07 Elster GmbH Edition 7 Translation from the German 057 D F L I E DK S P GR TR CZ PL RUS H wwwdocuthekcom Operating instructions Pressure switches for gas DGH, DG Pressure switch for gas DGI Cert version 7 Contents Pressure switches for gas DGH, DG Pressure switch for gas DGI Contents Safety Checking the usage Type code Part designations Type label Installation Connection facilities Installing DGH, DG Installing DGI Wiring Adjustment 5 Tightness test 5 Maintenance 5 Accessories 5 Technical data 7 Designed lifetime 7 Logistics 8 Certification 8 Declaration of conformity 8 Contact 8 Safety Please read and keep in a safe place Please read through these instructions carefully before installing or operating Following the installation, pass the instructions on to the operator This unit must be installed and commissioned in accordance with the regulations and standards in force These instructions can also be found at wwwdocuthekcom Explanation of symbols,,, = Action = Instruction Liability We will not be held liable for damage resulting from non-observance of the instructions and non-compliant use Safety instructions Information that is relevant for safety is indicated in the instructions as follows: DAGER Indicates potentially fatal situations WARIG Indicates possible danger to life and limb CAUTIO Indicates possible material damage All interventions may only be carried out by qualified gas technicians Electrical interventions may only be carried out by qualified electricians Conversion, spare parts All technical changes are prohibited Only use OEM spare parts Changes to edition 077 The following chapters have been changed: Installation Technical data Declaration of conformity -
Checking the usage DGH, DG, DGI For monitoring increasing and decreasing gas or air pressure Increasing negative pressure Decreasing negative pressure Increasing pressure Decreasing pressure -6-5 - - - - 0 5 6 Positive pressure egative pressure DGH, DG Gas, air, flue gas Air, flue gas DGI Air, flue gas Gas, air, flue gas DGH switches and locks off with rising pressure, DG switches and locks off with falling pressure They can be unlocked using the manual reset This function is only guaranteed when used within the specified limits see page 7 (Technical data) Any other use is considered as non-compliant Type code Code Description DG Pressure switch for gas,5 500 Max setting in mbar H Locks off with rising pressure Locks off with falling pressure I egative pressure for gas G - - -5-6 -9 K T T A Part designations With gold-plated contacts Electrical connection via screw terminals via screw terminals, IP 65 -pin plug, without socket -pin plug, with socket -pin plug, with socket, IP 65 Red/green pilot LED for V DC/AC Blue pilot lamp for 0 V AC Red/green pilot LED for 0 V AC Blue pilot lamp for 0 V AC Upper housing section with cover Lower housing section Hand wheel M6 cable gland 5 DGH, DG with manual reset External adjustment 5 - Type label D-908 Osnabrück, Germany DG CE Max inlet pressure p max = withstand pressure, mains voltage, ambient temperature, enclosure: see type label Installation CAUTIO Please observe the following to ensure that the DG is not damaged during installation and operation: Continuous operation with gases containing more than 0 %-by-vol H S or ozone concentrations exceeding 00 µg/m³ accelerate the ageing of elastomer materials and reduce the service life Dropping the device can cause permanent damage In this event, replace the entire device and associated modules before use Use approved sealing material only Check max ambient temperature see page 7 (Technical data) When using silicone tubes, only use silicone tubes which have been sufficiently cured Vapours containing silicone can adversely affect the functioning of electrical contacts Condensation must not be allowed to get into the housing At subzero temperatures malfunctions/failures due to icing can occur When installing outdoors, place the DG in a roofed area and protect from direct sunlight (even IP 65 version) To avoid condensation, a