Mechanical pressure switches Liquids and gases 40 DCM/DNM Pressure switches and pressure monitors for overpressure This universal pressure switch can be used in general mechanical engineering and the printing machine industry, as well as in pneumatics and hydraulics. SIL 2 according IEC 61508-2 DCM25 Technical data Pressure connection External thread G 1/2 (pressure gauge connection) according to DIN 16 288 and internal thread G 1/4 according to ISO 228 Part 1. Switching device Robust housing (200) made of seawaterresistant diecast aluminium GD Al Si 12. Protection class IP 54, in vertical position. Pressure sensor materials DNM025...DCM63 Metal bellows: 1.4571 Sensor housing: 1.4104 DCM025 - DCM 1 Metal bellows: Cu Sensor housing: Cu + Ms DCM4016/ Diaphragm: Perbunan DCM4025 Sensor housing: 1.4301 DCM1000 Diaphragm: Perbunan Sensor housing: Brass Mounting position Vertically upright and horizontal. DCM4016 and 4025 vertically upright. Ambient temp. at switching device -25...+70 C, except: DCM4016, 4025, 1000: -15...+60 C Max. medium temperature The maximum medium temperature at the pressure sensor must not exceed the permitted ambient temperature at the switching device. Temperatures may reach 85C for short periods). Higher medium temperatures are possible provided the above limit values for the switching device are ensured by suitable measures (e.g. siphon). Mounting Directly on the pressure line (pressure gaugeconnection) or on a flat surface with two 4 mm O screws. Switching pressure Adjustable from outside with screwdriver. Switching differential Not adjustable with DCM and types. Adjustable from outside with DCMV types. For values see Product Summary. Contact arrangement Single-pole changeover switch. Switching capacity Normal Type Setting range Switching Max. Materials in- Dimendifferential permissible contact with sioned (mean values) pressure medium drawing Switching differential not adjustable DCM4016 1...16 mbar 2 DCM4025 4...25 mbar 2 DCM1000 10...100 mbar 12 DCM025 0.04...0.25 bar 0.03 DCM06 0.1...0,6 bar 0.04 DCM1 0.2...1,6 bar 0.04 DNM025 0.04...0.25 bar 0.03 DCM506 15...60 mbar 10 DCM3 0.2...2.5 bar 0.1 DCM6 0.5...6 bar 0.15 DCM625 0.5...6 bar 0.25 DCM10 1...10 bar 0,3 DCM16 3...16 bar 0.5 DCM25 4...25 bar 1.0 DCM40 8...40 bar 1.3 DCM63 16...63 bar 2.0 mbar 1 mbar 1 mbar 10 bar 6 bar 6 bar 6 bar 6 mbar 12 bar 16 bar 16 bar 25 bar 25 bar 25 bar 60 bar 60 bar 130 Switching differential adjustable DCMV025 0.04...0.25 bar 0.03...0.4 bar DCMV06 0.1...0.6 bar 0.04...0.5 bar DCMV1 0.2...1.6 bar 0.07...0.55 bar DCMV3 0.2...2.5 bar 0.15...1.5 bar DCMV6 0.5...6 bar 0.25...2.0 bar DCMV625 0.5...6 bar 0.25...2.0 bar DCMV10 1...10 bar 0.5...2.8 bar DCMV16 3...16 bar 0.7...3.5 bar DCMV25 4...25 bar 1.3...6.0 bar DCMV40 8...40 bar 2.6...6.6 bar DCMV63 16...63 bar 3.0...10 bar 6 6 6 16 16 25 25 25 60 60 130 bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar Perbunan + 1.4301 Perbunan + MS Cu + Ms Cu + Ms Cu + Ms page 25 + 26 1 + 11 1 + 10 1 + 14 1 + 15 1 + 12 Sensor housing 1.4104 + Pressure bellow 1.4571 1 + 18 Cu + Ms 1 + 14 Sensor housing 1.4104 + Pressure bellow 1.4571 1 + 17 1 + 16 1 + 18 1 + 17 1 + 16 For smaller pressure ranges see also VCM, DGM, HCD and DPS sheets. For additional functions refer page 30 - 32. Calibration The DCM series is calibrated for falling pressure. This means that the adjustable switching pressure on the scale corresponds to the switching point at falling pressure. The reset point is higher by the amount of the switching differential. (See also page 27, 1. Calibration at lower switching point). 250 VAC 250 VDC 24 VDC (ohm) (ind) (ohm) (ohm) 8A 5A 0.3 A 8A -DCM/DNM see page 65 s Protection Class: IP 54 Diecast aluminium housing IP 54 or IP 65 version also available Wall mounting or directly on the pressure line Switching element (microswitch) Lead sealable setpoint adjustment Pressure switches Technical features / Advantages Pressure transmitters Mechanical pressure switches 19 Thermostats Mechanical pressure switches Technical features/Advantages Stainless steel bellows with internal stop Pressure connection G 1/2" external G 1/4" internal Centring pin Solenoid valves Stainless steel sensor housing Accessories Terminal connection or plug connection to DIN EN175301 Form A Flow monitors Temperature sensors Setting spindle locking element 20 Mechanical pressure switches Definitions Definitions Pressure data Overpressure Pressure over the relevant atmospheric pressure. The reference point is atmospheric pressure. Vacuum Pressure under the relevant atmospheric pressure. The reference point is atmospheric pressure. Absolute pressure Overpressure relative to absolute vacuum. Differential pressure Difference in pressure between 2 pressure measuring points. Relative pressure Overpressure or vacuum relative to atmospheric pressure. Pressure data in all FEMA documents refers to relative pressure. That is to say, it concerns pressure differentials relative to atmospheric pressure. Overpressures have a positive sign, vacuums a negative sign. Permissible working pressure (maximum permissible pressure) The maximum working pressure is defined as the upper limit at which the operation, switching reliability and water tightness are in no way impaired (for values see Product summary). Bursting pressure (test pressure) Type-tested products undergo a pressure test certified by TUV affirming that the bursting pressure reaches at least the values mentioned in the Product summary. During the pressure tests the measuring bellows are permanently deformed, but the pressurized parts do not leak or burst. The bursting pressure is usually a multiple of the permissible working pressure. Setting range Pressure range in which the cutoff pressure can be set with