Operating Instructions: Modular Flow Meter System Ts

GB
GB Operating Instructions
MODULAR
FLOW METER SYSTEM TS
with and without volume preselection
Read this operating instructions before start up!
To be retained for future reference.

1
GB
2
GB
Explanation of the operating unit
1 Unit of measurement used for flow volume (litres, US-gallons, IMP-gallons).

2 Unit of measurement used for flow rate (l/min, US-G/min, IMP-G/min).
3 Reset key for the displayed flow volume.
4 Start key for filling operation in the automatic mode.
Store key to transfer correction factors in the addressable memory.
5 Stop key to interrupt filling operation in the automatic mode.
Recall key to display calibration factors from addressable memories.
6 Changeover switch to access the higher-level function in dual-function keys.
„S“ 12 is indicated in the display.
7 Switching between manual and automatic mode.
In the automatic mode, the word „AUTO“ 13 is indicated in the display.
8 Reduced flow rate. „SLOW“ 16 is indicated in the display.
9 Numerical keypad 0-9.
10 Display of total volume as long as key remains depressed.
Activation of calibration mode. „CAL“ 17 is indicated in the display.
11 Display of flow volume in the selected unit of measurement as long as key remains depressed.
Key for confirming values (e.g. correction factor, preselected volume).
12 „S“ indicates that the SHIFT key has been pressed, making the higher-level function
(in keys no. 4,5,7,8,10,11) effective.
13 „AUTO“ indicates that the flow meter is operating in the automatic mode.
14 „START“ indicates that an automatic filling sequence has been started.
15 „STOP“ indicates that an automatic filling sequence has been interrupted.
16 „SLOW“ indicates that a step-by-step flow reduction has been activated.
17 „CAL“ indicates that the flow meter currently is in the calibration mode.
18 „BATT“ indicates that the batteries require changing.
19 Battery arrangement when changing the batteries.
20 Battery compartment lid.
21 Terminal socket for data line.
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General safety information
The operator must read the operating instructions before starting the flow meter and follow these instructions
during operation.
1 . Note the temperature and pressure limits. The pressure surges produced when closing shutoff valves
(valves, slides, etc.) must not exceed the maximum operating pressure.
2 . Disconnect the mains power supply and batteries before assembling and dismantling the various modules
and the data line.
3 . Ensure that all connections and fittings are tight and free from tension.
4 . Only alkaline-manganese batteries may be used.
5 . Repairs may only be carried out by the manufacturer.
The national accident prevention regulations must be observed without fail!
When metering flammable liquids according to Directive 67/548/EEC the following must be additionally
observed:
1 . Only use explosion proof flow meter modules.
2 . Before operation, ensure equipotential bonding of the delivery system.
3 . Use conductive hoses or pipes.
4 . Only use explosion proof relay modules.
5 . In explosion hazard areas only use explosion proof plugs.
6 . Electrostatic danger due to friction - to be wiped with wet cloth only. Do not use solvents for cleaning.
7 . Change of battery only outside of hazardous location with appropriate tools. Only use approved battery
types.
The national explosion protection regulations must be observed without fail.
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GB
Table of Contents
A. General 8
1. Hazard 9
2. Safety information 9
3. Scope of supply 9
B. Basic flow meter 10

1. Proper use 10
1.1 Application in explosion hazard areas 10
1.2 Technical data 11
1.3 Maximum pressure depending on temperature of the medium 11
1.4 Complete hose system 12
1.5 Pressure surges (water hammer) 12
1.6 Pressure drop 12
1.7 Accuracy of measurement and flow 13
1.8 Optimization of measurement accuracy by calibration 13
2. Installation 14
2.1 Connection for drum pump operation 14
2.2 Connection to the piping system – Flange connection 15
2.3 Valve connection 16
3. Maintenance and servicing 16
3.1 Cleaning the filter and check valve 16
3.2 Dismantling the basic flow meter 17
4. Repairs 17
C. Operating unit 18
1. Proper use 18
1.2.1 Electrical data 20
2. Installation 21
2.1 Insert the batteries 21
2.2 Turning the operating unit 21
2.3 Separate installation of the operating unit 22
2.4 Hose installation of the operating unit 23
3. Operation 24
3.1 Manual mode 24
3.1.1 Resetting the part volume meter 24
3.1.2 Displaying totalizer 24
3.1.3 Displaying flow rate 24
3.1.4 Key lock in manual mode 25
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GB
Table of Contents
3.2 Automatic mode 25

3.2.1 Switching between manual and automatic mode 25
3.2.2 Entering the filling volume 26
3.2.3 Starting the filling process 26
3.2.4 Interrupting the filling process 26
3.2.5 Correcting the filling process 27
3.2.6 Stopping the filling process 28
3.2.7 Repeating a preselected volume 28
3.2.8 Cycle counter 29
3.2.9 Filling with step-by-step interruption (SLOW mode) 29
3.2.9.1 Entering/deleting the SLOW volume 29
3.2.9.2 Displaying the SLOW volume 30
3.2.10 System protection through detection of faults 31
3.2.11 Locking function automatic mode 32
3.3 Calibration 32
3.3.1 Calibrating through comparative measurement 33
3.3.2 Changing the correction factor in the main memory 34
3.3.3 Displaying the correction factor from the main memory 34
3.3.4 Entering the correction factor into an addressable memory location 35
3.3.5 Displaying the correction factor from an addressable memory location 36
3.3.6 Copying the correction factor from the main memory into the
addressable memory location 36
3.3.7 Copying the correction factor from an addressable memory location
into the main memory 37
3.3.8 Calculating of the correction factor in automatic mode 38
3.4 Special functions 39
3.4.1 Changing the unit of measurement 39
3.4.1.1 Unit of measurement litres 39
3.4.1.2 Unit of measurement US-gallons 39
3.4.1.3 Unit of measurement IMP-gallons 39
3.4.1.4 Conversion of the flow volume in kilograms via the correction factor 40
Example 40
3.4.2 Deleting totalizer 41
3.4.3 Correcting operation errors 41
4.1 Changing the batteries 42
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GB
Table of Contents
D. Relay module RM1/RM3 and mains unit NG1 43

1. Proper use 43
1.2.1 Electrical data 45
2. Installation 46
2.1 Retrofitting the relay module/mains unit 46
2.2 Connection for automatic mode 47-49
2.3 Flow meter with separate installation of relay module RM1/mains unit NG1
and operating unit 50
2.4 Flow meter with relay module RM1/mains unit NG1 and separate installation
of operating unit 51
3.1 Changing the fuse in the relay module RM1/mains unit NG1 52
E. Relay module Ex-RM1m 53

1. Proper use 53
1.1.1 Special conditions (Ex-RM1m B 230 V) 54
2. Installation 54
2.1 Installation location 54
2.2 Dismantling/Assembly 55
2.2.1 Dismantling 55
2.2.2 Assembly 55
2.3 Electrical connection 55
2.3.1 Connecting the basic version Ex-RM1m B 230 V 56
2.3.2 Connecting the complete version Ex-RM1m K 230 V 57
3.1 Changing the fuse 58
F. Repairs 58
G. Traceability 59
H. Annex 59
1. Terminal assignment of cables and connectors 59
2. Trouble shooting 60/61
Certificates of Conformity 63
Spare-part list accessories for modular flow meter system 64-67
Spare part list flow meter program 68-71
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GB A. General
A. General
The flow meter operates according to the positive displacement principle. In a housing fitted with inlet and outlet
is a measuring chamber through which the fluid is forced to flow on its way through the housing. In the measuring
chamber, a nutating disc blocks the fluid‘s clear path. As it flows through the measuring chamber, the fluid
pushes the nutating disc to one side. It is the action of displacing the impediment which produces the wobble
movement of the disc and circular motion of the nutating disc shaft. By means of a driver, a magnet with several
poles is set into rotation, which is able to activate a magnetically switched contact through the lid of the housing.
Every revolution of the nutating disc is assigned to a constant volume and a fixed number of pulses, so permitting
the electonic evaluating system to determine the volumetric flow through the number of received pulses.
For practically-orientated application, the flow meter system is made up of various modules:
À Operating unit
Electronic evaluating unit with keypad and LCD display for operation of
the flow meter.
Á Protection cap
Protects the modules basic flow meter, relay module or mains unit when
the operating unit is decentrally installed.
Â Relay module
Switches the external electrical appliances such as pump motor and
solenoid valve and is controlled by the evaluating electronics of the
operating unit.
Mains unit
Supplies power to the operating unit when battery-powered operation is
not desired and when no relay module is needed.
Operating unit and basic flow meter
Ã Basic flow meter

Housing and measuring chamber with all components for volumetric
measurement which come into contact with the transported medium.
The flow meter can be used in two different operating modes:

Manual mode: For filling using a manually operated nozzle. The
part volume meter is reset to zero and the required
volume is metered while the nozzle is being
operated.
Automatic mode: The preselected volume is filled by pressing a key.
Automatic mode is possible only when relay module
is connected.
Relay module and protection cap
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A. General GB
1. Hazard
The modular flow meter system is developed and built in compliance with the relevant fundamental health- and
safety requirements and important EC Directives. Nevertheless, this product can cause danger if it is not used
as advised.
In case of maloperation or improper use guarantee is excluded and there is danger for
• life and health of the user,
• the flow meter and other material assets of the user,
• the efficiency with the flow meter.
All persons who are dealing with the installation/assembly, starting, operation, servicing and maintenance of
the flow meter have
• to be accordingly qualified,
• to observe the local safety and accident preventive rules,
• to exactly follow these operating instructions.
It is your safety!
2. Safety information
In these operating instructions the following symbols are used:
Danger!
Refers to a direct danger.
Non-observance of the precaution will cause death or extremely serious injury.
Warning!
Defines a possibly dangerous situation.
Non-observance of the precaution can cause death or extremely serious injury.
Caution!
Defines a possibly harmful situation.
The product or something in its environment may be damaged if this instruction is not observed.
3. Scope of supply
When unpacking the goods, check the articles that:
• there is no visible damage from transporting,
• the shipped articles, including accessories, are the articles you ordered,
• no screws have loosened during transportation.
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GB B. Basic flow meter
B. Basic flow meter

1. Proper use
The basic flow meter is used for measuring liquid volumes where gauging metering is not required. The basic
flow meter is precalibrated for the use of water. The measurement of other pure media is also possible. To do this,
a different user-specific calibration factor is entered at the operating unit.
Warning!
The metering of non-compatible liquids damages the flow meter.
Splashing liquid or flying parts can cause injury.
Check by means of the materials indicated in the technical data and a resistance table (e. g. Lutz
resistance table) whether the basic flow meter is suitable for the delivered liquid.
Warning!
Exceeding the temperature range and the operating pressure causes damage to the basic flow meter.
Splashing liquid or flying parts can cause injury.
The ranges indicated in the technical data for temperature of liquid and operating pressure have to be
observed.
1.1 Application in explosion hazard areas

Application in explosion hazard areas or the metering of flammable liquids can cause explosion
resulting in severe injury or death.
Following must be observed:

• Basic flow meters are non-electrical operating appliances not requiring official approval when used in zone 1.
• The basic flow meters VA, HC, LM and UN correspond to the directive 94/9/EC (group II, category 2, for
gases and temperature class T4).
• The basic flow meter may only be used at atmospherical conditions of 0.8 bar and a temperature range of -
20°C up to +40°C . An application is not allowed in atmospheres with flammable dust.
• The temperature of the liquid being pumped is limited for types LM and UN to max. 60°C and for types VA
and HC to max. 80°C.
• An equipotential bonding must be established between basic flow meter, pump tube and hose- or pipe line.
• Use only conductive pressure hoses or conductive pipes.
• For applications with a drum pump the basic flow meter must be mounted outside of the container.
• The admissible operating pressure (type LM, UN - 4 bar and VA, HC - 10 bar) must not be exceeded.
• In case another electronical device for analyzing is used than that provided by the manufacturer the
explosion protection regulations must be observed.
• In order to avoid fire sparkling, assembly works must be carried out by qualified personnel only.
• To prevent corrosion it must be ensured that the basic flow meter is resistant to the liquids being
transferred.
• To prevent an explosive gas atmosphere in the basic flow meter use a solid hose system.
Any other use as well as any modifications of the product have to be considered as improper use. The
manufacturer will not be held responsable for any damages resulting from such improper use, the risk lies
solely with the user.
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B. Basic flow meter GB
1.2 Technical data

Type ST SL LM UN VA I
Flow rate min. 10 l/min min. 10 l/min min. 10 l/min min. 10 l/min min. 10 l/min
max. 120 l/min max. 120 l/min max. 120 l/min max. 120 l/min max. 100 l/min
Temperature 60 °C 60 °C 60 °C 60 °C 80 °C
Viscosity 2000 mPas 2000 mPas 2000 mPas 2000 mPas 5000 mPas *
Operating pressure 4 bar 4 bar 4 bar 4 bar 10 bar
Accuracy ± 1% standard ± 1% standard ± 1% standard ± 1% standard
£ 1% with adjust- £ 1% with adjust- £ 1% with adjust- £ 1% with adjust- ± 1%
ment to appli- ment to appli- ment to appli- ment to appli-
cation conditions cation conditions cation conditions cation conditions
Inlet port G 2 male thread G 2 male thread G 2 male thread G 2 male thread G 1 1/4
to fit connector to fit connector to fit connector to fit connector male thread
with union nut with union nut with union nut with union nut
Outlet port G 1 1/4 G 1 1/4 G 1 1/4 G 1 1/4 G 1 1/4
male thread male thread male thread male thread male thread
Weight 745 g 780 g 900 g 900 g 3,240 g
Materials:
Housing PPO PPO PPS PPS SS (1.4581)
Measuring chamber PPO/PPS PPO/PPS LCP LCP SS/ETFE/ETFE
Seals Viton® Viton® FEP FEP FEP
Magnet BaFe, PA, PPS encapsulated BaFe, brass, PPS encapsulated ETFE encapsulated
SS (1.4401) SS
Suitable for no no yes yes yes
Ex-application conductive conductive conductive
Order No. 0212-100 0212-200 0212-300 0212-400 0212-500
Description of material * depending on the application
PPO = Polyphenylene Oxide LCP = Liquid Cristalline Polymere
PPS = Polyphenylene Sulfide PA = Polyamide
SS = Stainless steel FEP = Tetrafluoro Ethylene/
Viton® = Fluoro Elastomer Hexafluoro Propylene
BaFe = Barium-Ferrite
Viton® is a registered Trademark of DuPont Dow Elastomers.
1.3 Maximum pressure depending on temperature of the medium

p / (bar)
Type VA I, II
Type ST, SL, LM, UN
Diagram 1
Maximum pressure depending on
temperature of the medium T / (°C)
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1.4 Complete hose system

Before initial starting of the flow meter, the entire piping system must be vented from the pump through to the
shutoff element (nozzle, solenoid valve or similar). During operation, care must be taken to ensure that the
complete system is filled with liquid.
1.5 Pressure surges (water hammer)

Considerable pressure fluctuations with so-called water hammer can build up in the system as a result of delays
(disconnection/shutoff) or acceleration of the flowing liquid column when using long delivery lines or when using
solenoid valves with short opening and closing times.
Warning!
The brief pressure peaks or surges due to water hammer can cause serious damage and destroy the
flow meter, pump or other components in the system!
Damage by uncontrolled splashing liquid. Depending on the medium concerned, this can lead to
caustic burns, explosion hazards, toxic vapours, electric shocks, danger of slipping and other dangers!
Example: A valve closing time of 20 ms can cause a pressure surge of up to 10 bar in a 10 metres long 1" pipe
at a flow rate of 50 l/min.
Pressure surges can be prevented as follows:

• Use a larger nominal diameter (DN) to reduce the flow speed in the delivery line.
• Filling with step-by-step interruption (SLOW mode, see chapter C 3.2.9).
• Use relief valves and pressure limiting valves to eliminate impermissible pressure peaks.
1.6 Pressure drop

Diagram 2 indicates the pressure drop relative to flow. The solid line is applicable for aqueous liquids
(r » 1 kg/dm³, h » 1 mPas).
In case of media with different density (r ¹ 1 kg/dm³) the pressure drop values have to be taken from the solid
line in diagram 2 and multiplied by the density value of the liquid.
Media with a high dynamic viscosity (h >> 1 mPas) like high-density media, cause a higher pressure drop. The
limiting curve for permissible viscosity at r = 1 kg/dm³ is depicted in diagram 2 as a dotted line. If the density r
is greater than 1 kg/dm³, the pressure drops in the diagram must be multiplied by the actual density.
Diagram 2
Pressure drop depending on flow rate.
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1.7 Accuracy of measurement and flow

In the factory the meter is calibrated for a flow rate of 40 l/min. Other flow rates affect the measurement accuracy
of the flow meter (see diagram 3). The flow rate may be determined via the SPEED key 11 during the filling
process.
For adjusting the measuring result to the determined flow rate, the recent correction factor must be called in from
the main memory (see chapter C 3.3.3). The recent correction factor then is set off against the volume out of
diagram 3 related to the flow rate. Then the new correction factor is entered (see chapter C 3.3.2).
Example for type ST, SL, LM, UN

Q = 20 l/min Ü Krel = 0.01
K1 = 1.028
K2 = K1 + Krel
K2 = 1.028 + 0.01
K2 = 1.038
Example for type VA I:

Q = 20 l/min Ü Krel = 0.03
K1 = 3.37
K2 = K1 + Krel
K2 = 1.028 + 0.03
K2 = 3.4
Q: Flow rate
Krel: Relative correction factor out of diagram 3
K1: Recent correction factor out of main memory
K2: New correction factor
Diagram 3
Correction factor depending on flow rate
1.8 Optimization of measurement accuracy by calibration

