Setra Systems 540 Series User manual

Installation Guide
MODELS 540 / 541 / 542
Pressure Measuring Transducers
560550-0085
Rev A
1-800-257-3872 TOLL FREE
1-978-264-0292 FAX
www.Setra.com Web Site

Setra offers a complete line of
products for these industries:
Industrial
HVAC
Test & Measurement
Barometric
Ultra High Purity / Sanitary

Please Note: Series 540 / 541 / 542 are designed and manufactured in accordance with sound
engineering practice as defined by the Pressure Equipment Directive 97/23/EC. This product must not
be used as a “safety accessory” as defined by the Pressure Equipment Directive, Article 1, Paragraph
2.1.3. The CE Mark on the unit does not relate to the Pressure Equipment Directive.
INTRODUCTION
Series 54X are fluid pressure measuring transducers in which a four active arm Wheatstone bridge of
thin film gauges, integral with a beam structure connected to a pressure summing diaphragm, is used to
convert fluid pressures into a proportional electrical signal. These instruments are suitable for long,
continuous arduous service when operated within the published specifications.
Series 54X conform with the essential protection requirements of the EMC Directive 89/336/EEC
amended by certified type testing to EN 50082-2 and EN 60081-1.
Conformity with the requirements of the CE mark only applies when the installation
conditions described in these instructions have been met. For units supplied without
a cable assembly connection to the transducer must be accomplished using Setra
Systems approved cable. see APPROVED CABLE section.
All instruments conform to the appropriate specifications and/or drawings applicable and have been
subjected to relevant strict quality control procedures.
HAZARDOUS PRODUCTS
The Consumer Protection Act of 1987, Section 6 of the Heath and Safety at Work Act 1974 and the
Control of Substances Hazardous to Health Regulations 1988 require that we advise recipients and
users of our products of any potential hazards associated with their storage, handling or use.
The products which our Company supplies may be classified as Electrical, Electro-Mechanical and
Electronic equipment.
These products are tested and supplied in accordance with our published specifications or individual
special requirements that are agreed in writing at time of order. They are constructed so as not to affect
adversely the safety of persons and property when properly installed, maintained and used by qualified
personnel, in the applications for which they were designed and manufactured
ACTION ON RECEIPT
*Check details on Calibration Certificate agree with data etched on transducer body.
*Check accessories supplied include:
Calibration Certificate (or QA Certificate)
Seal, Dowty Bonded (where applicable)
Mating Connector (where applicable)
GENERAL
*Transducer should not be subjected to greater than the maximum allowable pressure listed
on label . See OPERATION section:
*Transducer should not be subjected to mechanical impact.

*In the event of fire the end user must ensure that the system pressure is vented to a safe
area.
*The effects of decomposition of unstable fluids should be considered by the user when
placing this device in service.
*The pressure transducer has no means of draining or venting, this must be performed by
another component in the end users system.
*Pressure range must be compatible with the maximum pressure being measured.
*Pressure media must be compatible with the transducer wetted parts which are:-
Ranges 1 and 1.6 bar, 15 and 30 psi : 15-7 Mo plus 17-4 PH stainless steels
Ranges 2.5 bar and 60 psi and above : 17-4 PH stainless steel
Pressure connection code B2 :Inconel alloy 625
Ranges 9000 and 10,000 psi: Inconel alloy 625
*Exposed end of cable must be kept free from moisture.
*Liquid must not be allowed to freeze in the pressure port.
MECHANICAL INSTALLATION
Pressure Connections: G¼ internal pressure connection as standard. Alternative fitted as specified
at time of order.
Pressure couplings screwed into G¼ pressure ports should have a maximum thread engagement ½”
(13mm) and UNDER NO CIRCUMSTANCES be allowed to touch the pressure sensitive
diaphragm. Pressure couplings should be sealed against the outer face at the pressure port entry using
bonded seal washer such as:-
Part
Number Description Dowty Ref
GA29 G¼ bonded seal up to +100°C operation 400-021-4490-02
GA30 G¼ bonded seal up to +200°C operation 300-021-0967-02
GA31 G1/8 bonded seal up to +200°C operation 300-020-0967-02
Refer to Dowty for external pressure ratings.
Mounting: Pressure Transducer is designed to be attached by the coupling thread only. Omni-
directional. To fit, use a 7/8 inch AF (22.2mm) wrench on the hexagon provided and apply maximum
torque of 20 lbf-ft (27Nm). The Customer must ensure that the pressure seal is suitable for the
application. If in doubt contact Setra Systems.
Vibration: Where present, mount in a saddle clamp such as part number GA17 (material:
Polypropylene) or GA20 (material: Polyamide). Position the clamp as close to the pressure port as
practicable.
Effects of Heat: Avoid mounting the transducer near a source of heat which is liable to create a
temperature gradient across the instrument. If this is unavoidable, use a heat shield to deflect uneven
radiated heat or wrap the transducer in glass fibre insulation so that an even temperature is assumed
throughout.

