18 Pressure switches

Mechanical pressure switches

Mechanical pressure switches

Te c h n i c a l f e a t u r e s / Advantages

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

Setting spindle locking element

Terminal connection
or plug connection to
DIN 43 650 Form A

Stainless steel sensor housing

Stainless steel bellows

with internal stop

Pressure connection
G 1/2“ external
G 1/4” internal

Centring pin
26 Pressure switches
Mechanical pressure switches

Pressure switches
General description

Operating mode
The pressure occurring in the sensor housing (1) acts on the measuring bellows (2). Changes in pres-
sure 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 pretension can be modified by the adjusting screw (9)
(switching point adjustment). Turning the setting spindle (9) moves the running nut (10) and modifies
the pretension 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 = Pressure connection
2 = Measuring bellows
3 = Sensor housing
4 = Thrust pin
5 = Connecting bridge
6 = Pivot points
7 = Microswitch or other switch-
ing elements
8 = Setting spring
9 = Setting spindle (switching
point adjustment)
10 = Running nut (switching point
indicator)
11 = Microswitch calibration
screw (factory calibration)
12 = 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 bel-
lows, 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 stain-
less 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
according to 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
sheet gasket 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 connect-
ed to a G 1/4 internal thread.
 Pressure switches 27
Mechanical pressure switches

General technical data

with microswitches of the DCM, VCM, DNM, DNS and DDC series.
The technical data of type-tested units may differ slightly.
(please refer to type sheet)

Normal version version

Plug connection Terminal connection

…200 …300 …700

Switch housing Diecast aluminium GD AI Si 12 Diecast aluminium GD AI Si 12

Pressure connection G 1/2 external thread (pressure gauge connection) and G 1/4 internal thread
G 1/4 internal thread for DDCM differential pressure switches
Switching function and con- Floating changeover contact. Floating changeover contact.
nection diagram With rising pressure switching With rising pressure switching
(applies only to version with single-pole from 3-1 to 3-2. single-pole from 3-1 to 3-2.
microswitch)

Switching capacity 8 A at 250 VAC 3 A at 250 VAC

(applies only to version with 5 A at 250 VAC inductive 2 A at 250 VAC inductive
microswitch) 8 A at 24 VDC 3 A at 24 VDC
0.3 A at 250 VDC 0.03 A at 250 VDC
min. 10 mA, 12 VDC min. 2 mA, 24 V DC
Mounting position preferably vertical vertical
(see technical data sheet)
Degree of protection (in vertical
position) IP 54; (for terminal connection …300 IP 65) IP 65
Ex degree of protection – EEx de IIC T6 tested to EN
50014/50018/50019 (CENELEC)
PTB approval Electrical connection – PTB 02 ATEX 1121
Plug connection to DIN 43 650 (200 series) Terminal connection
Cable entry or terminal connection (300 series)
Ambient temperature PG 11 / for terminal connection M 16 x 1.5 M 16 x 1.5
Switching point See data sheets –15 to +60°C
Adjustable via spindle. On switching device Adjustable via spindle after the
300 the terminal box cover must be removed terminal box lid is removed
Switching differential
Adjustable or not adjustable Not adjustable
Lead seal (see Product Summary)
Medium temperature Only possible on plug connection housing 200
Max. 70°C, briefly 85°C Max. 60°C
Higher medium temperatures are possible provided the above limits for the switching device are
Vacuum ensured by suitable measures (e.g. siphon).
All pressure switches can operate under vacuum. This will not damage the device.
Repetition accuracy of switch-
ing points < 1% of the working range (for pressure ranges > 1 bar)
Vibration strength
Mechanical life 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 fig-
ure can serve only as a rough estimate. With pulsating pressure or pressure impacts in hydraulic sys-
Isolation values tems, pressure surge reduction is recommended.
Overvoltage category III, contamination class 3, reference surge voltage 4000 V.
Oil and grease-free Conformity to DIN VDE 0110 (01.89) is confirmed.
The parts of all pressure switches with sensors made from steel or stainless steel are oil and grease-
free. The sensors are hermetically encapsulated. They contain no seals. (See also additional function
ZF 1979 Special Packing)
28 Pressure switches
Mechanical pressure switches

