at the highest point of the pipe system an air pocket can arise that results in measuring errors. Vent the pipe system thoroughly before commissioning. At a vertical installation of the flowmeter and the flow direction from top to bottom ensure that the liquid does not flow freely out of the flowmeter, for example by routing the pipe upwards or by reducing the pipe diameter with a reducer. During the installation of the flowmeter observe the recommendations for the installation variants and avoid error sources, see "Installing the flowmeter", page 27. Protect the flowmeter against soiling Notice: In order to protect the flowmeter against soiling we generally recommend the installation of an operating filter, mesh width see Tab. 1, page 32. CAUTION Damage through impurities in the pipe system. Installation, removal and connection During welding work attach protective covers in front of the connecting flanges. Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the flowmeter. After the connecting work clean the pipe system thoroughly, see "Cleaning the pipe system", page 32. Connecting the flowmeter to the pipe system The connection of the flowmeter to the pipe system must be stress-free. Fig. 2 Flange connections CAUTION Danger of damage to the device or impaired functionality through mechanical stresses. Ensure that the flowmeter mounting on the pipe system is free of mechanical stress. CAUTION Damage to device when the pipe threading is screwed in too far. Observe the thread length of the flowmeter. Use a standard cutting ring screwed connection. Operating Instructions OIO 14en Edition 07/

30 Installation, removal and connection Electrical connection 1. Remove the protective covers and store them. 2. Install the flowmeter stress-free in the pipe system while taking the preferred direction of flow into account and ensure that the connections of the pick ups and temperature sensors remain accessible. 3. The screw-in length of the piping may not exceed the threaded length of the flowmeter, since the flow cross-section is narrowed and internal components can be damaged. Electrical connection Safety instructions for electrical installation Observe the following safety instructions during the electrical installation: The following qualifications are required for the electrical connection: Practical electrotechnical training Knowledge of the safety guidelines at the workplace Knowledge of the electrotechnical safety guidelines The connecting lines of the connections for pick ups and temperature sensors are to be shielded and laid separately from the supply lines. Ensure that the supply voltage is correct. Observe the corresponding operating instructions for pick ups, temperature sensors and electronic equipment. Connection for the pick ups The flowmeter can be equipped with two pick ups for flow direction detection. The first signal measures the flow rate, the second signal determines the direction of flow. The pick ups have to be connected correctly in order to obtain the correct values. The connections are marked on the flowmeter housing with "1" and "2". This marking depends on the preferred direction of flow in accordance with the arrow on the rating plate, see Fig. 2, page 7. In the case of a direction of flow contrary to the preferred direction of flow the connections have to be swapped in order to obtain a correct signal. CAUTION Measuring error through incorrectly mounted pick ups. Ensure that the pick ups are mounted at the correct position. Observe the corresponding operating instructions for pick ups. Removing the flowmeter Prerequisite: System switched off Aids: Vessel to collect pumped liquid DANGER Risk of death resulting from electric shock while the heating is being removed. Ensure that the supply voltage is de-energized. The flowmeter may only be separated from the power supply by an authorized electrician. 30 OIO 14en Edition 07/2017 Operating Instructions

31 Removing the flowmeter WARNING Risk of injury through emitted hot, poisonous or corrosive pumped liquid when removing the flowmeter. Observe the safety regulations for handling dangerous liquids. Ensure that the flowmeter is not under pressure. Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner. 1. In case of operation at higher temperatures wait until the device has cooled down to the ambient temperature. 2. Drain the pipe system or divert the fuel via the bypass. 3. Dismantle the flowmeter. 4. Apply the protective cover. 5. Observe the chapters "Storage" and "Preserving" on the subject of storing the flowmeter. Installation, removal and connection Operating Instructions OIO 14en Edition 07/

