Dwyer 616C User Manual

Bulletin E-43

Series 616 Differential Pressure Transmitter

Specifications – Installation and Operating Instructions

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The Series 616 Differential Pressure Transmitter senses the pressure
of air and compatible gases and sends a standard 4-20 mA output
signal. A wide range of models are available factory calibrated to specific
ranges as listed in the chart below. The span and zero controls are for
use when checking calibration. They are not intended for re-ranging to a
significantly different span. Versatile circuit design enables operation in
2, 3 or 4-wire current loops.

For applications requiring direct pressure readings or percent of full span
output, the optional Model A-701 Digital Readout makes an ideal
companion device. It provides a bright red 0.6˝ high, 3-1/2 digit LED
display while supplying power to the Series 616 transmitter. For
additional information on these and other transmitters, see the Dwyer
Instruments, Inc. Full Line catalog.

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MOUNTING HOLE

TYP 2 PLACES

SPECIFICATIONS
Service: Air and non-combustible, compatible gases.
Wetted Materials: Consult factory.
Accuracy: 616: ±0.25% F.S.; 616C: ±1.0% F.S.
Stability: ± 1% F.S./yr.
Temperature Limits: 20 to 120°F (-6.67 to 48.9°C).
Pressure Limits: See Chart.
Thermal Effect: 616: ±0.055% F.S./°F (0.099% F.S./°C); 616C:

±0.070% F.S./°F (0.125% F.S./°C).

Power Requirements: 10-35 VDC (2, 3 or 4 wire); 16-26 VAC (4 wire).
Output Signal: 4 to 20 mA.
Zero and Span Adjustments: Potentiometers for zero and span.
Loop Resistance: DC: 0-1250 ohms maximum; AC: 0-1200 ohms

maximum.

Current Consumption: DC: 38 mA maximum; AC: 76 mA maximum.
Electrical Connections: Screw-type terminal block.
Process Connections: Barbed, dual size to fit 1/8˝ and 3/16˝

(3.12 mm and 4.76 mm) I.D. rubber or vinyl tubing.
Mounting Orientation: Vertical, consult factory for other position
orientations.
Weight: 1.8 oz. (51 grams).

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Series 616 Transmitter Models and Ranges*

Model Range Max. Press. Model Range Max. Press.
616-00 0-1 in. w.c. 2 psig 616-8 0-10 psid 29 psig
616-0 0-2 in. w.c. 2 psig 616-9 0-20 psid 58 psig
616-1 0-3 in. w.c. 2 psig 616-10 0-30 psid 58 psig
616-2 0-6 in. w.c. 5 psig 616-11 0-50 psid 150 psig
616-3 0-10 in. w.c. 5 psig 616-12 0-100 psid 150 psig
616-4 0-20 in. w.c. 11 psig 616-3B 1.5-0-1.5 in. w.c. 2 psig
616-5 0-40 in. w.c. 11 psig 616-6B 3-0-3 in. w.c. 5 psig
616-6 0-100 in. w.c. 29 psig 616-10B 5-0-5 in. w.c. 5 psig
616-7 0-200 in. w.c. 29 psig 616-20B 10-0-10 in. w.c. 11 psig

*All models available with 0.25% F.S. Accuracy.

Models available with 1.0% F.S. Accuracy include 616-1 through 616-20B.

DWYER INSTRUMENTS, INC.

Phone: [phone] www.dwyer-inst.com

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. Fax: [phone] e-mail: [e-mail]

Installation

POWER
SUPPLY

10-35 VDC

PRESSURE

TRANSMITTER

Jumper
Wire

Receiver

1.0 Location

Select a clean, dry mounting location free from excess vibration where
the temperature will remain between 20 and 120˚F (-6.7 and 48.9˚C).
Distance from the receiver is limited only by total loop resistance. See
Electrical Connections below. The tubing supplying pressure to the
instrument can be practically any length required, but long lengths will
increase response time slightly.