ZF additional functions — Pressure

switches and pressure monitors

Example for ordering: How to order:

DWR 6 – 205 Pressure switch
Code of additional function (e.g. maximum limiter) DWR 6–205
Code for pressure range or DWR 6
Sensor system with ZF 205

Additional functions / Connection diagrams

Plug connection Terminal connection Connection diagram Explanation
200 series (IP 54) 300 series (IP 65)

Normal version (plug connection)

Microswitch, single pole switching
Switching differential not adjustable

Terminal connection – housing (300) …301

Unit with adjustable switching differential ZF 203

Maximum limiter ZF 205 see

with reclosing lockout DWR series
Interlocking with rising pressure

Minimum limiter ZF 206 see

with reclosing lockout DWR series
Interlocking with falling pressure

Two microswitches, switching in parallel or in

ZF 307 *
succession. Fixed switching interval, only
possible with terminal connection housing.
State the switching interval (not possible
with all pressure switches, see data sheet
p. 2, pp. 40 - 43)

Two microswitches, 1 plug switching in ZF 217 *

succession. adjustable switching interval
Please indicate switching scheme*
(not possible with all pressure switches,
see data sheet p. 2, pp. 40 – 43)

Gold-plated contacts, ZF 213 Permitted contact

single pole switching (not available with load:
adjustable switching differential). Max: 24 VDC,100 mA
Min: 5 VDC, 2 mA

Switch housing with surface protection ZF 351

(chemical version).

*Switching point adjustment: Please specify switching point and direction of action (rising or falling pressure).
 Pressure switches 29
Mechanical pressure switches

Additional functions
for EEx-i equipment ZF 5…
· Housing (300) with terminal connection (IP 65), “blue” cable Non-Ex area Ex area
entry and terminals. Io Ii
· Also available with resistor combination for line break and
short-circuit monitoring (with isolating amplifier Ex 041). Uo Ui Pi

Important:
All pressure switches with the ZF 5… additional functions list-
ed here can only be operated in combination with a suitable For ZF513, ZF576, ZF574:
DWAM…-576 isolating amplifier (see pages 60 – 61). Ui = 15 V DC, Ii = 60 mA,
Pi = 0.9 W, Ci < 1 nF, Li < 100 µH

Additional functions for EEx-i equipment Connection diagram Isolating amplifier

Gold-plated contacts, single-pole ZF 513 Ex 011

switching. Switching differential fixed (not adjustable).
Switching capacity: max. 24 VDC,
100 mA, min. 5 VDC, 2 mA.
Versions with resistor combination for line break and short-circuit monitoring in control current circuit, see DBS series, pages 54 – 56:
Normally closed contact with resistor combination ZF 576 Ex 041
for maximum pressure monitoring,
gold-plated contacts,
plastic-coated housing
(chemical version).
Normally closed contact with reclosing lockout ZF 577 Ex 041
and resistor combination,
for maximum pressure monitoring
Plastic-coated housing
(chemical version).
Normally closed contact with resistor combination ZF 574 Ex 041
for minimum pressure monitoring,
gold-plated contacts,
plastic-coated housing
(chemical version).
Normally closed contact with reclosing lockout ZF 575 Ex 041
and resistor combination,
for minimum pressure monitoring
Plastic-coated housing
(chemical version).

Other additional functions Plug connection Terminal connection

200 series 300 series

Adjustment according to customer’s instruction: one switching point ZF 1970* ZF 1970*

two switching points or defined switching differential ZF 1972* ZF 1972*

Adjustment and lead sealing according to customer’s instruction:

one switching point ZF 1971* –
two switching points or defined switching differential ZF 1973* –
Labelling of units according to customer’s instruction with sticker ZF 1978 ZF 1978
Special packing for oil and grease-free storage ZF 1979 ZF 1979

Documents: Additional documents, e.g. data sheets, operating instructions, TÜV, DVGW or PTB certificates.