the setting spindle. Pressure units Unit 1 1 1 1 1 bar mbar Pa kPa MPa bar mbar Pa kPa MPa (psi) Ib/m2 1 0.001 10-5 0,01 10 1000 1 0.01 10 104 105 100 1 1000 106 100 0.1 0.001 1 1000 0.1 10-4 10-6 0.001 1 14.5 0.0145 1.45* 10-4 0,145 145 In FEMA documents pressures are stated in bar or mbar. Pressure data for a pressure switchbased on the example of DWR625: Setting range: 0.5-6 bar Perm. working pressure: 20 bar Bursting pressure: >100 bar Important: All pressure data refers to overpressures or vacuums relative to atmospheric pressure. Overpressures have a positive sign, vacuums a negative sign. 21 Definitions Direction of action In principle, any pressure switch can be used for both maximum pressure and minimum pressure monitoring. This excludes pressure limiters, whose direction of action (maximum or minimum) is predefined. The only thing to remember is that the scale reading may deviate by the amount of the switching differential. See example at bottom left: The scale value is 2.8 bar. Maximum pressure monitoring With rising pressure, switching takes place once the preset switching pressure is reached (SP). The reset point (RSP) is lower by the amount of the switching differential. Minimum pressure monitoring With falling pressure, switching takes place once the preset switching pressure is reached (SP). The reset point (RSP) is higher by the amount of the switching differential. Direction of action in vacuum range It is particularly important to define the direction of action in the vacuum range. Rising does not mean a rising vacuum, but rising pressure (as viewed from absolute "0"). "Falling" pressure means a rising vacuum. For example: Vacuum switch set to -0.6 bar falling means: Switching (SP) takes place under falling pressure (rising vacuum) at -0.6 bar. The reset point is higher by the amount of the switching differential (e.g. at -0.55 bar). Setting a pressure switch To define the switching point of a pressure switch exactly, it is necessary to determine the direction of action in addition to the pressure. "Rising" means that switching takes place at the set value when the pressure rises. The reset point is then lower by the amount of the switching differential. "Falling" means exactly the opposite. Pressure transmitters Thermostats Temperature sensors Adjustable switching differential/ calibration In the case of pressure switches with adjustable switching differential, the hysteresis can be set within the specified limits. The switching point (SP) and reset point (RSP) are precisely definable. When setting the pressure switch, the switching differential situation and the type of factory calibration must be taken into account. Some pressure switches (e.g. minimum pressure monitors of the DCM series) are calibrated under "falling" pressure, i.e. switching under falling pressure takes place at the scale value with the switching differential being above it. The device switches back at scale value + switching differential. If the pressure switch is calibrated under rising pressure, switching takes place at the scale value and the device switches back at scale value - switching differential (see direction of action). The calibration method is indicated in the data sheets. Flow monitors The switching differential (hysteresis) is the difference in pressure between the switching point (SP) and the reset point (RSP) of a pressure switch. Switching differential tolerances occur due to tolerances in the microswitches, springs and pressure bellows. Therefore the data in the product summaries always refers to average values. In the case of limiter functions the switching differential has no significance, as one is only interested in the switching point at which cutoff occurs, not the reset point. For a controller function, i. e. in the case of pressure switches used to switch a burner, pump etc. on and off, a pressure switch with an adjustable switching differential should be chosen. The switching frequency of the burner or pump can be varied by changing the switching differential. Solenoid valves Minimum pressure monitoring RSP = SP + xd Switching differential Please note when specifying the setting of a pressure switch: In addition to the switching point it is also necessary to specify the direction of action (falling or rising). Example for selection of a pressure switch: A pump is to be turned on at 2.8 bar and off again at 4.2 bar. Chosen type: DCMV6 according to data sheet DCM. Setting: Scale pointer to 2.8 bar (lower switching point). Switching differential to 1.4 bar (set according to pressure gauge). Cutoff point: 2.8 bar +1.4 bar = 4.2 bar. Accessories Maximum pressure monitoring RSP = SP - xd Pressure switches Mechanical pressure switches Definitions Mechanical pressure switches General description 22 Operating mode The pressure prevailing in the sensor housing (1) acts on the measuring bellows (2). Changes in pressure lead to movements of the measuring bellows (2) which are transmitted via a thrust pin (4) to the connecting bridge (5). The connecting bridge is frictionlessly mounted on hardened points (6). When the pressure rises the connecting bridge (5) moves upwards and operates the microswitch (7). A counter-force is provided by the spring (8), whose pre-tension can be modified by the adjusting screw (9) (switching point adjustment). Turning the setting spindle (9) moves the running nut (10) and modifies the pre-tension of the spring (8). The screw (11) is used to calibrate the microswitch in the factory. The counter pressure spring (12) ensures stable switching behaviour, even at low setting values. 