2. Position

A vertical position, with pressure connections pointing down, is
recommended. That is the position in which all standard models are
spanned and zeroed at the factory. They can be used at other angles, but
final spanning and zeroing must be done while transmitter is in that
alternate position.

Pressure Connections

Two integral barbed tubing connections are provided. They are dual­sized to fit both 1/8˝ and 3/16˝ (3.12 and 4.76 mm) I.D. tubing. Be sure
the pressure rating of the tubing exceeds that of the operating ranges.
On ranges over 20 psi, we recommend use of a suitable hose clamp to
assure the integrity of the connection.

Electrical Connections

CAUTION: Do not exceed specified supply voltage ratings.
Permanent damage not covered by warranty will result. This unit is
not designed for 120 or 240 volts AC line operation.

Electrical connections are made to the terminal block located on the top
of the transmitter. Terminals are marked 1, 2, 3 and 4 (see Fig. B below).
Determine which of the following circuit drawings applies to your
application and wire accordingly.

2-Wire Operation

An external power supply delivering 10-35 VDC with minimum current
capability of 40 mA DC (per transmitter) must be used to power the
control loop. See Fig. C for connection of the power supply, transmitter
and receiver. Note the jumper between terminals 3 and 4. The range of
appropriate receiver load resistance (RL) for the DC power supply voltage
available is expressed by the formula and graph in Fig. F. Shielded two
wire cable is recommended for control loop wiring. If grounding is
required, use the negative side of the control loop after the receiver.
Otherwise, in 2-wire operation it is not necessary to observe polarity of
control loop connections.

2-Wire Connections

Figure C

3-Wire Operation

An external power supply delivering 10-35 VDC with minimum current
capability of 40 mA DC (per transmitter) is required. See Fig. D for
connection of power supply, transmitter and receiver. The range of
appropriate receiver load resistance (RL) for the DC power supply
available is expressed by the formula and graph in Fig. F. Shielded cable
is recommended for control loop wiring. Do not employ a separate
ground in 3-wire operation. Unit will not function properly and/or damage
could result. Control loop polarity must be observed in the following
respect. Although power supply terminals 1 and 2 are not polarized, the
receiver must be connected between terminal 3 of transmitter and
negative side of power supply.

SPAN AND

ZERO ADJUST

1 2 3 4

HI LO

Figure B

Wire Length

The maximum length of wire connecting transmitter and receiver is a
function of wire size and receiver resistance. Wiring should not contribute
more than 10% of the receiver resistance to total loop resistance. For
extremely long runs (over 1000 feet), choose receivers with higher
resistance to minimize size and cost of connecting leads. Where wiring
length is under 100 feet, hook-up wire as small as 22 AWG can be used.

3-Wire Connections

PRESSURE

TRANSMITTER

Receiver

mA

POWER
SUPPLY

10-35 VDC

Figure D

4-Wire Operation

An external power supply delivering 10-35 VDC with a minimum current
capability of 40 mA DC (per transmitter) or 16-26 VAC with a minimum
current capability of 80 mA AC (per transmitter) is required. See Fig. E
for connection of power supply, transmitter and receiver. The range of
appropriate load resistance (RL) for the DC or AC power supply available
is expressed by the formulas and graphs in Fig’s. F and G. Shielded
cable is recommended for control loop wiring. Do not employ a separate
ground in 4-wire operation. Unit will not function properly and/or damage
could result. Control loop polarity must be observed; terminal 3 is
negative and terminal 4 is positive.

PRESSURE

TRANSMITTER

POWER
SUPPLY

10-35 VDC

VDC

PRESSURE

TRANSMITTER

4-Wire Connections

Receiver

mA

Figure E

Power Supply Voltage – VDC (2, 3 or 4-wire)

POWER

SUPPLY
10-35 VDC
16-26 VAC

1. With the transmitter connected to the companion receiver, insert an
accurate milliameter in series with the current loop. Full scale range
should be approximately 30 mA.

