EX-DWR - Pressure switch HONEYWELL - Free user manual and instructions

Brand	HONEYWELL
Model	EX-DWR
Category	Pressure switch (pressostat)
Type	Pressure switch with Ex execution (ATEX) for zones 1, 2, 21, 22
Pressure ranges	According to type code (e.g., DWR6: 0.5-6 bar); see data sheet
Switching differential	See data sheet; not adjustable on Ex-DWR
Electrical contact	Single-pole microswitch; breaking capacity 8 (5) A, 250 V AC (basic); Ex: 3 A 250 V AC, 2 A 250 V AC (inductive)
Electrical connection	Terminal box (500) or plug connector (200) according to DIN 43650; Ex: terminals under cover
Protection	IP 54 (200), IP 65 (500); Ex: IP 65
Ambient temperature	-25 to 70 °C (DWR); -15 to 60 °C (Ex-DWR)
Max. medium temperature	70 °C (DWR); 60 °C (Ex-DWR); values maintained by appropriate measures
Pressure connection	External thread G 1/2 A (pressure gauge connection) and internal thread G 1/4 according to ISO 228-1
Housing material	Seawater-resistant die-cast aluminum
Mounting position	Vertical upward or horizontal; Ex: vertical, directed upward
Cable entry (Ex)	M 16 x 1.5 for fixed installation
Approvals	VdTüv, DVGW, DIN 3398, DGR 97/23 EC; Ex: PTB 02 ATEX 1121, II 2 G D EEx de IIC T6
Main functions	Max/min pressure monitoring, limitation with lockout, intrinsic safety (EEx-i), gold contacts (low voltage)
Maintenance and cleaning	No opening or readjustment of lacquered screws; avoid vibrations, aggressive agents; use flat gaskets for gas >4 bar
Safety	Observe local regulations; risk of burns (up to 70 °C); protection against inductive overloads; mandatory grounding for Ex
Spare parts and repairability	Precision device factory-set; do not open or readjust; for repair, contact Honeywell GmbH
General information	Usable for gas (according to G260), EL fuel oil, steam, hot water; do not use for acids or aggressive agents; protect from sun and rain

Frequently Asked Questions - EX-DWR HONEYWELL

What is the pressure range of the EX-DWR?

The range depends on the type code (e.g., DWR6: 0.5-6 bar). Consult the data sheet for exact values. The scale gives approximate values.

How to adjust the switching point?

Use a screwdriver on the adjustment pin after loosening the set screw. Turn right to decrease, left to increase. Use a pressure gauge for precise adjustment. On Ex-DWR, remove the terminal box cover.

What are the electrical connections?

Wiring is done on the angled plug (200) or on the terminal board (500). Terminals 1, 2, 3: at increasing pressure, 3-1 opens, 3-2 closes. Cut power before intervention.

Can the EX-DWR be used in explosive atmospheres?

Yes, the Ex-DWR version is ATEX certified for zones 1, 2, 21, 22 (II 2 G D EEx de IIC T6). Follow the mounting instructions and use a fixed cable entry M16x1.5.

What is the difference between DWR and DGM?

DWR is for pressure switches, DGM for limiters. The technical characteristics are similar, but DGM has a max. medium temperature of 60 °C instead of 70 °C.

How to install the pressure connection?

Connect directly to the line with external thread G 1/2 or internal thread G 1/4. Use flat gaskets for gas >4 bar. Tighten only on the hexagon, not on the housing.

Which media are compatible?

Gas according to DVGW G260, EL fuel oil, steam, hot water. Do not use for acids, aggressive agents, unstable gases (acetylene, etc.) or heavily polluted media without a pressure intermedium.

What to do in case of malfunction?

Do not open the device, it is factory-set. Check the wiring, inductive loads, and sensor contamination. Contact Honeywell for repair.

What is the IP protection?

Plug connector housing (200): IP 54. Terminal box housing (500): IP 65. For Ex-DWR: IP 65 in vertical mounting.

How does the mechanical lockout work?

The limiters DWR...-205 (max pressure) and -206 (min pressure) have a bistable microswitch. After tripping, unlock by pressing the red button after pressure has returned to the range.