cover with pressure equalization element (see page 6 (Pressure equalization element)) can be used Avoid strong impact on the unit In case of highly fluctuating pressures, install a restrictor orifice (see page 6 (Restrictor orifice)) The DG must not be in contact with masonry Minimum clearance 0 mm Ensure that there is sufficient installation space Ensure unobstructed view of the hand wheel Installation position as required, preferably with vertical diaphragm Then the switching point p S corresponds to the scale value SK set on the hand wheel In other installation positions, the switching point p S will change and no longer correspond to the scale value SK set on the hand wheel Check the switching point
Positive pressure measurement at port 5 Seal port DGH, DG p S = SK p S = SK + 08 mbar p S = SK - 08 mbar DG,5I p S = SK + 0 mbar eg SK = : p S = + 0 = p S = SK 6 mbar eg SK = -: p S = - + 0 = -08 mbar DG I p S = SK + 05 mbar eg SK = 5: p S = 5 + 05 = p S = SK 55 mbar eg SK = -0: p S = -0 + 05 = -95 mbar DG 8I, DG 0I, DG 50I DG 8I: p S = SK + 05 mbar eg SK = -0: p S = SK p S = -0 + 05 = -95 mbar DG 0I, DG 50I: p S = SK + 0 mbar Connection facilities and Gas, air, flue gas and Air, flue gas 0 Rp / Rp / p max = egative pressure measurement at port 5 Seal port Rp /8 egative pressure measurement at port 5 Seal 0port 0 Rp /8 Rp /8 Ports and are suitable for air and flue gas only If the electrical contacts in the DG could be soiled by dirt particles in the surrounding air or in the medium, use a filter pad (see page 6 (Filter pad set)) at port / On IP 65 units, the filter pad is fitted as standard, see type label Disconnect the system from the electrical power supply Shut off the gas supply Ensure that the pipeline is clean Purge the pipe Installing DGH, DG Positive pressure measurement at port 5 Seal port Rp / Rp /8 Differential pressure measurement Use port or for the higher absolute pressure and port or for the lower absolute pressure 5 Seal the remaining ports -
Installing DGI It is recommended that the port which is best protected from dirt and water be left open egative pressure measurement at port 5 Seal port Rp / C = µf R = O Disconnect the system from the electrical power supply egative pressure measurement at port 5 Seal port 0 5 6 7 Rp / Rp / p max = M6 x,5: ø 0 mm Contacts and close when subject to increasing pressure Contacts and close when subject to falling pressure Wiring If the DGG has switched a voltage > V and a current > 0 A at cos φ = or > 005 A at cos φ = 06 once, the gold plating on the contacts will have been burnt through It can then only be operated at this power rating or higher power rating Pressure switch DG can be used in Zone () and () hazardous areas if an isolating amplifier is installed upstream in the safe area as Ex-i equipment pursuant to E 60079- (VDE 070-7):0 DG as simple electrical equipment pursuant to E 60079-:0 corresponds to the Temperature class T6, Group II The internal inductance/ capacitance is Li = 0 μh/ci = 8 pf CAUTIO To ensure that the DG is not damaged during operation, note the switching capacity, see page 7 (Technical data) In the case of low switching capacities, such as V, 8 ma, for example, we recommend using an RC module ( Ω, μf) in air containing silicone or oil L O O DG,5I and DG I The connection of DG,5l and DG l depends on the positive or negative adjusting range - -0-9 -8-7 - -6-5 7-6 - 5 00 Pa = mbar p s = - -; 7 mbar - - DG I DG,5I - -0,5 -,5 p s = -,5-0,5; 0,5 mbar In the negative adjusting range, the template which can be found in the unit displays the connection diagram O O µ 0,5 00 Pa = mbar,5,5 -
