BD SENSORS DS 400, DS 400 P, DS 401, DS 401 P Service Manual

E

Operating Manual

Electronic Pressure Switch DS 4XX

DS 400, DS 400 P, DS 401, DS 401 P

DS 400

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BD SENSORS GmbH

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The addresses of our distribution partners are listed on our homepage www.bdsensors.com. It is possible to download data sheets, operating manuals, ordering codes and certificates, as well.

Table of contents

1.General information

2.Product identification

3.Mechanical installation

4.Electrical Installation

5.Initial start-up

6.Operation

7.Placing out of service

8.Maintenance

9.Service / Repair

10.Disposal

11.Warranty conditions

12.Declaration of conformity

1. General information

1.1 Information on the operating manual

This operating manual contains important information on proper usage of the device. Read this operating manual carefully before installing and starting up the pressure measuring device.

Adhere to the safety notes and operating instructions which are given in the operating manual. Additionally applicable regulations regarding occupational safety, accident prevention as well as national installation standards and engineering rules must be complied with!

This operating manual is part of the device, must be kept nearest its location, always accessible to all employees.

This operating manual is copyrighted. The contents of this operating manual reflect the version available at the time of printing. It has been issued to our best knowledge. However, errors may have occurred. BD SENSORS is not liable for any incorrect statements and their effects.

–Technical modifications reserved –

1.2Symbols used

DANGER! – dangerous situation, which may result in death or serious injuries

WARNING! – potentially dangerous situation, which may result in death or serious injuries

CAUTION! – potentially dangerous situation, which may result in minor injuries

!CAUTION! – potentially dangerous situation, which may result in physical damage

NOTE – tips and information to ensure a failure-free operation

1.3 Target group

WARNING! To avoid operator hazards and damages of the device, the following instructions have to be worked out by qualified technical personnel.

1.4 Limitation of liability

By non-observance of the operating manual, inappropriate use, modification or damage, no liability is assumed and warranty claims will be excluded.

1.5Intended use

-The electronic pressure switch DS 4XX has been developed, according to the type for applications, for absolute, vacuum and overpressure measurement. It is equipped with a 4-digit LED-display to show the current system pressure. Depending on the device and the mechanical connection it is suitable for various areas of use.

-It is the operator's responsibility to check and verify the suitability of the device for the intended application. If any doubts remain, please contact our sales department in order to ensure proper usage. BD SENSORS is not liable for any incorrect selections and their effects!

-Permissible media are gases or liquids, specified in the data sheet. In addition it has to be ensured, that this medium is compatible with the media wetted parts.

-The technical data listed in the current data sheet are engaging and must be complied with. If the data sheet is not available, please order or download it from our homepage. (http://www.bdsensors.com/products/download/datasheets)

WARNING! – Danger through improper usage!

1.6 Package contents

Please verify that all listed parts are undamaged included in the delivery and check for consistency specified in your order:

-electronic pressure switch, series DS 4XX

-for mechanical pressure ports DIN 3852: o-ring (pre-assembled)

-sheet of unit labels

-mounting instructions

2.Product identification

The device can be identified by its manufacturing label. It provides the most important data. By the ordering code the product can be clearly identified. The programme version of the firmware, (e. g. P07) will appear for about 1 second in the display after starting up the device. Please hold it ready for inquiry calls.

nominal	type	ordering	serial
pressure	designation	code	number
range
signal	supply	connector pinout

Fig. 1 manufacturing label

!The manufacturing label must not be removed from the device!

3. Mechanical installation

3.1 Mounting and safety instructions

WARNING! Install the device only when depressurized and currentless!

WARNING! This device may only be installed by qualified technical personnel who has read and understood the operating manual!

DANGER! Explosion hazard, with devices for oxygen applications, when used improperly. To ensure a usage without danger, the following points must be adhered to:

-Make sure, your device has been ordered and delivered as a special version for oxygen applications. You can check the manufacturing label (see figure 1). If the ordering code ends with "007", then the device is suitable for oxygen applications.

-At time of delivery the device is packed into a plastic bag in order to prevent it from impurity. Please observe the indication label "Device for oxygen, unpack only directly before assembling". Also, avoid any skin contacts during unpacking and assembly, in order to prevent greasy residues on the device.

-During installation, the respective explosion protection regulations have to be met. Check, if ATEXapproval is necessary for this type (oxygen) device. (the delivered device has no ATEX-approval)

-Note the entire design requirements meet the standard demand of BAM (DIN 19247).

-For devices with oxygen capability up to 50 bar, o- rings V747-75 with BAM-approval are being used. The max. capabilities allowed, are 40 bar/130° C and 50 bar/100° C.