Test certificates according to EN 10 204

Factory certificate 2.2 based on non-specific specimen test WZ 2.2 WZ 2.2

Acceptance test certificate 3.1 based on specific test AZ 3.1 AZ 3.1
Acceptance test certificate for ZFV separating diaphragms AZ 3.1 –V AZ 3.1 –V

*Switching point adjustment: Please specify switching point and direction of action (rising or falling pressure).
30 Pressure switches
Mechanical pressure switches

Setting instructions
Factory calibration of pressure switches
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 adjust-
ment and the actual switching pressure correspond as closely as possible in the middle of the range.
Possible deviations spread to both sides equally.
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 cali-
brated and checked in accordance with normal practice using a pressure gauge.

1. Calibration at lower switching point 2. Calibration at upper switching point

Setpoint xS corresponds to the lower Setpoint xS corresponds to the upper
switching point, the upper switching point xO switching point, the lower switching point xU
is higher by the amount of the switching is lower by the amount of the switching differen-
differential xd. tial xd.

The chosen calibration type is indicated in the technical data for the relevant type series.

Clockwise: Setting switching pressures

lower switching
pressure 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
Anticlockwise: shown by the scale.
higher switching To set the switching points accurately it is necessary to use a pressure gauge.
pressure

Direction of action of setting

spindle

Clockwise:
greater 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”, ZF 203)
difference
By means of setscrew within the spindle. The lower switching point is not changed by the differential
Anticlockwise:
adjustment; only the upper switching point is shifted by the differential. One turn of the differential
smaller
difference screw changes the switching differential by about of the total differential range. The switching differen-
tial is the hysteresis, i.e. the difference in pressure between the switching point and the reset point.

L e a d s e a l o f s e t t i n g s p i n d l e (for plug connection housing 200 only)

With pressure switches of the
DWAMV and DWR…-203 series, The setting spindle for setting the desired value and switching differential can be covered and sealed
the direction of action of the with sealing parts available as accessories (type designation: P2) consisting of a seal plate and cap-
differential screw is reversed. stan screw. The sealing parts may be fitted subsequently. The painted calibration screws are likewise
covered.
32 Pressure switches
Mechanical pressure switches

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 a code
which is separated from the basic type by a hyphen. Ex versions (explosion protection EEx-d) are iden-
tified by the prefix “Ex” in front of the type designation.

Basic version with additional function Ex-version

(based on the example of DCM series)
DCM XXX DCM XXX-YYY Ex-DCM XXX

DCM Series code (e.g. DCM)

XXX Codes for pressure range
YYY Code for additional functions
Ex Code for Ex version

Switch housing version

DCM XXX Basic version with plug connection housing

DCM XXX-2… Basic version with plug connection housing
DCM XXX-3… Terminal connection housing (300)
Ex-DCM XXX EEx-d switching device (700)
DCM XXX-5… EEx-i version

Which additional function goes with which pressure switch?

Plug connection, 200 series Terminal connection, 300 series

Additional function ZF Additional function ZF

203 213 217 301 307 513 574 575 EEx-d

576 577
DCM/VCM •1 • •1 • •1 • •
VNM/DNS/VNS • • • • • • •
DWAM • • • • •
DDCM • •2 • •2 • •
DWR • • • • • • •
DGM • • • • • •

• available 1
except DCM 4016, DCM 4025, VCM 4156 and DCM 1000
2
except DDCM 252, 662, 1602, 6002

Ex-versions (EEx-d) can only be supplied in basic form.

Additional functions are not possible.
44 Pressure switches
Pressure switches of “special design”

Pressure switches “of special

construction”
Definitions and information

TÜV Pressure monitoring and pressure limiting in

· Steam boilers · Hot water heating systems

· District heating systems · Gas installations
DVGW · Oil pipelines · Firing systems
· Liquid gas installations etc.

is extremely important with regard to safety.

Component testing

Pressure monitoring devices for safety-critical applications must work reliably and be tested according
to the relevant directives in each case. The reliability of pressure monitors and pressure limiters
must be certified by a component test which is performed by the testing agencies responsible in
each case (e.g. TÜV and DVGW). The following section deals with the FEMA product range for safe-
ty-critical pressure monitoring in thermal and process engineering systems.

Special construction

The term “of special construction” originates from the VdTÜV Memorandum “Pressure 100/1”,
issue 04.83, which defines the requirements for pressure monitors and pressure limiters for
steam boilers and hot water systems. Originally used only for pressure monitoring in the area of
steam and hot water, the “special construction” characteristic is increasingly used as a quality and
safety argument for other applications as well. The following section describes the requirements for
pressure limiters “of special construction”. Recommendations for the correct selection of pressure lim-
iters are given by reference to safety analyses.