32 Operation Commissioning Operation Commissioning Cleaning the pipe system To protect the flowmeter against soiling carefully clean the complete pipe system carefully before commissioning. Possibilities: Rinsing via bypass Rinsing with flowmeter CAUTION Damage to equipment through usage of an incorrect rinsing liquid. Under no circumstances may water or superheated steam be used to rinse the pipe system. Rinsing via bypass: Close the shut-off devices before and after the flowmeter. - or - Rinsing with flowmeter: An operating filter has to be installed before the flowmeter. Take the mesh width of the filter into account, see Tab. 1, page 32. The mesh width of the operating filter is relevant to the size of the flowmeter. flowmeter size OMG [mm] 0.1 OMG [mm] 0.34 Mesh width max. Tab. 1 Mesh width of the operating filter Checking the function Test Installation Electrical installation Power supply Procedure Check the direction of flow of the flowmeter. Check the installation and installation position of the pick ups and of the temperature sensor. Check the pipe threading/flange and the temperature sensors for leaks under operating pressure. Observe the corresponding operating instructions for pick ups, temperature sensors and electronic equipment. Observe the corresponding operating instructions for pick ups, temperature sensors and electronic equipment. Tab. 2 Function check table Commissioning the flowmeter Prerequisite: The ambient conditions correspond to the operating data, see "Technical data", page 8 Flowmeter correctly installed into the pipe system, see "Installing the flowmeter", page 27 Flowmeter connection to the pipe system is free of mechanical stress Pipe system is free of contamination and dirt particles Pipe system vented Shut-off devices in the supply and discharge lines opened 32 OIO 14en Edition 07/2017 Operating Instructions

33 Switching off the flowmeter CAUTION Measuring error through gas inclusion in the pipe system. Before commissioning, make sure that the flowmeter is filled. Vent the pipe system. Operation CAUTION Increased wear and/or blocking of the flowmeter due to solid particles or abrasive fine particles in the liquid. Protect the flowmeter by a correspondingly dimensioned operating filter in the pipe system. Switch on the system. The flowmeter measures when the pick up generates a signal. Switching off the flowmeter Safety instruction for switching off the flowmeter Pay attention to the following when switching off the flowmeter: Strong changes to the flow rate (e.g. rapid shutdown, pulsations...) cause marked pressure differences on the flowmeter and can damage the measuring unit. The pressure loss of the flowmeter must not exceed the values given in the chapter "Technical data", see "Load-bearing capacity", page 12. Switching off the flowmeter When the flow through the flowmeter is stopped, the generation of the signal stops automatically. No further measures are required to switch off. Recommissioning the flowmeter Prerequisite: The requirements for commissioning are met, see "Commissioning", page 32 CAUTION Damage to device through hard, gummy or crystallized liquid in the flowmeter. Before commissioning, ensure that there is no hard, gummy or crystallized liquid in the flowmeter. 1. Disassemble and clean the flowmeter before recommissioning - or - Heat up the liquid during standstill by means of a heating system. 2. Switch on the system. Under the requirements mentioned above, the flowmeter is ready for operation at any time. Operating Instructions OIO 14en Edition 07/

34 Maintenance Safety instructions on maintenance Maintenance Safety instructions on maintenance The following safety instructions must be observed during all the repair work: All the work may only be carried out by authorized qualified personnel. Wear protective clothing during all the work. Replacement of the measuring unit consisting of the set of screws, roller bearings and pole wheel may only be carried out in the factory. The flowmeter has to be recalibrated after the measuring unit or the roller bearing has been replaced. Observe the pick up operating instructions when replacing the pick up insert. Observe the corresponding operating instructions when replacing the temperature sensor insert. Do not twist the dry sleeve. The guarantee for the flowmeter expires if the red sealing point is damaged. Also observe the general drawings during all the work at the flowmeter, see "General drawings", page 46. Required maintenance Flowmeters are fundamentally maintenance-free. Under observance of the operating limits, see "Technical data", page 8, no significant change in the characteristics could be established, even after years of use in many cases. Conditions lying clearly above the nominal flow rate can, however, result in excessive wear. In the case of liquids with higher abrasiveness (e.g. heavy oil with catalyst residues, plastic components with fillers, etc.) strongly accelerated wear can occur in the flowmeter. Notice: In cases of doubt the manufacturer recommends already carrying out the first inspection of the flowmeter after twelve weeks operation time. Signs of progressive wear of individual flowmeter elements: Finding Cause Remedy Increased running noises Incipient damage to bearing Replace the bearing. Leakage Damage to sealing Replace the seals or dry sleeve. Measured values not realistic see "Fault table", page 45 see "Fault table", page 45 Tab. 1 Check table for required maintenance 1. Check the flowmeter visually and acoustically every four weeks. 2. Check for signs of wear as listed in the table above and eliminate the cause. Re-calibration of the flowmeters In order to maintain the high measuring precision of the flowmeter, the manufacturer recommends carrying out the first re-calibration after about one year of operation. The results reveal any wear starting on the measuring unit. The interval at which recalibration is actually required depends strongly on the operating conditions of the device. The manufacturer provides the factory calibration as standard. If higher requirements are placed on the measuring instrument, an accredited calibration according to EN ISO/IEC is also possible. 34 OIO 14en Edition 07/2017 Operating Instructions