USER MANUAL EX-DWR HONEYWELL

Close-up of a metallic industrial pressure relief valve with threaded ports and a black connector (no visible text or symbols)

Grundtypen Basic models Types de base

DWR... ...203 ...574 DGM... ...205 ...575 Ex-DWR... ...206 ...576 Ex-DGM... ...213 ...577 ...513

Simple line drawing of a mechanical component with a handle and arrow indicating direction (no text or symbols)

$$ R S P = S P + x d $$

Technical line drawing of a mechanical sensor or actuator device (no text or symbols visible)

VdTÜV pressure 100/1, issue 4.83

VdTÜV pressure 100/1, issue 4.83

VdTÜV pressure 100/1, issue 4.83

DIN 3398-3 (01.11.1992)

DIN 3398-4 (1986-10)

DGR 97/23 EG

Testing basis (DMG)

DIN 3398-3 (01.11.1982)

+ DIN EN 1854 (01.11.1997)

DIN 3398-1 (01.1992) + DIN 3398-3 (11.1982)

Function

Pressure monitor

Pressure limiter (with internal or external interlock)

Action direction

for maximum pressure and minimum pressure monitoring (DWFS, SDBFS)

Type series

DWR Installations acc. to TRD 604

DWR Installations acc. to DIN 4751,

DWR + DGM P. 2 DVGW-Worksheet G 260

DWR e.g. fuel oils

Registration No.

ID: 0000007042

ID: 0000020757

ID: 0000020756

NG-4347AQ1411

3C028/5

CE-0035BN0004

Registration No.

NG-4346AP1011

CE-0085AQ1088

Sensor

"Special design" by testing

with 2 million operations

DVGW

TÜV

Type code

Basic versionDWR XXX	Version with additional functionDWR XXX-YYY	Ex versionEx-DWR XXX
DWR	Identification for series
XXX	Identification for pressure range
YYY	Identification for additional function
Ex-	Identification for Ex version

The type code also roughly applies for series DGM...

Version of the switch housing

DWR XXX

DWR XXX-2...

Plug connection housing (200) (plug connection to DIN 43650)

DWR XXX-5...

Terminal connection housing (500)

Ex-DWR...

Ex switching device (700)

Important note:

The pressure switches are precision devices which are set and adjusted in the factory. Therefore do not open the device, do not change the adjustment of the varnished adjustment screws.

The switching points would change – readjustment would be necessary.

Important safety information

Please read before installing and commissioning.

Installation and commissioning

1. Pressure switches may only be installed by personnel trained in this application area (electric/hydraulic/mechanical) in accordance with the installation instructions and local legal requirements.
2. The device must only be installed (mechanical, pressure-side connection) on electrochemically matched materials, otherwise there is risk of damage to base metals through contact corrosion which can result in loss of stability and leakage.
3. Caution when touching device – risk of burns. Device can reach a medium temperature of up to 70 °C. Risk of freezing when working with media up to -20 °C.

Safety instructions

1. Devices of the DWR series are designed for use as pressure monitors for gases in accordance with DVGW worksheet G260 and for liquid fuels (e.g. heating oil EL) and steam and hot water systems in accordance with TRD 604 and DIN 4751, part 2.

2. The device must only be used within the electric, hydraulic and thermal limits specified in the data sheet.

3. Inductive loads can cause contact burns or fuse the contacts. Preventative measures must be implemented by the customer, e.g. through use of suitable RC elements.
4. When using the version with ZF 1979 (oil and grease-free) take care to avoid recontamination of surfaces that are in contact with media, right through from opening the packaging to completed installation. Generally, no liability will be assumed for oil and grease-free.
5. High quality stainless-steel sensor parts in contact with media enable the devices to be used with a variety of media. However a chemical resistance test MUST be carried out before selection.
6. Use with acids and other aggressive media, such as hydrofluoric acid, copper chloride, aqua regia or hydrogen peroxide is not permitted.
7. Use in systems with unstable gases and liquids such as hydrogen cyanide, dissolved acetylene or nitrogen oxide is not permitted.

8. Devices must be protected from solar radiation and rain.

9. Pressure switches are precision devices, which are calibrated in the factory. For this reason, never open the device and do not change the adjustment of the varnished calibration screws.

10. Prevent excessive vibrations from reaching the pressure switch, e.g. with mechanical isolation or other vibration damping measures.
11. Heavily contaminated media can clog the sensor and cause errors and/or malfunction. If the device is being used for this purpose, suitable pressure mediators must be connected.
12. Pressure switches and pressure mediators form a function unit and must not be disconnected from each other in the field.
13. Before disassembly (removing the pressure switch from the system), the device must be disconnected from the power supply and the system must be emptied. Observe the Accident Prevention Regulations.
14. Never use the pressure switches as a climbing aid.
15. Honeywell GmbH accepts no liability for non-compliance.

PLT protection devices

1. If the device is installed in a PLT protection device in accordance with IEC61511, the relevant technical data on the SIL certificate must be observed.

