BA-KDS/GER/2010-REV1
HYDROPA
®
is a registered trademark of HYDROPA Hydraulische
Erzeugnisse GmbH & Cie. KG.
BA-KDS/GB/2017-REV2
Operating Manual / Piston Pressure Switch
Contents
1
General information ....................................................................................................... 3
1.1 For operating personnel ................................................................................................... 3
1.2 Liability .............................................................................................................................. 3
1.3 For improved understanding of this manual ..................................................................... 3
2 Safety ............................................................................................................................... 4
2.1 Correct use ....................................................................................................................... 4
2.2 Qualifications of personnel ............................................................................................... 4
2.3 Basic safety instructions ................................................................................................... 4
2.3.1 General information .......................................................................................................... 4
2.3.2 During installation ............................................................................................................. 4
2.3.3 Instructions relating to electrical connection .................................................................... 5
2.3.4 Maintenance ..................................................................................................................... 5
2.3.5 Cleaning ........................................................................................................................... 5
2.3.6 Instructions relating to environmental damage ................................................................ 5
2.3.7 Disposal ............................................................................................................................ 5
3 Structure and function ................................................................................................... 6
3.1 Structure ........................................................................................................................... 6
3.2 Function ............................................................................................................................ 6
3.3 Adjusting elements ........................................................................................................... 6
3.4 Rating plate ....................................................................................................................... 7
4 Transportation and storage ........................................................................................... 8
4.1 Transportation .................................................................................................................. 8
4.1.1 Instructions relating to transportation ............................................................................... 8
4.1.2 Dimensional and weight specifications ............................................................................ 8
4.2 Storage ............................................................................................................................. 8
5 Technical data ................................................................................................................. 9
6 Installation ..................................................................................................................... 10
6.1 General information ........................................................................................................ 10
6.2 Prior to installation .......................................................................................................... 10
6.2.1 Required installation material and auxiliary equipment .................................................. 10
6.2.2 Required tools ................................................................................................................ 10
6.3 Installing the pressure switch ......................................................................................... 10
6.3.1 Standard G1/4“ internal thread version (DS-3** / DS-4** series) ................................... 11
6.3.2 Standard G1/4“ internal thread version (DS-11* / DS-5** series) .................................. 11
6.3.3 Flange version ................................................................................................................ 11
6.3.4 Flange version with intermediate plate (PZ-***) ............................................................. 12
6.3.5 Flange version with 90° elbow connection plate ............................................................ 12
6.3.6 Panel installation version ............................................................................................... 12
6.4 Electrical connection ....................................................................................................... 13
6.4.1 Connecting the pressure switch ..................................................................................... 13
6.4.2 Terminal assignment ...................................................................................................... 13
6.4.3 Earthing the pressure switch .......................................................................................... 13
6.4.4 Cable socket ................................................................................................................... 14
6.4.5 Contact protection .......................................................................................................... 14
BA-KDS/GB/2017-REV2
1
Operating Manual / Piston Pressure Switch
7 Commissioning ............................................................................................................. 15
7.1 Operation ........................................................................................................................ 15
7.1.1 Switching point setting (by manufacturer, only on request)............................................ 15
7.1.2 Switching point setting for rising pressure (by customer) ............................................... 15
7.1.3 Switching point setting for failing pressure (by customer) .............................................. 15
8 Dismantling, replacement and decommissioning ..................................................... 16
8.1 Dismantling ..................................................................................................................... 16
8.2 Replacement ................................................................................................................... 16
8.3 Spare parts ...................................................................................................................... 16
8.4 Decommissioning ............................................................................................................ 16
8.5 Disposal .......................................................................................................................... 16
8.6 Troubleshooting .............................................................................................................. 17
9 EC Declaration of Conformity ...................................................................................... 17
2
BA-KDS/GB/2017-REV2
Operating Manual / Piston Pressure Switch
1 General information
For operating personnel
1.1
This operating manual provides you with information on the safety, structure, function and
operation of the pressure switch.
If heeded carefully, the manual will ensure long and reliable operation free of malfunctions.
Applicable documents
EC Declaration of Conformity (see appendix)
1.2 Liability
Any liability on the part of HYDROPA
the event of damages resulting from incorrect use and unilateral interventions not foreseen in this
operating manual.
Please refer to the HYDROPA
material defects.
Unilateral structural changes to the pressure switch are not permitted for reasons of safety.