Definitions of the VdTÜV Memorandum “Pressure 100/1”:

Pressure monitors (DW)

Pressure monitors are devices which switch off the heating system on exceeding and / or falling below a
predefined pressure limit and release the heating system again only after a change in pressure.

Pressure limiters (DB)

Pressure limiters are devices which switch off the heating system on exceeding and / or falling below a
predefined pressure limit and lock it to prevent automatic restarting.

Pressure limiters “of special construction” (SDB)

Pressure limiters “of special construction” perform the same tasks as pressure limiters. In addition they
must satisfy the extended safety requirements of section 3.3 (of “Pressure 100/1”).
 Pressure switches 45
Pressure switches “of special construction”

Safe condition

According to DIN VDE 0660, Part 209, the safe condition of the system is reached if a cut-off com-
mand is present at the output contact which means that in the safe condition, the microswitch in the
pressure limiter is actuated (opened) and the control circuit is interrupted. Series connected switching
devices must react in the same way. The operating mode of the safety pressure limitation thus corre-
sponds to the closed circuit principle.

Additional requirements for pressure limiters “of special construc-

tion”

Section 3.3 of VdTÜV Memorandum “Pressure 100/1”:

8 Pressure limiters “of special construction” must, in the event of a breakage in the mechanical
part of the measuring element, lead to cut-off and interlock of the heating. This requirement is
also fulfilled if the mechanical part of the measuring element is calculated for vibrating stress or has
withstood a test with 2 million operating cycles and the pressurized parts of the measuring
element are made of corrosion-resistant materials.
7 3 (Abbreviated excerpt from VdTÜV Memorandum “Pressure 100/1”).
6 2
1
Therefore there are two possible ways of meeting the requirements for pressure limiters “of
5 special construction”:
a) By a self-monitoring pressure sensor which is designed so that a breakage in the mechanical part of
the measuring element leads to cut-off to the safe side (see Fig. 1)
b) By certification of endurance testing with 2 million operating cycles during the component test (see
Fig. 2)
Self-monitoring maximum pressure
limiter with safety diaphragm a) Self-monitoring pressure sensor with safety diaphragm
DWAM…, DWAMV…, SDBAM… (for maximum pressure monitoring only)
Fig. 1 is a cross-sectional diagram of a pressure sensor which fulfils the “special construction” require-
ments. The measuring chamber is bordered by the housing (1), base (2) and measuring bellows (3). All
parts are made of stainless steel and are welded together without filler metals. When the pressure rises
the measuring bellows (3) moves upwards, supported by the back pressure spring (5). The setpoint
spring installed in the switching device acts as a counterforce. A transfer bolt (6) which transfers the
pressure-dependent movements of the measuring bellows (3) to the switching device located above is
placed on the inside of the base. A plastic diaphragm (7), which is not in contact with the medium and
in normal operation follows the movements of the measuring bellows but itself has no influence on the
position of the bellows, is clamped in the upper part of the transfer bolt. On breakage of the measuring
bellows (3), the medium can escape into the interior of the bellows. The medium pressure is now on
the underside of the diaphragm (PL). An additional force is generated because of the far larger effective
area of the diaphragm compared with the bellows, and this pushes the transfer bolt (6) upwards. This
results in cut-off to the safe side. The cut-off condition thus achieved is normally interlocked electrically
or mechanically, so that the system also remains cut off when the pressure drops again. The plastic
diaphragm (7) is not a pressure-bearing part; it has no function in normal operation and is effective only
if a leakage occurs to the measuring bellows. Safety diaphragms of the described design are permis-
sible up to 32 bar. This should be sufficient for most applications.

b) Pressure sensors with certification of 2 million operating cycles (DWR series)