In the positive adjusting range, remove the template and wire the unit as shown in the engraved connection diagram Adjustment O The switching point is adjustable via hand wheel Disconnect the system from the electrical power supply Detach the housing cover, see page 7 (Technical data) Connect an ohmmeter O O *** Mean switching differential at min and max setting Deviation from the switching point during testing pursuant to E 85: Gas pressure switches: ± 5% Air pressure switches: Deviation DGH,, I ± 5% DG,5I ± 5% or ± 0 mbar DG I ± 5% or ± 05 mbar DG 8I ± 5% or ± 05 mbar If the DG does not trip at the desired switching point, correct the adjusting range using the hand wheel Relieve the pressure and repeat the process Tightness test Shut off the downstream gas pipeline close to the valve Open the valve and the gas supply Check all used ports for tightness Set the switching point using the hand wheel 5 Connect a pressure gauge 0 900 mbar max bar < 5 min cm = mbar 6 Apply pressure In doing so, monitor the switching point on the ohmmeter and the pressure gauge Type Adjusting range* [mbar] Reset pressure** [mbar] DG 0H, DG 0 0 0 DG 50H, DG 50 5 50 DG 50H, DG 50 0 50 5 DG 500H, DG 500 00 500 7 Type DG,5I DG I Adjusting range* [mbar] -5 to -0,5 and +05 to + - to - and + to +7 Max inlet pressure p max [mbar] 600 Switching Max inlet differential*** pressure [mbar] p max [mbar] 0 05 ±00 05 ±00 DG 8I - to -8 05 5 ±00 DG 0I -0 to -0 ±600 DG 50I -80 to -50 0 0 ±600 * Adjusting tolerance = ± 5% of the scale value ** Difference between switching pressure and possible reset -5 Maintenance In order to ensure smooth operation: check the tightness and function of the DG every year, or every six months if operated with biogas A function check can be carried out in case of decreasing pressure control eg with the PIA After carrying out the maintenance work, check for tightness, see page 5 (Tightness test) Accessories Connecting set For monitoring a minimum and maximum inlet pressure p u with two pressure switches attached to one another Order o: 7950 Remove from both pressure switches
Install on one pressure switch Test key PIA To test the min pressure switch, the DG can be vented in its switched state using the PIA test key (contains non-ferrous metals) R ¼ Click Filter pad set To protect the electrical contacts in the DG from dirt particles in the surrounding air or in the medium, use a filter pad at the /8" negative pressure port As standard on IP 65 units 5-piece filter pad set, Order o: 79699 Weather protection cover Protection against condensation and weathering Order o: 79909 Further information can be found in Technical Information bulletin DG (D,, F) wwwdocuthekcom External adjustment In order to set the switching pressure from the outside, the cover for external adjustment (6 mm Allen key) for DGI can be retrofitted Rp ¼ Order o: 7966 Tube set To be used with air only TEST Order o: 7995 Fastening set with screws, U-shape bracket 75 (95") 7,5 (87") Order o: 79655 0 (57") Pressure equalization element To avoid the formation of condensation, the cover with pressure equalization element can be used The diaphragm in the screw connector is designed to ventilate the cover, without allowing water to enter 0 (079") M x 50 (97") 0 (8") 0 (079") M x 0 5 (77") 5 (098") Order o: 799 Restrictor orifice In the case of high pressure fluctuations, we recommend using a restrictor orifice (contains non-ferrous metals) Rp ¼ R ¼ Hole diameter 0 mm, Order o: 7556, hole diameter 0 mm, Order o: 757 6 (0") 6 (06") Order o: 79587 (09") -0, (69") 6 (5") 5, (0") 0 9 (5") (0"),0 +0, (07") -6
Standard socket set L L O O Order o: 79588 Standard coupler plug + O O Order o: 790 Pilot lamp set, red or blue Pilot lamp, red: 0/0 V AC, I = ma, Order o: 7900; 0/50 V AC, I = 06 ma, Order o: 7909 Pilot lamp, blue: 0/0 V AC, I = ma, Order o: 796; 0/50 V AC, I = 06 ma, Order o: 796 L O O L LED set, red/green O O O V DC, I = 6 ma; V AC, I = 8 ma, Order o: 79089; 0 V AC, I = 06 ma, Order o: 7975 Technical data Gas type: natural gas, town gas, LPG (gaseous), flue gas, biogas (max 0 %-by-vol H S) and air Max inlet pressure p max = withstand pressure, see page 5 (Adjustment) Max test pressure for testing the entire system: temporarily < 5 minutes bar Switching capacity: U I (cos φ = ) I (cos φ = 0,6) DG 50 V AC 005 5 A 005 A 5 50 V AC 00 5 A 00 A DGG 5 8 V DC 00 A Maximum medium and ambient temperatures: DGH, DG: -5 to +60 C, DGI: -0 to +80 C Storage