When using a flow meter as an automatic batch meter (frequent handling of the same volume), the meter should
be calibrated to the operating point. By comparative measurement, the displayed volume is coordinated to the
actual volume (see chapter C 3.3.1). For this operating point, the measurement accuracy is 1 digit (corresponding
to ± 0.1 litres, ± 0.01 US-G, ± 0.01 IMP-G).
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2. Installation
2.1 Connection for
drum pump operation
Mounting steps flow meter
type ST, SL, LM and UN:
1. Mount the check valve (option)
and filter screen into the inlet
(arrow). The non-return valve
may be only installed together
with a strainer.
2. Insert the o-rings into the collar
bush. Wet the sealing surfaces
and o-rings with a suitable
lubricant.
3. Place the wing nut onto the
collar bush
4. Screw the collar bush onto the
outlet of the pump tube
5. Screw the wing nut with the flow Connection for drum pump operation type ST, SL, LM and UN
meter
6. Screw the hose fitting onto the
flow meter outlet G 1 1/4

type VA I:
1. Insert the seal into the wing nut
2. Screw the drum pump
connection onto the outlet of
the pump tube
3. Insert the seal into the wing nut
and screw it with the flow
meter
4. Screw the hose fitting onto the
flow meter outlet G 1 1/4
Connection for drum pump operation type VA I
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2.2 Connection to the piping system – Flange connection

Caution!
For connecting the flow meter to the piping system, the following must be observed:
• Pipes, fittings, etc. must be suitably supported so that additional weight and vibrations are not
transmitted to the flow meter!
• Suction and discharge lines must always be connected without tension. The piping must be rerouted
if an offset cannot be compensated by appropriate means!

type ST, SL, LM and UN
1. Mount the check valve (option)
and filter screen into the inlet
(arrow)
2. Push the o-ring onto the collar
bush. The non-return valve may
be only installed together with
a strainer.
3. Place the wing nut onto the
collar bush and screw it with
the flow meter. Wet the sealing
surfaces and o-rings with a
suitable lubricant.
4. Insert the seals into the screw
sockets
5. Screw the screw sockets onto
the flow meter and collar bush
6. Insert the seals into the screw
sockets
7. Mount the flange
8. Screw on the flanged bush
Flange connection type ST, SL, LM and UN

type VA I:
1. Place the flange plate onto the
collar bush
2. Insert the seal into the collar
bush
3. Screw on the collar bush to the
flow meter
Flange connection type VA I
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2.3 Valve connection

Mounting steps:
1. Screw the double nipple

G 3/4 – G 1 1/4 into the inlet
and outlet side of the solenoid
valve
2. Mount the hose connection

G 1 1/4 on both sides of the
hose
3. Connect the hose with the flow

meter outlet and the solenoid
valve inlet
Note flow direction of the
solenoid valve!
4. Screw the discharge bend onto

the outlet side of the solenoid
valve
Valve connection
3. Maintenance and servicing
3.1 Cleaning the filter and check valve

It is advisable to flush and clean the basic flow meter after handling aggressive, tacky, crystallizing or very
contaminating liquids.
Procedure type ST, SL, LM and UN
1. Empty the flow meter
2. Release the wing nut
3. Remove the filter and clean with a paintbrush or blow through with compressed air
4. Press in the check valve manually and blow through with compressed air
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3.2 Dismantling the basic flow meter

The basic flow meter can be dismantled for cleaning the measuring chamber
or for troubleshooting.
Warning!
The basic flow meter can still contain liquid during dismantling!
In case of aggressive liquids, this can lead to burns, poisoning,
irritation of the skin etc.
Wear appropriate protective clothing when handling aggressive liquids.
Basic flow meter must be emptied before dismantling. Despite of
previous emptying, residual liquid can still be in the flow meter housing
during dismantling process. Therefore always remove the cover À
upwards.
+ When dismantling the basic flow meters of type LM, UN and VA it is
recommended to replace the o-ring Á. Wet the sealing surfaces and
o-rings with a suitable lubricant.
Dismantling the basic flow meters type ST, SL, LM and UN:
1. Release the screws Å on the bottom side of the flow meter.
2. Remove the cover À upwards.
3. Lift the measuring chamber Ã out of the basic body Ä.
4. Remove the o-ring Â of the measuring chamber.
5. Carefully open the measuring chamber.
The assembly is effected in reverse order.
When mounting the cover À take care of the right position to the
basic body Ä.
Dismantling the basic flow meter type VA I:

1. Release the screws Å on the bottom side of the meter.
2. Remove the cover À upwards.
3. Remove the clamp Ã.
4. Lift the measuring chamber Â out of the basic body.
5. Carefully open the measuring chamber.
The assembly is effected in reverse order.

When mounting the cover À take care of the right position to the
basic body Ä.
4. Repairs
When returning the device to the supplier it is compulsary to attach the
decontamination certificate duly filled out and signed by the operator (see
service area www.lutz-pumpen.de).
Dismantling the basic flow meter

17
GB C. Operating unit
C. Operating unit
1. Proper use
Caution!
Device failure by corrosion!
Use the operating unit BE1 V or Ex-BE1 V for applications in aggressive environments.
Caution!
The electromagnetic compatibility of the device is compatible with the radiated interference and
interference immunity for residential and industrial areas. To avoid interfering influences in a
decentralised installation of individual modules, only use data cables from the Lutz company and route
the data cables separate from low-voltage lines.
1.1 Technical data

Type BE1 BE1 V Ex-BE1 Ex-BE1 V
Display 6-digit LCD-display, 19 mm character height
Quantity l, US-G, IMP-G
Flow rate l/min, US-G/min, IMP-G/min
Change battery, function mode, individual quantity,
total quantity, number of filling processes
Functions • Reset partial quantity and total quantity
• Automatic calibration
• Storing differing calibration factors
• Lock keys against unauthorised access
• Changeover to manual or automatic mode with relay module (optional)
• Cycle counter
• System protection through detection of faults
• Advance cut-out
Type of protection IP 54 in combination with flow meter or optional modules
Power supply 3 x 1.5 V alkaline manganese batteries or by relay module, mains unit
Explosion protection class - - II 2G EEx ib IIA T4 II 2G EEx ib IIA T4
Use in aggressive areas not recommended suitable not recommended suitable
Electronics replaceable completely replaceable completely
potted potted
Repairs yes no yes no
Weight 200 g 300 g 220 g 310 g
Order No. 0212-001 0212-003 0212-002 0212-004
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C. Operating unit GB

Danger!
Fire and explosion hazard due to delivered liquid!
Combustion hazard. Blast wave: Flying parts can cause death.
For measuring inflammable liquids according to Directive 67/548/EEC
use operating unit Ex-BE1 or Ex-BE1 V only.
Danger!
Danger of explosion! Friction causes electrostatic charges!
Blast wave: Flying parts can cause death.
Operating unit to be wiped with wet cloth only.
Danger!
Danger of explosion due to inadmissible warming up!
Following electrical data and terminal assignment must be observed.
19
1.2.1 Electrical data

Internal power supply 4.5 V (DC); Approved battery types
for the power supply:
• VARTA Alkaline, No.4001, Size LR1, 1.5V
• VARTA High Energy, No.4901, Size LR1, 1.5V
• DURACELL Alkaline, Type MN9100, Size N, 1.5V
• Energizer Alkaline; Type E90, LR1, 1.5V
Change only outside of hazardous location.
Module input Explosion protection class intrinsic safety EEx ib IIB;

[Socket 1(+), 3(-), 4, 6 or Max. values:
internal plug St1 or St2] Uo = 5V
Io = 55 mA
Po = 68 mW
Characteristic curve: linear
Ci = 1.1 µF
Li unconsidered small
Max. admissible outer values for:
(following values correspond to the computer program
for PTB report ThEx-10)
IIB
Lo (mH)
Co (µF)
2 16
1 19
0.5 24
when connecting with an active module output in explosion

protection class intrinsic safety with max. admissible values:
Uo = 6.6 V
Io = 165 mA
Po = 272 mW
Characteristic curve: linear
following max. admissible outer values are valid for the connection
with the module: (these values correspond to the computer
program for PTB report ThEx-10)
IIB
Lo (mH)
Co (µF)
2 6.9
1 9.9
0.5 12
20
2. Installation
2.1 Insert the batteries

Mounting steps:
1. Unscrew the battery compartment lid 20
2. Remove batteries from styrofoam buffer of packaging
3. Insert batteries, checking for correct polarity 19
4. Screw on the battery compartment lid 20
2.2 Turning the operating unit

The operating unit can be turned to the required position in 90°-steps.
Mounting steps:
1. Remove cap
2. Release screws
3. Carefully lift the operating unit, paying attention to cable length!
4. Turn the operating unit to the required position
5. Mount the operating unit
6. Tighten the screws
7. Mount the cap
Turning the operating unit
21
2.3 Separate installation of the operating unit