1 2 3 4 5 6 7 = = = = = = = 8 = 9 = 10 = 11 = 12 = Pressure connection Measuring bellows Sensor housing Thrust pin Connecting bridge Pivot points Microswitch or other switching elements Setting spring Setting spindle (switching point adjustment) Running nut (switching point indicator) Microswitch calibration screw (factory calibration) Counter pressure spring Pressure sensors Apart from a few exceptions in the low-pressure range, all pressure sensors have measuring bellows, some made of copper alloy, but the majority of high-quality stainless steel. Measured on the basis of permitted values, the measuring bellows are exposed to a minimal load and perform only a small lifting movement. This results in a long service life with little switching point drift and high operating reliability. Furthermore, the stroke of the bellows is limited by an internal stop so that the forces resulting from the overpressure cannot be transmitted to the switching device. The parts of the sensor in contact with the medium are welded together without filler metals. The sensors contain no seals. Copper bellows, which are used only for low pressure ranges, are soldered to the sensor housing. The sensor housing and all parts of the sensor in contact with the medium can also be made entirely from stainless steel 1.4571 (DNS series). Precise material data can be found in the individual data sheets. Pressure connection The pressure connection on all pressure switches is executed in accordance with DIN 16288 (pressure gauge connection G 1/2A). If desired, the connection can also be made with a G 1/4 internal thread in accordance with ISO 228 Part 1. Maximum screw-in depth on the G 1/4 internal thread = 9 mm. Centring pin In the case of connection to the G 1/2 external thread with seal in the thread (i.e. without the usual stationary seal on the pressure gauge connection), the accompanying centring pin is not needed. Differential pressure switches have 2 pressure connections (max. and min.), each of which are to be connected to a G 1/4 internal thread. ...200 Diecast aluminium GDAISi 12 G 1/2" external thread (pressure gauge connection) and G 1/4" internal thread. 1/4" internal thread for DDCM differential pressure switches Switching function and Floating changeover contact. With rising pressure connection scheme single pole switching (applies only to version from 3-1 to 3-2. with microswitch) 8 A at 250 VAC Switching capacity 5 A at 250 VAC inductive (for microswitches with 8 A at 24 VDC a silver contact) 0.3 A at 250 VDC min. 10 mA, 12 VDC Preferably vertical (see technical data sheet) Mounting position IP 54 Protection class (in vertical position) Plug connection Electrical connection Pg 11 Cabel entry -25 to +70 C (exceptions: Ambient temperature DWAM, DWAMV, SDBAM series -20 to +70 C DGM and FD series: -25 to +60 C DCM4016, 4025, 1000, VCM4156: -15 to +60 C) Switching point Adjustable using the setting spindle (for 300 device: after removing switch housing cover) Hysteresis Adjustable or not adjustable (see Product Summary) Medium temperature Max. 70 C, briefly 85 C Relative humidity 15 to 95 % (non-condensing) Repetition accuracy of switching points Vibration resistance Mechanical durability (pressure sensor) Electronical durability (microswitch) Isolation values Oil and grease-free Terminal connection M 16 x 1.5 -25 to +70 C (exceptions: DWAM, DWAMV, SDBAM series -20 to +70 C DGM and FD series: -25 to +60 C DCM4016, 4025, 1000, VCM4156: -15 to +60 C) Adjustable using the setting spindle once the switch housing cover is removed Adjustable or not adjustable (see Product Summary) Max. 70 C, briefly 85 C 15 to 95 % (non-condensing) Pressure switches Higher medium temperatures are possible provided the above limits for the switching device are ensured by suitable measures (e.g. siphon). All pressure switches can operate under vacuum. This will not damage the device (exception DCM1000). < 1 % of the working range (for pressure ranges > 1 bar). No significant deviations up to 4 g. With sinusoidal pressure application and room temperature, 10 x 106 switching cycles. The expected life depends to a very large extent on the type of pressure application, therefore this figure can serve only as a rough estimate. With pulsating pressure or pressure impacts in hydraulic systems, pressure surge reduction is recommended. 100.000 switching cycles at nominal current 8 A, 250 VAC. A reduced contact load increases the number of possible switching cycles. Overvoltage category III, contamination class 3, reference surge voltage 4000 V. Conformity to DIN VDE 0110 is confirmed. The parts of all pressure switches in contact with the medium are oil and grease-free (except the HCD...and DPS...series). The sensors are hermetically sealed and contain no seals (also see ZF1979, special packing). Solenoid valves Vacuum Diecast aluminium GDAISi 12 G 1/2" external thread (pressure gauge connection) and G 1/4" internal thread. 1/4" internal thread for DDCM differential pressure switches Floating changeover contact. With rising pressure single pole switching from 3-1 to 3-2 3 A at 250 VAC 2 A at 250 VAC inductive 3 A at 24 VDC 0.1 A at 250 VDC min. 2 mA, 24 VDC Vertical IP 65 Accessories Switch housing Pressure connection ...300 Pressure transmitters Valid for all pressure switches of the DCM, DNM, DWAM, DWAMV, SDBAM, VCM, VNM, DNM, DWR, DGM, DNS and DDCM series that have a microswitch. The technical data of type-tested units may differ slightly (please refer to particular type sheet). Standard version Plug connection Terminal connection Thermostats Principal technical data Temperature sensors 23 Flow monitors Mechanical pressure switches Principal technical data Mechanical pressure switches Principal technical data 24 Principal technical data Valid for all pressure of the DCM, VCM, DNM, DWR, DGM, DNS and DDCM series that have a microswitch. The technical data of type-tested units may differ slightly (please refer to particular type sheet). Ex-i-version version (Ex-d) ...500 Switch housing Pressure connection Diecast aluminium GDAISi 12 G 1/2" external thread (pressure gauge connection) and G 1/4" internal thread. 