Danfoss BCP1H, BCP4H, BCP5H, BCP3H, BCP2H Installation Manual

Danfoss

17 - 888.20

Danfoss

17 - 904.30

Installation guide

Pressure switch
Type BCP

© Danfoss | DCS (az) | 2017.11 IC.PI.P10.K8.53 / 520B8307 1

017R9328

017R9328

1

2

3

6

5

Mounting accessories

1

2

3

7

8

4

BCP01

min. 20 mm

permissible torque

50/60 Ncm

2 IC.PI.P10.K8.53 / 520B8307 © Danfoss | DCS (az) | 2017.11

Technical data

BCP pressure controller with auto reset (fig.1)
BCP pressure limiter with manual reset (fig.2)

Typ e Range

[bar]

Max. work ing

pressure

*

MWP

[bar]

Controller Min. limiter Max. limiter

BCP 01 – – 0.03 – 0.3 0.4

BCP1 – – 0.1 – 1.1 6
BCP2 BCP2L BCP2H 0 – 2. 5 10
BCP3 BCP3L BCP3H 0 – 6.0 16
BCP4 BCP4L BCP4H 1 – 10 25
BCP5 BCP5L BCP5H 2 – 16 32

BCP6

**

BCP6L BCP6H

**

5 – 25 40

BCP7

**

– BCP7H

**

10 – 40 63

Max. test pressure: 1.1 × MWP
Min. test pressure: 1 bar
Media: steam, water, air
Max. allowable vacuum: 0.5 bar (BCP1 type only)
Max. media temperature: max. 120 °C
Ambient temperature: -20 − 70 °C

***

Enclosure: IP65
Pressure connection: G ½A
Action type according to EN 60730:
Type BCP 2B
Type BCPL/ BCPH 2BD

*)

If the sy stem pressure e xceeds MWP then ac curacy of the sw itch

setti ng can be lost.

**)

Pressure switches with double bellows

***)

For BCP01 type: -10 – 70 °C

Installation

In order to prevent malfunction of the pressure switch, the
installation must be carried out acc. to the below description.
The cover of BCP should never be dismounted. This is not
necessary neither for installation nor for use of the switch.
The plug should be mounted after installation of the pressure
switch.
Mount the pressure switch directly on the pipe. Always use a
wrench. (fig.3).
Damp strong pressure pulsations. A damping loop will often be
sufficient. Insert a water filled loop as a temperature barrier - for
example a 10 mm copper tube - if there is a risk of the pressure
connection to the switch becoming heated to more than 120 °C.

Steam boilers:

Connecting pipes for the limiter should be connected to the
steam space of the boiler and if necessary, the limiter shall be
protected against the steam temperature by a water seal.
If isolating valve is fitted on the connection pipe, the valve must
be fitted with a position locking device.

Fully flooded hot water generators:

The limiter should be connected to the supply pipe before the
first shut-off valve. The limiter body should be installed vertically
so that dirt does not enter the limiter. If there is the possibility of
sludge build-up in the connection pipe it should be possible to
purge the pipe. Such purging must not remove the water seal or
introduce dirt into the water seal.
In addidition, the connection pipe and its boiler connection must
be designed for cleaning and inspection and have a clear bore of
at least:

1. Where pipe supplies only the limiter:
ø8 mm - if pipe is less than 1m long
ø15 mm - if pipe is more than 1 m long

2. Where pipe supplies the limiter in addition to other limiters:
ø20 mm - for all lengths of pipes.

Functional testing of the limiter

Since the pressure limiter has no internal possibility for functional
testing, there has to be a provision made for functional testing of
the device at the boiler site.
The result of the test must be clearly visible to the boiler operator.
The test function should not decrease the boiler safety or lead the
pressure limiter to become inoperable e.g. by possible permanent
override.

Wiring

Electrical connection:
Plug DIN 43650, Pg 11 (fig. 4)

Contact load

Type A contact s
gold plate d silver

Type B contact s
silver-cadium oxide

When used a s gold
contacts:
Min. 1 mA, 5 V
Max. 100 mA , 30 V

When used a s silver
contact s

1)

Max:
AC-1: 6 A, 2 50 V

2)

AC-15: 1 A, 250 V

3)

DC 13 10 W, 250 V

4)

Min. 500 mA , 250 V
Max:
AC-1: 10 A, 250 V

2)

AC-15: 2 A, 250 V

3)

DC 13 50 W, 250 V

4)

1)

If used with current higher than 100 mA and voltage higher than 30 V the gold

layer will be burned away and the unit can not be use d as gold again.