In this design it is assumed that the pressure sensors which have withstood dynamic loading of 2 mil-
lion operating cycles during component testing can be considered as reliable elements. They do not
have an additional safety device in the sensor. Although the units are produced and tested with very
great care, maximum pressure limiters without additional safety device can lead to dangerous condi-
tions if errors which cannot be detected in the tests occur due to secondary effects. These may be
caused by hole corrosion due to deposited metal particles on the (usually very thin-walled) bellows of
the pressure sensor, material defects in the pressure bellows or a broken weld seam. Despite careful
production and testing, a residual risk remains in the case of maximum pressure monitoring. It is ulti-
mately up to the user and operator of the systems themselves to decide on the degree of safety to which
Pressure limiter without safety- pressure vessels should be monitored.
diaphragm (not self-monitoring for
maximum pressure) DWR… Pressure sensors without safety diaphragm are self monitoring when used in minimum pressure moni-
toring applications.
46 Pressure switches
Pressure switches “of special construction”

Safety analysis for maximum

pressure monitoring
Observing the direction of action

The preceding description and safety considerations relate to the monitoring of maximum pressure.
The safe side here means: The energy supply is cut off (e.g. burner is turned off) to avoid a further
pressure rise. Minimum pressure monitoring requires an entirely different approach. The safe side here
means: Preventing the pressure from falling further (for example: hotwater systems with external pres-
sure retention or monitoring of water level in heating systems). Based on a safety analysis, a pressure
limiter without safety diaphragm is clearly the best option. In the event of leakage in the sensor, “low
pressure” is signalled and the system switches over to the safe side. A pressure sensor without safety
diaphragmis therefore “of special construction” within the meaning of Memorandum “Pressure 100/1”,
if it is used as a minimum pressure limiter. On the other hand, it is clear from the above that pressure
sensors with safety diaphragms, which offer considerable advantages in maximum pressure monitor-
ing, should never be used for minimum pressure monitoring. Incorrect use can create a dangerous con-
dition. It is therefore essential for users and planners to observe the direction of action when selecting
pressure limiters.
In summary it may be said:
Pressure limiters “of special construction” with safety diaphragms (self-monitoring pressure sensors)
offer the highest degree of safety in maximum pressure monitoring. Such devices must not however
be used for minimum pressure monitoring. Pressure limiters “of special construction” with certification
of 2 million operating cycles are self-monitoring in the case of minimum pressure monitoring, even
without a safety diaphragm. In the case of maximum pressure monitoring, however, a residual risk
remains.

Safety analysis for maximum pressure monitoring

If one considers the switch positions in the possible operating conditions, the difference compared
with pressure sensors “of special construction” becomes clear. The left column shows normal opera-
tion in which the switch connects terminals 3 and 1. The cut-off condition when pressure is too high is
shown in column 2. The control circuit is interrupted via terminals 3 and 1.
The difference in safety terms is clear from column 3, which shows the switch position in the event of
a leak in the pressure sensor. With a safety-engineered sensor the control circuit is interrupted, where-
as in the case of a sensor without a safety diaphragm the control circuit remains closed, and thus a
“dangerous condition” can arise.

Devices with safety diaphragm (DWAM, 1 2 3

DWAMV, SDBAM) Normal operation Limit exceeded Leakage in
In pressure limiters “of special construction” pressure sensor
which are equipped with safety sensors,
different operating conditions occur in the
following switch positions:

Control circuit Control circuit Control circuit

closed interrupted interrupted
Device without safety diaphragm
“Special construction” must also be proven by an endurance test with 2 million operating cycles.
In the case of breakage/leakage (e.g. material defect, fault in weld seams, hole corrosion), the system
does not cut off to the safe side (no self-monitoring).

In the different operating conditions the fol- Normal Limit Leakage in

lowing switch positions occur in the case operation exceeded pressure sensor
of maximum pressure monitoring: In the
event of leakage in the pressure sensor, the
pressure monitors/limiters according to b)
are not safe. A “dangerous condition” can
arise.
Control circuit Control circuit Control circuit
closed interrupted interrupted
Dangerous
condition!
Pressure switches 47
Pressure switches “of special construction”

Further observations and summary

Minimum pressure
All minimum pressure monitors and minimum pressure limiters are self-monitoring within the
meaning of “Pressure 100/1” (with or without safety diaphragm).

