Ashcroft F5509 Instruction Manual

IM-F5509/F5509-EN-Rev A05/2020 Page 1 of 27
P/N 095I108-02EN
Installation and Maintenance
Instruction Manual
Differential pressure gauge, model F5509/F6509
for industrial application in the following configuration:
•###F5509/F6509###ATEX differential pressure gauge without switching contact
•###F5509/F6509###I###ATEX differential pressure gauge with inductive proximity switches

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Table of contents:
1General remarks.........................................................................................................................................................3
1.1 Purpose of this Manual........................................................................................................................................3
1.2 Symbols...............................................................................................................................................................3
1.3 Limits of liability ...................................................................................................................................................3
1.4 Copyright .............................................................................................................................................................3
1.5 Warranty..............................................................................................................................................................3
1.6 Manufacturer’s address, customer services........................................................................................................3
2Safety..........................................................................................................................................................................4
2.1 General sources of hazards ................................................................................................................................4
2.2 Use in accordance with intended purpose ..........................................................................................................4
2.3 Operator’s responsibility......................................................................................................................................4
2.4 Staff qualifications (target group assessment)....................................................................................................4
2.5 Signs/Safety markings.........................................................................................................................................4
2.6 Safety equipment ................................................................................................................................................5
2.7 The window uses multi-layer safety glass.Environmental protection..................................................................5
3Use in explosion risk areas pursuant to Directive 2014/34/EU (ATEX) .....................................................................5
3.1 F5509 and F6509 without switching contact.......................................................................................................5
3.2 F5509 I#### and F6509 I#### with inductive proximity switches SJ2-N............................................................6
4Technical data ............................................................................................................................................................7
5Labeling on the device................................................................................................................................................7
5.1 Labeling on the device for explosion risk areas (ATEX) .....................................................................................7
6Construction and function...........................................................................................................................................8
6.1 Overview..............................................................................................................................................................8
6.2 Description of function.........................................................................................................................................8
6.3 Description of components..................................................................................................................................8
6.4 Accessories .........................................................................................................................................................8
7Transport ....................................................................................................................................................................8
7.1 Safety ..................................................................................................................................................................8
7.2 Transport inspection............................................................................................................................................8
7.3 Storage ................................................................................................................................................................9
8Assembly/Installation..................................................................................................................................................9
8.1 Safety ..................................................................................................................................................................9
8.2 Preparations (requirements for the installation location).....................................................................................9
8.3 Mounting/Installation ...........................................................................................................................................9
8.4 Starting up .........................................................................................................................................................10
8.5 Subsequent relocation of the gauge (by the customer) ....................................................................................11
9Servicing ...................................................................................................................................................................11
9.1 Safety ................................................................................................................................................................11
9.2 Gauge performance and calibration..................................................................................................................11
9.3 Cleaning and maintenance ...............................................................................................................................11
10 Faults ....................................................................................................................................................................11
10.1 Safety.............................................................................................................................................................11
10.2 Conduct in the event of faults ........................................................................................................................11