35 Mounting instructions OMG 13 Mounting instructions OMG 13 Removing seals and bearings Maintenance ** 128 Fig. 1 Fig A Fig. 3 Fig. 4 A ** A ** Distance sleeve Sleeve Spacer Bearing cover Measuring housing Pole wheel Measuring screw large Measuring screw small O-ring O-ring Deep-groove ball bearing Deep-groove ball bearing Deep-groove ball bearing Deep-groove ball bearing Socket screws Grooved insert pin two units if two pick up holes exist Prerequisites: Flowmeter removed from system End connection consisting of socket screws, flanges and seals removed Pick up inserts removed 1. Remove the socket screws 915.1, take off the bearing cover Remove the O-ring 739.5** from the bearing cover, see Fig. 1, page Remove the spacer 062 and O-ring 739.1, pull the screw set together with distance sleeve 039 from the measuring housing 128. Take the combination into account to ensure subsequent assembly, see Fig. 2, page Pull the pole wheel 259, ball bearing 817.1, sleeve 041 and ball bearing from the measuring screw large 672.1, and the ball bearings and from the measuring screw small 672.2, see Fig. 3, page 35. Operating Instructions OIO 14en Edition 07/

36 Maintenance Mounting instructions OMG 13 Installing seals and bearings 1. Slide the sleeve 041 onto the measuring screw large 672.1, while taking the mounting direction into account, see Fig. 3, page Press the ball bearings 817.1, 817.2, and onto the measuring screw large and measuring screw small Notice: Press the ball bearings on only over the inner ring. Press the pole wheel 259 onto the measuring screw large. 3. Insert the O-ring 739.5** into the bearing cover Push the screw set into the measuring housing 128, paying attention to the configuration. Slide the distance sleeve 039 into the hole of the measuring screw small 672.2, see Fig. 4, page Insert the O-ring into the measuring housing. Lay on the spacer 062, ensuring that it is positioned correctly, see Fig. 2, page Place the bearing cover onto the measuring housing, ensuring that the grooved insert pins A in the measuring housing fit into the corresponding holes. Tighten the socket screws Mount the flange cover while pretensioning the oiled screws crosswise. Tightening torque see Tab. 2, page OIO 14en Edition 07/2017 Operating Instructions

37 Mounting instructions OMG 20/32 Mounting instructions OMG 20/32 Removing seals and bearings ** Maintenance Fig. 5 Fig. 6 Fig Fig. 8 A 039 A *** Fig. 9 Fig *** Distance sleeve Spacer Supporting ring Supporting ring End cover End cover Measuring housing Pole wheel Measuring screw large ** Measuring screw small O-ring O-ring O-ring Deep-groove ball bearing Deep-groove ball bearing Deep-groove ball bearing Deep-groove ball bearing Circlip A Circlip Lock washer Lock washer Socket screws Socket screws Socket screws Socket screws Grooved insert pin ** *** two units if two pick up holes exist only for OMG 32 Prerequisites: Flowmeter removed from system End connection consisting of socket screws, flanges and seals removed Pick up inserts removed Operating Instructions OIO 14en Edition 07/