Due to the modular construction of the flow meter system, it is possible to install the operating unit with or
without relay module separately to the flow meter itself. For separate installation, a protection cap, an intermediate
plate and a data line are required.
Mounting steps:
1. Remove batteries out of the
operating unit
2. Remove the cap and release
the screws
3. Carefully lift the operating
unit, paying attention to cable
length!
4. Release the plug
5. Remove the cap from the
intermediate plate
6. Screw the intermediate plate
onto a base (screws not
included in the scope of
supply)
7. Mount the cap
8. Screw the operating unit onto
the intermediate plate and
mount the cap
9. Connect the ribbon cable to
the plug in the protection cap
10. Screw the protection cap onto
the flow meter and mount the
cap
11. Connect the operating unit
and protection cap using the
data line
12. Insert the batteries
Separate installation of the operating unit
22
2.4 Hose installation of the operating unit

Mounting steps:
1. Remove the batteries out of
the operating unit
the screws
3. Carefully lift the operating unit,
paying attention to cable
length!
4. Release the plug
intermediate plate
6. Screw the hose clamps under
mount the cap
7. Screw the operating unit onto
mount the cap
8. Press the hose into the hose
clamps. Snap the clamp into
place
9. Connect the ribbon cable to
the plug in the protection cap
10. Screw the protection cap onto
the flow meter and mount the
cap
11. Connect the operating unit and
protection cap using the data
line
Assembly of the operating unit at the hose
23
3. Operation
+ Following described key sequences must be pressed step by step.
3.1 Manual mode

In manual mode, the filling process is carried out using a manually operated nozzle. The part volume meter is
reset to zero and the required volume is metered.
3.1.1 Resetting the part volume meter

Operation Display
+ Only possible in manual mode
3.1.2 Displaying totalizer

The totalizer adds all individual metering processes carried out in the manual or automatic mode.
Operation Display
+ The total volume appears as long as the key is depressed.
3.1.3 Displaying flow rate

Operation Display
+ The total flow rate appears as long as the key SPEED is depressed.
The flow rate is displayed in the selected volume unit per minute.
24
3.1.4 Key lock in manual mode

Avoiding maloperations – as inadvertent calibration – all keys, except RESET, SPEED and TOT can be locked.
Operation Display
+ The key lock appears in the display L. The key lock also remains if there is no power supply (battery).
Releasing the key lock, press the key RESET and repeat the combination above.
3.2 Automatic mode

In automatic mode, a preselected volume can be repeatedly filled by pressing a key. To permit this function a relay
module and a solenoid valve are required in addition to the flow meter (for installation see chapter D 2.2).
3.2.1 Switching between manual and automatic mode

Operation Display
+ Switching from automatic to manual mode is carried out in the same way.
The display AUTO disappears.
+ Switching between manual and automatic mode is only possible if a relay module is connected.
25
3.2.2 Entering the filling volume

Operation Display
Enter filling volume e.g. 50 LITRES
The entered filling volume flashes
+ Complete the input by pressing the ENTER key. To correct the filling volume, the input must have
been completed (by pressing ENTER). It is then possible to enter a new filling volume.
3.2.3 Starting the filling process

Operation Display
+ The process runs through to the end.

It can be interrupted at will and restarted.
0.0 appears on the display when the process has been completed correctly.
3.2.4 Interrupting the filling process

Operation Display
+ The filling process is resumed by pressing START (see chapter C 3.2.3).

+ If the filling process is interrupted by the system without any apparent reason, there is a fault in the
system and the self-protection device has been activated (remedy the fault).
26
3.2.5 Correcting the filling process

During the filling process, it is possible to correct the filling volume.
In this case, the already transported volume is offset against the new filling volume.
Operation Display
Display static
continued on next page
27
Operation Display
+ The correction process is only successful if the new filling volume is greater than the volume which has
already been transported.
3.2.6 Stopping filling process

Operation Display
+ It is possible to make a new input (see chapter C 3.2.2)

or to repeat the current filling volume using the RESET key (3).
3.2.7 Repeating a preselected volume

Operation Display
Filling volume flashes
+ The entered filling volume flashes The filling process can be started (see chapter C 3.2.3).
28
3.2.8 Cycle counter

The cycle counter registers the number of filling cycles with the same volume filled. This means that the user
does not have to count the cycles, e.g. when 100 containers have to be filled with the same volume. The cycle
counter starts at zero again when a new filling volume is entered. Interrupted filling processes are not counted.
Changing the SLOW quantity has no effect on the cycle counter.
Operation Display
+ The cycle counter is displayed as long as the key is depressed. It cannot be displayed while filling is
in process.
3.2.9 Filling with step-by-step interruption (SLOW mode)

In the automatic mode, it is possible to carry out the filling process using two different flow volumes. This is
particularly useful for fast, precise filling of large quantities, or when transporting a foaming medium.
Two solenoid valves arranged in parallel are required for this process. The valves are closed at different times, so
reducing pressure surges in the system, and helping to avoid overflowing when transporting foam-forming media.
A throttle element, such as a ball valve in line with the valve disconnected last, to regulate the flow volume is
beneficial. The reduced flow speed volume is entered using the SLOW function.
3.2.9.1 Entering/deleting the SLOW volume
Operation Display
Filling volume flashes
Actual SLOW volume flashes
29
Operation Display
Enter slow volume, e.g. 1 litre (for deleting enter 0)
+ If the SLOW volume is greater than the intended filling

volume, the main valve remains closed during the
entire filling process.
+ Only possible in the automatic mode
3.2.9.2 Displaying the SLOW volume

Operation Display
+ Only possible in the automatic mode
30
3.2.10 System protection through detection of faults

The filling process can be controlled automatically by the flow meter, since faults may develop in the connecting
lines, such as running dry, blockages, defective solenoid valves, etc.
When the START key is pressed, the flow meter monitors the time during which no liquid is registered. The flow
meter switches off when a certain time limit is exceeded. STOP appears on the display. The interruped filling
process can be resumed by pressing START again when the fault has been remedied.
The monitoring time can be freely selected between 1 and 999 seconds. A time of 3 seconds is set by the
manufacturer. The monitoring function is deactivated by entering 0.
+ The monitoring time can only be changed in manual mode.
Operation Display
Enter the monitoring time, e.g. 5 seconds

(enter 0 to deactivate the function)
31
Operation Display
The new monitoring time flashes
3.2.11 Locking function automatic mode

The locking function in automatic mode makes it impossible to change over to manual mode and prevents
inadvertent input of a new filling volume. This helps to prevent operator errors when filling always the same
volumes.
The following functions remain active even when the keypad is locked: RESET, START, STOP, totalizer (TOT),
display flow rate (SPEED) and cycle counter (see chapter C 3.2.8).
Operation Display
+ The key lock appears in the display L. The key lock also remains if there is no power supply.
The above combination must be entered again in order to deactivate the locking function.
3.3 Calibration
In the factory the meter is calibrated for the medium water transported at a mean flow rate of 40 l/min. Various
operating conditions such as slower flow rates or the transportation of media with greater viscosity can result in
measurement inaccuracy (see chapter B 1.6).
To adjust to these operating conditions, a changeable correction factor can be used to recalibrate the flow meter
in manual mode. The correction factor is either entered directly or the electronic evaluating unit calculates the
right correction factor according to a comparative measurement between the displayed and the actual filled
volume.
The flow meter is also equipped with nine addressable memory locations (memory numbers 1-9), in which
already ascertained correction factors can be stored and copied to the main memory (memory number 0) if
required.
32
3.3.1 Calibration through comparative measurement

Operation Display
Fill the volume into a measurement vessel
Read the value on the measurement vessel and enter at numerical keypad
Calculated correction factor flashes
+ In automatic mode input is not possible (see chapter C 3.2.1).
33
3.3.2 Changing the correction factor in the main memory

Operation Display
Entering the correction factor
3.3.3 Displaying the correction factor from the main memory

Operation Display

34
Operation Display
3.3.4 Entering the correction factor into an addressable memory location

Operation Display
Entering the correction factor
Entering the memory number
35
3.3.5 Displaying the correction factor from an addressable memory location

Operation Display
3.3.6 Copying the correction factor from the main memory into the
addressable memory location
Operation Display
36
Operation Display
3.3.7 Copying the correction factor from an addressable memory location

into the main memory
Operation Display
37
Operation Display
3.3.8 Calculation of the correction factor in automatic mode

In the automatic mode direct calibration is not possible. However, the possibility of filling a preselected quantity
into a measuring vessel and calculating the new correction factor then is given. Following steps are required:
• Enter filling volume (see chapter C 3.2.2)
• Start filling process (see chapter C 3.2.3)
• Change into manual mode at the end of filling process (see chapter C 3.2.1)
• Have correction factor displayed from the main memory (see chapter C 3.3.3)
• Calculate new correction factor according to the below formula
VM k 1
k2 =
VV
k1 : Correction factor from the main memory

k2 : New correction factor
VV : Preselected volume
VM : Read volume in measuring vessel
• Enter calculated correction factor into the main memory (see chapter C 3.3.2)
38
3.4 Special functions

3.4.1 Changing the unit of measurement
In manual mode the flow meter can be switched between the units of measurement litres, US-gallons and
IMP-gallons without altering the calibration.
3.4.1.1 Unit of measurement litres