High Temperature Pressure Measurement: Possible using a length of piping or a "syphon" to
isolate the instrument from the hot media. Since there is no flow, the temperature drop along the tubing
is considerable and usually a relatively short length is sufficient to bring the pressure media temperature
within acceptable limits for the instrument. Alternatively a temperature isolator, part number GA33, can
be fitted (G¼ connection only). Pressure media must not be allowed to solidify in the tube and/or
pressure port.
ELECTRICAL INSTALLATION
All types include suppression devices providing transient protection to EN 61000-4-2 and EN 61000-
4-4.
For all types conformity with the requirements of the CE mark only applies when
connection is made with Setra Systems approved cable, See APPROVED CABLE
section, and the shield of that cable is connected to a reliable ground point at the
instrumentation end.
Types 540 / 542 Water Submersible Cable (IP68 rated): These types are capable of being
immersed to a maximum depth of 200m WG.
Types 540 / 542: To combat the effects of lightning strike these types are fitted with suppression
devices providing surge immunity to IEC 801 Part 5. To protect the ‘receiving’ equipment it is
recommended the end user fits a Lightning Protection Unit (LPU) at the instrumentation end close to the
point of cable entry into the building, installed as recommended by the LPU manufacturer, to protect
against the likely high current surge resulting from lightning strikes.
Types 540 / 542 Weatherproof Cable (IP66): These types employ a weatherproof (IP66 rated)
cable assembly.
Types 540 / 541 / 542 10-6 Bayonet Connector: These types are fitted with a MIL-C size 10,
6 pin receptacle. The mating socket (not supplied) must conform to MIL-C-00264872.
APPROVED CABLES
Setra Systems uses cable comprising 6 color-coded wires, with a central vent tube, enclosed by an
aluminium/polyester shield where the screen is in intimate contact with a separate drain wire. The outer
sheath can be of various material, depending upon application and operating temperature, e.g. Exar
(non-immersible, +150°C max), PTFE (non-immersible, +200°C max), Polyurethane (immersible,
+70°C).
OPERATION
Having installed the transducers as instructed they are ready for use. The transducer should not be
removed while the system is at pressure. Before applying power, check that the correct polarity and
excitation levels are being applied. See ELECTRICAL REQUIREMENTS.