-For devices with oxygen capability over 50 bar, o- rings FKM 90 are being used. These have been tested up to 95° C and 215 bar in the scientific coal research institute in Ostrava – CZ.

!Handle this high-sensitive electronic precision measuring device with care, both in packed and unpacked condition!

!There are no modifications/changes to be made on the device.

!Do not throw the package/device!

!To avoid damaging the diaphragm, remove packaging and protective cap only directly before starting up the device. A delivered protective cap must be stored!

!Place the protective cap on the pressure port again immediately after disassembling.

!Handle the unprotected diaphragm very carefully - it is very sensitive and may be easily damaged.

!Do not use any force when installing the device to prevent damage of the device and the plant!

!For installations outdoor and in damp areas following these instructions:

-To prevent moisture admission in the plug the device should be installed electrically after mounting, at once. Otherwise a moisture admission has to be blocked e.g. by using a suitable protection cap. (The ingress protection in the data sheet is valid for the connected device.)

-Choose an assembly position, which allows the flow-off of splashed water and condensation. Avoid permanent fluid at sealing surfaces!

-When using a cable gland device, turn the outgoing cable downwards. If the cable has to be turned upwards, then point it downward so the moisture can drain.

-Install the device in such a way that it is protected from direct solar irradiation. Direct solar irradiation can lead to the permissible operating temperature being overstepped in the worst case. By this the operability of the device can be affected or damaged. If the internal pressure increases due to solar irradiation, measurement errors may be caused.

!For devices with gauge reference in the housing (small hole next to the electrical connection), install the device in such a way, that the gauge reference is protected from dirt and moisture. Should the device be exposed to fluid admission, the functionality will be blocked by the gauge reference. An exact measurement in this condition is not possible. Furthermore this can lead to damages on the device.

Take note that no assembly stress occurs at the pressure port, since this may cause a shifting of the characteristic curve. This is especially important for very small pressure ranges as well as for devices with a pressure port made of plastic.

In hydraulic systems, position the device in such a way that the pressure port points upward (ventilation).

Provide a cooling line when using the device in steam piping.

If installing the device outdoor and there is any danger of lightning or overpressure we suggest putting a overpressure protection unit between the supply/switch cabinet and the device to prevent damage.

3.2General installation steps

-Carefully remove the pressure measuring device from the package and dispose of the package properly.

-Go ahead as detailed in the specific instructions below.

3.3 Installation steps for DIN 3852

-Check to ensure the proper groove fitting of the o-ring and additionally to ensure no damage to the o-ring.

-Ensure that the sealing surface of the taking part is perfectly smooth and clean.

-Screw the device into the corresponding thread by hand.

-If you have a device with a knurled ring, the transmitter has to be screwed in by hand only.

-Devices with a spanner flat have to be fully tightened with an open-end wrench (wrench size of steel: G1/4": approx. 5 Nm; G1/2": approx. 10 Nm; G3/4": approx. 15 Nm; G1": approx. 20 Nm; wrench size of plastic: max. 3 Nm).

3.4Installation steps for EN 837

-Use a suitable seal, corresponding to the medium and the pressure input (e. g. a cooper gasket).

-Ensure that the sealing surface of the taking part is perfectly smooth and clean.

-Screw the device into the corresponding thread by hand.

-Tighten it with a wrench (for G1/4": approx. 20 Nm; for G1/2": approx. 50 Nm).

3.5Installation steps for NPT

-Use a suitable seal, corresponding to the medium and the pressure input (e. g. a PTFE-strip).

-Screw the device into the corresponding thread by hand.

-Tighten it with a wrench (for 1/4" NPT: approx. 30 Nm; for 1/2" NPT: approx. 70 Nm).

3.6Installation steps for dairy pipe

-Check to ensure that the O-ring fits properly into the intended groove in the mounting part.

-Centre the dairy pipe connection in the counterpart.

-Screw the cup nut onto the mounting part.

-Then tighten it with a hook wrench.

3.7Installation steps for Clamp and Varivent

-Use a suitable seal corresponding to the medium and the pressure input.

-Put the seal onto the corresponding mounting part.

-Centre the Clamp or Varivent connection on the fitting counterpart with seal.

-Then fit the device with a suitable fastening element (e. g. semi-ring or retractable ring clamp) according to the supplier’s instructions.

3.8Positioning of the display module

The display and operating module is continuously rotatable so that clear readability is guaranteed even in unusual installation positions. To change the position, go ahead as follows:

-Screw off the metal cap by hand.

-Turn the display and operating module carefully into the desired position by hand. The module is equipped with a rotational limiter.

-Before screwing on the cap again, the o-ring and sealing surfaces of the housing have to be checked for damage and if necessary have to be changed!