1/4" internal thread for DDCM differential pressure switches Switching function and Floating changeover contact. With rising pressure connection scheme single pole switching (applies only to version from 3-1 to 3-2 with microswitch) max.: 100mA, 24VDC Switching capacity min.: 2mA, 5VDC Mounting position Protection class (in vertical position) Explosion protection Code EC Type Examination Certificate Number Electrical connection Cabel entry Ambient temperature Medium temperature Relative humidity Switching point Hysteresis Vacuum Repetition accuracy of switching points Vibration resistance Mechanical durability (pressure sensor) Electronical durability (microswitch) Isolation values Oil and grease-free ...700 Vertical IP 65 Diecast aluminium GDAISi 12 G 1/2" external thread (pressure gauge connection) and G 1/4" internal thread. 1/4" internal thread for DDCM differential pressure switches Floating changeover contact. With rising pressure single pole switching from 3-1 to 3-2 3 A at 250 VAC 2 A at 250 VAC inductive 3 A at 24 VDC 0.1 A at 250 VDC min. 2 mA, 24 VDC Vertical IP 65 II 1/2G Ex ia IIC T6 Ga/Gb II 1/2D Ex ia IIIC T80 C IBExU12ATEX1040 II 2G Ex d e IIC T6 Gb II 1/2D Ex ta/tb IIIC T80 C Da/Db IBExU12ATEX1040 Terminal connection Terminal connection M 16 x 1.5 M 16 x 1.5 -25 to +60 C (exceptions: -20 to +60 C DWAM, DWAMV, SDBAM series -20 to +60 C DGM and FD series: -25 to +60 C DCM4016, 4025, 1000, VCM4156: -15 to +60 C) Max. 60 C Max. 60 C 15 to 95 % (non-condensing) 15 to 95 % (non-condensing) After removing switch housing cover After removing switch housing cover Not adjustable Not adjustable Higher medium temperatures are possible provided the above limits for the switching device are ensured by suitable measures (e.g. siphon). All pressure switches can operate under vacuum. This will not damage the device. < 1 % of the working range (for pressure ranges > 1 bar). No significant deviations up to 4 g. With sinusoidal pressure application and room temperature, 10 x 106 switching cycles. The expected life depends to a very large extent on the type of pressure application, therefore this figure can serve only as a rough estimate. With pulsating pressure or pressure impacts in hydraulic systems, pressure surge reduction is recommended. 100.000 switching cycles at nominal current 8 A, 250 VAC. A reduced contact load increases the number of possible switching cycles. Overvoltage category III, contamination class 3, reference surge voltage 4000 V. Conformity to DIN VDE 0110 is confirmed. The parts of all pressure switches in contact with the medium are oil and grease-free (except the HCD...and DPS...series). The sensors are hermetically sealed and contain no seals (also see ZF1979, special packing). Dimensioned drawings of switch housings (mm) Housing 200 (plug connection) 2 Housing 300 (terminal connection) 3 Housing 500 (terminal connection Ex-i) 4 Housing 700 (terminal connection Ex-d) 10 11 hex24 Accessories Dimensioned drawings of pressure sensors (mm) Solenoid valves Flow monitors Temperature sensors Thermostats 1 Pressure switches 25 Pressure transmitters echanical pressure switches M Dimensioned drawings echanical pressure switches M Dimensioned drawings 26 Dimensioned drawings of pressure sensors (mm) 12 13 hex22 14 15 hex41 hex22 16 19 hex 20 Dimensioned drawing hex 16 17 18 19 22 24 30 32 21 hex41 In view of tolerances in the characteristics of sensors and springs, and due to friction in the switching kinematics, slight discrepancies between the setting value and the switching point are unavoidable. The pressure switches are therefore calibrated in the factory in such a way that the setpoint adjustment and the actual switching pressure correspond as closely as possible in the middle of the range. Possible deviations are equally distributed on both sides. The device is calibrated either for falling pressure (calibration at lower switching point) or for rising pressure (calibration at higher switching point), depending on the principal application of the type series in question. Where the pressure switch is used at other than the basic calibration, the actual switching point moves relative to the set switching point by the value of the average switching differential. As FEMA pressure switches have very small switching differentials, the customer can ignore this where the switching pressure is set only roughly. If a very precise switching point is needed, this must be calibrated and checked in accordance with normal practice using a pressure gauge. 1. Calibration at lower switching point Setpoint xS corresponds to the lower switching point, the upper switching point xO is higher by the amount of the switching differential xd. 2. Calibration at upper switching point Setpoint xS corresponds to the upper switching point, the lower switching point xU is lower by the amount of the switching differential xd. The chosen calibration type is indicated in the technical data for the relevant type series. Flow monitors Prior to adjustment, the securing pin above the scale must be loosened by not more than 2 turns and retightened after setting. The switching pressure is set via the spindle. The set switching pressure is shown by the scale. To set the switching points accurately it is necessary to use a pressure gauge. Direction of action of setting spindle Clockwise: greater difference Anticlockwise: smaller difference With pressure switches from the DWAMV and DWR...