Contents

1. Basic version
   1.1 Technical data
   1.2 Electrical connection
   1.3 Pressure connection
   1.4 Setting the switching pressure
   1.5 Electrical interlock in the switchgear cabinet
2. Pressure monitors with adjustable switching difference DWR XXX-203
3. Pressure limiters with mechanical interlock of the switching state (restart lockout) DWR XXX-205 DWR XXX-206
4. Pressure monitors with gold plated contacts DWR XXX-213
5. Pressure monitors in intrinsically safe control circuits (EEx-i) DWR XXX-513
6. Maximum pressure monitors in intrinsically safe control DWR XXX-574–577 circuits with open-circuit and short-circuit monitoring (EEx-i)
7. Pressure monitors in Ex version Ex-DWR XXX
   DWR XXX

* The type identification also roughly corresponds to series DGM...

Type identification\*

1 Basic Equipment of the pressure monitors DWR.../DGM...

Chapter 1 describes the basic equipment and the installation of the pressure monitors DWR/DGM XXX (without any additional functions). Chapters 2-7 describe versions and additional functions.

1.1 Technical data (basic equipment)

Basic calibration:

Depending on series and intended purpose, FEMA pressure switches are either calibrated for falling or rising pressure. The table shows the calibration of the various devices and their versions.

	Basic device	Versions
Calibrated under rising pressure	DWREx-DWR...	DWR...-203, -205, -213, -301,-303, -305, -313, -351, -353, -363, -513, -563, -576, -577
	DGM...,EX-DGM...	DGM...-205, -213, -301, -305,-313, -351, -363, -513, -563, -576, -577
Calibrated under falling pressure	n/an/a	DWR...206, -306, -574, -575DGM...206, -306, -574, -575

For devices calibrated under rising pressure the following applies:

If the maximum value of the setting range is set as the switching point, the reset point is lower by the value of the average switching differential. (e.g. DWR6: setting range 0.5-6 bar, switching point 6 bar, reset point 5.8 bar) If the minimum value of the setting range is used, then the lowest setting value is also the reset point. The switching point must be set higher by the value of the average switching differential (e.g. DWR6: 0.5-6 bar, switching point 0.7 bar, reset point 0.5 bar).

For devices calibrated for falling pressure the following applies:

If the minimum value of the setting range is used, then the lowest setting value is also the switching point. The reset point must be set higher by the value of the average switching differential (e.g. DWR6-206: 0.5-6 bar, switching point 0.5 bar, reset point 0.8 bar). If the maximum value of the setting range is used, then the highest value of the setting range is also the reset point. The reset point must be set higher by the value of the average switching differential (e.g. DWR6-206: setting range 0.5-6 bar, reset point 6 bar, switching point 5.7 bar).

The following applies for all devices:

All switching and reset points must be within the limits of the specified setting range given in the technical data sheet.

Switch

Single-pole changeover

Switching capacity

8 (5) A, 250 V AC

Installation position

Vertical to the top and horizontal

Max. ambient temperature

-25 to 70 °C (DWR...)

-25 to 60 °C (DGM...)

Max. medium temperature

70 °C, (60 °C on DGM) higher medium temperatures are possible if the above limiting values at the switching device are not exceeded by suitable measures (e.g. water pocket tube). At ambient temperatures below 0 °C, ensure that no water condensation can arise in the sensor and in the switching device.

Switching difference

For values see data sheet

Pressure connection

External thread G ^1/2 A (pressure gauge connection) according to DIN 16288 and internal thread G ^1/4 according to ISO 228, Part 1. (For gas applications internal thread permissible only up to 4 bar. Use flat gasket ring for pressure > 4 bar.)

Switching device

Sturdy housing made of sea-water resistant aluminium die casting with plug connection (200) or terminal connection (500).

Degree of protection acc. to EN 60529

IP 54 (housing 200)

IP 65 (housing 500)

Materials

See data-sheet

1.2 Electrical wiring

Connection layout

With rising pressure: 3–1 opens, 3–2 closes With falling pressure: 3–2 opens, 3–1 closes

Wiring

Wiring is on the angled plug. The cable outlet can be in any of 4 positions, which are at 90^ in relation to each other.

1. Remove screw.
2. Insert the screwdriver in the slot and press downwards.

Simple line drawing of a mechanical component with a tool inserted (no text or symbols)

On devices with terminal connection housing the terminal board is available after removing the terminal box lid.

Caution: Switch of voltage.

1.3 Pressure connection

Installation: Directly on the pipeline (pressure gauge connection G 12 ) or with 2 screws (4 mm) on a level surface. Tighten only on the hexagonal of the pressure organ, never use the housing or plug as lever arm.