2. Connect a controllable pressure source to one leg of a tee with the
other two legs connected to the high pressure port of the transmitter and
the third leg to an accurate test gage or manometer, in an appropriate
range. The low pressure port should be vented to atmosphere.
Calibration must be performed with the unit in the same position in which
it will be mounted.

3. Apply electrical power to the unit and allow it to stabilize for 10
minutes.

1500
1400
1300
1200
1100
1000

R Max. =

900

L

800
700
600
500
400
300

Total Receiver Resistance (W)

200
100

50

0 5 10 13 15 20 25 30 35 40

Maximum Value (1250 W)

Vps–10.0

20mA DC

Operating

Region

Figure F

Power Supply Voltage – VAC (4-Wire)

1300

1200

1100

1000

900

800

700

Total Receiver Resistance (W)

600

0 5 10 15 16

Maximum Value (1200 W)

R Max. = 65 (Vps)-490

L

Operating

Region

18 20 25 26 30

Figure G

4. With no pressure applied to the transmitter, adjust ZERO control so

that loop current is 4 mA.

5. Apply full range pressure and adjust loop current to 20 mA using SPAN
control.

6. Relieve pressure and allow transmitter to stabilize for 2 minutes.

7. Zero and span controls are slightly interactive, so repeat steps 4

through 6 until zero and full range pressures consistently produce
currents of 4 and 20 mA respectively.

8. Remove the milliameter from the current loop and proceed with final
installation of the transmitter and receiver.

Voltage Input

Series 616 Transmitters can be easily adapted for receivers requiring 1­5 or 2-10 VDC inputs. Insert a 249 ohm, 1/2 watt (1-5 VDC) or 499 ohm
(2-10 VDC) resistor in series with the current loop but in parallel with the
receiver input. Locate this resistor as close as possible to the input.
Because resistor accuracy directly influences output signal accuracy, we
recommend use of a precision ±0.1% tolerance resistor to minimize this
effect. See Fig. H and J below.

3-Wire Connection (1-5 or 2-10 VDC Output)

Figure H

Calibration Check

Each Series 616 Transmitter is factory calibrated to the range given in
the model chart. To check calibration and adjust if necessary, the
following procedure should be used. For purposes of clarification in these
instructions, range is defined as that pressure which, applied to the
transmitter, produces 20 milliamps of current in the loop. Zero pressure
is always assumed to be 4 milliamps.

4-Wire Connection (1-5 or 2-10 VDC Output)

PRESSURE

TRANSMITTER

VDC

POWER

SUPPLY
10-35 VDC
16-26 VAC

Figure J

Multiple Receiver Installation

An advantage of the standard 4-20 mA DC output signal produced by the
Series 616 Transmitter is that any number of receivers can be connected
in series in the current loop. Thus, an A-701 Digital Readout, an analog
panel meter, a chart recorder, process controlling equipment or any
combination of these devices can be operated simultaneously. The only
requirement is that each component be equipped for a standard 4-20 mA
input and the proper polarity of the input connections be observed when
inserting the device in the current loop. If any of the units display a
negative or downscale reading, the signal input leads are reversed.

Maintenance

Upon final installation of the Series 616 Differential Pressure Transmitter
and the companion receiver, including the A-701 Digital Readout, no
routine maintenance is required. A periodic check of the system
calibration is recommended following the procedures explained on page
3 under Calibration Check. The Series 616 Transmitter is not field
serviceable and should be returned, freight prepaid, to the factory if
repair is required. Please enclose a description of the problems
encountered plus any available application information. The A-701
should be returned directly to its manufacturer for service. See the A-701
instructions for address.

©Copyright 2010 Dwyer Instruments, Inc.

DWYER INSTRUMENTS, INC.

Printed in U.S.A. 5/10

Phone: [phone] www.dwyer-inst.com

FR# 01-440886-00 Rev. 5

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. Fax: [phone] e-mail: [e-mail]