Operation Display
Number sequence 0123
3.4.1.2 Unit of measurement US-gallons

Operation Display
3.4.1.3 Unit of measurement IMP-gallons

Operation Display
39
3.4.1.4 Conversion of the flow volume in kilograms via the correction factor
For special applications, the flow meter is able to display the measured volume in a unit of mass such as kilograms.
The correlation between volume V and mass m is ascertained using density r.
m=ρ•V
If the correction factor for volume measurement is known (see chapter C 3.3.1 or correction factor diagram 3),
this is offset with the density r. Convert the correction factor according to the below formula
k1 : Correction factor after calibration

k2 = ρ • k1 k2 : Correction factor for display of the unit of mass
r : Fluid density
Example
Operation Display
Enter the calculated correction factor k2
The entered correction factor flashes
The entered correction factor flashes
+ The unit of volume (litres or gallons) displayed on the flow meter is now no longer valid.
Recommendation: Cover over the displayed unit of volume using a foil indicating the valid unit of mass.
40
3.4.2 Deleting totalizer

Operation Display
3.4.3 Correcting operation errors

Using the key combination SHIFT + RESET, the flow meter is reset to the starting status of the manual or automatic
mode.
This function is useful if the operating status of the meter is unclear, or when it does not respond to commands,
or if the display does not indicate the desired result when making an input.
Operation Display
41

4.1 Changing the batteries
The flow meter is running on 3 alkaline manganese batteries LR 1, SIZE N. The LCD display indicates the approaching
end of the battery life with the word „BATT“ 18.
+ If the „BATT“ display flashes, the batteries must be changed within 1-2 weeks.
Once the „BATT“ display is indicated permanently, the batteries require immediate changing.
Danger!
When changing the batteries in explosion hazard areas danger of explosion occurs!
Change of battery only outside of hazardous location with appropriate tools. Only following battery
types are approved:
• VARTA High Energy; No. 4901; Size LR1
• VARTA Electronic Alkaline; No. 4001; LR1; LADY; N; AM5
• DURACELL ALKALINE; SIZE N; MN9100; LR1
• Energizer Alkaline; E90; LR1; N
Mounting steps:
1. Unscrew the battery compartment lid 20
2. Remove the batteries
3. Insert new batteries, checking for correct polarity 19
4. Screw the battery compartment lid 20
5. Press key RESET
+ If the flow meter is not used for longer periods, the batteries must be removed!
42
D. Relay module RM1/RM3 and mains unit NG1 GB
D. Relay module RM1/RM3 and mains unit NG1

1. Proper use
For automatic mode (preselected volume), the relay module is required
alongside the basic flow meter and operating unit modules. The relay
module is controlled by the evaluating electronics of the operating unit
and switches the external electrical appliances such as pump motor and
solenoid valve. The electrical connection between the operating unit and
relay module is effected by means of a 10-core ribbon cable.
The relay module RM1/RM3 or the mains unit NG1 includes a power supply
for the operating unit. The batteries only then have a buffer function in the
event of a power failure.
The relay module RM1 and RM3 are fitted with three sockets permitting
the connection of external appliances À,Á and the power supply Â.
The mains unit NG1 is fitted only with a connection for the power supply Â.
Relay module
Danger!
Live mains connection!
Electric shocks can cause death.
An operating unit or a protection cap must be mounted to the relay modules RM1, RM3 or to the
mains unit NG1 as protection against touching and contact with water.
Caution!
The electromagnetic compatibility of the device is compatible with the emitted interference and
43
GB D. Relay module RM1/RM3 and mains unit NG1
1.1 Technical data

Type RM1 230 V RM1 120 V RM3 400/230 V NG1 230 V
Voltage 220-240 V 110-125 V 230/400 V 220-240 V
Frequency 50 – 60 Hz
Switching outputs 2 switching outputs (potentially bound) –
Pump switching current 4 A, cosj > 0.7 8.5 A, cosϕ > 0.7 16 A, cosϕ > 0.7 –
Solenoid valve switching current 0.5 A –
Type of protection IP 44
Explosion protection class II 2G [EEx ib] IIC – – –
Connections round connector
Weight 440 g 430 g 634 g 290 g
Order No. 0212-020 0212-030 0212-060 0212-090
Danger!
Danger of explosion!
Combustion hazard. Blast wave: Flying parts can cause death.
The relay module RM1, the mains unit NG1 and the connecting cables are not suitable for use in explosion
hazard areas!
If the relay module itself is not located in an explosion hazard area the relay module RM1 230 V may
supply the power and signals to the operating unit in zone 1.
For this application the relay module must be used with an ambient temperature of -20 up to +40°C. This
temperature range is also applied to the measured liquid when the relay module is mounted on the basic
flow meter.
44
1.2.1 Electrical data

Input: U = 220 - 240 V ~
(ST3) Imax = 8A
cos ϕ > 0.7
Pmax = 1760-1920 W
Outputs:
Output 1 (Pump): U = 220 - 240 V ~
(ST4 and ST5) Imax = 4A
cos ϕ > 0.7
Pmax = 880 - 960 W
Output 2 (Valve): U = 220 - 240 V ~

(ST4 and ST5) Imax = 0.5 A
cos ϕ > 0.7
Pmax = 77 - 84 W
Output intrinsic safety U = 6.6 V =

(ST1 or ST2) I = 165 mA
P = 272 mW
Max. admissible outer

values for: L (mH) C (mF)
2 1
1 1.6
0.5 2.2
0.2 3
0.1 3.8
45
2. Installation
2.1 Retrofitting the relay module/mains unit

Mounting steps:
operating unit
2. Remove the cap and release the
screws
paying attention to cable length!
4. Release the plug
5. Plug the connector in the socket
on the underside of the
intermediate plate
6. Carefully mount the intermediate
plate in the desired position and
tighten up the screws
7. Plug the connecting cable in the
socket on the topside of the
intermediate plate and on the
circuit board of the relay module/
mains unit
8. Mount the relay module/mains
unit onto the intermediate plate
9. Plug the ribbon cable of the relay
module/mains unit into the Retrofitting of the relay module
socket on the circuit board of the
operating unit
10. Mount the relay module/mains
unit onto the intermediate plate
11. Tighten the screws and
replace the cap
46
2.2 Connection for automatic mode

A number of ready-configured cables are available for connecting up external units:
À Power supply cable relay module RM1/mains unit NG1, 5 m long (Order No. 0211-155)
Á Connecting cable main valve, 5 m long (Order No. 0211-150)
For actuation of a solenoid valve via the relay module RM1or RM3.
Â Connecting cable SLOW-valve, 5 m long (Order No. 0211-151)
Using this cable, a second solenoid valve can be actuated in conjunction with the cable set motor/SLOW,
3-way.
Ã Connecting cable motor/SLOW 1-way, 0.5 m long (Order No. 0211-153)
To actuate a pump motor or second solenoid valve via the relay module RM1.
Ä Connecting cable motor/SLOW 3-way, 0.5 m long (Order No. 0211-154)
This cable is required for connection of 3 external appliances such as motor and two solenoid valves.
Å Power supply cable RM3 230 V, 5 m long (Order No. 0211-387)
For A.C. power supply of the relay module RM3.
Æ Connecting cable motor 230 V, 0.5 m long (Order No. 0211-385)
For actuation of an A.C. driven pump motor via the relay module RM3.
Ç Power supply cable RM3 400 V, 5 m long (Order No. 0211-388)
For 3-phase current power supply of the relay module RM3.
È Connecting cable motor 400 V, 0.5 m long (Order No. 0211-386)
For actuation of a 3-phase current driven pump motor via the relay module RM3
l Extension cable, 5 m long (Order No. 0211-152) (without illustration.)
For extension of the connecting cables À,Á,Ã,Ä.
47
Relay module RM1: Connection of pump motor and solenoid valve
Relay module RM1: Connection of pump motor, main valve and SLOW valve
48
Relay module RM3: Connection of pump motor (AC) and solenoid valve
Relay module RM3: Connection of pump motor (3-phase current) and solenoid valve
49
2.3 Flow meter with separate installation of relay module/mains unit and operating unit
Danger:
Electric shocks can kill you.
Disconnect the relay
module/mains unit by
pulling the plug from the
power supply before
dismantling!
Mounting steps:
operating unit
the screws
3. Carefully lift the operating unit
and relay module/mains unit,
length!
4. Loosen the connector from the
intermediate plate
5. Unscrew the intermediate plate
6. Carefully remove the
intermediate plate, paying
attention to cable length!
intermediate plate
intermediate plate
included in the scope of
supply)
10. Mount the cap
11. Insulate the intermediate plate
using the cap
12. Screw the operating unit and
relay module/mains unit onto
mount the cap
13. Connect the ribbon cable to the
plug in the protection cap
14. Screw the protection cap onto the
flow meter and mount the cap
15. Connect the operating unit and Separate installation of relay module/mains unit and operating unit
protection cap using the data line
50
2.4 Flow meter with relay module/mains unit and separate installation of operating unit
Danger!
Disconnect the relay
module/mains unit by
pulling the plug from the
power supply before
dismantling!
Mounting steps:
operating unit
the screws
length!
circuit board of the operating
unit
intermediate plate
included in the scope of supply)
7. Mount the cap
8. Mount the operating unit on the
intermediate plate using the
short screws supplied with the
protection cap, and then mount
the cap
9. Connect up the cable between
the relay module/mains unit
and the protection cap
10. Screw the protection cap and
relay module/mains unit onto
the flow meter using the long
screws and replace the cap
11. Connect the operating unit and
protection cap using the data
line
Separate installation of the operating unit
51
3.1 Changing the fuse in the relay module/mains unit
Danger!
Disconnect the relay module / mains unit by pulling the plug from the power supply before dismantling!
Danger!
Danger of explosion from short circuit!
Combustion hazard. Blast wave: Flying parts can kill you.
Only use the types of fuses listed below. The unit can be damaged and the explosion protection is at
risk if higher fusing ratings are used.
As the blowing of a fuse generally precedes a fault, have the unit checked by an electrical specialist before
changing a fuse.
The units are adequately protected when 5 x 20 mm IEC 127 finewire fuses are used:
RM1 230 V RM1 120 V RM3 NG1 230 V
Power supply SI3: 0.1 A semi 0.1 A semi 0.1 A semi 0.1 A semi
time-lag (mT) time-lag (mT) time-lag (mT) time-lag (mT)
Motor connection SI1: 4 A time-lag (T) 6.3 A time-lag (T) fuse protection –
by mains supply
with max. 16 A
Valve output SI2: 0.5 A semi 0.5 A semi 0.5 A semi –
time-lag (mT) time-lag (mT) time-lag (mT)
1. Pull out the plug of the relay module/mains unit