Pressure limiters must interlock the cut-off state

Memorandum “Pressure 100/1” specifies that pressure limiters must cut off and interlock against auto-
matic restarting. For this purpose, pressure limiters are offered with integrated mechanical interlock
(reclosing lockout). The direction of action is also important in the selection of the interlock. Depending
on the direction of action it is necessary to determine whether the interlock should operate on rising
(maximum pressure monitoring) or falling (minimum pressure monitoring) pressure.

External interlock is also possible

A pressure monitor can become a pressure limiter if an electrical interlock is connected in series. The
figures on page 29 show suggested interlock circuits for maximum pressure and minimum pressure
monitoring. The direction of action must be observed when deciding the circuit. For the combination
of pressure monitor with external interlock to be considered as a limiter “of special construction”, the
pressure monitor itself must satisfy the “special construction” requirements.

Other considerations

“Special construction” — not just for steam and hot water systems
According to current standards, pressure limiters “of special construction” are mandatory for steam -
boilers according to TRD 604 and for heating systems according to DIN 4751 Part 2. They are consid-
ered to be failsafe elements within the meaning of TRD 604 and can therefore be used on installations
in 24-hour operation and 72-hour operation (for further information see TRD 604). It is clearly advanta-
geous to transfer the positive experience from pressure monitoring of steam boilers to other applica-
tions. In the interest of greater safety it is desirable to incorporate the requirements for pressure lim-
iters “of special construction” used in safety-critical monitoring applications into other standards as
well. This applies particularly to applications in the field of gas, which are covered by DIN 3398 Parts 1
and 3, and liquid fuels, covered by DIN 3398 Part 4.

For even greater safety:

Positive opening contacts
In maximum pressure monitoring, safety can be further increased through additional measures. The
microswitches, normally equipped with a spring contacts, can be fitted with positive opening con-
tacts (to protect against contact sticking).

Line break and short-circuit monitoring

The power supply to the pressure limiter is monitored for short-circuit and interruption by an external
isolating amplifier (EX 041). In the case of faults in the power supply, the system cuts off to the safe
side. EEx-d and EEx-i versions, where applicable combined with sensors “of special construction”,
open up a wide range of possibilities in the field of Ex applications for process engineering systems
and gas engineering. See DBS series.

Summary

It is apparent that safety can be improved significantly and numerous causes for the occurrence of
dangerous conditions can be eliminated through the appropriate use of technical measures. However,
it is also apparent that a residual risk remains. Careful planning and conscientious maintenance and
testing of existing systems are absolutely essential for reliable pressuremonitoring on pipelines and
pressure vessels.
48 Pressure switches
Pressure switches “of special construction”

Standards – Directives –
Component tests

VdTÜV Steam and hot water

Pressure 100/1 Pressure monitors and pressure limiters for steam and hot water in systems to DIN 4751 T2 and TRD
604. Series DA and DWR.

DVGW Fuel gases

DIN 3398 T.1 and 3 Pressure monitors and limiters for fuel gases in accordance with DVGW Worksheet G 260.
Series DGM and DWR.

Liquid fuels
TÜV
Pressure monitors and pressure limiters for liquid fuels (heating oil) Series DWR.
DIN 3398 T.4

Safety-engineered pressure limiters

For safety-critical pressure monitoring in liquid gas systems, chemical and process engineering sys-
TÜV, Pressure 100/1
tems.
(DIN 3398 T.3 and 4)

Pressure Equipment Directive 97/23EC

PED 97/23EC Pressure monitors and limiters to DIN 3398 Parts 3 + 4 fall into Category IV of the PED

-versions
For Ex areas Zones 1 and 2, all pressure switches can be supplied in pressure-proof encapsulated
ATEX 94/9 EC design (Ex degree of protection EEx de IIC T 6).
PTB approval: PTB 02 ATEX 1121
For intrinsically safe control circuits (Ex degree of protection EEx-ia), pressure switches with gold con-
tacts,proximity switches and the blue terminals and cable entries customary in EExi areas can be sup-
plied. In addition to the pressure switch, an isolating amplifier which transfers the control commands of
the pressure switch from an intrinsically safe control circuit (EEx-ia) to a non-intrinsically safe active circuit
is required

Medium Steam Hot water Fuel gases Liquid fuels Pressure vessels
DVGW Worksheet (fuel oil) (e.g. for
G260/1 liquefied gas)