1.3 For imp roved understanding of this manual
®
with regard to defects and liability claims is rendered void in
®
General Business Terms and Conditions for details of liability for
DANGER
This hazard warning label indicates an immediate and major hazard which will
definitely result in severe injuries or even fatalities if the hazard is not avoided.
WARNING
This hazard warning label indicates a potential hazard which can result in severe
injuries or even fatalities if the hazard is not avoided.
CAUTION
This hazard warning label indicates a potentially hazardous situation which can
result in medium or light injuries or material damage if it is not avoided.
NOTE
This label indicates helpful information.
(Cross-references are indicated with italics.)
BA-KDS/GB/2017-REV2
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BA-K
S/GB/2017-
EV2
5
Operating Manual / Piston Pressure Switch
3 Structure and function
3.1 Structure
The piston pressure switch fundamentally consists
of the following components:
(1) Housing
(2) Microswitch
(3) Adjusting element
(4) Compression spring
(5) Spring plate
(6) Piston
(7) Nozzle
Function
3.2
The pressure switch functions on the basis of
the piston-spring principle. The microswitch (2)
is actuated if the pressure lies below the
configured value. The piston (6) acts against
the spring plate (5) when pressure builds up.
This braces itself against the continuouslyadjustable compression spring (4). The piston
(6) transfers the force onto the spring plate (5)
when the configured pressure is reached on
the nozzle (7), enabling the microswitch (2)
and triggering an electrical signal. The
pressure to be monitored is determined by the
preload tension of the spring (4). Adjustment is
achieved by turning the adjusting element (3).
Anticlockwise rotation reduces the switching
pressure, while turning in a clockwise direction
increases the switching pressure. The
adjusting element (3) is fixed with the securing
screw and fixing cover. A mechanical stop
prevents the compression spring (4) from
seizing due to excessive turning.
6
3.3 Adjusting elements
Three adjusting elements can be selected for
setting the pressure.
The adjusting screw cover
•
The adjusting knurl with scale
•
The lockable adjusting knurl with scale
•
(except for DS-11* series)
BA-KDS/GB/2017-REV2
Operating Manual / Piston Pressure Switch
3.4 Rating plate
The rating plate is affixed to the pressure switch housing.
Field
Field designation Customer specifications
no.
1 Type key e.g.: DS 307
2 Switching pressure
e.g.: PV = 10-100 bar
range
3 Max. operating
e.g.: Pmax = 400 bar
pressure
4 Pressure default e.g.: Pfix = 70 bar
5 Electrical connection e.g.: max. .24V DC 5A
max. 250V AC 5A
6 Switch symbol e.g.: DS 302 DS 307
NOTE
Please state the order number in the event of malfunctions, when ordering
spare parts and prior to calling our customer service department.
BA-KDS/GB/2017-REV2
7
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Switch
Transp
4.1 Tr
4.1.1
General
4.1.2
Dimensio
pressure
4.2 St
The pres
following
•
•
•
In
Di
CAUTI
Do not
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afety instru
ensional
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witch.
N
Impact
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ure switch
riteria:
store in the
against risi
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store unde
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sportation.
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NOTE
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HYDR
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should be
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r periods lo
storage.
ger than si
BA
8
KDS/GB/201
7-REV2
Operating Manual / Piston Pressure Switch
Technical data
5
Technical data is contained in the data sheet for the respective pressure switch and on the rating
plate.
BA-KDS/GB/2017-REV2
9
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erating Ma
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n Pressure
Switch
Install
6.1 Ge
DANG
6.2 Pri
Extrem
functio
Condu
6.2.1
Fixing
(diamet
1)
A torqu
be underst
tightening
6.2.2
Only com
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R of injur
It is im
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r in mm)
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ightly oiled.
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ues. See VDI
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4.2
ening torque
alculation of
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6.3 Ins
DANG
WARNI
NOTE
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switch
rial dama
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ly permitte
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pressure
ing of temp
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lation and o
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in plants in
al data or r
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pressure p
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age.
n environm
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-energized
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to
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ound in the
BA
10
KDS/GB/201
7-REV2
D
3Ththa
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6.
.1
Stand
e standard
t the instal
(s
e Fig. 1). F
th
unit plug (
parately) (s
T
hreaded flange A/F
6.
.2
Stand
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talling the
ectly on th
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ation span
xing option
ee Fig. 2)
e Fig. 3).
