Instruction Manual

DS21 Differential Pressure Switch

Table of Contents
1. Safety Instructions
2. Intended Applications
3. Product Description and Functions
4. Installation
5. Commissioning
6. Maintenance
7. Transport
8. Service
9. Accessories
10. Disposal
11. Specifications
12. Dimensions
13. Ordering Code
14. Declaration of Conformity
15. Annex

1. Safety Instructions 1.3. Risks of Disregarding Safety Instruc-

tions
1.1. General
Disregarding safety instructions, use of this pro-
This manual contains detailed duct for purposes for which it is not intended, and/
information about the product, or operation of this product outside the limits
and instructions for its installa- specified for any of its technical parameters, can
tion, operation and main- result in harm to persons, the environment, or the
tenance. Operators and other plant on which it is installed. Fischer Mess- und
technical personnel responsible for the equipment Regeltechnik GmbH will not be responsible for
must read this thoroughly before attempting to in- consequences in such circumstances.
stall or operate this equipment. A copy of this ma-
nual must always be kept accessible at the place 1.4. Safety Instructions for Operators
BA_GB_DS21.fm

of work for reference by concerned personnel.

Safety instructions for the proper use of this pro-
duct must be followed. This information must be
Chapter 1 (sections 1.2 through 1.7) contains
available at all times by personnel responsible for
general as well as specific safety instructions.
installation, operation, maintenance and inspec-
Chapters 2 through 10, covering topics ranging
tion of this product. Adequate steps must be taken
from intended purpose of the equipment to its final
to prevent the occurrence of hazardous conditions
8.6.10

disposal, also include important points relating to

that can be caused by electric energy and the con-
safety. Overlooking or ignoring any of these safety
vertible energy of the process media. Such condi-
points can endanger humans and animals, and
tions can, for example, be the result of improper
possibly cause damage to other equipment.
electrical or process connections. Detailed infor-
mation is available in relevant published norms
1.2. Personnel Qualification
(DIN EN, UVW in Germany; and equivalents in
Personnel responsible for installation, operation, other countries), industrial standards
maintenance and inspection of this product must such as DVWG, Ex-, GL-, VDE
have the qualifications, training and experience guidelines, as well as regulations of
necessary to carry out such work on this type of the local authorities (e.g., EVUs in
equipment. Germany).
1.5. Modifications Forbidden 3. Product Description and Functions
Modification or other technical alteration of the product is
not permissible. This also applies to the use of unautho- 3.1. Schematic Diagram
rized spare parts for repair / maintenance of the product.
Any modifications to this product, if and as necessary,
should be done only by Fischer Mess- und Regeltechnik
GmbH.

1.6. Operational Restrictions

The operational reliability of the product is guaranteed 1. Pressure chamber
only when used for intended purposes. The product must 2. Motion work
be selected and configured for use specifically with 3. Tappet
defined process media. The limiting values of operating 4. Microswitch actuating
parameters, as given in the product specification sheet, elements
must never be crossed. 5. Measuring springs
6. Measuring diaphragm
1.7. Safety Considerations during Installation and
Maintenance 3.2. Principles of Operation
The safety instructions given in this manual, existing na- The monitoring and switching instrument is based on a
tional regulations relating to accident prevention, and the rugged and uncomplicated diaphragm movement su-
internal safety rules and procedures of the user organiza- itable for overpressure, partial vacuum, and differential
tion regarding safety during installation, operation and pressure measurements. The operating principle of the
servicing must all be followed meticulously. system is identical in all three applications.