2)

AC-1 Ohmic load, cosφ 1.

3)

AC-15 induc tive load like coil

and contac tors with cosφ 0.3.

4)

DC 13 Direct current load.

Using the appliance in other than described AC-1, AC-3, AC-15 or
DC-13 modes, may not be as a limiter.

Short circuit protection

The BCP contact system and any co-operated external contactors
or relays should, against the effects of short circuits, be over­current protected with 0.6 safety factor.
It means that the nominal current of the device, as stated by the
manufacturer, is to be multiplied by a safety factor of 0.6.

Example:

Rated load for AC-15 is 2A.
Safety factor is 0,6 in consequence: fuse = 2A x 0,6 = 1,2A or less.

Expected electrical life time:

Min. 250.000 cycles under full contact load.

Adjustment

IMPORTANT:

- Do not adjust pointers beyond the highest or lowest indicator
marks on the scale plate, as this may cause inaccurate switch
operation.

- Do not apply torque greater than 50 Ncm as it can damage the
pointers.

- The scale plate is only for reference and for more precise
setting a pressure gauge should be used.

- Low Switching Point must be above absolute vacuum!
If the differential is set too high on the controller then it will not
switch.

Pressure controller

Scale plate directly indicates High Switching Point (HSP) and
Differential.

1. Set High Switching Point (HSP) by adjusting range screw (fig. 7)

2. Then set Differential by adjusting differential screw (fig. 8)

3. Low Switching Point (LSP) is equal to High Switching Point (HSP)
less Differential:
LOW = HIGH − DIFFERENTIAL

ENGLISH

© Danfoss | DCS (az) | 2017.11 IC.PI.P10.K8.53 / 520B8307 3

Low pressure limiter

Scale plate directly indicates Low Switching Point. There is no
pointer for Differential.
Differential value is fixed and printed on the scale plate.

1. Set Low Switching Point by adjusting range screw (fig. 7)

2. High Switching Point is equal to Low Switching Point plus
Differential:

HIGH = LOW + DIFFERENTIAL

High pressure limiter

Scale plate directly indicates High Switching Point. There is no
pointer for Differential.
Differential value is fixed and printed on the scale plate.

1. Set High Switching Point by adjusting range screw (fig. 7)

2. Low Switching Point is equal to High Switching Point less
Differential:

LOW = HIGH - DIFFERENTIAL

Protection for settings

The protective cap on adjustment screws may be used to lock
and seal the settings (fig. 6)

Manual reset

For resetting use the screwdriver (Fig. 5)
Manual reset is possible to operate only after return of pressure
to cut-in level.
Before releasing the reset, the cause of the shutdown must be
found and eliminated.

BCP pressure controller with auto reset as a limiting
device

Since the pressure controller BCP has no lockout with manual
resetting, this function must be realized externally as a part of a
safety logic e.g. by external contactors and/or relays which then
are to be used according to the requirements of prEN50156-1
standard for safety relevant hardware.

External closure must not be interlocked, while loss of auxiliary
energy must lead to a closure.
Resetting must not be automated; it has to be performed
manually.
Resetting on fault must lead to a repeated closure. When BCP
limits, for rising or falling application, the external safety logic
must change to the fail safe position.

Endurance of any external contactors and relays must be
according to EN12952-11, which means 250000 switching cycles
under conditions similar to operating conditions and be capable
of a mechanical life time of 2 000 000 switching cycles.
Conditions similar to operating conditions include chemical and
climatic influences as well as electrical and mechanical stresses.
In addition, contactors must fulfil EN60947 and relays must fulfil
EN60255.

BCP with double bellows

BCP6, BCP6H, BCP7, and BCP7H have a double bellows; an outer
bellows and a regulating (inner) bellows.
When system pressure exceeds the set value, the BCP will
automatically stop the plant. The double bellows system prevents
loss of media in the event of bellows rupture. A rupture in the
inner bellows will cause the switch cut-out pressure to fall about 3
times less the set value, thus the system will stop. A rupture in the
outer bellows will cause the switch cut-out pressure to fall to about
3 bar under the set value, thus providing a fail-safe function.