38 Maintenance Mounting instructions OMG 20/32 1. Remove the socket screws and 915.2, take off the end covers and 070.2, see Fig. 5, page Remove the O-rings 739.1, and 739.5**, see Fig. 6, page Pull the distance sleeve 039 together with the set of screws out of the measuring housing, see Fig. 7, page Remove the circlips and from the measuring screws. Overview see Fig. 9, page Screw out the socket screws and and remove the lock washers 904.1, and support rings 064.1***, Turn in the socket screw back completely in order to pull the pole wheel 259 and spacer 056 from the measuring screw large using an extractor. Remove the socket screw again. 7. Pull the ball bearings from the screws using the extractor. Installing seals and bearings 1. Insert the O-rings and into the end covers and 070.2, insert the O-ring 739.5** into the pick up hole. 2. Press the ball bearings 817.1, 817.2, and onto the measuring screw large and measuring screw small Notice: Press the ball bearings on only over the inner ring. 3. Slide the spacer 056 onto the measuring screw large 672.1, press the pole wheel 259 on. 4. Pull the wedge lock washers and and support rings 064.1*** and onto the sockets screws and Overview see Fig. 9, page 37. Notice: Ensure that the wedge lock washers are positioned correctly (wedge surface to wedge surface), see Fig. 8, page Mount the socket screws and 915.7, with Loctite 242 applied, with mounted washer and ring onto the measuring screws and tighten with torque, see Tab. 2, page Mount the circlips and on the floating bearing end. 7. In case of BSPP connection: Place the end cover on the measuring housing, lay out the socket screws or - In case of flange connection: Place the end cover and flange cover 115.2* with O-ring 739.4* on the measuring housing, lay out the socket screws 915.4*. Overview see Fig. 2, page Pretension the oiled screws crosswise and tighten with torque, see Tab. 2, page Slide the set of screws in the measuring housing. Slide the distance sleeve 039 into the hole of the measuring screw small 672.2, see Fig. 10, page Place the end cover onto the measuring housing, ensuring that the grooved insert pins A in the measuring housing fit into the corresponding holes. 11. In case of BSPP connection: Lay out the socket screws or - In case of flange connection: Place on the flange cover 115.1* with O-ring 739.3* and lay out the socket screws 915.3*. Overview see Fig. 2, page Pretension the oiled screws crosswise and tighten with torque, see Tab. 2, page OIO 14en Edition 07/2017 Operating Instructions

39 Mounting instructions OMG 52/68 Mounting instructions OMG 52/68 Removing seals and bearings Maintenance Fig. 11 Fig ** Fig. 13 Fig. 14 Fig ** Fig. 16 Fig. 17 Fig. 18 Operating Instructions OIO 14en Edition 07/

40 Maintenance Mounting instructions OMG 52/ Spacer Spacer Threaded ring Threaded ring Supporting ring Supporting ring Bearing cover Measuring housing Pole wheel Measuring screw large ** Measuring screw small O-ring O-ring Deep-groove ball bearing Deep-groove ball bearing Angular-contact ball bearings Angular-contact ball bearings Support ring Support ring Circlip ** Circlip Lock washer Lock washer Socket screw Socket screw two units if two pick up holes exist Prerequisites Flowmeter removed from the system End connection consisting of socket screws, flanges and seals removed Pick up inserts removed 1. Remove the socket screws and 915.2, take off the bearing cover Remove the O-ring 739.2, without picture. 2. Use light blows of a plastic tip hammer to drive the screw set together with the bearing cover out of the measuring housing 128 and pull out, see Fig. 11, page Screw out the socket screw with lock washer and supporting ring from the measuring screw large Remove the pole wheel 259 and the spacer 056, see Fig. 12, page Screw out the socket screw with lock washer and supporting ring from the measuring screw small 672.2, see Fig. 12, page Remove the screw set from the bearing cover using an extractor. 6. Screw out the threaded rings and of the bearing cover, see Fig. 14, page 39. For allen key widths, see Tab. 2, page Take the spacer 054 out, and pull the bearings and out of the bearing cover using an extractor. 8. Remove the O-rings and 739.5**, see Fig. 15, page Remove the circlips and and support rings and from the measuring screws, see Fig. 16, page Pull the bearings and from the measuring screws using an extractor. 40 OIO 14en Edition 07/2017 Operating Instructions