It is the responsibility of the users to ensure that only su- In a state of equilibrium, the forces of the springs on both
itably qualified and experienced technical personnel are sides of the diaphragm are balanced. The pressure or
used for installation, operation and servicing of this differential pressure to be measured creates an
equipment. unbalanced force at the diaphragm. This force moves the
diaphragm system against the force of the springs for the
2. Intended Applications measuring range until a new equilibrium is reached.
These type series instruments are used as flow-opera- When subjected to excessive pressure, the diaphragm
tion safety device in heat carrier oil plants acc. to DIN rests on metal supporting plates.
32 727 and hot water plants acc. to VdTÜV data sheet
flow 100. The flow-operation safety devices consist of a A centre-mounted tapped transfers the motion of the dia-
differential pressure device, e.g. an orifice plate, diffe- phragm system to the motion work and to the actuating
rential pressure switch and adequate shut-off valves. elements of the microswitches.
Follow mounting instructions in accordance to applica-
tion. All instruments of this type series meet these 4. Installation
demands. Successful structural testing of this type series
is confirmed by the following marks of conformity: 4.1. General
The instrument is intended for wallmounting by default.
• for flow-operated safety devices The instrument can be attached directly to flat walls by th-
DIN 32 727 DIN record No. 1B012/07 ree mounting feet cast to the casing. The instrument can
be mounted into switchboard by panel mounting kit
• acc. to VdTÜV data sheet flow 100
DZ11. It is factory-callibrated in vertical position and may
TÜV . SW/SB . 07 - 020 not be mounted otherwise. To ensure proper operation
during installation and maintenance, appropriate shut-off
fittings have to be installed at the plant.

4.2. Installation Regulations for Flow-operated

Safety Devices in Heat Transfer Plants acc. to
DIN 4754
• The set-up of measuring instruments has to be done
acc. to VDE/VDI 3512, sheet 1 for differential pressu-
re producers acc. to DIN 1952/ VDI 2041.
• Shut-off valves in differential pressure pipes may only
be manipulated with tools. Screw joints in these pipes
need to be conducted that way they are leak proof wit-

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 hout aid of sealants. 4.5. Electrical Connections
• The clear diameter of the differential pressure pipes’ • Only qualified technicians authorized for this type of
length needs to be designed that way, that with cold work should undertake installation.
pipework (approx. 20°C) the reaction time of the inst- • Electrical connections must comply with relevant in-
rument is no more than 5 secs. ternational, national and local regulations and norms
• Differential pressure pipes need to be of metal, their relating to electrical and instrumentation installations.
clear width may be no less than 4mm and their stret- • Switch off electrical power to the plant before attempt-
ched length must be at least 500mm. When arranged ing electrical installation work of any kind.
acc. to VDE/VDI 3512, sheet 1 with valve block the
• Make electrical connections to the instrument through
stretched length of the differential pressure pipe bet-
a suitable fuse.
ween valve block and differential pressure transmitter
must be at least 500mm.
5. Commissioning
• Locking und unlocking conditions must be made sure
Power supply and signal cabling to the instrument must
by subsequent electrical wiring during installation.
be correctly selected to meet operational requirements,
and installed in a way that does not cause physical stress
4.3. Installation Regulations for Flow Limiters in
to the instrument.
Steam Boiler and Hot Water Plants
• Apply measuring instruments acc. to DIN 1952 / VDI Pressure lines must have a downward gradient
3212, sheet 1, Itabar or Annubar sensors. throughout, from the pressure instrument to the process
• The set-up of measuring instruments has to be done vessel / pipe. This is to prevent formation of air / gas po-
acc. to VDE/VDI 3512, sheet 1 for differential pressu- ckets (for liquid applications) and liquid plugs (for air / gas
applications). If this continuous downward gradient
re producers acc. to DIN 1952 / VDI 2041.
cannot be provided for any reason, then suitable water
• The differential pressure pipes must be suitable to be and / or air separation devices must be inserted in the
shut off and blown out with fivefold valve block. pressure line.
• The differential pressure pipes need to be of metal
The pressure lines must be kept as short as possible and
and their clear width must be at least 8mm. The stret-
must not have short bends to avoid measurement errors
ched length of the differential pressure pipes must be
induced by pressure line delays.
at least 500mm.
• Shut-off valves in differential pressure pipes may only When used with liquid media the lines must be vented to
be manipulated with tools. Screw joints in these pipes avoid measurement errors induced by different heights in
need to be conducted that way they are leak proof wit- liquid columns. The instrument and lines must be pro-
hout aid of sealants or the conjunction needs to be tected against frost when used with water.
welded or brazed.
Check all pressure connections for leaks before commis-
4.4. Process Connections sioning.
• Only qualified technicians authorized for this type of
5.1. Pressure Connections
work should undertake installation.
The instruments pressure ports are marked by ““ and
• Ensure that process equipment and pressure lines ““ symbols. The pressure applications need to be in-
are at atmospheric pressure before making pressure stalled according to the label.
connections.
• The instrument should be provided with suitable pro- Differential pressure measurement: higher pressure
 lower pressure
tection against pressure surges (e.g., snubber or
pulsation damper).
Pressure measurement:  pressure port
• Ensure that the mechanical configuration and mate-
rials of construction of the instrument are compatible Negative pressure measurement:  negative pressure
with the process media. port
• Ensure that process pressure is always less than the
specified safe pressure rating.

