Setra 546, 547 Manual

Installation Guide

MODELS 546 / 547

Fluid Measuring Pressure Transducers

560550-0091

Rev A

1-800-257-3872 TOLL FREE
1-978-264-0292 FAX

www.Setra.com Web Site

Setra offers a complete line of

products for these industries:

Industrial

HVAC

Test & Measurement

Barometric

Ultra High Purity / Sanitary

Please Note: The Series 546 / 547 are designed and manufactured in accordance with sound

engineering practice as defined by the Pressure Equipment Directive 97/23/EC. This product must not
be used as a “safety accessory” as defined by the Pressure Equipment Directive, Article 1, Paragraph

2.1.3. The CE Mark on the unit does not relate to the Pressure Equipment Directive.

INTRODUCTION

Series 546/547 are fluid pressure measuring transducers in which a four active arm Wheatstone bridge
of sputtered thin film gauges, integral with a beam structure connected to a pressure summing diaphragm,
is used to convert fluid pressures into a proportional electrical signal. These instruments are suitable for
long, continuous arduous service when operated within the published specifications.

Common integral electronics converts the input from the gauge to a 4-20mA, 2-wire output signal.

Series 546/547 conform with the essential protection requirements of the EMC Directive 89/336/EEC
amended by certified type testing to EN 50082-2 and EN 60081-1.

Conformity with the requirements of the CE mark only applies when the installation
conditions described in these instructions have been met. For units supplied without
a cable assembly connection to the transmitter must be accomplished using Setra
Systems approved cable. see APPROVED CABLE section.

All instruments conform to the appropriate specifications and/or drawings applicable and have been
subjected to relevant strict quality control procedures.

HAZARDOUS PRODUCTS

The Consumer Protection Act of 1987, Section 6 of the Heath and Safety at Work Act 1974 and the
Control of Substances Hazardous to Health Regulations 1988 require that we advise recipients and
users of our products of any potential hazards associated with their storage, handling or use.

The products which our Company supplies may be classified as Electrical, Electro-Mechanical and
Electronic equipment.

These products are tested and supplied in accordance with our published specifications or individual
special requirements that are agreed in writing at time of order. They are constructed so as not to affect
adversely the safety of persons and property when properly installed, maintained and used by qualified
personnel, in the applications for which they were designed and manufactured

ACTION ON RECEIPT

* Check details on Calibration Certificate agree with data etched on transducer body.
* Check accessories supplied include:

Calibration Certificate (or QA Certificate)
Seal, Dowty Bonded
Mating Connector (where applicable)

GENERAL

* Transducer should not be subjected to greater than the maximum allowable pressure

listed on label and the operating temperature specifications. SEE OPERABLE

TEMPERATURE RANGE:
* Transducer should not be subjected to mechanical impact.
* In the event of fire the end user must ensure that the system pressure is vented to a safe

area.
* The effects of decomposition of unstable fluids should be considered by the user when

placing this device in service.
* The pressure transducer has no means of draining or venting, this must be performed by

another component in the end users system.
* Pressure range must be compatible with the maximum pressure being measured.
* Pressure media must be compatible with the transducer wetted parts which are:-

Model 546: Ranges 1 and 1.6 bar, 15 and 30 psi : 15-7 Mo plus 17-4 PH stainless steels
Ranges 2.5 bar and 60 psi and above : 17-4 PH stainless steel

Model 547: All Ranges: Inconel alloy 625
* Exposed end of cable must be kept free from moisture.
* Liquid must not be allowed to freeze in the pressure port.

MECHANICAL INSTALLATION

Pressure Connections: G¼ internal pressure connection to BS2779 as standard. Alternative fitted

as specified at time of order.

Pressure couplings screwed into G¼ pressure ports should have a maximum thread engagement 0.5”
(13mm) and UNDER NO CIRCUMSTANCES be allowed to touch the pressure sensitive
diaphragm. Pressure couplings should be sealed against the outer face at the pressure port entry using
bonded seal washer such as:-

Part Number Description

GA29 G¼ bonded seal up to +100°C operation.
Dowty Ref: 400-021-4490-02
Refer to Dowty for external pressure ratings.

Mounting : Pressure transducer is designed to be attached by the coupling thread only. Omni­directional. To fit, use a 7/8 inch (22.2mm) AF wrench on the hexagon provided and apply maximum
torque of 20 lbf-ft (27Nm). The Customer must ensure that the pressure seal is suitable for the
application. If in doubt contact Setra Systems.

Vibration: Where present, mount in a saddle clamp such as part number GA19 (material:
Polypropylene). Position the clamp as close to the pressure port as practicable.

Effects of Heat: Avoid mounting the transducer near a source of heat which is liable to create a
temperature gradient across the instrument. If this is unavoidable, use a heat shield to deflect uneven
radiated heat or wrap the transducer in glass fibre insulation so that an even temperature is assumed
throughout.

High Temperature Pressure Measurement : Possible using a length of piping or a "syphon" to
isolate the instrument from the hot media. Since there is no flow, the temperature drop along the tubing
is considerable and usually a relatively short length is sufficient to bring the pressure media temperature
within acceptable limits for the instrument. Alternatively a temperature isolator, part number GA33, can
be fitted (G¼ connection only). Pressure media must not be allowed to solidify in the tube and/or
pressure port.