Plant directives

DIN 4751
Part 2 TRD
604

Directives for component testing

VdTÜV DIN 3398 DIN 3398 TÜV

Pressure 100/1 Part 3 Part 4 Pressure 100/1
Issue 4.83 Issue 11.82 Issue 10.86 DIN 3398 T.4

Type series DA DWR… DWR… FD…

DWR… DGM… DWAM…
 Pressure switches 49
Pressure switches “of special construction”

Selection according to function and

application

Application Steam and Fuel gases Heating oil Other

hot water to DVGW- and other media
systems to Worksheet liquid (check compatibil-
ity with the materi-
Function TRD 604 G 260 fuels als used)
and DIN 4751 T.2

Pressure monitor Pressure monitoring DWAM… DGM… DWR… DWAM…

Pressure regulation DWAMV… DWR… DWR…-203 DWAMV…
(e.g. burner or DWR… DWR…-203 DWR…
pump control) DWR…-203 DWR…-203
Maximum pressure
limitation SDBAM… DGM…-205 DWR…-205 SDBAM…
with internal interlock DWR…-205 DWR…-205 DWR…-205
with external DWAM… DGM… DWAM…
interlock DWR… DWR… DWR… DWR…
Minimum pressure
limitation DWR…-206 DGM…-206 DWR…-206 DWR…-206
with internal interlock DWR…-206
with external DWR… DGM…
interlock DWR… DWR… DWR…

…The code number for the pressure range must be inserted here (see datasheets). A final number of
2… (e.g. DWR…-205) means a plug connector according to DIN 43650.

DWR series
The DWR series covers all the applications mentioned above.
Pressure limiter with internal
interlock DA series (self-monitoring sensor)
DWAM, DWAMV and SDBAM are only suitable for maximum pressure monitoring. They offer
additional safety due to the safety diaphragm (selfmonitoring sensor). They are TÜV-tested for
steam and hot water, but thanks to the self-monitoring sensor can also be recommended for other,
particularly safety-critical applications (e.g. in process engineering).

Sensors of the DWR series are self-monitoring when used in minimum pressure monitoring applica-
tions.

Equipment of a boiler with pressure

monitor and pressure limiter

Pressure monitor DWAM… or DWR… Pressure monitor Pressure limiter

for burner control: (without adjustable switching differ- DWAM… SDBAM… or
ential) or DWR… DWR…-205
or
(better, because switching differen-
tial adjustable) DWAMV… or
DWR…–203

Pressure limiter for SDBAM… or DWR…–205

safety monitoring: (with internal interlock, unlocking
button on the pressurelimiter)
or
DWAM… or DWR… (with external
interlock in the control cabinet)
Suggested connection for the
external interlock, see page 31.
52 Pressure switches
Pressure switches “of special construction”

DWR-B series
P r e s s u r e l i m i t e r s f o r s t e a m a n d h o t w a t e r,
fuel gases and liquid fuels

The pressure limiters are equipped with a reclos- ing to be possible, the pressure at the sensor
ing lockout for the mechanical interlocking of the must have fallen (in the case of maximum pres-
switch-off state. If the switching point set on the sure limiters) or risen (in the case of minimum
pressure limiter is reached, the limiter switches pressure limiters). The pressure change values
off. The switch-off state is retained even if the are listed in the Product Summary.
pressure changes again. It can only be reset by
manually operating the reset button. For unlock-
DWR 625-205

Technical data Component tested for Steam Systems according to TRD 604
Hot water Systems according to DIN 4751, T. 2
Pressure connection
External thread G 1/2 (pressure gauge connec- Fuel gases DVGW Worksheet G 260
tion) to DIN 16 288 and internal thread G 1/4 to Liquid fuels e.g. fuel oils
ISO 228 Part 1 (for gas applications internal
thread permissible only up to 4 bar).

Switching device
Testing basis Registration no. TÜV
Pressure 100/1, Issue 4.83
Rugged housing (200) made of seawater-
resistant diecast aluminium. For maximum pressure limiter TÜV.SDB.02 – 310 DVGW
For minimum pressure limiter TÜV.SDB.02 – 309
Materials
Pressure bellows: Material no. 1.4571 DIN 3398, Part 3, Issue 11.92 NG-4347AQ1411
Sensor housing: Material no. 1.4104 DIN 3398, Part 4, Issue 10.86 3 C028/05
Switch housing: GD AI Si 12 (DIN 1725)

Mounting position Vertically upright and horizontal. Function Pressure limiter (with internal interlock)
Ambient temperature at switching device
–25…+70°C Direction of action For maximum and minimum pressure monitoring (SDBFS)

Medium temperature –25…+70°C.