Safety requirements

Installation

• Internal rules and legislation current in the country concerned
with respect to health and safety at work must be observed

• For safety reasons, the installation of pressure switches must
be carried out only by qualified staff, trained in all technical
aspects of their operation,

• Before installation the pipes must be depressurised and purged
(empty of its fluid) in order to avoid any danger to the operator,

• It is essential to isolate the power supply before wiring
connections are made to avoid possible electrical shock or
damage to equipment. Never touch live parts with your fingers
or with any tool,

• DIN plug supplied by Danfoss and cable approved for the
application must be used. The cable must be connected with
adequate stress relief in order to prevent that pulling forces can
be carried through the cable to the plug.

Commissioning

Before putting pressure switch into operation, check that:

• The working conditions are compatible with the details given
in the product label and this instruction notice,

• All electrical connections have been properly made,

• Installation is tight after assembly.

Operation

• This notice must be available on site where pressure switches
are installed,

• Internal rules and legislation current in the country concerned
with respect to health and safety at work must be observed

• Personnel carrying out any intervention on the pressure switch
must be qualified for the task,

• The pressure switch should be checked regularly to see if it
operates properly,

• The BCP cover must not be removed under any circumstances

• Any overload of the pressure switch must be prevented.
Overloaded or damaged switch must be exchanged.

• It is essential to disconnect the plug before dismounting the
switch from the system,

• All operations must be performed using suitable tools

• It is the responsibility of the user to check that there is no
leakage after a faulty operation or on a periodic basis under
normal conditions,

• Only pressure switches designed, constructed and released
by Danfoss must be used for the applicaiton concerned.
Danfoss can accept no responsibility in case of alterations
made on the pressure switches or the use of them against the
instructions of Danfoss,

• Danfoss is not responsible for any damage which may be
caused by the use of parts, accessories or switches which are
not original Danfoss parts.

4 IC.PI.P10.K8.53 / 520B8307 © Danfoss | DCS (az) | 2017.11

Tekniske data

BCP Pressostat med automatisk reset (fig.1)
BCP Trykbegrænser med manuel reset (fig.2)

Typ e Område

[bar]

Maks.

arbejdstryk

*

MWP

[bar]

Pressostat

Min.

Begrænser

Maks.

Begrænser

BCP 01 – – 0.03 til 0.3 0.4

BCP1 – – 0.1 t il 1.1 6
BCP2 BCP2L BCP2H 0 til 2.5 10
BCP3 BCP3L BCP3H 0 til 6.0 16
BCP4 BCP4L BCP4H 1 til 10 25
BCP5 BCP5L BCP5H 2 til 16 32

BCP6

**

BCP6L BCP6H

**

5 til 25 40

BCP7

**

– BCP7H

**

10 til 40 63

Maks. prøvetryk: 1.1 × MWP
Min. prøvetryk: 1 bar
Medie: damp, vand, luft
Maks. tilladte vakuum: 0,5 bar (BCP1 type kun)
Maks. medietemperatur: maks. 120 °C
Omgivelsestemperatur: -20 til 70 °C

***

Kapsling: IP 65
Tryktilslutning: G ½A
Handlingstype i.h.t. EN 60730:
Type BCP 2B
Type BCPL/ BCPH 2BD

*)

Hvis systemtrykket overstiger MWP, kan kontrolindstillingens

nøjagtighed gå tabt.

**)

Pressostat med dobbeltbælg

***)

Til BCP01 typ e: -10 – 70 °C

Montering

Installationen skal udføres i overensstemmelse med
nedenstående beskrivelse for at forhindre funktionsfejl på
pressostaten.
BCPs beskyttelseshætte må aldrig afmonteres. Dette er ikke
nødvendigt. Hverken ved installation eller ved anvendelse af
pressostaten.
Stikket skal monteres efter installation af pressostaten.
Monter pressostaten direkte på røret. Anvend altid en skruenøgle.
(fig.3).
Dæmp stærke trykpulsationer. En dæmpesløjfe vil ofte
være til-trækkelig. Indsæt en vandfyldt rør søjle som en
temperaturbarriere - f.eks. et 10 mm kobberrør - hvis der er risiko
for, at tryktilslutningen til pressostaten kan blive varmere end
120 °C.

Dampkedler:

Tilslutningsrørene til begrænseren bør tilsluttes damprummet
i kedlen og, hvis det er nødvendigt, skal pressostaten beskyttes
mod damptemperaturen med en vandlås. Hvis der monteres en
ventil på forbindelsesrøret, skal den monteres med en positionslå­seanordning.