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10.3 When action is required to repair/replace the gauge:....................................................................................11
10.4 Gauge repair/replacement.............................................................................................................................12
11 Removal, disposal.................................................................................................................................................12
11.1 Safety.............................................................................................................................................................12
11.2 Removal.........................................................................................................................................................12
11.3 Disposal .........................................................................................................................................................12
12 Appendix ...............................................................................................................................................................12
12.1 Data sheet for differential pressure gauge F5509/F6509..............................................................................12
12.2 Declaration of conformity model F5509 / F6509 without contacts ................................................................13
12.3 Declaration of conformity model F5509 and F6509 inductive proximity switches.........................................15
12.4 EU design type test certification for inductive proximity switches of types SJ2-N ........................................17
1 General remarks
1.1 Purpose of this Manual
This Operating Manual contains fundamental and essential advice to be followed for the installation, operation and
servicing of the device. It must be read before assembly and start-up of the device by the fitter, the operator and the
specialist personnel responsible for the device. This Operating Manual must be available at the point of use at all
times.
The following sections about general safety information (2) and also the following specific advice regarding the
intended purposes (2.2) and through to disposal (11.3) contain important safety information which, if not followed, may
result in risks for people and animals, or to property and buildings.
1.2 Symbols
Warning!
This indicates a possibly hazardous situation where failing to follow advice may result in risks to people,
animals, the environment and buildings.
Information!
This emphasizes key information for efficient, fault-free operation.
1.3 Limits of liability
Refer to Ashcroft standard terms of sale for limits of liability.
1.4 Copyright
This Operating Manual may only be copied and passed on as a complete document without the special permission of
the publisher.
1.5 Warranty
For the product described here, we offer a warranty pursuant to our General Terms and Conditions on Delivery and
Payment, Section 6: Liability for Defects.
1.6 Manufacturer’s address, customer services
Ashcroft Instruments GmbH
Max-Planck-Strasse 1
D-52499 Baesweiler. Germany
Tel.: [phone]
Fax.: [phone]
E-mail: [e-mail]
Web: www.ashcroft.eu

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2 Safety
2.1 General sources of hazards
Pressure gauges are pressurized parts where failure can result in hazardous situations. The selection of pressure
gauge should be made in accordance with the rules set out in EN 837-2 & DIN 16003.
2.2 Use in accordance with intended purpose
The devices are only to be used for the intended purpose as described by the manufacturer.
The devices are used for direct display of differential pressure.
The integrated switching elements are magnetic spring contacts or inductive proximity switches with a groove design,
supplied by isolating switch amplifiers. If the set limit values are exceeded, the output circuits are opened or closed.
For each use scenario, the corresponding set-up regulations must be respected. The use in explosion risk areas is not
permitted.
2.3 Operator’s responsibility
Safety instructions for proper operation of the device must be respected. They are to be provided by the operator for
use by the respective personnel for installation, servicing, inspection and operation. Risks from electrical energy and
from the released energy of the medium, from escaping media and from improper connection of the device must be
eliminated. The details for this are to be found in the corresponding applicable set of regulations, such as DIN EN,
UVV (accident prevention regulations) and in sector-specific instances of use (DVWG, Ex-. GL, etc.) the VDE
guidelines and the regulations supplied by local utilities companies.
The device must be taken out of service and secured against inadvertently being restarted, if the presumption is that
risk-free operation is no longer possible (see Chapter 10: Faults).
Conversion works or other technical alterations to the device by the customer will violate the approval for
hazardous area and are not permitted. This also applies to installation of spare parts. Possible conversations
or alterations may only be carried out by the manufacturer.
The operational safety of the device is only guaranteed where it is used for its intended purpose. The specification of
the device must be adapted to the medium used in the plant. The limit values indicated in the technical data must not
be exceeded.
The safety information detailed in this Operating Manual, existing national regulations for accident prevention, and the
operator’s internal regulations regarding working, operations and safety must be respected.
The operator is responsible for all specified servicing, inspection and installation works being carried out by authorized
and qualified specialists.
The operator is responsible that the device is used in the correct ATEX zone.
2.4 Staff qualifications (target group assessment)
The device may only be installed and started up by specialist staff who are qualified for installation, start-up and
operation of the product.
Specialist staff is people who are able to assess the work assigned to them on the basis of their specialist training,
their knowledge and experience and their knowledge of the relevant standards, and can identify possible risks.
For devices in explosion-protected configuration, these staff must have been trained or instructed in, or be authorized
for, working on explosion-protected devices in potentially explosive plants.
2.5 Signs/Safety markings
The pressure gauge and its surrounding packaging carry markings. These markings show the article number,
measurement range, maximum static pressure, maximum overload and manufacturer. The pressure gauge can be
provided with additional signs and safety markings advising on special conditions:
Advice on the filling liquid
Advice on calibration
Ex (for ATEX configuration)
Oil-can deleted (if oxygen is used)