7
Fig.
1:
rd G1/4“ i
n spanner
S-5** seri
housing w
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ternal thr
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er (A/F 27)
are provid
r Ø5.5mm t
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ternal thr
A/F 24) sh
s (see Fig.
en installin
e Fig. 5).
ead versi
ion can be
is only app
d by two M
rough-hole
F
g. 2:
ead versi
ould also o
4). The in
g the DS-1
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mounted dir
lied to the t
x10mm dee
in conjunc
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ly be appl
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ating Manu
DS-4** se
ctly on a pi
readed fla
p threaded
ion with an
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Fig
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nner (A/F
ing option
al / Piston
ries)
e connecti
ge during i
oles locate
dapter plat
mm
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ries)
hreaded fla
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stallation
opposite
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360° rotateable
ge when
e applied
d by two
itch
Threaded flange A/
6.
.3
Flang
the pressu
in
the case of
mi
ssing or da
F24
Fi
. 4:
version
e switch to
low pressur
aged durin
he flange p
ranges an
installation
ovided usin
normal op
.
Ø5.3m
Fi
two or four
rating condi
. 5:
screws. Tw
ions. Ensur
screws ar
e that the o-
sufficient
ring is not
BA-K
S/GB/2017-
EV2
11
O
p
6
a
e
a
o
G
o
a
d
*
°
e
n
*
n
p
a
-
s
f
erating Ma
6.3.4
Fl
The flang
NG6 (PZ-
6.3.5
Fl
nual / Pisto
nge versi
version ca
6/1/**) or N
nge versi
n Pressure
n with int
n be used in
10 (PZ-10/
n with 90
Switch
rmediate
conjunction
*) sandwich
elbow co
plate (PZ-
with an inte
arrangeme
nection
**)
mediate pl
ts.
late
te (ordered
eparately)
or
6.3.6
Pa
nel install
tion versi
M5x10mm
on
eep
Switch pa
Ø3
nel cutout
mm
BA
12
KDS/GB/201
7-REV2
D
D
4Thcoop
twit
b
4Th
o
o
rTer
4
n
R
f
u
b
d
t
n
g
n
s
t
r
n
r
n
n
e
c
c
c
o
p
g
.
w
h
c
p
a
m
i
p
p
s
w
P
a
e
w
r
o
a
o
u
u
h
e
s
t
c
w
q
e
r
t
y
o
c
w
h
e
r
o
d
g
s
e
1
u
n
d
s
p
e
e
a
a
k
e
c
o
b
r
s
n
g
P
c
a
c
s
a
1
p
p
w
Ope
ating Manu
al / Piston
ressure S
itch
6.
4 Electric
ANGER o
6.
.1
Conne
e electrical
mpliance wi
erating reg
sh
ould be o
in
roducing an
h regulatio
sh
ort circuitin
O
serve the 5
al conne
hazardou
Electrical w
worker.
cting the
connection
th prevailin
lations (e.g
served. Po
screwing t
s to conne
and interru
electrical s
tion
s electric
rk should b
ressure s
should be
safety and
for cable c
er supply
e connecti
tion termin
tions.
fety rules:
-
Disc
-
Sec
-
Ens
-
Eart
Cov
-
part
l voltage!
entrusted
itch
established
accident p
ross-section
conforming
n cable tha
ls. Ensure
5 Safet
nnect
re against rea
re that the unit
and short circ
r or cordon off
.
xclusively t
by a skille
evention re
, fuse prot
to EN 50
cable cond
that the co
Rules
tivation
is de-energize
uit
adjacent energ
a trained s
electrical
ulations. P
ction, prote
78, SELV,
ctors are c
nection ca
ized
killed electri
engineering
rtinent inst
ctive earth
PELV. En
nnected in
le is not be
al
worker in
llation and
onnection)
ure when
ccordance
nt to avoid
6.
e pressure
m
del type A
c
nnection op
Te
minals 1-2: co
minals 1-3: co
6.
E
sure that th
.2
.3
Termi
Earthi
al assign
witch is del
.
Please refe
ions.
tact breaks if
tact makes if
g the pre
pressure s
ent
vered from
r to the tec
ressure rises
ressure rises
sure swit
itch is ade
he factory
hnical data
h
uately eart
ith a cable
for the res
T
T
ed:
ocket confo
ective pres
rminals 1-3: co
rminals 1-2: co
ming to
EN
sure switch
ntact breaks if
ntact makes if
75301-803,
for further
ressure rises
ressure rises
The prote
electrical
tive earth (
onnection.