2. Remove the cap and release the screws
3. Carefully lift the operating unit/protection cap and relay module/mains unit, paying attention to cable length!
4. Release the reed contact plug
5. Check the finewire fuses and replace if necessary
6. Connect the reed contact plug
7. Mount the relay module/mains unit with operating unit/protection cap onto the flow meter
8. Tighten the screws and replace the cap
52
E. Relay module Ex-RM1m GB
E. Relay module Ex-RM1m

1. Proper use
For automatic mode (preselected volume), the relay module is required alongside the basic flow meter and operating
unit modules. The relay module is controlled by the evaluating electronics of the operating unit and switches the
external electrical appliances such as pump motor and solenoid valve. The electrical connection between the
operating unit and relay module is effected by means of a 10-core ribbon cable.
The relay module Ex-RM1m includes a power supply for the operating unit. The batteries only then have a buffer
function in the event of a power failure.
The relay module Ex-RM1m is supplied in two versions.
• The basic version of the Ex-RM1m B 230 V is without fuses, cable glands or cabling for customer-specific
applications. Particular attention shall be paid in the following chapters to the requirements on components
not included in the scope of supply.
• The full version Ex-RM1m K 230 V includes cable glands, 5 m power supply cable with Ex-plug, fusing elements
and Ex-flange boxes for pump and valve.
The relay module Ex-RM1m consists of three housing parts. The upper section houses the potted electronics.
The lower section is designed as the connection compartment in the method of explosion protection „e“ for
greater safety. The connections are made here for the power supply, pump and the solenoid valve. The lower
housing connection constitutes an intermediate plate so that it can be mounted to the lower body of the flow
meter or to any permanent base (e.g. wall, mounting plate). The upper connection of the relay module forms part
of a further module from the system.
1.1 Technical Data

Danger!
Fire and explosion hazard due to electric current.
Compliance with the following electrical characteristics is required.
Type Ex-RM1m B 230 V Ex-RM1m K 230 V

Voltage 220 - 240 V, 50 – 60 Hz
Input supply
terminals 1+2 max. 8 A, cosj > 0.7 max. 1760-1920 W
Switching outputs 2 switching outputs (potentially bound)
Output 1 (Pump): max. 4 A fuse on construction side, 4 A fuse, cosj > 0,7
terminals 3+5 cosj > 0.7, max. 880-960 W max. 880-960 W
Output 2 (Valve) max. 4 A fuse on construction side, 0.5 A fuse
terminals 4+5 cosj > 0.7, max. 880-960 W max. 110–120 W
Type of protection IP 54
Explosion protection class II 2G EEx me[ib] IIC T4
Connections terminal block, no screw
Electronics completely potted
Accessories Basic version without fuses, Full version with fuses,
cable glands and cables. cable glands, 5 m mains connecting
For customer specific applications. cable with Ex-plug, Ex-flange
boxes for pump and valve
Weight 1000 g 3000 g
Order No. 0212-040 0212-050
53
GB E. Relay module Ex-RM1m
1.1.1 Special conditions (Ex-RM1m B 230 V)

As a protection against short circuits, a fusing of appropriate rating (max. 3 x IB according to DIN 41571 or IEC
127) for the designed current rating, or a starting circuit-breaker with short-circuit and instantaneous thermal
(set to the design current) release, must be connected in series for each relay module Ex-RM1. This fuse either
can be positioned in the appropriate power supply or has to be connected before the device. The fuse-design
current must be equal to or greater than the given voltage rating for the relay module. The breaking capacity of the
fuse used must be equal to or greater than the maximum short-circuit current (normally 1500 A) that can be
assumed for the location of installation.
If the pump and the valve are protected in the connecting compartment of the relay module from short circuits,
then the design voltage for the fuse must be equal to or greater than the given voltage rating for the pump or
valve. The breaking capacity of the fuse used must be equal to or greater than the maximum short-circuit current
(normally 1500 A) that can be assumed for the location of installation. If the breaking capacity of the installed
fuse differs from this, then the value for the maximum admissible short-circuit current shall be indicated on the
relay module.
2. Installation
2.1 Installation location

The relay module Ex-RM1m can be mounted to the lower body of the flow meter or to any permanent base
(e.g. wall, mounting plate). The upper connection of the relay module forms part of a further module from the
system. The completely mounted system meets the requirements of protection class IP 54.
Caution!
The electromagnetic compatibility of the device is compatible with the emitted interference and
54
2.2 Dismantling/Assembly
2.2.1 Dismantling
1. Remove the cap
2. Release the screws
3. Carefully lift off the top module À and pull off the connector Á
4. Carefully lift off the relay module Ã and pull off the connector Ä
5. Release the screws
6. Carefully lift off the intermediate plate Å and pull off the connector Æ
7. Take out the screws with washers from the groove in the
intermediate plate Å
2.2.2 Assembly
Caution!
Pinching the electrical leads can damage the unit.
When assembling the unit, do not route electrical connections at
points where these can be pinched.
8. Insert the screws and washers in the groove of the intermediate

plate Å. Screws to be used: Stainless steel flow meter – screws with
metric threads / plastic flow meter – screws with cutting threads
9. Plug in the connector Æ and carefully mount the intermediate plate Å
such that the points Â on the intermediate plate coincide with the
points on the relay module Ã
11. Insert the connector Ä and carefully mount the relay module Ã
12. Insert the connector Á and carefully mount the top module À in the
desired position
14. Insert the cap
2.3 Electrical connection

Danger!
The electrical connections may only be carried out by qualified personnel – a trained electrician. The
power supply shall be disconnected and prevented from accidental re-connection throughout duration
of the work.
Ensure before connecting the relay module that:

• The values for voltage and frequency given on the nameplate agree with the data for the mains.
• The mains connection is fused in accordance with chapter E 1.1 and 1.1.1
• All poles of the mains connection have been disconnected when permanently connecting the relay module.
• Atex-approved cable protection covers are used.
• Metal cable entries with grounding tongues connected to the protective conductor.
• Cables of the design HO7RN-F 3G1.5 are used.
55
GB E. Relay module Ex-RM1m
2.3.1 Connecting the basic version Ex-RM1m B 230 V

The electrical connection between the mains, the pump and solenoid
valve is made in the connecting compartment on the underside of the
relay module.
The relay module Ex-RM1m must be dismantled in accordance with

steps 1-4 of chapter E 2.2.1 when the flow meter system is mounted.
The electrical connection is made in accordance with the following
circuit diagram:
Refer to chapter E 1.1 (Technical data) when making electrical connections
56
2.3.2 Connecting the complete version Ex-RM1m K 230 V

The electrical connection is made using explosion proof plug-in connections. The mains is connected to the
explosion proof plug (CEAG). The maximum rating of the fuse for mains outlet socket shall be 16 A. Pump and
solenoid valve are connected to the two flange boxes of the relay module with plug system eXLink (CEAG) or mini
CLIX (steel). Maximum load: Pump 4 A, solenoild valve 0.5 A.
57
GB E. Relay module Ex-RM1m / F. Repairs
3.1 Changing the fuse