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2.6 Safety equipment
This device is fitted with a (S3) solid front and rear wall (F6509) or (S1) blow plug (F5509) according DIN 16003,
capable of being blown out. For the description, please refer to Chapter 6.3.4.
2.7 The window uses multi-layer safety glass.Environmental protection
This device may optionally contain a filling liquid (e.g. glycerin or silicone oil). The provisions set out in the REACH
regulation on production and use of chemicals are to be respected, and the relevant safety data sheets from the
manufacturers of the chemicals are available on our website for download.
Electric contacts are offered as a gauge option. The provisions set out in the WEEE regulation EU directive
2012/19/EC on electrical and electronically equipment are to be respected, and the products are registered at the EAR
under the number DE 26646349.
3 Use in explosion risk areas pursuant to Directive 2014/34/EU
(ATEX)
3.1 F5509 and F6509 without switching contact
Area of use:
Explosion risk areas Zone 1 and 2, and 21 and 22, risk from gases and dry dust
Permitted temperatures:
The maximum occurring surface temperature of 95 °C was determined with no covering of dust and with no safety
factor.
For dust clouds and dust layers the ignition temperature must be specified pursuant to ISO / IEC 80079-20-2
For dust clouds the maximum allowable medium temperature inside of the measuring instrument must not exceed
2/3 of the dust ignition temperature
For dust layer the maximum allowable medium temperature inside of the measuring instrument must be 75K lower
than the dust ignition temperature
Permitted ambient temperature -20°C to +60 °C.
Permitted medium temperature in the pressure gauge < 85 °C.
Permitted environment air with usual oxygen content (21%), ambient pressure 80 kPa (0,8 bar) to 110 kPa (1,1 bar)
Warning! With gaseous media, the device temperature may increase due to compression heat. In
such cases, the rate of the pressure change must be regulated or the permitted temperature of the
measuring medium reduced.
Note:
For a change in differential pressure between 10 % and 90 % of the measuring range and a pulse frequency of <
0.06 Hz, the temperature increase is <10 K.
To avoid additional temperature increase, the devices should not be exposed to direct exposure to sunlight when in
operation!
For the non-electrical part of the devices, the, EN ISO 80079-36, EN ISO 80079-37, EN 60079-0 and EN 60079-31,
are applicable with regard to explosion protection. The relevant requirements of these standards are satisfied.
The documentation has been filed with TÜV-Nord-Cert NB 0044 (see declaration of conformity).
Labeling:

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3.2 F5509 I#### and F6509 I#### with inductive proximity switches SJ2-N
Area of use:
Explosion risk areas Zone 1 and 2, and 21 and 22, risk from gases and dry dust.
Permitted temperatures:
The maximum occurring surface temperature of 95 °C was determined with no covering of dust and with no safety factor.
For dust clouds and dust layers the ignition temperature must be specified pursuant to ISO / IEC 80079-20-2
For dust clouds the maximum allowable medium temperature inside of the measuring instrument must not exceed
2/3 of the dust ignition temperature
For dust layer the maximum allowable medium temperature inside of the measuring instrument must be 75K lower
than the dust ignition temperature
Permitted ambient temperature -20 °C to +60 °C.
Permitted medium temperature in the pressure gauge < 85 °C.
Permitted environment air with usual oxygen content (21%), ambient pressure 80 kPa (0,8 bar) to 110 kPa (1,1 bar)
Warning! With gaseous media, the device temperature may increase due to compression heat. In
such cases, the rate of the pressure change must be regulated or the permitted temperature of the
measuring medium reduced.
Note:
For a change in differential pressure between 10 % and 90 % of the measuring range and a pulse frequency of <
0.06 Hz, the temperature increase is <10 K.
To avoid additional temperature increase, the devices should not be exposed to direct exposure to sunlight when in
operation!
EU design type test certification for the installed inductive proximity switches:
PTB 99 ATEX 2219X 4. supplement
The integrated proximity switch is indicated on the type label/wiring diagram.
The surrounding housing has protection class IP65 as per EN 60529.
For use in explosion risk areas, the devices must be connected to certified intrinsically safe power circuits:
Max. voltage Umax = 16 V
Max. current Imax = 25 mA
Max. power Pmax = 64 mW
Device data (per contact):
max. internal capacitance Ci max = 30 nF
max. internal inductance Li max = 100 μH
The permitted limit values for Ui, Iiand Pifor the intrinsically safe feed power circuits depend on the proximity switch
type. They are to be found in the respective EU design type test certifications.
For the non-electrical part of the devices, the standards, EN ISO 80079-36, EN ISO 80079-37, EN 60079-0 and EN
60079-31 are applicable with regard to explosion protection. The relevant requirements of these standards are
satisfied.
The documentation for the mechanical part has been filed with TÜV-Nord-NB 0044 (see declaration of conformity).
Labeling:

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Recommended isolating switch devices:
MTL 5011B 1-channel, for contacts/inductive proximity switch, operating voltage 20-35 VDC
MTL 5015 2-channel, for contacts/inductive proximity switch, operating voltage 20-35 VDC
KFA6-SR2-Ex1.W 1-channel, for contacts/inductive proximity switch, operating voltage 230 VAC
KFA6-SR2-Ex2.W 2-channel, for contacts/inductive proximity switch, operating voltage 230 VAC
4 Technical data
The detailed technical information can be found in the documents in the Appendix, Chapter 12.
5 Labeling on the device
The label with the serial number and type designation is located on the outside of the housing. The materials identifier
is encoded in the type designation.
5.1 Labeling on the device for explosion risk areas (ATEX)
The label with the marking for explosion risk areas is located on the outside of the housing.
Device without switching contacts:
###F5509####ATEX
Device with integrated inductive proximity switch:
###F5509#### I####ATEX

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6 Construction and function
6.1 Overview
1. Sensing diaphragm
2. Sealing / spring bellows
3. Connecting rod
4. Pointer mechanism
6.2 Description of function
The pressures to be compared, differential pressure, act on a flexible stainless steel diaphragm, which separates the
two pressure champers.
The diaphragm is mechanically linked by a rigid connecting rod. When pressures are equal on both sides, the
diaphragm is on zero position. When there is a difference in pressures the diaphragm is deflected from the high
pressure side, towards the lower pressure side, causing a displacement of the connecting rod.
A precision mechanism translates the linear displacement of the diaphragm connecting rod to angular movement of
the gauge's dial pointer. The pointer's displacement range of 270° corresponds to the full scale differential pressure.
6.3 Description of components
6.3.1 Scale with pointer
The differential pressure gauge is equipped with a dial face and pointer pursuant to DIN 16003, nominal size 100 mm
or 160 mm.
6.3.2 Instrument connection
The instrument connection is located on the underside of the differential pressure gauge and can be male or female
threaded process connection. Distance between ports is 37 mm, please consider this when selecting a 5-way
manifold.
6.3.3 Vent valve
The vent valve for the housing is located on the top side. If the nipple is pulled out, the housing is vented and the
pressure which has built up in the housing due to the influence of temperature is discharged. With the valve closed,
protection class IP 66 is achieved.
6.3.4 Rear wall/plug with blow-out capability
The pressure gauge has a plug capable of blowing out on the rear wall of the housing (Model F5509) or a rear wall
capable of blowing out (Model F6509). These act as a safety feature pursuant to DIN 16003 and simultaneously allow
for temperature compensation for the housing, via a rubber membrane.
6.4 Accessories
Please contact the manufacturer regarding available accessories.
7 Transport
7.1 Safety
The differential pressure gauge should be protected against the effects of knocks and impacts. The device should only
be transported in the packaging provided, to protect against glass breakage. The device should only be transported in
a clean condition (free of residues of measuring media).
7.2 Transport inspection
The delivery must be checked for damage during transport. In the event of damage during transport, the delivery must
not be accepted, or only accepted subject to reservation of the scope of the damage being recorded and, if necessary,
a complaint initiated.