41 Mounting instructions OMG 52/68 Installing seals and bearings 1. Insert the O-rings and into the bearing cover and Insert the O-ring 739.5** into the pick up hole. 2. Press the ball bearings and into the bearing cover Notice: Press the angular-contact ball bearings on in face-to-face arrangement, see Fig. 18, page 39. To avoid damages press the ball bearings on only over the outer ring. 3. Put spacer 054 on ball bearing Press the ball bearing onto the measuring screw large and the ball bearing onto the measuring screw small Notice: Press the ball bearings on only over the inner ring. 5. First screw the threaded ring 057.2, then the threaded ring into the bearing cover using the allen key. Allen key widths and tightening torques, see Tab. 2, page Press the measuring screws into the bearings in the bearing cover. Notice: To avoid damages support the inner rings of the ball bearings. 7. Pull the lock washer and supporting ring onto the socket screw Notice: Ensure that the lock washers are positioned correctly (wedge surface to wedge surface), see Fig. 17, page Mount the socket screw 915.7, with Loctite 242 applied, with mounted washer and ring onto the measuring screw small and tighten with torque, see Tab. 2, page Slide the spacer 056 onto the measuring screw large Press the pole wheel 259 on. 10. Pull the lock washer and supporting ring onto the socket screw Mount the socket screw 915.6, with Loctite 242 applied, with mounted washer and ring onto the measuring screw large and tighten with torque, see Tab. 2, page Mount the support rings and and circlips and on the floating bearing end. 13. Place the bearing cover onto the measuring housing 128 and tighten with torque the socket screws Slide the bearing cover with pre-mounted measuring unit, consisting of screw set and pole wheel, into the measuring housing, tighten with torque the socket screws Mount the flange cover while pretensioning the oiled screws crosswise. Tightening torque see Tab. 2, page 53. Maintenance Size Measuring screw Pos. no. Allen key width [mm] Tightening torque [Nm] 52 large small large small Tab. 2 Allen key width and tightening torque for threaded ring Operating Instructions OIO 14en Edition 07/

42 Maintenance Mounting instructions OMG100/140 Mounting instructions OMG100/140 Removing seals and bearings ** Fig. 19 Fig. 20 Fig. 21 Fig *** 739.5** Fig *** Sleeve Spacer Supporting ring Supporting ring Bearing cover Measuring housing Pole wheel Measuring screw large Measuring screw small ** O-ring O-ring Deep-groove ball bearing Deep-groove ball bearing Four-point contact bearings Four-point contact bearings Support ring Support ring Support ring Support ring Circlip Circlip Circlip Circlip Lock washer Lock washer Socket screw Socket screw ** *** two units if two pick up holes exist OMG140: replaced by sleeve, spare part OIO 14en Edition 07/2017 Operating Instructions

43 Mounting instructions OMG100/140 Prerequisites: Flowmeter removed from the system End connection consisting of socket screws, flanges and seals removed Pick up inserts removed 1. Remove the socket screws and 915.2, take off the bearing cover Remove the O-ring Use light blows of a plastic tip hammer to drive the set of screws together with the bearing cover out of the measuring housing 128, see Fig. 20, page 42 and pull out. 3. Loosen the circlips and from recesses in the bearing cover, see Fig. 21, page 42, screw out the socket screw Remove the lock washer and supporting ring Turn in the socket screw back completely in order to pull the pole wheel 259 and bearing cover from the set of screws using an extractor. Remove the spacer 056*** or sleeve 041 respectively. see Fig. 23, page Remove the measuring screws from the bearing cover Remove the O-rings and 739.5**, see Fig. 19, page Screw out the socket screw with lock washer and supporting ring at the measuring screw small Remove the circlips and and support rings and from the measuring screws. 8. Pull the bearings from the screws using the extractor. Avoid damage to the threads. Notice: and are four-point contact bearings. 9. Screw the socket screw out again and remove the support rings and Maintenance Installing seals and bearings 1. Insert the O-ring and into the bearing cover and Insert the O-ring 739.5** into the pick up hole. 2. Slide the circlips and and support rings and onto the measuring screw large and measuring screw small Press the ball bearings 821.1, 817.1, and onto the measuring screw large and measuring screw small Notice: Press the ball bearings on only over the inner ring. 4. Pull the wedge lock washer and supporting ring onto the socket screw Notice: Ensure that the wedge lock washers are positioned correctly (wedge surface to wedge surface), see Fig. 22, page Mount the socket screw 915.7, with Loctite 242 applied, with mounted washer and ring onto the measuring screw small and tighten with torque, see Tab. 2, page Slide the measuring screws into the bearing cover Mount the circlips and Slide the spacer 056** or sleeve 041 onto the measuring screw large. Press the pole wheel 259 on. 8. Pull the wedge lock washer and supporting ring onto the socket screw Notice: Ensure that the wedge lock washers are positioned correctly (wedge surface to wedge surface), see Installation step Mount the socket screw 915.6, with Loctite 242 applied, with mounted washer and ring onto the measuring screw large and tighten with torque, see Tab. 2, page Mount the support rings and and circlips and on the floating bearing end. 11. Place the bearing cover onto the measuring housing 128 and tighten with torque the socket screws Slide the bearing cover with pre-mounted measuring unit, consisting of set of screws, bearings and pole wheel, into the measuring housing, tighten with torque the socket screws Mount the flange cover while pretensioning the oiled screws crosswise. Tightening torque see Tab. 2, page 53. Operating Instructions OIO 14en Edition 07/