E ) should
be connect
d in compli
nce with re
ulations for
the
BA-K
S/GB/2017-
EV2
13
O
p
a
o
o
a
a
e
t
e
e
2
e
s
g
p
e
r
e
e
r
e
A
k
n
n
r
s
5
s
m
5
s
m
3
s
m
0
s
m
p
d
s
e
e
h
d
a
-
a
a
o
e
w
o
v
erating Ma
6.4.4
nual / Pisto
ble socke
C
n Pressure
Switch
Cabl
socket confo
-
for cable diamet
-
torque for fixing
Cabl
socket confo
-
for cable diamet
torque for fixing
-
Cab
le socket with
-
for 12 to 220V
ordering add-on
-
-
torque for fixing
Cab
le socket with
-
with LED/lamps
ordering add-on
-
-
torque for fixing
ming to EN 17
r Ø6-8mm
crew (M3) 0.4N
ming to EN 17
r Ø8-10mm
crew (M3) 0.4N
LED function
C/DC connection
DS-307/LED34-
crew (M3) 0.4N
LED function
insert for 24V, 12
DS-307/L-MP24-
crew (M3) 0.4N
301-803, mod
301-803, mod
display
voltages
50
display
0V or 220V
350 and DS-307/
l type A, PG9
l type A, PG11
L-MP220-350
6.4.5
The micr
order to
occur, a
to suit th
C
ntact prot
switches u
void dama
ppropriate
operational
M1
x1 cable soc
-
only available o
axial or 90° angl
-
et, 4-pole
request
ed version
ction
ed are des
e to the co
rotective ci
case in que
igned for o
tacts cause
cuit (spark
tion.
eration wit
d by any in
uppression
both direct
uctive, cap
or current li
and altern
citive and l
mitation) sh
ting voltag
mp loads
uld be pro
. In
hich
ided
BA
14
KDS/GB/201
7-REV2
D
o
W
.
e
p
.
L
R
N
T
R
.
L
Rto
N
T
R
R
TcTwT
c
g
e
g
x
e
h
u
i
g
x
p
e
h
u
i
j
n
e
a
r
t
e
t
x
s
r
o
f
c
t
x
s
s
e
r
o
f
c
s
o
r
h
s
x
w
l
o
a
r
i
x
w
l
y
a
r
S
m
p
a
e
e
u
f
e
s
w
e
s
f
b
v
w
e
r
l
n
n
a
s
f
a
s
e
o
h
p
f
a
s
h
o
h
p
a
e
e
d
p
i
a
n
s
n
e
t
s
a
n
o
c
n
e
t
S
e
P
e
o
r
a
w
t
Ope
ating Manu
al / Piston
ressure S
itch
7 C
mmissio
ARNING o
7.1
Operatio
7.1
1
Swit chi n
Th
switching
sti
ulated on th
7.1
2
Swit chi n
1.
oosen the fi
2.
egulate the
3.
ow increas
d
esired switc
s
teps 2 to 3
ning
f risk of in
he correct
ommissioni
he pressur
ho have re
he pressu
ompare the
n
point se
points are
rating plat
point se
ing screw/fi
system pre
the system
ing pressu
ntil the micr
ury and m
pressure
aterial da
witch instal
age
lation shou
d be insp
cted prior
o initial
g.
switch sh
d and unde
e switch s
technical da
uld only be
stood the o
ould only
ta in the dat
commissio
erating ma
be operate
sheet in th
ed by train
ual.
within s
is respect).
ed skilled p
ecifications
rsonnel
(please
ting (by m
set by the
with Pfix.
ting for ri
ing cover
sure to a va
pressure sl
e. Correct if
switch trigg
anufactur
manufactur
ing press
ith the aid o
lue clearly b
wly and ob
necessary
ers at the d
r, only on
r to the v
re (by cu
a hexagon
low the de
erve wheth
ith the aid
sired switc
request)
lues specif
tomer)
l socket sp
ired switchi
r the micro
f the adjusti
ing pressur
ied in the
nner.
g pressure.
witch trigge
g element.