Oversvømmet varmtvandsgenerator:

Begrænseren skal tilsluttes forsyningsrøret før den første afspær­ringsventil. Pressostaten skal monteres lodret, så der ikke kommer
snavs ind i denne. Hvis der kan opstå slamophobning i tilslutning­srøret, skal det være muligt at rense røret. Ved rensning skal det
sikres at vandlåsen bevares og at der ikke kommer snavs i denne.

Desuden skal tilslutningsrøret og den tilhørende kedeltilslutning
være udviklet til rensning og eftersyn og have en klar lysning på
mindst:

1. Hvor røret kun forsyner pressostaten:
ø8 mm - hvis røret er kortere end 1 m
ø15 mm - hvis røret er længere end 1 m

2. Hvor røret forsyner pressostaten såvel som andre pressostater
ø20 mm - for alle rørlængder

Funktionstest af pressostaten

Da trykbegrænseren ikke har nogen indbygget mulighed for
funktionstest, skal der laves en mulighed for funktionstest af
enheden ved kedlen.
Testresultatet skal være tydeligt synligt for kedelbrugeren,
testfunktionen bør ikke reducere kedelsikkerheden eller
forårsage, at trykbegrænseren bliver ikke-funktionel f.eks., ved
mulig permanent tilsidesættelse.

Kabelføring

Elektrisk tilslutning:
Stik DIN 43650, Pg 11 (fig. 4)

Kontaktbelastning

Type A kontak ter
Au belagte A g

Type B kontak ter
Sølv (AgCdO)

Anvendt som guldkon­takter
Min. 1 mA, 5 V
Maks. 100 m A, 30 V

Anvendt som sølvkon­takter

1)

Maks:
AC-1: 6 A, 2 50 V

2)

AC-15: 1 A, 250 V

3)

DC 13 10 W, 250 V

4)

Min. 500 mA , 250 V
Maks:
AC-1: 10 A, 250 V

2)

AC-15: 2 A, 250 V

3)

DC 13 50 W, 250 V

4)

1)

Ved anvendelse under strøm højere end 100 mA og en spænding over 30 V,

forsvin der guldet og enheden kan ikke længere anvendes.

2)

AC-1 ohmsk belastning, cosφ 1.

3)

AC-15 induk tiv last som spoler og kontakter me d cosφ 0.3.

4)

DC 13 Jævnstrømslast.

Hvis apparatet anvendes på en anden måde end de beskrevne
AC-1, AC-3, AC-15 eller DC-13 tilstande, må det ikke være i
egenskab af en begrænser.

Kortslutningsbeskyttelse

BCP kontaktsystemet og alle samarbejdende eksterne kontaktorer
eller relæer skal være overstrømsbeskyttet mod kortslutninger
med en sikkerhedsfaktor på 0.6.
Det betyder, at apparatets normale strømstyrke, som angivet af
producenten, skal ganges med en sikkerhedsfaktor på 0.6.

Eksempel:

Den nominelle belastning for AC15 er 2A.
Sikkerhedsfaktor er 0.6, hvilket betyder: sikring = 2A x 0.6 = 1.2A
eller mindre.

Forvendet elektrisk levetid

MIN. 250.000 koblinger ved fuld kontaktbelastning.

Justering

VIGTIGT:

- Juster ikke visere ud over de højeste eller laveste indikatormar­ keringer på skalapladen, da dette kan resultere i upræcise
styrefunktioner.

- Anvend ikke et moment højere end 50 Ncm, da dette kan skade
viserne.

- Skalapladen er kun til reference. Der bør anvendes et mano­ meter for at opnå præcis indstilling.

- Lavt omskiftepunkt skal være over absolut vakuum!
Hvis forskellen er indstillet for højt på pressostaten, vil den ikke
omkoble.

Pressostat

Skalapladen angiver direkte det høje omskiftepunkt (HSP=High
Switching Point) og differens:

1. Indstil det høje omkoblingspunkt (HSP=High Switching Point)
ved at justere indstillingsskrue (fig. 7).

2. Indstil derefter differensen ved at justere på differensskruen. (fig. 8).

3. Det lave omskiftningspunkt (LSP=Low Switching Point) er lig
med det høje omskiftningspunkt minus den indstillede differens.

LAV = HØJ − DIFFERENS

DANSK