44 Troubleshooting Possible faults Troubleshooting Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for elimination. Possible faults Fault Cause/Elimination Flowmeter leaks 1, 2, 8 No flow rate 3, 9, 10, 22, 24, 25 Negative flow rate 5, 17, 19 Flowmeter does not generate a pulse 3, 4, 5, 6, 7, 8, 10, 13, 20, 22, 24, 25 Pressure loss too high 11, 14, 22, 23 Measured values not realistic 3, 4, 5, 6, 7, 9, 12, 15, 16, 17, 18, 19, 20, 21, 22, 23 Troubleshooting No. Cause Remedy 1 Seal preload too low Preload the screws. 2 Seal damaged Replace the seal. Check the chemical resistance of the seal. 3 Foreign bodies in the liquid and/or flowmeter Dismantle the flowmeter and clean it. Use the commissioning filter. 4 Pick up not positioned correctly Position the pick up correctly, see "Connection for the pick ups", page 30. Observe the pick up operating instructions. 5 Pick up not connected correctly Check the connection of the pick up, see "Connection for the pick ups", page 30. Check the supply voltage for the pick up, while observing the pick up operating instructions. 6 Pick up defective Check the function of the pick up, while observing the pick up operating instructions. 7 Dry sleeve not adjusted correctly Set the dry sleeve correctly, while observing the pick up operating instructions. 8 Dry sleeve destroyed Replace dry sleeve, please contact the manufacturer for information. 9 Liquid lubricates too little Use the OMK series. 10 Feed pressure too low Increase the inlet pressure. 11 Viscosity of the liquid too high Increase the temperature, while observing the permissible temperature range. 12 Viscosity of the liquid too low Use the OMK series. 13 Flow rate too low Increase the flow rate - or - Use a suitable flowmeter size - or - Use linearization, while observing the electronic operating instructions. 14 Flow rate too high Reduce the flow rate - or - Use a suitable flowmeter size. 15 Airlocks Deaerate the system and check for leaks. 44 OIO 14en Edition 07/2017 Operating Instructions

45 Troubleshooting No. Cause Remedy 16 Outgassing Increase the system pressure. Reduce the temperature. 17 Pulsations too high Use another feed pump. Carry out changes to the system. 18 Back pressure too low Increase the back pressure. 19 Flow rate fluctuations too high Ensure a continuous flow rate by taking suitable measures (use of a different pump. valve, damper, etc.) - or - Smoothen the indication, while observing the electronic operating instructions. 20 Filling amount too low Use a suitable flowmeter size. Use a suitable flowmeter type. 21 Strongly deviating operating data Use a suitable flowmeter type. Adapt the operating data to the flowmeter. 22 Wear at the measuring unit and bearing Renew the measuring unit. Replace the bearing. Filter out the abrasive materials. 23 Sluggishness through deposits Disassemble the flowmeter and clean it carefully. 24 Flow impaired at the system end Check whether the fluid flows in the system (pump in operation, slide valve opened, etc.). Check whether shut-off devices before and after the flowmeter are opened. 25 Flowmeter switched to bypass Switch the flowmeter to through-flow. Troubleshooting Tab. 1 Fault table Operating Instructions OIO 14en Edition 07/