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5.2. Zero Point Adjustment and Setting of Swit- 6. Maintenance
ching Points
The instrument is inherently maintenance-free.
Zero point adjustment sc-
rew However, to ensure reliable operation and maximize the
operating life of the instrument, it is recommended that
the instrument, its external electrical and process con-
nections, and external connected devices be regularly in-
spected, e.g.:

• Check the display.

• Check the switching function in connection with exter-
nal devices.
• Check all pressure connections for leak-tightness.
• Check the integrity of all electrical connections of the
instruments.
Inspection and test schedules depend on operating and
Switching point adjustment site conditions. The operating manuals of other equip-
ment to which the instrument is connected must be read
5.2.1. Zero Point Adjustment thoroughly to ensure that all of them work correctly when
• Charge pressure chamber with existent static pressu- connected together.
re.
7. Transport
• Remove cover.
The product must be protected against shock and vibra-
• Set measuring indicator to zero by zero point adjust- tion during transport. It must therefore be properly pack-
ment screw. ed, preferably in the original factory packaging,
• Mount cover. whenever it is to be transported.

8. Service
5.2.2. Setting of Switching Points
Any defective devices or devices with missing parts
• Unscrew plugs from cover.
should be retourned to Fischer Mess- und Regeltechnik
• Set desired switching points according to marks on GmbH. For quick service contact our service department.
reference value scale by screwdriver. Achievable
accuracy: 5% FS. More exact settings can be achie- Remaining medium in and on dismantled
ved by using accessories like testing manometer, measuring instruments may cause danger
ohmmeter on site or ex factory. to persons, environment and equipment.
Take reasonable precautions! Clean the
• Screw plugs in. instrument thoroughly if necessary.
5.3. Connection Scheme
9. Accessories
N.A.
Instrument pressureless and dead
10. Disposal
Protect your environment!
Use the product in accordance with
relevant regulations. Please be aware
of environmental consequences of dis-
posal at the end of the product's life,
and take care accordingly.

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11. Specifications
General
Measuring range 0... 400 mbar up to 0... 6 bar (see ordering code)
Nominal pressure 25 bar
Max. static operating pressure Acc. to measuring range (see ordering code)
Max. pressure load One-sided overpressure protected up to nominal pressure
on () - and () side of diaphragm, partial vacuum protected
Perm. ambient temperature -10... +70°C
Perm. medium temperature 70°C
Protection class IP 54 acc. to DIN EN 60529
Mounting position Vertical
Measuring accuracy ± 2.5% FS
Zero adjustment Located in the dial

Switching Elements
Contact output 1 or 2 microswitches, 1-channel change-over contacts
Adjustment of switching points External adjustment by standard value scales
smallest adjustable value: approx. 5% FS
Switching hysteresis Approx. 2.5% FS
Load data / contacts U~max. = 250 V AC, Imax. = 5 A, Pmax. = 250 VA
U=max. = 30 V DC, Imax. = 0.4 A, Pmax. = 10 W

Electrical Connection Numbered cable, prewired terminal box, 7-channel plug

Pressure Connection Thread G1/4 female, cutting ring connection for 6, 8, 10,12 mm  tube
of brass, zinced steel or chrome nickel steel
connection shank G1/4 male DIN EN 837