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7.3 Storage
The differential pressure gauge must be stored in dry, clean conditions, within a temperature range of -20 to +70 °C,
protected against direct exposure to sunlight and protected against impact damage.
8 Assembly/Installation
8.1 Safety
To ensure safe working during installation and servicing, suitable shut-off valves must be installed in the plant (see 6.4
Accessories), enabling the device:
To be depressurized or taken out of operation;
To be disconnected from the pressure source for repair or check within the relevant plant;
Or to enable function tests of the device to be performed “on site”.
During the works to mount/install the gauge, the plant must be protected against being switched back on.
8.2 Preparations (requirements for the installation location)
A check on suitability of the device for the medium to be measured, the scope of the measurement range and
static pressure and of the protection against special conditions such as vibration, pulsation and pressure spikes.
A bracket must be installed to support the pressure gauge if the mounting process pipe is not able to provide
adequate support.
The installation location should be chosen such that the work-spaces for operating personnel are not located to
the rear of the pressure gauge.
8.3 Mounting/Installation
8.3.1 Process connection
The instrument is intended and factory adjusted for vertical mounting, pressure ports downward. When mounted
in other orientation (max. ± 10°) the pointers’ zero position needs to be adjusted (see 8.4.1 Zero point adjustment).
Connection to be made by authorized and qualified personnel only.
Use only with the mechanical process connection provided – regarding the configuration, see order code on the
device type label, with a matching threaded seal.
When connecting the device, the process piping must be depressurized.
The process pipe must be installed on an incline so that:
- for fluid measurement, no air pockets are created
- for gas measurement, no water pockets are created
If the necessary incline is not achieved, then at suitable points water separators or air separators must be
installed.
The pressure process pipe must be kept as short as possible and installed without sharp bends, to avoid a
delayed response time.
The instruments pressure ports are marked by "+" and "-" symbols:
"+" port must be connected to the higher pressure
"-" port must be connected to the lower pressure.
With liquid measurement media, the pressurized connection pipe must be degassed, since any gas bubble
inclusions result in measurement error.
If water is used as the measurement medium, the device must be frost-protected.
Safety notice: Only mount using the correct open-jawed wrench, and do not twist the device itself.
8.3.2 Electrical connection
Take note of the electrical data in the EU design type test certification and the locally-applicable regulations
and guidelines for installing and operating electrical plant in explosion risk areas (e.g. EN 60079-14,
EN 60079-17 etc.).

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Connection to be undertaken by authorized and qualified specialist staff only.
The electrical connection of the device is to be undertaken in accordance with the relevant regulations of the VDE
and the regulations supplied by the local utilities company.
Disconnect the plant from the mains supply before wiring electrical connections.
Install appropriate fuses upstream.
Please refer to type label
for configuration of
connections.
Switch 1 Switch 2
8.4 Starting up
The precondition for start-up is proper installation of all electrical feed lines and metering pipes. All connecting lines
must be installed so that no mechanical forces can act on the device.
Before start-up, the seal on the pressurized connection line must be checked.
8.4.1 Zero point adjustment
The pressure gauges are supplied calibrated at the factory, so that as a rule there is no need for calibration at the
installation point. For devices with Micrometer pointer (see order code), zero pointer adjustment on site is possible. For
this, proceed as follows:
Equalize pressure in both chambers.
Check if internal pressure was built up in the case
due to
ambient temperature effect. Open valve (position B), wait for
pressure relief and close valve again (position A)
Lift up on vent plug.
Use zero pointer adjustment screw to set the pointer to zero.
Mount vent plug
Filled Models need to be vented before commissioning
by opening the air valve on the upper side of instrument!
8.4.2 Setting the electric contacts
An adjustable lock is fitted in the front panel of the pressure
gauge. Using the removable adjustment key, the contacts
mounted on the target value indicators can be set to any point on
the range covered by the scale.
For reasons relating to accuracy of switching and the lifetime of
mechanical measurement systems, the switch points should be
positioned between 10% and 90% of the range.
Place the adjustment key on the axle of the adjustable lock.
Press the axle inwards, until the carrier arm grips behind the
adjuster pin on the target value indicator.