-203 series, the direction of action of the differential screw is reversed. C h a n g i n g t h e s w i t c h i n g d i f f e r e n t i a l (only for switching device with suffix "V", ZF203) By means of setscrew within the spindle. The lower switching point is not changed by the differential adjustment; only the upper switching point is shifted by the differential. One turn of the differential screw changes the switching differential by about 1/4 of the total differential range. The switching differential is the hysteresis, i.e. the difference in pressure between the switching point and the reset point. Solenoid valves Anticlockwise: higher switching pressure Setting switching pressures L e a d s e a l i n g o f s e t t i n g s p i n d l e (for plug connection housing 200 only) The setting spindle for setting the desired value and switching differential can be covered and sealed with sealing parts available as accessories (type designation: P2) consisting of a seal plate and capstan screw. The sealing parts may be fitted subsequently. The painted calibration screws are likewise covered. Accessories Clockwise: lower switching pressure Pressure switches Factory calibration of pressure switches Pressure transmitters Setting instructions Thermostats 27 Temperature sensors echanical pressure switches M Setting instructions 28 Mechanical pressure switches Pressure switch with locking of switching state (reclosing lockout) Pressure switch with switching state locking (reclosing lockout) In the case of limiter functions, the switching state must be retained and locked, and it may be unlocked and the system restarted only after the cause of the safety shutdown has been eliminated. There are two ways of doing this: 1. Mechanical locking inside the pressure switch Instead of a microswitch with automatic reset, limiters contain a "bi-stable" microswitch. If the pressure reaches the value set on the scale, the microswitch trips over and remains in this position. The lock can be released by pressing the unlocking button (identified by a red dot on the scale side of the switching device). The lock can operate with rising or falling pressure, depending on the version. The device can only be unlocked when the pressure has been reduced (or increased) by the amount of the predefined switching differential. When selecting a pressure limiter, it is necessary to distinguish between maximum and minimum pressure monitoring. Ex-d versions cannot be equipped with internal locking. Maximum pressure limitation Minimum pressure limitation Switching and interlocking with rising pressure. Additional function ZF205. Switching and interlocking with falling pressure. Additional function ZF206. Connection of control current circuit to terminals 1 and 3. Connection of control current circuit to terminals 2 and 3. 2. External electrical interlock in the control cabinet (suggested circuits) A pressure monitor (microswitch with automatic reset) can also be used as a limiter if an electrical interlock is added. For pressure limitation in steam and hot water boilers, an external interlock is only permitted if it has been ascertained that the pressure monitor is "of special construction". Maximum pressure limitation with external interlock Minimum pressure limitation with external interlock Where the above lock circuit is used, the requirements of DIN 57 116/VDE 0116 are met if the electrical equipment (such as contactors or relays) of the external interlock circuit satisfy VDE 0660 or VDE 0435. Explanation of type designations - type codes The type designations of FEMA pressure switches consist of a combination of letters followed by a number denoting the setting range. Additional functions and version variants are indicated by an extra code which is separated from the basic type by a hyphen. Ex versions (explosion protection Ex-d) are identified by the prefix "Ex" in front of the type designation. With additional function Ex version DCMXXX-YYY Ex-DCMXXX DCM XXX YYY Ex Series code (e. g. DCM) Codes for pressure range Code for additional function Code for Ex-version Thermostats Basic version (based on the example of DCM series) DCMXXX Switch housing version Which additional function fits with which pressure switch? Terminal connection, 300/500 series Additional function ZF Additional function ZF 203 213 217 DCM/VCM *1 * *1 VNM/DNS/VNS * * * DWAM * DDCM * DWR * * DGM * 1 301 307 513 574 351 576 * *1 * * * * * * * * * * * * * * * except DCM4016, DCM4025, VCM4156 and DCM1000 Combination of several additional functions not possible! Ex versions (Ex-d) can only be supplied in basic form. Additional functions are not possible. 575 577 * * * Solenoid valves Plug connection, 200 series Flow monitors Temperature sensors Basic version with plug connection housing Basic version with plug connection housing Terminal connection housing (300) Ex-d switching device (700) Ex-ia version (500) Accessories DCMXXX DCMXXX-2... DCMXXX-3... Ex-DCMXXX DCMXXX-5... * available Pressure switches 29 Pressure transmitters echanical pressure switches M Explanation of type designations - type codes 30 Mechanical pressure switches Additonal functions/Connecting schemes Pressure switches and pressure monitors Additional functions / Connection schemes Plug connection, 200 series (IP 54) Terminal connection, 300 series (IP 65) Standard version (plug connection) Micro switch, single pole switching, switching differential not adjustable Terminal connection housing (300) ZF301 Unit with adjustable switching differential ZF203 Maximum pressure limiter with reclosing lockout Interlocking with rising pressure see DWR series ZF205 Minimum pressure limiter with reclosing lockout Interlocking with falling pressure see DWR series ZF206 Connection scheme 31 ZF213 Switching capacity: max. 24 VDC, 100 mA, min. 