ELECTRICAL INSTALLATION

All types include suppression devices providing transient protection to EN 61000-4-2 and EN 61000­4-4.

For all types conformity with the requirements of the CE mark only applies when
connection is made with Setra Systems approved cable, See APPROVED CABLE
section, and the shield of that cable is connected to a reliable grounding point at the
instrumentation end.

APPROVED CABLES

Setra Systems uses cable comprising 7 color-coded wires, with a central vent tube, enclosed by an
aluminium/polyester screen where the screen is in intimate contact with a separate drain wire. The outer
sheath material is Polyurethane (immersible, +50°C). Other sheath materials available on request for
harsh environments.

OPERATION

Having installed the transducer as instructed it is ready for use. The transducer should not be removed
while the system is at pressure. Before applying power, check that the correct polarity and excitation
levels are being applied. See ELECTRICAL REQUIREMENTS.

OPERABLE TEMPERATURE RANGE

Cable Versions: -4°F to +122°F (-20°C to +50°C)

Connector Versions: -13°F to +185°F (-25°C to +85°C)

Process Media (connector version only): -22°F to +212°F (-30°C to +100°C)

OPERATIONAL LIFE:

Limited to 3 million full scale cycles.

CALIBRATION

Transducers are calibrated to the range requested at time of order.

G - gauge datum vented to atmosphere via the electrical connection
A - absolute datum
S - sealed reference; reference side of the instrument is sealed and the output

electrically adjusted to zero with 14.69 psi (1013mb) applied to pressure port

ADJUSTMENT OF ZERO AND SPAN CONTROLS

Switch and potentiometers provide continuous adjustment over the range 130% to 17% of nominal
pressure range.

Zero and Span controls are precisely set during manufacture and should only need adjustment if there is
a change in the required pressure measurement.

Access to these controls is provided by means of a removable end plate. Remove the 3 retaining screws
using 2.5mm A/F hex wrench and withdraw end plate.

Caution: Care should be taken in withdrawing end plate so as not to disconnect
internal plug.

To maintain sealing integrity ensure end cap ‘O’ ring is correctly seated and clean prior to re-fitting.

RANGE SWITCH DETAILS

Switch Position
(Current Mode)

0 130 to 80% A 36 to 20%
1 102 to 62% B 34 to 19%
2 82 to 49% C 32 to 17%
3 70 to 42% D Not Used
4 61 to 36% E Not Used
5 54 to 32% F Not Used
6 49 to 28%
7 45 to 25%
8 42 to 23%
9 39 to 22%

Downranging

Scope

(Nominal)

Switch Position
(Current Mode)

Downranging

Scope

(Nominal)

LOAD RESISTANCE

The total permissible resistive load in the loop (to include all the cable resistance, and in the I.S. versions
the internal resistance of the Galvanic Isolator) can be from 'zero to 50 x (supply volts -8.5) ohms' e.g.
with a 24V d.c. supply the permissible load is from zero up to 775 ohms (Figure 1).

FIGURE 1

SUPPLY VOLTAGE

Non I.S: 8.5V to 40V d.c.
I.S: 9.5V to 28V d.c.

MAINTENANCE

Routine Inspection: Not required except for periodic inspection of the cable and molding to ensure

that these are neither damaged nor softened by incompatible liquid.

CAUTION

CARE MUST BE TAKEN NOT TO TOUCH THE PRESSURE SENSITIVE
DIAPHRAGM WHILE CLEANING THE PRESSURE PORT. FAILURE TO
OBSERVE THIS PRECAUTION CAN CAUSE IRREPARABLE DAMAGE.

WARRANTY

The Company warrants its products to be free from defects in material and workmanship in normal use
and service for a period of two years from date of shipment. The Company reserves the right and
option to refund the purchase price in lieu of repair or replacement upon evaluation of the returned
original part. Modification, misuse, attempted repair by others, improper installation or operation shall
render this guarantee null and void. The Company makes no warranty of merchantability or fitness for a
part or purpose.

SERVICING

The transducer cannot be repaired locally and if damaged should be returned to Setra Systems with the
following:

1. Name and phone number of person to contact

2. Shipping and billing information

3. Full description of malfunction

4. Remove any pressure fittings and plumbing that you may have installed and enclose any required

mating electrical connectors and wiring diagrams.

Please ship prepaid to Setra Systems at the address shown below or to your local Setra Distributor
when a replacement/repair is required:

United States Outside The United States
Setra Systems Inc Contact your local Setra Distributor
159 Swanson Road
Boxborough. MA 01719
Attn: Repair Department

RETURN TO FACTORY

PLEASE NOTE: To comply with Health and Safety requirements, the instrument must be clean and

safe to handle and accompanied by a formal statement to that effect duly signed by an authorised officer
of the Company.

Any instrument returned without certification will be quarantined and no action will occur until cleared. It
may ultimately be returned to you and subject to a transportation charge.

ELECTRICAL CONNECTION

Wiring

ELECTRICAL CONNECTION

(+) (-) Earth

E2 DIN 1 2 4
B3 10-6 Bayonet A B E
V1 IP68 Cable R BL Drain

UA

Molded Immersible Cable
(up to 200 meters (565 ft)

R BL Drain

159 Swanson Road, Boxborough, MA 01719-1304
Tel: [phone]

OP546/547 Rev A 11/03