46 Appendix General drawings Appendix General drawings 107.2* * ** Fig. 1 Exploded view OMG OIO 14en Edition 07/2017 Operating Instructions

47 General drawings 115.2* 915.4* Appendix 739.4* 115.1* 739.3* 915.3* 915.2* 739.5** * *** Fig. 2 Exploded view OMG 20/32 Operating Instructions OIO 14en Edition 07/

48 Appendix General drawings * * ** Fig. 3 Exploded view OMG 52/68 48 OIO 14en Edition 07/2017 Operating Instructions

49 General drawings * Appendix * ** *** Fig. 4 Exploded view OMG100/140 Operating Instructions OIO 14en Edition 07/

50 Appendix Parts list Parts list Pos. no. Part Pos. no. Part 039 Distance sleeve 739.5** O-ring 041 Sleeve Deep-groove ball bearing 054 Spacer Deep-groove ball bearing 056 Spacer Deep-groove ball bearing 056*** Spacer Deep-groove ball bearing Threaded ring Angular-contact ball bearings Threaded ring Angular-contact ball bearings 062 Spacer Four-point contact bearings Supporting ring Four-point contact bearings 064.1**** Supporting ring Support ring Supporting ring Support ring End cover Support ring End cover Support ring Bearing cover Circlip Bearing cover Circlip 107.1* Pipe threaded flange Circlip 107.2* Pipe threaded flange Circlip 115.1* Flange Lock washer 115.2* Flange Lock washer 128 Measuring housing Socket screw 259 Pole wheel 915.1* Socket screw Screw plug Socket screw Screw plug 915.2* Socket screw Measuring screw large Socket screw Measuring screw small 915.3* Socket screw O-ring Socket screw O-ring 915.4* Socket screw O-ring Socket screw 739.3* O-ring Socket screw O-ring Socket screw 739.4* O-ring * parts for pipe threading or flange connection alternatively ** two units if two pick up holes exist *** for OMG140: replaced by sleeve, spare part 041 **** only for OMG 32 Tab. 1 Parts list 50 OIO 14en Edition 07/2017 Operating Instructions

51 Accessories Accessories Junction box The junction box simplifies the electrical connection of the various sensors. Up to three sensors can be connected. The sensor cables are combined to form a multi-strand connecting cable which can be supplied as well optionally if required. The detailed assignment plan can be found on the inside of the junction box lid. Appendix The junction boxes are suitable for flowmeters with pipe threading or flanged connection and can be mounted on the sizes OMG Fig. 5 Junction box UZA 11 Fig. 6 OMG 32 with installed UZA 11 1 Output 2 Sensor inputs Junction boxes UZA 09 UZA 10 UZA 11 suitable for BEG 43D, BEG 44 EET 32 EET 33, EET 34 Electrical specification Sensor inputs Outputs Mechanical specification Liquid temperature max. [ C] +150 Housing material Aluminum Connection thread M6 Fastening type directly on device Operating Instructions OIO 14en Edition 07/

52 Appendix Accessories Mounting and connecting the junction box Fig. 7 Junction box Temperature sensor cable 2 Pick up cable 3 Base plate junction box 4 Socket screw and washer 5 Socket screws and washers 6 Cable gland sensor inputs 7 Junction box lid Fig. 8 Mounting the junction box 1. Disconnect the cables of the pick up 2 and the temperature sensor 1. Ensure that the cable length is sufficient. 2. Fasten the base plate of the junction box 3 to the flowmeter using the screw Fasten the lower part of the junction box to the base plate 3 using the screws Carry out the cabling through the cable gland 6, using the connection circuit diagram, see Fig. 9, page Screw tight the lid of the junction box V Q BEG 1 BEG 2 EET 0 V Q 24 V Q Sig.1 Q 0 V Q 24 V Q Sig.2 Q Com. t Com. t Sig. t V Q Sig.1 Q Sig.2 Q Com. t Com. t Sig. t BEM Fig. 9 Connection circuit diagram junction box 52 OIO 14en Edition 07/2017 Operating Instructions