External thread G ^1/_2

(Pressure gauge connection) When using flat seals, turn in the centering screw (depth A approx. 0.3–0.5 mm).

Internal thread G ^1/_4

In gas applications internal thread only up to 4 bar permissible. Use flat gasket ring for pressure > 4 bar.

1.4 Setting the switching pressure

The switching pressure is set using the setting spindle. Before setting loosen the setscrew located above the scale by approx. 2 turns and tighten it again after setting.

The scale value corresponds to the upper switching point (for rising pressure). The lower switching point (for falling pressure) is lower by the switching difference. The scale serves as estimated value scale, a pressure gauge is required for accurate settings.

On terminal connection housings the setting screw is available after removing the cover.

Caution: Switch off voltage.

1.5 External electrical interlock in the switchgear cabinet (circuit proposal)

A pressure monitor can also be used as limiter if an electrical interlock is connected in series.

In pressure limitation in steam and hot water boilers, the external interlock is permissible only if it is assured that the pressure monitor is of “special design”.

1.5.1 Maximum pressure limitation with external interlock

graph TD
    L1["Power Supply L1"] --> A["Resistor"]
    A --> B["DWR"]
    B --> C["Switch 1-2-3"]
    C --> D["Control Signals T1-T2"]
    D --> E[" Safety Circuit"]
    E --> F["Switch K1"]
    F --> G["Switch N"]
    G --> H["Ground"]
    I["2A"] --> J["Resistor"]
    J --> K["DWR = pressure monitor"]
    K --> L["T1 = STOP"]
    K --> M["T2 = START"]
    K --> N["S = signal (as required)"]
    K --> O["K1 = relay with self-hold"]
    P["T1"] --> Q["Switch"]
    R["T2"] --> S["Switch"]
    T["S"] --> U["Switch"]
    V["N"] --> W["Ground"]

1.5.2 Minimum pressure limitation with external interlock

When the interlock circuit shown above is used, the requirements according to DIN 57116/VDE 0116 are fulfilled if the electrical plant, such as contactors or relays, correspond to the external interlock circuit VDE 0660 or VDE 0435 respectively.

2. Pressure monitors with adjustable switching difference DWR...-203 (not for DGM...)

2.1 Technical data as for 1.1
2.2 Electrical connection as for 1.2
2.3 Pressure connection as for 1.3
2.4 Setting

One spindle each is available for setting the switching pressure and the switching difference. Both spindles are arranged concentrically. The outer spindle with larger diameter influences the lower switching point, the switching difference and thus the upper switching point, is changed with the small grub screw located internally.

The action direction is indicated by the arrow direction.

Setting sequence

a) Lower switching (with decreasing pressure), with outer spindle, according to scale or pressure gauge.
b) Switching difference (with increasing pressure), with small, internal grup screw, results in upper switching point.

When the switching difference is changed, the lower switch-off point remains unchanged, the upper switching point is shifted by the switching difference.

3. Pressure limiters with mechanical interlock of the switching state (applies for DWR and roughly for DGM)

Maximum pressure limiter DWR...-205 ID: 0000020756

Minimum pressure limiter DWR...-206 ID: 0000020757

Instead of the microswitch with automatic reset, a “bistable” microswitch is installed in the limiters.

When the pressure reaches the value set on the scale, the microswitch switches over and remains in this position. The catch can be released by pressing in the unlocking button (marked on the scale side of the switching device by a red dot). The limiter can not be unlocked until the pressure has decreased by a certain amount or, in the case of interlocking at the lower switching point, is increased again. According to version, the interlock can be effective for a rising value DWR...-205 or for a falling value DWR...-206.

3.1 Technical data as for 1.1

3.2 Electrical connection

3.2.1 Maximum pressure limiter

Switching over and interlocking on rising temperature.

Additional function (...205). Connection of control circuit to terminal 1 and 3.

3.2.2 Minimum pressure limiter

Switching over and interlocking on falling temperature.

Additional function (...206). Connection of control circuit to terminal 2 and 3.

3.3 Pressure connection as for 1.3

Technical line drawing of a mechanical sensor or actuator component (no text or symbols visible)

DWR...-205

DWR...-206

3.4 Setting as for 1.4

Please note:

For maximum pressure limiters (205) the scale value corresponds to the upper switching point, for minimum pressure limiters (206) to the lower switching point.

4. Pressure limiters with gold plated contact DWR...-213, DGM...-213

Gold plated contacts are used exclusively in the low voltage range in order to keep the transit resistance at the contacts low.