.
rder and
s at the
Repeat
4.
hen fix the f
eadjustmen
7.1
3
Swit chi n
1.
oosen the fi
2.
egulate the
the max. o
3.
ow lower th
d
esired switc
s
teps 2 to 3
4.
hen fix the f
eadjustmen
Step 1
xing screw/
t may be ne
point se
ing screw/fi
system pre
erating pre
system pr
ing pressu
ntil the micr
xing screw/
t may be ne
ixing cover
essary afte
ting for fa
ing cover
sure to a va
sure of the
ssure slowl
e. Correct if
switch trigg
ixing cover
essary afte
nd check th
fixing.
Step 2-3
ling pres
ith the aid o
lue clearly a
respective p
and obser
necessary
ers at the d
nd check th
fixing.
e switching
ure (by cu
a hexagon
ove the de
ressure swit
e whether t
ith the aid
sired switc
e switching
ressure set
tomer)
l socket sp
ired switchi
h at the m
e microswit
f the adjusti
ing pressur
ressure set
ting again.
tep 4
nner.
g pressure,
st.
ch triggers
g element.
.
ting again.
but only
t the
Repeat
Step 1
BA-K
S/GB/2017-
EV2
Step 2-3
St
p 4
15
Operating Manual / Piston Pressure Switch
8 Dismantling, replacement and decommissioning
8.1 Dismantling
DANGER of injury and material and environmental damage
It is imperative that the safety instructions in chapter “X2X XSafetyX“ on page 4 are
observed.
The following points should be realised prior to dismantling for reasons of safety:
Deactivate the pressure switch and disconnect from the power supply network.
No cables, connections or components should be loosened as long as the plant is energized.
Loads on the plant should be lowered in advance, pressure accumulators, etc. relieved of
pressure, pumps deactivated and secured against reactivation. General safety regulations
should be observed (see chapter “
8.2 Replacement
The pressure switch to be used should exhibit the same parameters as the pressure switch to be
replaced.
8.3 Spare parts
Spare parts can be ordered on the basis of the parts list or rating plate.
X2X XSafety” on page X4X ").
The order should be forwarded to the following address, stipulating the order number:
HYDROPA
®
Därmannsbusch 4
D-58456 Witten (Herbede)
Telephone (0 23 02) 70 12-0
Fax (0 23 02) 70 12-47
Internet: www.hydropa.de
E-mail: info@hydropa.de
8.4 Decommissioning
The following should be observed when decommissioning the pressure switch:
Dismantling work should only be entrusted to a trained skilled electrical worker (see section
X2.2X XQualifikation des PersonalsX on page X4X);
“
8.5 Disposal
Thoughtless disposal of the pressure switch can lead to environmental pollution.
Residues on the pressure switch can, depending on the medium used, pose a danger to skilled
personnel and the environment. Appropriate safety measures should be taken where necessary
and the pressure switch disposed of correctly.
DISPOSAL
16
Dispose of the pressure switch in a professional manner in compliance with the
national regulations of your country.
The component should not be disposed of with household waste.
BA-KDS/GB/2017-REV2
Operating Manual / Piston Pressure Switch
8.6 Troubleshooting
Error Possible cause Error detection / Remedy
No signal from pressure
switch
No signal from pressure
switch, or pending signal
does not drop off
No signal from pressure
switch, or pending signal
does not drop off
No signal from pressure
switch, or pending signal
does not drop off
Switching point
displacement
Pressure switch oily Internal leakage flows
Pressure switch exhibits
leaks on connection
thread
No power supply Check power supply (skilled electrical worker)
Check with the aid of a measuring device whether a
Defective microswitch
Mechanical defect
(e.g. piston)
Adjusting element
unscrewed too far
Material wear (compression
spring)
Mechanical damage
switching cycle occurs during pressure change
between the contacts on the pressure switch (skilled
electrical worker)
Check with the aid of a measuring device whether a
switching cycle occurs during pressure change
between the contacts on the pressure switch (skilled
electrical worker)
Screw in the adjusting element somewhat and
check the switching point
Readjust the switching point (see chapter “7
Commissioning” on page 15)
Remove the pressure switch as described in chapter
“8 Dismantling” and forward it for inspection
Remove the pressure switch as described in chapter
“8 Dismantling” and forward it for inspection
9 EC Declaration of Conformity
The unit delivered meets legal requirements. Directives, harmonised standards and documents
applied are listed in the EC Declaration of Conformity valid for the product. The operational
reliability and safety of the unit is also confirmed by the CE symbol on the rating plate
BA-KDS/GB/2017-REV2
17
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