By turning the key, adjust the target value indicator to the
desired switch point.
Release the pressure on the axle, and remove the adjustment key.

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8.4.3 Contact function
Function 1: Close contacts with the indication rising in a clockwise direction.
Function 2: Open contacts with the indication rising in a clockwise direction.
Contact assignment:
1st contact left target value indicator,
2nd contact middle target value indicator,
3rd contact right target value indicator
8.5 Subsequent relocation of the gauge (by the customer)
Recommendation: Do not remove the differential pressure gauge from one pressure monitoring location to
another place, as there is a risk of the process media being mixed, with unforeseeable chemical reactions.
9 Servicing
The device is maintenance-free. However, to ensure reliable operation and a long lifetime for the device, we
recommend that it is checked regularly.
9.1 Safety
When servicing the pressure gauge, the process pressure line must be depressurized, the electrical connections
isolated from the mains supply, and special attention should be taken to ensure process pressure is not applied.
9.2 Gauge performance and calibration
Gauge performance and recalibration is carried out at regular intervals, depending on the application. The precise
testing cycles should be adjusted in line with the operating conditions and ambient conditions. In the event of various
device components interacting, the operating instructions for all other devices should also be taken into account.
Check on display.
Check on function, in conjunction with downstream components.
Check of pressurized connection pipes for seal condition.
Check of electrical connections.
9.3 Cleaning and maintenance
Cleaning is carried out using a non-aggressive cleaning agent, with the ventilation valve closed and respecting the
protection category of the device.
10 Faults
10.1 Safety
Defective or faulty pressure gauges put the operational safety and process safety of the plant at risk, and can lead to a
risk or injury to persons, the environment or the plant.
10.2 Conduct in the event of faults
All defective of faulty devices must be taken out of service. If a repair is required, contact service department.
10.3 When action is required to repair/replace the gauge:
Possible situations when action should be taken:
Jerky or random movement of the pointer
Pointer does not set to zero for pressure less display

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Bent or loose pointer
Cracked window
Leaks when the device is filled
Damage to housing
Indications that the measurement system seal (diaphragm) has been breached (discoloration to dial display or of
filling liquid)
In these instances, repair or replacement of the pressure gauge is always required.
10.4 Gauge repair/replacement
See Chapter 8.3 Mounting/Installation
11 Removal, disposal
11.1 Safety
Residues of measuring media in and on removed gauges can constitute a risk to people, the environment
and equipment. Adequate precautionary measures must be adopted. If necessary, the devices must be
cleaned thoroughly (see advice in safety data sheets).
11.2 Removal
When servicing the gauge, the process pressure line must be depressurized, the electrical connections isolated
from the mains supply, and special attention should be taken to ensure process pressure is not applied.
Remove the gauge using a suitable tool.
11.3 Disposal
Please help to protect the environment and dispose of or recycle the devices and components used in
accordance with the applicable regulations.
12 Appendix
12.1 Data sheet for differential pressure gauge F5509/F6509
Detailed data sheet is available from supplier’s website (see 1.6 Manufacturer’s address, customer services)
This Table refers to specific documents:
Model
Description
Document
F5509/F6509
Stainless steel differential pressure gauge model F5509/F6509
G1.F5509
K5500
Electrical contact devices for pressure and temperature gauges
G1.K5500

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12.2 Declaration of conformity model F5509 / F6509 without contacts

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12.3 Declaration of conformity model F5509 and F6509 inductive proximity switches

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12.4 EU design type test certification for inductive proximity switches of types SJ2-N

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