BD SENSORS DS 400, DS 400 P, DS 401, DS 401 P Service Manual
E
EUROPE
ASIA
nal +
DS 400
Operating Manual
Electronic Pressure Switch DS 4XX
DS 400, DS 400 P, DS 401, DS 401 P
www.bdsensors.com
Headquarter Western Europe / International
BD SENSORS GmbH
BD-Sensors-Str. 1
D - 95199 Thierstein
Germany
Tel: +49 (0) 92 35 / 98 11-0
Fax: +49 (0) 92 35 / 98 11-11
Headquarter Eastern Europe
BD SENSORS s.r.o.
Hradištská 817
CZ - 687 08 Buchlovice
Czech Republic
Tel: +42 (0) 5 72 / 4 11-0 11
Fax: +42 (0) 5 72 / 4 11-4 97
further agencies in:
• Belgium
• Denmark
• France
• Greece
• Italy
• Lithuania
• Luxemburg
• Netherlands
• Norway
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!
Russia
BD SENSORS RUS
39a, Varshavskoe shosse
RU - Moscow 117105
Russia
Tel: +7 (0) 9 59 81 / 09 63
Fax: +7 (0) 9 57 95 / 07 21
• Poland
• Romania
• Sweden
• Switzerland
• Slovakia
• Spain
• Turkey
• UK
• Ukraine
• Iran
• Israel
• Kazakhstan
• Taiwan
• Thailand
AUSTRALIA
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 –
1.2 Symbols 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.
1.5 Intended 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
pressure
range
signal
Fig. 1 manufacturing label
!
The manufacturing label must not be removed from the
device!
type
designation
supply
ordering
code
connector pinout
serial
number
3. Mechanical installation
3.1 Mounting and safety instructions
WARNING! Install the device only when depressurized
and currentless!
WARNING! This device may only be install ed 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, orings 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, orings 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 i ncreases 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.
3.2 General 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).
3.4 Installation 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).
3.5 Installation 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).
3.6 Installation 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.
3.7 Installation 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 Variventconnection 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.
3.8 Positioning of the display module
The display and operating module is continuously rotatable
so that clear readability i s 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
connections
Supply +
Supply –
3-wire: Sig
Contact 1
Contact 2
Shield
Wiring diagrams:
2-wire-system (current)
supply +
p
supply –
contact 1
I
contact 2
3-wire-system (current/voltage)
supply +
p
supply –
signal +
contact 1
I/U
contact 2
!
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.
M12x1, metal
(5-pin)
1
3
2
4
5
plug housing /
pressure port
A/V
cable colours
(DIN 47100)
wh (white)
bn (brown)
gn (green)
gr (grey)
pn (pink)
(green/yellow)
VS
R
L
R
L
V
S
R
L
R
L
gn/ye
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
contact 1
▼-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.
unit
LED-contact 2
4-digit seven
segment display
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.