-Afterwards screw the metal cap on by hand and make sure that the housing is firmly locked again.

!Pay attention that no moisture can enter the device. Moreover, the seals and the sealing surfaces should not get dirty, as this may cause a reduction of the degree of protection depending on the case of application or place of installation. This can lead to a breakdown of the devices or to irreparable damages on the device.

4.Electrical Installation

WARNING! Install the device only when depressurized and currentless!

Establish the electrical connection of the device according to the technical data shown on the manufacturing label, the pin configuration and the respective wiring diagram shown below.

Pin configuration:

	Electrical	M12x1, metal	cable colours
	connections	(5-pin)	(DIN 47100)
	Supply +	1	wh (white)
	Supply –	3	bn (brown)
	3-wire: Signal +	2	gn (green)
	Contact 1	4	gr (grey)
	Contact 2	5	pn (pink)
	Shield	plug housing /	gn/ye
		pressure port	(green/yellow)

Wiring diagrams:

2-wire-system (current)

supply +

p

supply –

contact 1

I contact 2

3-wire-system (current/voltage)

supply +

p

supply –

A/V

signal +

I/U contact 1 contact 2

VS

RL

RL

VS

RL

RL

!For the installation of a device with cable outlet following bending radiuses have to be complied with:

cable without ventilation tube:

static installation : 5-fold cable diameter dynamic application: 10-fold cable diameter

cable with ventilation tube:

static installation : 10-fold cable diameter dynamic application: 20-fold cable diameter

!Prevent the damage or removal of the PTFE filter which is fixed over the end of the air tube on devices with cable outlet and integrated air tube.

For the electrical connection a shielded and twisted multicore cable is recommended.

5. Initial start-up

WARNING! Before start-up, the user has to check for proper installation and for any visible defects.

WARNING! The device can be started and operated by authorized personnel only, who have read and understood the operating manual!

WARNING! The device has to be used within the technical specifications, only (check the technical data in the data sheet)!

6. Operation

6.1 Operating and display elements

LED	unit	LED-contact 2
contact 1

4-digit seven segment display

▼-button ▲-button

Fig. 2 touchpad for device with two contacts

The device has, according to the order max. two LEDs which are allocated to the resp. contacts. The LEDs will light up when the respective set point has been reached and the contact is active. The display of the measured value as well as the configuration of the individual parameters occurs menu-driven via the seven-segment display.

6.2 Configuration

The menu system is a closed system allowing you to scroll both forward and backward through the individual set-up menus to navigate to the desired setting item. All settings are permanently stored in an EEPROM and therefore available again even after disconnecting from the supply voltage. The structure of the menu system is the same for all types of devices, regardless of the number of contacts. However, they only differ by the number of menus. Following figure and the menu list shows all possible menus. On devices with 3-wire output 4 ... 20 mA and 0 ... 20 mA, the menus ZP and EP have special functions. The menu DP is not applied, as the decimal point is already factory set during production.

Please follow the manual meticulously and remember that changes of the adjustable parameters (switch-on point, switch-off point, etc.) become only effective after pushing both buttons simultaneously and leaving the menu item.

!Pay attention that no moisture can enter the device during configuration. Moreover, the seals and the sealing surfaces should not get dirty, as this may cause a reduction of the degree of protection depending on the case of application or place of installation. This can lead to a breakdown of the device or to irreparable damages on the device. Right after configuration, the metal cap has to be screwed on again.

6.3 Password system

To avoid a configuration by unauthorized persons, the possibility is given to lock the device by an access protection. More information is given in menu 1 of the menu list.

6.4Configuration example of the analogue output for 3-wire devices

By the menus ZP and EP, the analogue output for 3-wire devices (4...20 mA and 0...20 mA) can be configured. In the following, the function of these menus shall be made clear by an example: assuming you have a pressure switch with a nominal pressure range 0 ... 400 bar with an analogue signal of 4...20 mA / 3-wire. By factory the following performance is set:

0 bar = 4.00 mA 200 bar = 12.00 mA 400 bar = 20 mA

If you change the value in the menu ZP from 0 to 20 and the value in the menu EP from 400 to 300, the following performance will appear:

20 bar = 4.00 mA 160 bar = 12.00 mA 300 bar = 20 mA

The values of ZP and EP are adjustable up to 1:6 of the nominal pressure range.

6.5. Description of hysteresis and compare mode

To invert the respective modes, you have to exchange the values for the switch-on and switch-off points.

Fig. 3 compare mode		Fig. 4 compare mode
		inverted

Fig. 5 hysteresis mode	Fig. 6 hysteresis mode
	inverted