temperature: -0 to +0 C Long-term use in the upper ambient temperature range accelerates the ageing of the elastomer materials and reduces the service life (please contact manufacturer) Diaphragm pressure switch, silicone-free Diaphragm: BR Housing: glass fibre reinforced PBT plastic with low gas release Lower housing section: AlSi Enclosure: IP 5 or IP 65 Safety class: Line diameter: 05 to 8 mm (AWG to AWG ) Line entrance: M6 x 5, clamping range: diameters of to 0 mm Type of connection: screw terminals Max tightening torque, see Technical Information bulletin DG (D,, F) wwwdocuthekcom Weight: 70 to 0 g depending on equipment Safety information, see Safety manual DG (D, ) wwwdocuthekcom Designed lifetime This information on the designed lifetime is based on using the product in accordance with these operating instructions Once the designed lifetime has been reached, safety-relevant products must be replaced -7
Designed lifetime (based on date of manufacture) in accordance with E 6, E 85 for pressure switches: Medium Designed lifetime Switching cycles Time [years] Gas 50,000 0 Air 50,000 0 You can find further explanations in the applicable rules and regulations and on the afecor website (wwwafecororg) This procedure applies to heating systems For thermoprocessing equipment, observe local regulations Logistics Transport Protect the unit from external forces (blows, shocks, vibration) On receipt of the product, check that the delivery is complete, see page (Part designations) Report any transport damage immediately Storage Store the product in a dry and clean place Storage temperature: see page 7 (Technical data) Storage time: 6 months before using for the first time If stored for longer than this, the overall service life will be reduced by the corresponding amount of extra storage time Packaging The packaging material is to be disposed of in accordance with local regulations Disposal Components are to be disposed of separately in accordance with local regulations Certification Declaration of conformity We, the manufacturer, hereby declare that the product DG with product ID o CE-0085AP067 complies with the requirements of the listed Directives and Standards Directives: 009//EC GAD (valid until 0 April 08), 0/5/EU LVD Regulation: (EU) 06/6 GAR (valid from April 08) Contact Standards: E 6:05+AC:06, E 85:00 The relevant product corresponds to the tested type sample The production is subject to the surveillance procedure pursuant to Directive 009//EC Annex II paragraph (valid until 0 April 08) and to Regulation (EU) 06/6 Annex III paragraph (valid from April 08) Elster GmbH Scan of the Declaration of conformity (D, ) see wwwdocuthekcom SIL, PL The pressure switches are suitable for single-channel systems (HFT = 0) up to SIL /PL d, and up to SIL / PL e when two redundant pressure switches are installed in a double-channel architecture (HFT = ), provided that the complete system complies with the requirements of E 6508/ISO 89 The safety function value which is actually achieved is derived by taking all components into account (sensor logic actuator) For this, the demand rate and structural measures to avoid/detect nonconformity are to be observed (eg redundancy, diversity, monitoring) Characteristic values for SIL/PL: HFT = 0 ( device), HFT = ( devices), SFF > 90, DC = 0, type A/category B,,,,, high demand mode, CCF > 65, ß 0 PFH D = λ D = = x n MTTF op d B 0d U I B 0d value V DC 0 V AC 0 ma ma 6,689,77 V DC 70 ma 0 V AC 0 ma,,06 0 V AC A 97,800 RoHS compliant, Eurasian Customs Union, AGA approved AGA Directive on the restriction of the use of hazardous substances (RoHS) in China Scan of the Disclosure Table China RoHS see certificates at wwwdocuthekcom If you have any technical questions, please contact your local branch office/agent The addresses are available on the Internet or from Elster GmbH We reserve the right to make technical modifications in the interests of progress -8 Elster GmbH Strotheweg, D-950 Lotte (Büren) Tel +9 5-0 Fax +9 5-70 htslotte@honeywellcom, wwwkromschroedercom