The relay module Ex-RM1m in the
full version Ex-RM1m K 230 V
includes two fusing elements to
protect the outputs for pump and
solenoid valve in the connecting
compartment.
À Pump:
Fusing element Ex 4 A
semi time-lag
Â Solenoid valve:
Fusing element Ex 500 mA
semi time-lag
Danger!
Replacing the fuse may only be carried out by qualified personnel – a trained electrician. The power
supply shall be disconnected and prevented from accidental re-connection throughout duration of the
work. As the blowing of a fuse generally precedes a fault, have the unit checked before changing the
fusing elements.
Danger!
Fire and explosion hazard due to electric current.
Use only original fusing elements.
1. To replace the fuses, dismantle the relay module in accordance with steps 1-4 of chapter E 2.2.1
2. Disconnect the defective fusing element and remove from the top hat rail.
3. Snap a new fusing element onto the top hat rail and connect.
4. Mount the relay module in accordance with steps 11-14 of chapter E 2.2.2
F. Repairs
Repairs should only be made by the manufacturer or authorized Lutz-dealers.
Only use genuine Lutz spare parts.
58
G. Traceability / H. Annex GB
G. Traceability
Products manufactured by Lutz-Pumpen for potentially explosives atmospheres are identified by an individual
batch number which allows them to be traced. This number provides the year of construction and the design of
the equipment.
This product is an appliance for potentially explosive atmospheres. In this regard and in compliance with the
EC ATEX 94/9 Directive, provisions must be made to ensure ascending and descending traceability.
Our ATEX notified quality system ensures this traceability up to the initial point of delivery.
Except as otherwise agreed in writing, anyone that guarantees to redeliver said equipment undertakes to put in
place a system that allows for equipment that is not conform to be recalled if necessary.
H. Annex
1. Terminal assignment of cables and connectors
1 Plus (Battery approx. 4.5 V,

Relay module approx. 5 V)
2 Counting impulse 5 Not in use
3 Minus 6 Relay valve
4 Relay pump 7 Not in use
Data outlet operating unit Terminal assignment of data line
RM1 Ex-RM1m
1 Neutral conductor
1+2 110-230V / 50-60 Hz 2 Pump motor / SLOW-Valve
3 Not in use 3 Main valve
Earth conductor 4 Not in use
PE Earth conductor
Relay module RM 1- mains connection Relay module RM 1 - connection of external electrical appliances
59
60
Operating mode Fault Cause Remedy
General No liquid registered Correction factor 0 in the main memory Calibrate flow meter (chapter C 3.3)
GB
Measured quantity differs significantly Correction factor does not match Calibrate flow meter (chapter C 3.3)
from the actual quantity operating conditions
Wrong unit of measure set Set correct unit of measure
(chapter C 3.4.1)
Leaks in hose system Install check valve if necessary
2. Trouble shooting
Radio interference on the data line Place data line separate from
low-voltage conduits
Liquid leaks from the housing Seal defective Replace seal
Hairline cracks in housing and/or on Check installation conditions for
screw connection due to mechanical mechanical stresses and correct them
influences
Screw connection not tightened Check that screw connections are
securely secure
Operating pressure exceeded, pressure Check pressure conditions
surges e.g. due to water hammer
Inadequate chemical resistance Contact manufacturer
Throughput decreases Filter screen soiled Remove and clean filter screen
Measuring chamber soiled Flow meter must be flushed and cleaned
regularly after handling aggressive,
tacky, crystallizing or very
contaminating liquids
Manual mode „Batt“ indication flashes or remains End of battery service life Replace batteries (chapter C 4.1)
permanently on
No indication after changing batteries Batteries fitted incorrectly Open battery compartment and check
polarity
Battery contacts corroded Clean contacts
Automatic mode No liquid registered Dry running Prevent air pockets in connecting lines,
Filling process interrupted by flow meter use a solid hose system
„STOP“ appears on display Solenoid valve does not open Check solenoid valve
Time required to fill the connecting lines Increase monitoring time
exceeds the set monitoring time (chapter C 3.2.10)
Operating mode Fault Cause Remedy
Automatic mode Swash plate blocked Clean flow meter, check resistance
Fuse in relay module defective Check fuses

(chapter D or E 3.1)
No liquid delivered after starting, Correction factor too high Reduce correction factor, recalibrate
0.0 appears on display flow meter
Solenoid valve does not operate, Cable connection interrupted Check connecting cable and secure fit of
pump is running plug connections
(chapter D 2.2)
Fuse in relay module defective Check fuses
(chapter D or E 3.1)
Solenoid valve blocked Check solenoid valve and clean
if necessary
SLOW value exceeds entered filling Reduce SLOW value
volume (chapter C 3.2.9)
Pump motor will not start, Motor switched off Switch on motor
solenoid valve switches
Pump motor with low-voltage release Use pump motor without low-voltage
switches off automatically release
Cable connection interrupted Check connecting cable and secure fit of
plug connections
(chapter D 2.2)
Separate installation of Occasional transmission errors Data line exposed to strong Data line must be shielded against
control unit and/or Display OK, but operator inputs electromagnetic fields electromagnetic interference
relay module impossibe (large machines, power cables, etc.)
Data line defective Check data line for damage and secure
fit of plug connection
(chapter D 2.3 and 2.4)
GB
61
GB
62
GB
Lutz - Pumpen GmbH
Erlenstraße 5-7
D-97877 Wertheim
Declaration of Conformity
Herewith we declare that the below-mentioned machine in it‘s conception and design and in the execution
marketed by us fully complies with the EC directives.
This declaration ceases to be valid if the machine is modified in any way without prior consultation with us.
Type of device: Modular Flow Meter System
Relay module Ex-RM1m 230V

Relay module RM3 400/230V
Relay module RM1 230V
Relay module RM1 120V

Operating unit Ex-BE1 V
Operating unit Ex-BE1
Mains unit NG1 230V
Basic flow meter VA I

Module:
Operating unit BE1 V
Basic flow meter LM

Basic flow meter UN
Basic flow meter HC

Operating unit BE1
EC Directive on low voltage installations

(2006/95/EC) l l l l
Applicable
EC Directives: EC Directive EMC (2004/108/EC) l l l l l l l l l
EC Directive ATEX (94/9/EC) l l l l l l l l
EC-Type examination
PTB 00 ATEX 2135 X l
EC-Type examination
PTB 0102,
PTB 01 ATEX 2204 l l
Bundesallee 100,
38116 EC-Type examination
Braunschweig PTB 03 ATEX 2093 l
Registered number 05 ATEX D136
Identification: II 2G T4 l l l l
EN 1127 l l l l
EN 13463-1 l l l l
EN 13463-5 l l l l
EN 50014 l l l l
Applicable
harmonized EN 50019 l
standards EN 50020 l
EN 50028 l
EN 55014 l l l l l l l l l
EN 61000-3-2 l l
EN 50082-2 l l l l l l l l l
Wertheim, 08.04.2008
Jürgen Lutz, Managing Director

63
GB
Spare parts list

Accessories for Modular Flow Meter System
Order No. Description Qty.
0211-225 PE transformer cpl. 1
0211-235 impulse adapter 1/4" NPT cpl. 1
0211-239 impulse adapter 1" NPT cpl. 1
0211-269 grounding plate 1-fold 1
0211-374 cover for relay 1
0211-394 screwed cable gland cpl. 1
0212-010 intermediate plate consisting of: 0301-248, 0301-249, 1
0301-251, 0373-003, 3373-004
0300-065 screw 2
0301-039 phillips screw 2
0301-102 ejot-PT-screw 2
0301-126 hexagon nut 2
0301-217 tapping screw 12
0301-222 ejot-PT-screw (for relay module RM1) 4
0301-243 ejot-PT-screw (for relay module Ex-RM1m and RM3) 4
0301-248 ejot-PT-screw (for types ST, SL, LM, UN) 4
0301-249 phillips screw (for type VA I) 4
0301-251 washer 4
0302-150 quick change screw 3
0302-151 hose connector 1
0303-153 plastic hose 3
0314-180 o-ring NBR 5
0314-761 o-ring Perbunan 2
0333-335 locking screw 2
0335-212 finewire fuse 6.3A time-lag (for relay module 120V) 1
0335-213 finewire fuse 4A time-lag (for relay module 230V) 1
0335-214 finewire fuse 0.1A semi time-lag (for relay module RM1) 1
(for relay module RM3) 1
0335-215 finewire fuse 0.5A semi time-lag (for relay module RM1) 1
(for relay module RM3) 2
0335-247 fuse Ex, 4A 1
0335-248 fuse Ex, 500 mA 1
0335-254 relay 1
0336-060 connecting cable relay module 4
0336-061 socket 3
0336-062 plug 1
0336-093 flange box cpl. 1
0336-095 plug 1
0336-096 angle coupling 1
0336-099 coupling 1
0336-106 coupling plug 4
0336-162 power cable relay module Ex-RM1m consisting of: 0336-536 1
0336-536 explosion proof plug 3-pole 1
0363-053 protection foil 1
0373-003 cap 4
0373-008 protection cap for socket 3
0373-009 protection cap for plug 1
64
GB
65
GB