5 VDC, 2 mA The prices shown are additional prices compared to the basic device of the 200 series (plug connection). * Connection schemes for switching schemes, see page 36. Please state interval when ordering! Example for ordering: DCM10-217A-S. Additional text: switching scheme A4 ZF351 Example for ordering: DCM 6 - 205 Code of additional function (e.g. maximum limiter) Code for pressure range Sensor system Flow monitors Switch Housing with surface protection (chemical version) How to order: Pressure switch DCM6-205 or DCM6 with ZF205 Solenoid valves Gold-plated silver contact, single pole switching (not available with adjustable switching differential). Thermostats Two micro switches, 1 plug ZF217 * switching in succession, no adjustable switching differential. State the switching scheme * (not possible with all pressure switches). (See page 34 - 37). Connection scheme selection, see page 36 Temperature sensors ZF307 Accessories Two micro switches, switching in parallel or in succession. Fixed switching differential, only possible with terminal connection housing. State the switching differential (not possible with all pressure switches). (See page 34 + 35). Pressure transmitters Plug connection Terminal connection Connection scheme 200 series (IP 54) 300 series (IP 65) Pressure switches echanical pressure switches M Additonal functions/Connecting schemes Mechanical pressure switches Additonal functions/Connecting schemes 32 Pressure switches and pressure monitors Additional functions for Ex-i-equipment * Housing (500) with terminal connection (IP 65), "blue" cable entry and terminals. * Also available with resistor combination for line break and short-circuit monitoring (with isolating amplifier). ! Important: All pressure switches with the ZF5... additional functions listed here can only be operated in combination with a suitable isolating amplifier. DWAM6-576 i Additional information: Our pressure switches and thermostats are considered to be "simple electrical equipment" within the meaning of standard EN60079-11: 2007. Testing is not mandatory for this type of equipment. i ATEX-Certificate: please see page 10 - 13 Additional functions for Ex-ia-equipment Connection scheme II 1/2G Ex ia IIC T6 Ga/Gb II 1/2D Ex ia IIIC T80 C Gold-plated contact ZF513 single pole switching, fixed hysteresis, not adjustable Switching capacity: max. 24 VDC, 100 mA, min. 5 VDC, 2 mA For the power supply circuit: Ui 24 V DC 100 mA Ii Ci 1 nF 100 H Li Versions with resistor combination for line break and short-circuit monitoring in control current circuit, see DBS series, pages 54 - 56: For Ui Ri Ci Li the power supply circuit: 14 V DC 1500 Ohm 1 nF 100 H Normally closed contact with resistor combination, for minimum pressure monitoring, gold-plated contact, plastic-coated housing (chemical version). ZF574 Normally closed contact with reclosing lockout and resistor combination, for minimum pressure monitoring, plastic-coated housing (chemical version). ZF575 see DBS series pages 54 - 56 Normally closed contact with resistor ZF576 combination, for maximum pressure monitoring, gold-plated contact, plastic-coated housing (chemical version). Normally closed contact with reclosing ZF577 lockout and resistor combination, for maximum pressure monitoring, plastic-coated housing (chemical version). Service functions Devices with service functions will be produced according to the customer's specifications. The system requires that these product combinations are identified in such a way as to prevent any possibility of confusion. These combinations are characterised by a product code with the suffix "-S" on the packaging label as well as separate labels with barcodes for each service function. Plug connection Terminal connection Ex-i/ 200 series Adjustment according to customer's instruction: one switching point ZF1970* two switching points or defined switching differential ZF1972* Adjustment and lead sealing according to customer's instruction: one switching point ZF1971* two switching points or defined switching differential ZF1973* Labelling of units according to customer`s ZF1978 instruction with sticker ZF1979 Special packing for oil and grease-free storage Test reports according to EN 10 204 Certificate 2.2 based on non-specific specimen test WZ2.2 Inspection test certificate 3.1 based on specific test AZ3.1B1 Inspection test certificate for FV separating diaphragms AZ3.1-V 300 series Ex-d ZF1970* ZF1972* ZF1970* - - - - - ZF1978 ZF1978 ZF1979 ZF1979 WZ2.2 AZ3.1B1 AZ3.1-V WZ2.2 AZ3.1B1 AZ3.1-V Thermostats Service functions Pressure switches 33 Pressure transmitters echanical pressure switches M Service functions Included items:Labels with barcodes on the packaging: Pack contents: 1 DCM6 (without "S" suffix) marked DCM6-S 1 ZF1970: set to 4 bar rising ZF1970: set to 4 bar rising 1 ZF1978: PSH008 ZF1978: PSH008 1 AZ3.1 will be sent by extra post AZ3.1B1 1 Installation and operating instructions Flow monitors Example: Ordering 1 DCM6, set at 4 bar rising, identified with code PSH008 as requested by the customer and acceptance test certificate 3.1. The order confirmation contains: 1 DCM6-S ("S" is need for factory = following lines belong to this item) 1 ZF1970: set to 4 bar rising 1 ZF1978: PSH008 1 AZ3.1B1 Solenoid valves Ordering devices with service functions Accessories Service functions are available for the following type series (including Ex versions): Pressure switches: DCM, DNM, DNS, VNS, VCM, VNM, DDCM, DWR, DWAM, DWAMV, SDBAM, DGM, FD Temperature sensors * Switching point adjustment: Please specify switching point and direction of action (rising or falling pressure). 