The medium temperature at the pressure sensor Sensor “Of special construction” by testing with 2 million cycles.
must not exceed the permitted ambient temper-
ature at the switching device. Temperatures may Important: When selecting the limiter, it is necessary to decide whether the device is to be
reach 85°C for short periods.
Higher medium temperatures are possible pro- used for maximum or minimum pressure monitoring. The direction of action cannot be
vided the above limit values for the switching reversed at the pressure limiter.
device are ensured by suitable measures
(e.g. siphon).
Product Summary
Mounting Type Setting range Switching Maximum Connection
Directly on the pressure line (pressure gauge
connection) or on a flat surface with two differential working pressure diagram
4 mm Ø screws. (mean values) 1* 2*
Calibration
The DWR-205 series is calibrated for rising pres- Maximum pressure limiters
sure. This means that the adjustable switching DWR 06–205 0.1…0.6 bar 0.06 bar 6 bar 6 bar
pressure on the scale corresponds to the switch-
ing point at rising pressure. The reset point is DWR 1–205 0.2…1.6 bar 0.09 bar
lower by the amount of the switching differen- DWR 3 –205 0.2…2.5 bar 0.20 bar 10 bar 16 bar
tial. (See also page 30, 2. Calibration at upper
switching point). The DWR-206 series is cali- DWR 6–205 0.5…6 bar 0.30 bar
brated for falling pressure. This means that the DWR 625 –205 0.5…6 bar 0.50 bar 20 bar 25 bar
adjustable switching pressure on the scale cor-
responds to the switching point at falling pres-
DWR 16 –205 3…16 bar 0.70 bar
sure. The reset point is higher by the amount of DWR 25 –205 4…25 bar 1.4 bar 50 bar 63 bar
the switching differential. (See also page 30, DWR 40–205 8…40 bar 2.3 bar
1. Calibration at lower switching point).

Bursting pressure For all types ≥ 100 bar, Minimum pressure limiters
verified by TÜV test.
DWR 06–206 0.1…0.6 bar 0.06 bar 6 bar 6 bar
Switching differential For values see Product DWR 1 –206 0.2…1.6 bar 0.09 bar
Summary. DWR 3 –206 0.2…2.5 bar 0.20 bar 10 bar 16 bar
Contact arrangement Single pole changeover DWR 6–206 0.5…6 bar 0.30 bar
switch.
Switching
DWR 625 –206 0.5…6 bar 0.50 bar 20 bar 25 bar
250 VAC 250 VDC 24 VDC
capacity (ohm) (ind) (ohm) (ohm) DWR 16 –206 3…16 bar 0.70 bar
Normal 8 A 5 A 0.3 A 8A DWR 25 –206 4…25 bar 1.4 bar 50 bar 63 bar
Degree of protection IP 54 according to DIN DWR 40–206 8…40 bar 2.3 bar
40 050 * Maximum working pressure and dimensions as for type series DWR. Pressure monitors DWR…
IP 65 (alternative ver-
sion) (page 51) can also be used as maximum pressure and minimum pressure limiters with external inter-
Sealing P2 lock. You will find other maximum pressure limiters with safety sensor, type series SDBAM…, on page
On request (can be fitted later). 50. Types DWAM… can also be used with external interlock as maximum pressure limiters.

DVGW
s tested TÜV
Degree of protection:
IP 54/65
58 Pressure switches
Dimensioned drawings

Dimensioned drawings of switch housings

1 Housing 200 (plug connection) 2 Housing 300 and 500 (terminal connection)

FORM A

3 Housing 700 (Ex)

Dimensioned drawings of pressure sensors

10 11
Pressure switches 59
Dimensioned drawings

Dimensioned drawings of pressure sensors

12 13

14 15

16 19

SW
Dimensioned SW
drawing

16 22
17 24
18 30
19 32

20 21