4.1 Technical data as for 1.1

Switching capacity:

max. 24 V DC

max. 100 mA

min. 5 V DC

min. 4 mA

At higher voltages and currents, the gold layer on the contacts will be damaged.

All other data correspond to the basic equipment.

5. Pressure monitors in intrinsically safe control circuits (EEx-i) DWR/DGM...-513

To be used only together with a suitable isolating amplifier, (e.g. Ex 011).

The attached connection diagram to the isolating amplifier has to be noted.

Connection diagram

6. Pressure limiters/Pressure monitors in intrinsically safe control circuits with open-circuit and short-circuit monitoring (EEx-i)

The pressure monitors correspond in all technical data to the Type DWR (DGM). In addition, a resistance combination is provided in the switching device, which, together with the isolating amplifier EX 041, monitors the electric cables between isolating amplifier and pressure monitor for open circuit or short circuit. In the case of open circuit or short circuit, the system switches off towards the safe side. When choosing the type and when connecting please strictly distinguish between maximum pressure and minimum pressure monitoring, as well as monitoring and limitation function.

Ex-Zone 1 or 2, 21 or 22

Ex-free Zone

7. Pressure monitors in EEx-d version Ex-DWR..., Ex-DGM...

Ex-pressure monitors must be supplied in the form that has been tested according to ATEX.

Versions and additional functions are basically not possible.

7.1 Technical data of the Ex switching device

Type of Ex-protection

EX II 2 G D EEx de IIC T6 IP65 T80°C

Ex approval

PTB 02 ATEX 1121

Ex-Zone

Compatible for zones 1 and 2, 21 and 22

Form of protection

IP 65 (vertical position)

Ambient temperature

-15 to +60 °C

Max. temperature at pressure switch

60 °C

Max. medium temperature

for pressure switches

60 °C.

Higher medium temperatures are possible if the appropriate measures (e.g. water sack pipe) are taken so that the above mentioned ranges are not exceeded on the switch.

Cable entry

M 16 x 1,5

For fixed installation only

Switching difference

Not adjustable, approximate values see data sheet

Fitting position

Vertically upwards

7.2 Electrical data

Connection plan

The terminal board can be accessed after the protective casing has been removed. After connecting the supply lines, the protective casing should in all cases be reattached.

With increasing pressure 3–1 will be interrupted and 3–2 will be closed.

Switching element

Single-poled, changeover microswitch.

Protection of the conductive connection

Can be accessed after removing the terminal board casing.

Earthing connection/potential connection

The maximal cross section of the cable is 4 mm^2 .

Switching power

3 A 250 V AC, 2 A 250 V AC (inductive)

0.03 A 250 V DC, 3 A 24 V DC

7.3 Pressure connection as for 1.3

7.4 Setting of switching point

The switching point can be set within the range given in the datasheet by using a screwdriver on the setting spindle. Additionally you should remove the terminal board casing (with 4 hexagon screw M 4). The affixing screw on the front end (above the scale) has to be removed and should be reattached after setting the switching point.

Turning the setting spindle clockwise gives a lower switching point, turning anticlockwise gives a higher switching point.

The scale should be used as a guide, for more exact settings you should use a manometer.

7.5 Serial numbers

All switch units and their respective terminal board casings are marked with a serial number. When installing you should ensure that the terminal board casings do not get mixed up.

Important notice:

When installing the Ex switch units and setting them up for operation you should comply with the recognised rules and guidelines for installations in Ex-areas.

Ex-cable gland (4) only to be used for fixed installation.

1 Potential equalisation
2 Protective casing for terminals (removable)
3 Connection terminals
4 Cable inlet M 16 x 1,5
5 Switching point adjustment
6 Locking bolt for setting spindle
7 Protection of the conductive connection

Utilisation

Vapeur

Eau chaude

Gaz combustibles

Combustibles liquides

Simple line drawing of a mechanical component with a tool inserted (no text or symbols)

Attention: Couper la tension.

SP = point de commutation

Technical line drawing of a mechanical sensor or actuator component (no text or symbols visible)

Manufactured for and on behalf of the Environmental and Combustion Controls Division of Honeywell Technologies Sàrl, Ecublens, Route du Bois 37, Switzerland by its Authorized Representative:

FEMA Regelgeräte

Honeywell GmbH

Böblinger Straße 17

71101 Schönaich

Deutschland

Telefon 0 70 31 / 6 37-02

Telefax 0 70 31 / 6 37-8 50

FEMA Controls

Honeywell GmbH

Böblinger Straße 17

71101 Schönaich

Germany

Phone 0 70 31 / 6 37-02

Fax [phone]

7157.134/20

MU2B-0264GE51 R0708