0373-052 sealing cover 2
3373-004 cap 1
5000-270 air valve spool with magnet (for double diaphragm pump 1/2" and 1") 1
5000-274 clip with magnet (for double diaphragm pump 1/4") 1
5000-278 air valve cpl. with magnet (for double diaphragm pump 1/2" and 2") 1
5000-280 air valve spool with magnet (for double diaphragm pump 3") 1
0301-230 phillips screw (for mounting two modules without
intermediate plate on type VA I) 4
additional spare parts

relay module type Ex-RM1m
to Ser. No. 000999
0211-268 grounding plate 2-fold 1

0211-394 screwed cable gland cpl. 2
0314-761 o-ring Perbunan 1
0336-164 connecting cable, valve consisting of: 0336-533 1
0336-165 connecting cable, pump consisting of: 0336-533 1
0336-222 connecting wire fuse – strip terminal 2
0336-533 explosion proof coupling 3-pole 2
State of art 08/04
• wearing part + new part
When ordering spare parts always indicate the corresponding order No. and production No. or order No. of the unit to
be repaired.
66
GB
67
GB
Spare Part List

Flow Meter Program Types ST, SL, LM, UN, VA I
0160-205 seal PTFE (for type VA I with connection G 1 1/2 ) 1
0208-632 collar bush 2
0211-056 swash plate PVDF (for measuring chamber 0211-220) 1
0211-062 measuring chamber cpl.encapsulated (for type SL),
consisting of: 0314-183, 0343-236, 0343-234 1
0211-063 measuring chamber cpl. encapsulated (for type UN), consisting of: 0314-190, 0343-234 1
0211-074 measuring chamber cpl. (for type LM), consisting of: 0314-190 1
0211-085 battery closing cap Ex (for types LM, UN, VA I) 1
0211-086 battery closing cap (for types ST, SL) 1
0211-088 headed liner R 1 1/4" OT (for types ST, SL) 1
0211-089 headed liner R 1 1/4" OT (for types LM, UN) 1
0211-092 screw socket R 1 1/4" (for types ST, SL) 2
0211-093 screw socket R 1 1/4" (for types LM, UN) 2
0211-094 flanged bush R 1 1/4" OT (for types ST, SL) 2
0211-095 flanged bush R 1 1/4" OT (for types LM, UN) 2
0211-140 check valve PTFE/Viton (for types ST, SL), consisting of: 0314-185 1
0211-141 check valve PTFE/Viton-FEP (for types LM, UN), consisting of: 0314-189 1
0211-144 measuring chamber cpl. (for type ST) consisting of: 0343-236 1
0211-172 cover cpl. (for type ST, SL) 1
0211-173 cover cpl. (for type LM, UN) 1
0211-193 measuring chamber cpl. consisting of: 0211-208, 0211-200, 0211-209, 1
0370-029, 0211-196, 0343-237, 0300-598, 0300-070
0211-195 clamp 2
0211-196 sealing sleeve 1
0211-197 cover cpl. 1
0211-200 swash plate cpl. 1
0211-208 base support 1
0211-209 top support 1
0211-211 connector VA I G 1 1/4 consisting of: 0313-195 1
0211-214 connector VA I G 1 1/2 consisting of: 0160-205, 0313-195 1
0211-220 measuring chamber cpl. encapsulated for nitric acid and sulphuric acid 1
(for types ST, SL)
consisting of: 0314-190, 0211-056, 0370-031
0211-323 key board with cover not Ex, (for types ST, SL) 1
0211-324 key board with cover, Ex (for types LM, UN, VA I) 1
0212-001 operating unit BE1 not Ex, (for types ST, SL)
consisting of: 0211-086, 0300-010, 0300-059,
0300-221, 0314-180, 0332-020, 0373-002,
0373-003, 0375-007 1
0212-002 operating unit Ex-BE1 (for types LM, UN, VA I)
consisting of: 0211-085, 0300-010, 0300-059,
0300-221, 0314-180, 0332-020, 0373-002,
0373-003, 0375-007 1
0212-003 operating unit BE1 V electronics spilled, not Ex, (for types ST, SL)
consisting of: 0211-086, 0300-010, 0300-059,
0300-221, 0314-180, 0332-020, 0373-002,
0373-003, 0375-007 1
0212-004 operating unit Ex-BE1 V electronics spilled, (for types LM, UN, VA I)
consisting of: 0211-085, 0300-010, 0300-059,
0300-221, 0314-180, 0332-020, 0373-002,
0373-003, 0375-007 1
0300-010 screw 1
0300-059 phillips screw (for type VA I) 4
68
GB
Relaismodul see spare part list

flow meter programm accessories
69
GB

0300-062 hexagon screw 8
0300-070 cylinder head screw 2
0300-089 cylinder head screw 8
0300-598 sping washer 2
0300-708 washer 8
0301-221 ejot-PT-screw (for types ST, SL, LM, UN) 4
0302-023 wing nut G 2 (for types LM, UN) 1
0303-006 wing nut G 2 (for types ST, SL) 1
0313-005 distance washer (for type VA I) 4
0313-195 seal PTFE (for type VA I with connector G 1 1/4) 2
0313-195 seal PTFE (for type VA I with connector G 1 1/2) 1
0313-196 seal PTFE (for type VA I with flange connection) 2
0314-166 o-ring Viton/FEP 1
0314-179 o-ring Viton-FEP (for types LM,UN with flange connection) 4
0314-179 o-ring Viton-FEP (for types LM, UN with drum pump adapter) 1
0314-180 o-ring NBR 1
0314-181 o-ring Viton (for types ST, SL) 1
0314-185 o-ring Viton for check valve (for types ST, SL) 1
0314-187 o-ring Viton-FEP (for types LM, UN) 1
0314-189 o-ring Viton-FEP for check valve (for types LM, UN) 1
0332-020 battery 3
0343-220 basic body (for types ST, SL) 1
0343-222 basic body (for types LM, UN) 1
0343-225 bush R 1 1/4" internal thread (for types ST, SL) 1
0343-226 bush G 1 1/4" internal thread (for types LM, UN) 1
0343-230 filter 1
0343-234 • guide pin (for types ST, SL, LM, UN) 1
0343-236 swash plate PPS (for types ST, SL, LM, UN) 1
0343-237 bearing washer 1
0370-029 measuring chambers plate 1
0370-031 • guide pin (for measuring chamber 0211-220) 1
0370-620 flange plate NW 25, ND 6 2
0373-002 protection cap 1
0373-003 cap 4
0373-005 flange 2
3314-021 o-ring Viton (for types ST, SL with flange connection) 4
For order no. 0211-172 and 0211-173 please also advise order no. and serial no. of flow meter.
+ spare parts for special models
0211-322 bearing washer (for type PU) 1
0314-247 o-ring EPDM (for type PU) 1
State of art 08/05
• wearing part + new part
When ordering spare parts always indicate the correspondending order No. and production No. or order No. of the unit to be repaired.
70
GB
Relaismodul see spare part list

flow meter programm accessories
71
GB
Lutz - Pumpen GmbH

Erlenstraße 5-7
D-97877 Wertheim
Phone (93 42) 8 79-0
Fax (93 42) 87 94 04
e-mail: info@lutz-pumpen.de
http://www.lutz-pumpen.de
Subject to technical changes. 04/08 Best.-Nr. 0698-951 Printed in Germany / Dru.

72

Operating Instructions: Modular Flow Meter System Ts

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Operating Instructions: Modular Flow Meter System Ts

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GB

Read this operating instructions before start up!

To be retained for future reference.

Explanation of the operating unit

1 Unit of measurement used for flow volume (litres, US-gallons, IMP-gallons).

General safety information

The national explosion protection regulations must be observed without fail.

B. Basic flow meter 10

3.2 Automatic mode 25

D. Relay module RM1/RM3 and mains unit NG1 43

E. Relay module Ex-RM1m 53

Operating unit and basic flow meter

Ã Basic flow meter

The flow meter can be used in two different operating modes:

B. Basic flow meter

1.1 Application in explosion hazard areas

Following must be observed:

1.2 Technical data

1.3 Maximum pressure depending on temperature of the medium

Type ST, SL, LM, UN

1.4 Complete hose system

1.5 Pressure surges (water hammer)

Pressure surges can be prevented as follows:

1.6 Pressure drop

1.7 Accuracy of measurement and flow

Example for type ST, SL, LM, UN

Example for type VA I:

1.8 Optimization of measurement accuracy by calibration

Mounting steps flow meter

Connection for drum pump operation type VA I

2.2 Connection to the piping system – Flange connection

Mounting steps flow meter

Mounting steps flow meter

Flange connection type VA I

2.3 Valve connection

1. Screw the double nipple

2. Mount the hose connection

3. Connect the hose with the flow

4. Screw the discharge bend onto

3. Maintenance and servicing

3.1 Cleaning the filter and check valve

3.2 Dismantling the basic flow meter

Dismantling the basic flow meter type VA I:

The assembly is effected in reverse order.

Dismantling the basic flow meter

1.1 Technical data

1.2 Application in explosion hazard areas

1.2.1 Electrical data

Module input Explosion protection class intrinsic safety EEx ib IIB;

when connecting with an active module output in explosion

2.1 Insert the batteries

2.2 Turning the operating unit

Turning the operating unit

2.3 Separate installation of the operating unit

Separate installation of the operating unit

2.4 Hose installation of the operating unit

Assembly of the operating unit at the hose

3.1 Manual mode

3.1.1 Resetting the part volume meter