6.4 Configuration 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
6.6. Structure of the menu system
menu 1
–
access protection
menus 3 and 4
– set zero point / end point
menu 5
–
set damping
menu 6
–
exceeding message
menus 7and 9
– set switch
-
on points
menus 8 and 10
– set switch
-
off points
menus 11 and 12
– select hysteresis or compare mode
menus 13 and 15
– set switch
-
on delay
menus 14 and 16
– set switch
-
off delay
menus 17 and 18
–
maximum / minimum pressure display
menu 19
– measured value update (display)
men
us 20 and 21
– simulate contacts (only 3
-
wire-system)
menu 22
–
simulate analogue output (only 3
-
wire-system)
menu 23
– error signal definition (only 3
-
wire-system)
menu 24
– offset compensation / position correction (only 3
-
wire-system)
menu 25
– load
defaults (only 3
-
wire-system)
menu 26
– load configuration (only 3
-
wire-system)
menu 27
– store configuration (only 3
-
wire-system)
special menus
special menu 1
– full scale compensation
special menu 2
– offset compensation / position correction (only 2
-
wire-system)
special menu 3
– load defaults (only 2
-
wire-system)
special menu 4
– set password
2-wire-version P07
3-wire-version P07
6.7 Menu list
- ▲-button: move in the menu system (forward) or increase the displayed value; it will also lead you to the operating mode
(beginning with menu 1)
- ▼-button: move in the menu system (backward) or decrease the displayed value; it will also lead you to the operating mode
(beginning with the last menu)
- both buttons simultaneously: confirm the menu items and set values
to increase the counting speed, when setting the values: keeping the respective button pushed for more than 5 seconds
Execution of configuration:
- set the desired menu item by pushing the ▲- or ▼-button
- activate the set menu item by pushing both buttons simultaneously
- set the desired value or select one of the offered settings by using the ▲- or ▼-button
- store the set value / selected setting and exit the menu by pushing both buttons simultaneously
PAon password active to deactivate: set password
PAof password inactive to activate: set password
default setting for the password is "0005"; modification of the password is described in special menu 4
menu 2 – set decimal point position (only 2-wire-system)
for devices with 3-wire output 4 ... 20 mA and 0 ... 20 mA the decimal point was already set during production
menu 2a – indication of the starting point, which was defined with the order (only 3-wire-system)
no configuration is possible
menu 2b – indication of the end point, which was defined with the order (only 3-wire-system)
no configuration is possible
the device has been configured correctly before delivery, so a later setting of a 2-wire device is only necessary, if a
differing displayed value is desired (e. g. 0 ... 100 %)
For devices with 3-wire output 4 ... 20 mA and 0 ... 20 mA this menu has a different meaning: The configuration of the zero point causes a changing of the analogue output, whereas the display value remains unchanged. (zero and end point can be configured within the limits of the nominal pressure range, according to
the manufacturing label); for more information see "6.4 Configuration example of the analogue output for 3wire-devices"
this function allows getting a constant display value although the measuring values may vary considerably; the time
constant for a simulated low-pass filter can be set (0.3 up to 30 sec permissible)
set "on" or "off"
set the particular values, for the activation of contact 1 (S1on) or 2 (S2on)
set the particular values, for the deactivation of contact 1 (S1oF) or 2 (S2oF)
select the hysteresis mode (HY 1/2) or compare mode (CP 1/2) for the contacts 1 or 2
(no. corresponds to the contact)
compare "6.5. Description of hysteresis and compare mode"
set the particular value of the switch-on delay after reaching contact 1 (d1on) or 2 (d2on)
(0 up to 100 sec permissible)
set the particular value of the delay after reaching the switch-of point 1 (d1oF) or 2 (d2oF)
(0 up to 100 sec permissible)
view high pressure (HIPr) or low pressure (LoPr) during the measurement process
(the value will not remain stored if the power supply is interrupted)
to erase: push both buttons again within one second
set the length of the update cycles for the display (0.0 up to 10 sec permissible)
with the ▲- or ▼-button the contacts 1 (tES1) or 2 (tES2) can be activated or deactivated
select one of the following settings: "oi 4" (4 mA or 2 V), "oi12" (12 mA or 6 V) and "oi20" (20 mA or 10 V)
(to access a special menu, select the menu item "PAof" with the ▲- or ▼-button and confirm it; "1" appears in the display)
set the desired error signal (this is given out in case of a defect); permissible settings are "OFF" (no error signal
output), "C 0" (0 mA or 0 V), "C L0" (3.5 mA or 1.75 V) and "C HI" (23 mA or 11.5 V)
an output of the error signal is only given when menu 6 is set on "on"
confirm menu item "P0SI"; if offset ≠ ambient pressure it is necessary to place the device under pressure (pressure
reference has to corresponding to the zero point of the pressure measuring range); push both buttons to store the
signal being emitted from the pressure switch as offset; in the display the set zero point will appear although the
sensor signal in the offset is displaced
a position correction is necessary, if the installation position differs from the calibration position (otherwise this
can cause a little deviation of the signal, which gives a wrong value indication)
the analogue output signal (for devices with analogue output) is not affected by this change;
when displacing the offset, the full scale will also be displaced
to load the defaults, push both buttons simultaneously, after confirming the menu item
any changes carried out will be reset (password will be set on "0005")
to load a stored configuration (via menu 39), set the desired number 1 up to 5
to store a configuration, set the desired number 1 up to 5
for full scale compensation, which is necessary if the indicated value for full scale differs from the real full scale
value in the application (a compensation is only possible with a respective reference source, if the deviation of the
measured value is within defined limits); set "0238"; confirm with both buttons; "FS S" will appear in the display; now
it is necessary to place the device under pressure (the pressure must correspond to the end point of the pressure
measuring range); push both buttons, to store the signal being emitted from the pressure switch as full scale; in the
display the set end point will appear although the full scale sensor signal is displaced.