34 Mechanical pressure switches S2 type series S2 type series Pressure switches with 2 microswitches - technical data FEMA pressure switches of the DCM (except DCM1000, DCM4016 and DCM4025), VCM (except VCM4156), VNM, DNS, VNS series can be equipped with 2 microswitches. Technical data Standard equipment The standard equipment of every two-stage pressure switch includes a switching device with 2 microswitches, both single-pole switching. Switch I monitors the low pressure, switch II the higher pressure. The setting ranges indicated in the data sheets for the basic types apply to the two-stage pressure switches as well. It should be noted that the switching differentials of the individual microswitches may not be exactly the same due to component tolerances. The applicable data sheet for the basic types contains the technical data for the two-stage pressure switches. This includes all limits of use, such as temperature, maximum pressure, mounting position, protection class, electrical data etc. The principal dimensions are the same as for single-stage pressure switches with comparable pressure ranges and design features. Additional Switching difference Electrical function between the two connection micro switches Ordering information required Factory setting according to customer's instruction Switching difference fixed Terminal connection (All terminals of both microswitches are accessible (6 terminals) 2 x single-pole switching 1. Basic type with ZF 307 2. S witching points I and II, with direction of action in each case (rising or falling pressure) Example: DCM16-307 Switching point I: 10 bar falling Switching point II: 12 bar falling or switching interval only. ZF217 Adjustable via adjustment knobs I and II in accordance with "Switching difference" table Plug connection in accordance with DIN EN175301 (3-prong + earth conductor) Functionappropriate internal wiring in accordance with "Switching functions" table Example selection in accordance with "Switching schemes" table, page 36. 1. Basic type with ZF217 2. Switching scheme For example: DCM16-217/B 4 Since all values are adjustable within the specified limits, no further data is required. Switching differential The switching differential, i.e. the hysteresis of the individual micro switches, corresponds to the values of the relevant basic version referred to in the Product summary. In the case of two-stage pressure switches, the switching differential of the individual micro switches is not adjustable. Versions Two-stage pressure switches are available in three different versions, each identified by a ZF number. The versions differ in terms of their connection schemes and electrical connection types (terminal or plug connection). Connection diagram ZF307 Switching difference The switching interval of the two microswitches is the difference (in bar or mbar) between the switching points of the two micro switches. Example for ZF307: When the pressure rises (e.g. 2.8 bar), a two-stage pressure switch turns on a warning light, and if the pressure continues to rise (e.g. 3.2 bar) the system shuts down. The switching interval is 3.2-2.8 = 0.4 bar. The following applies to all versions: The switching interval remains constant over the whole setting range of the pressure switch. If the switching pressure setting is changed with the setting spindle, the switching interval does not change - the switching points are moved in parallel. This is not possible with any other type series or with Ex versions. Note on ordering additional function ZF217 Switching scheme Switching device Ordering position Additional text A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 A C C A B D D B B D D B A C C A DCM6-217A-S DCM6-217C-S DCM6-217C-S DCM6-217A-S DCM6-217B-S DCM6-217D-S DCM6-217D-S DCM6-217B-S DCM6-217B-S DCM6-217D-S DCM6-217D-S DCM6-217B-S DCM6-217A-S DCM6-217C-S DCM6-217C-S DCM6-217A-S Switching scheme A1 Switching scheme A2 Switching scheme A3 Switching scheme A4 Switching scheme B1 Switching scheme B2 Switching scheme B3 Switching scheme B4 Switching scheme C1 Switching scheme C2 Switching scheme C3 Switching scheme C4 Switching scheme D1 Switching scheme D2 Switching scheme D3 Switching scheme D4 Switching difference of two-stage pressure switches (ZF217, ZF307) Type series S2 ZF217 ZF307 min. switching difference Type Factory default DCM06 DCM025 DCM1 DCM3 DCM6 DCM10 DCM16 DCM25 DCM40 DCM63 DNM025 VCM095 VCM101 VCM301 VNM111 40 20 40 0.1 0.15 0.25 0.3 0.6 0.9 1.3 35 40 40 20 50 mbar mbar mbar bar bar bar bar bar bar bar mbar mbar mbar mbar mbar Higher pressure Lower pressure max. switching difference (mean values) Switching scheme A1/A3/B2/B4 C1/C3/D2/D4 + ZF307 165 140 240 0.65 0.95 1.6 2.0 4.0 6.0 8.5 215 300 260 100 310 mbar mbar mbar bar bar bar bar bar bar bar mbar mbar mbar mbar mbar Switching scheme A2/A4/C2/C4 190 160 280 0.75 1.2 1.85 2.3 4.6 6.9 9.8 240 340 300 120 360 mbar mbar mbar bar bar bar bar bar bar bar mbar mbar mbar mbar mbar Switching scheme B1/B3/D1/D3 140 120 200 0.55 0.8 1.35 1.7 3.4 5.1 7.2 180 260 220 80 260 mbar mbar mbar bar bar bar bar bar bar bar mbar mbar mbar mbar mbar Pressure switches ZF217 pressure switches with two microswitches and switching difference Pressure transmitters S2 type series (selection) Thermostats 35 Temperature sensors echanical pressure switches M S2 type series Recommended adjustment method for switching devices with ZF217 1. Set adjustment knobs I and II to their basic positions. Turn adjustment knob I anticlockwise as far as possible. Turn adjustment knob II clockwise as far as possible. 2. Adjust the setting spindle S by the scale to a value midway between the desired upper and lower switching points. 