Measuring System Diaphragm measuring system, diaphragm of reinforced Viton®

Materials
Pressure chamber Aluminium GkAlSi10(Mg), varnished black
Aluminium GkAlSi10(Mg) HART-COAT® surface protection
Chrome nickel steel 1.4305
Measuring diaphragm Diaphragm measuring system and gaskets of Viton®
Materials: medium Stainless steel 1.4310, 1.4305
Materials: housing Macrolon
Weight Pressure chamber of Aluminium = 1.2 kg, pressure chamber of 1.4305 = 3.5 kg
Mounting Wallmounting - 3 fastening elements
Panel mounting - panel mounting kit DZ11 ø132 mm
Pipe mounting, pressure connections = (), () symbols
- by screwed-in cutting ring or clamping ring connection
- by screwed-in connection shank acc. to DIN EN 837 for nipple fitting acc. to
DIN 16284

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12. Dimensions (all units in mm unless otherwise stated)

M16x1.5
plastic cable
gland

Cutting ring DS21

connection Wallmounting
(standard)

Prewired terminal box

or 7-pin connector

M20x1.5 cable gland Connections G¼ female

Variants of Electrical Connection Variants of Process Connection

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13. Ordering Code

Differential Pressure
Switch DS21 0 # # # 0

Range Max. static pressure

0 . . . 250 mbar 6 bar ............................................ > 8 2
0 . . . 400 mbar 6 bar ............................................ > 8 3
0 . . . 0.6 bar 10 bar ............................................ > 0 1
0 . . . 1 bar 16 bar ............................................ > 0 2
0 . . . 1.6 bar 16 bar ............................................ > 0 3
0 . . . 2.5 bar 16 bar ............................................ > 0 4
0 . . . 4 bar 16 bar ............................................ > 0 5
0 . . . 6 bar 16 bar ............................................ > 0 6

Application
Thermal oil DIN 32727 / Hot water / Flow 100...................................................... > 0

Pressure Chamber
Aluminium ........................................................................................................................... > A
Aluminium HART COAT® ................................................................................................... > D
Chrome-nickel-steel 1.4305................................................................................................ > W

Pressure Connection
Female thread G1/4........................................................................................................................> 0 1
Cutting ring fitting of steel for 6 mm tube ......................................................................................> 2 0
Cutting ring fitting of steel for 8 mm tube ......................................................................................> 2 1
Cutting ring fitting of steel for 10 mm tube ......................................................................................> 2 2
Cutting ring fitting of steel for 12 mm tube ......................................................................................> 2 3
Cutting ring fitting of 1.4571 for 6 mm tube...................................................................................> 2 4
Cutting ring fitting of 1.4571 for 8 mm tube...................................................................................> 2 5
Cutting ring fitting of 1.4571 for 10 mm tube...................................................................................> 2 6
Cutting ring fitting of 1.4571 for 12 mm tube...................................................................................> 2 7

Switching Elements
1 adjustable microswitch.........................................................................................................................................> A
2 adjustable microswitches.....................................................................................................................................> B

Electrical Connection
1 m numbered cable, prewired ...........................................................................................................................................> 1
2.5 m numbered cable, prewired ........................................................................................................................................> 2
5 m numbered cable, prewired ...........................................................................................................................................> 5
Prewired terminal box .........................................................................................................................................................> K
GL approved model, 3 m supply cable H07 RNF ...............................................................................................................> Z

Shaded marks are not indicated in data sheet and only available on request!

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14. Declaration of Conformity

8
15. Annex
DIN CERTCO certificate DIN 32723

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10
TÜV Certificate

11
EC type-examination certificate acc. to directive 97/23/EC

12
GL type approval certificate

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 Technische Änderungen vorbehalten • Subject to change without notice • Changements techniques sous réserve
Fischer Mess- und Regeltechnik GmbH • Bielefelder Str. 37a • D-32107 Bad Salzuflen • Tel. +49 5222 9740 • Fax +49 5222 7170
eMail: info@fischermesstechnik.de • www.fischermesstechnik.de
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