the analogue output signal (for devices with analogue output) is not affected by this change
set "0247"; the menu description is identical with menu "P0SI" (menu 24) for 3-wire-devices
set "0729"; the menu description is identical with menu "FAct" (menu 25) for 3- wire-devices
set "0835"; confirm with both buttons; "SEtP" appears in the display; set the password using the ▲- or ▼-button
(0 ... 9999 are permissible, the code numbers 0238, 0247, 0729, 0835 are exempt); confirm the password by
pushing both buttons simultaneously
7. Placing out of service
WARNING! When dismantling the device, it must
always be done in the depressurized and currentless
condition! Check also if the medium has to be drained
off before dismantling!
WARNING! Depending on the medium, it may cause
danger for the user. Comply therefore with adequate
precautions for purification.
8. Maintenance
In principle, this device is maintenance-free. If desired, the
housing of the device can be cleaned when switched of
using a damp cloth and non-aggressive cleaning solutions.
Depending on the measuring medium, however, the diaphragm may be polluted or coated with deposit. If the medium is known for such tendencies, the user has to set
appropriate cleaning intervals. After placing the device out of
service correctly, the diaphragm can usually be cleaned
carefully with a non-aggressive cleaning solution and a soft
brush or sponge. If the diaphragm is calcified, it is recommended to send the device to BD SENSORS for decalcification. Please read therefore the chapter “Service/Repair”
below.
!
An incorrect cleaning can cause irreparable damages
on diaphragm. Never use spiky objects or pressured air
for cleaning the diaphragm.
9. Service / Repair
9.1 Recalibration
During the life-time of the device, the value of offset and
span may shift. As a consequence, a deviating signal value
in reference to the nominal pressure range starting point or
end point may be transmitted. If one of these two phenomena occurs after prolonged use, a recalibration is recommended to ensure furthermore high accuracy.
9.2 Return
Before every return of your device, whether for recalibration,
decalcification, modifications or repair, it is necessary to
contact us to ensure a fast handling of your request. Please
inform us by sending an email to: return@bdsensors.de.
Include the number of devices sent and request a RMA.
Then clean the device and pack it shatterproof before send it
to BD SENSORS indicating the RMA.
10. Disposal
The device must be disposed according to the
European Directives 2002/96/EG and
2003/108/EG (on waste electrical and electronic
equipment). Waste of electrical and electronic
equipment may not be disposed by domestic
refuse!
WARNING! Depending on the measuring medium,
deposit on the device may cause danger for the user
and the environment. Comply with adequate precautions for purification and dispose of it properly.
11. Warranty conditions
The warranty conditions are subject to the legal warranty
period of 24 months from the date of delivery. In case of
improper use, modifications of or damages to the device, we
do not accept warranty claims. Damaged diaphragms will
also not be accepted. Furthermore, defects due to normal
wear are not subject to warranty services.
12. Declaration of conformity / CE
The delivered device fulfils all legal requirements.
The applied directives, harmonised standards and documents are listed in the EC declaration of conformity, which is
available online at: http://www.bdsensors.com/products/
download/certificates.
Additionally, the operational safety is confirmed by the CE
sign on the manufacturing label.
DS4XX_E_110310
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