3. With pressure applied, set the lower switching point with adjustment knob I. 4. In the same way as in step 3, set the upper switching point with adjustment knob II. 5. If the desired upper and lower switching points cannot be reached, turn the setting spindle S in the appropriate direction and repeat steps 3 and 4. Solenoid valves Adding together the adjustments on knobs I and II results in the switching difference between the two micro switches. Changes made with the setting spindle do not affect the switching difference. The switching difference remains constant over the whole setting range of the spindle. The two switching points are moved up or down in parallel. Accessories Additional function ZF217 On switching devices with additional function ZF217, the switching differene is continuously adjustable via two adjustment knobs I and II accessible from outside. The maximum possible switching difference is stated in the "Switching difference" table. Turning adjustment knob I clockwise produces a lower switching point for microswitch I Turning adjustment knob II anticlockwise produces a higher switching point for microswitch II Adjustment knobs I and II have an internal stop to prevent the micro switches from being adjusted beyond the effective range. Flow monitors Switching devices with adjustable switching difference Mechanical pressure switches S2 type series 36 S2 type series Two-stage pressure switches, switching schemes for ZF217 Function-appropriate internal configuration of microswitches I and II, switching scheme selection table. The switch position shown corresponds to the pressureless state. On the horizontal axis is the switching function of microswitch I (A-D); on the vertical axis is the switching function of microswitch II (1-4). At the intersection is the switching scheme which satisfies both conditions (e.g. A 2). Microswitch I (lower switching point) rising, close falling, open rising, open rising, close falling, open rising, open Microswitch II (upper switching point) falling, close falling, close Information required when ordering: As well as the basic type (e.g. DCM10) and the switching scheme (e.g. A 2), for factory setting it is also necessary to indicate the switching points and direction of action: Example: DCM 10-217C-S, switching scheme: A2, Switch I: 6.5 bar falling, Switch II: 7.5 bar rising. Examples of use for two-stage pressure switches Pressure monitoring and controlling can be greatly simplified by using pressure monitors with two built-in microswitches which can be made to operate one after the other under rising or falling pressure. For example, minimum and maximum pressure monitoring can be achieved with only one pressure switch, doing away with the need for a second pressure switch (including the cost of installation). Step switching, e.g. pressure-dependent control of a two-stage pump, is of course also possible using this special series. For pressure-dependent control of automatic expansion valves and pressure holding devices Example 1: Requirement Pressure holding devices and automatic expansion valves usually have a gas cushion whose pressure must be kept constant within a certain range. If the pressure is too low, a compressor is switched on. If the pressure is too high, a solenoid valve must be opened to vent the gas. Between these two levels is a neutral zone, in which the compressor and the solenoid valve are at rest. Solution All pressure switches of types DCM, DNS, each with additional function ZF217 and switching scheme A 2, are suitable. All pressure ranges listed in the technical documents are possible. Example for ordering: see page 24 Pressure switches S2 type series Pressure transmitters 37 Thermostats echanical pressure switches M S2 type series Solution The first contact of a DCM3-307 pressure switch with 2 microswitches opens under falling pressure at 2.2 bar; the second microswitch opens under rising pressure at 2.6 bar. If the pressure is >2.2 bar or <2.6 bar, the circuit is closed via both microswitches and the signal lamp is lit. Flow monitors Requirement In a process engineering system, the pressure in a nitrogen line has to be monitored. A green signal lamp indicates that the pressure in the line is between 2.2 and 2.6 bar. If the pressure goes below 2.2 bar or above 2.6 bar, the indicator lamp goes out and the system shuts down. Solenoid valves Example 2: Accessories Minimum and maximum pressure monitoring in a nitrogen line Switch II:With rising pressure, contact 2-3 closes (valve open) With falling pressure, contact 2-3 opens (valve closed). In between there is a neutral zone in which the compressor is not switched on and the solenoid coil is not energized (off position). Temperature sensors Switching function / connection scheme Switch I:With falling pressure, contact 1-2 closes (compressor on) With rising pressure, contact 1-2 opens (compressor off) Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Honeywell: DCM1-303 DCM1-301 DCM06-213 DCM1000-351 DCM4025-313 DCM6-351 DCM6-355 DCM3-205 DCM16-351 DCM16-353 DCM506-301 DCM1000-301 DCM6-353 DNM025-213 DCM3-206 DCM1-353 DCM6-305 DCM63213 DCM40-205 DCM6-301 DCM6-303 DCM16-363 DCM6-306 DCM1-351 DNM025 DNM025-301 DCM1-205 DCM6-513 DCMV6-213 DCM625-353 DCM025 DCM025-353 DCM63-313 DCM16-213 DNM025-513 DCM40-513 DCM625-351 DCM025-351 DCM10-313 DCM1-206 DCM4025 DCM16-513 DCMV625 DCM4025-213 DCM06 DCM40-301 DCM025-363 DCM4016-513 DCM6-205 DNM025-351 DCM10-206 DCM40-305 DCM10-205 DNM025-205 DCM6-206 DCM40-306 DCMV63 DCM16-303 DCM4016-351 DCM1000-363 DCM16-301 DCM16305 DCM4016-206 DCM10-363 DCM40-351 DCM10-213 DCM25-303 DCM625-205 DCM25-301 DCM506 DCM3-306 DNM025-313 DCM1-363 DCMV16-213 DCM625 DCM1000-563 DCM63-301 DCM625-206 DCM025563 DCM025-206 DCM025-205 DCM4016 DCM3-303 DCMV10 DCMV16 DCM3-301 DCM63-353 DCM10-563 DCM3-305 DCM1-213 DCM06-301 DCM025-313 DCM10 DCM6-213 DCM16 DCM25-213 DCMV025 DCM3-351 DCM06-513 DCM3-353