Compensated Temperature Range
Model Electrical Connector Temperature
540 / 542 10-6 Bayonet Connector -65°F to +250°F (-54°C to +120°C)
541 10-6 Bayonet Connector -65°F to +390°F (-54°C to +200°C)
540 / 542 Weatherproof Cable -65°F to +250°F (-54°C to +120°C)
540 / 542 Molded Immersible Cable -65°F to +250°F (-54°C to +120°C)
541 10-5 Screw Lock Connector -65°F to +390°F (-54°C to +200°C)
Operating Temperature Range
Model Electrical Connector Temperature
540 / 542 10-6 Bayonet Connector -65°F to +275°F (-54°C to +135°C)
541 10-6 Bayonet Connector -65°F to +385°F (-54°C to +195°C)
540 / 542 Weatherproof Cable -65°F to +250°F (-54°C to +120°C)
540 / 542 Molded Immersible Cable -4°F to 122°F (-20°C to +50°C)
541 10-5 Screw Lock Connector -65°F to +450°F (-54°C to +230°C)
OPERATIONAL LIFE:
Limited to 100M cycles to maximum allowable pressure.
CALIBRATION
Transducers are calibrated to the datum requested at time of order; this can be identified as follows:-
Code G- gauge datum vented to atmosphere via the electrical connection
Code A - absolute datum
Code S - sealed reference; reference side of the instrument is sealed and the output electrically adjusted
to zero with 1013 mb applied to pressure port
Code U - uni-directional differential
Code B - bi-directional differential
CHARACTERISTICS
Millivolt Output Transducers: All millivolt (mV) output transducers should be used with a
stabilized d.c. excitation supply. Output errors directly proportional to supply instability.
Specifications are given with 10V d.c. excitation. However, a lower supply may be used with a
corresponding decrease in output.
There are no adjustments for zero and span on the transducer. If local provision is required, the circuit
diagram below may be employed. 12V d.c. stabilized supply is used instead of standard 10V to allow
span adjustment to be obtained.

MAINTENANCE
Routine Inspection: Not required except for periodic inspection of the cable and molding to ensure
that these are neither damaged nor softened by incompatible liquid.
If Malfunction Occurs: Isolate the free end of the cable and measure the input and output
resistance. If vastly different from specification, either lower or higher, the strain gauge is damaged and
the instrument will have to be replaced.
If the reading is satisfactory but the operation is still suspect, join the input and output conductors
together. Using a low voltage insulation tester, measure the insulation resistance between the conductors
and the case; the reading should be 100 Mohms or greater.
DO NOT use high voltage insulation testers or any device which generates more than 50V d.c. for this
test.
Causes of Failure: Excess pressure of more than twice the rated range (1.5 times rated range for
Inconel "wetted parts" versions). A short duration pressure cycle having such a peak value may be
sufficient to damage the strain gauge.
The instrument may withstand some excess pressure without failure, but a change in residual output may
result. If this is not excessive the instrument may be re-zeroed externally, although other changes in
characteristics might occur which can only be determined by total re-calibration.
Failure can also occur if the system is driven into resonance by a fast pressure pulse, even though the
pulse peak is within the nominal pressure range. System resonance is sometimes referred to as "water
hammer" and is typically the result of valve slam or bounce, causing a shock wave through the system.
Use a pressure restrictor such as part number GA32 if it is suspected that adverse transient pressure
pulses are present.

CAUTION
CARE MUST BE TAKEN NOT TO TOUCH THE PRESSURE SENSITIVE
DIAPHRAGM WHILE CLEANING THE PRESSURE PORT. FAILURE TO
OBSERVE THIS PRECAUTION CAN CAUSE IRREPARABLE DAMAGE.
WARRANTY
The Company warrants its products to be free from defects in material and workmanship in normal use
and service for a period of two years from date of shipment. The Company reserves the right and
option to refund the purchase price in lieu of repair or replacement upon evaluation of the returned
original part. Modification, misuse, attempted repair by others, improper installation or operation shall
render this guarantee null and void. The Company makes no warranty of merchantability or fitness for a
part or purpose.
SERVICING
The transducer cannot be repaired locally and if damaged should be returned to Setra Systems with the
following:-
1. Name and phone number of person to contact
2. Shipping and billing information
3. Full description of malfunction
4. Remove any pressure fitting and plumbing that you may have installed and enclose any required
mating electrical connectors and wiring diagrams.
Please ship to Setra Systems at the address shown below or to your local Setra Distributor when a
replacement/repair is required.
United States Outside The United States
Setra Systems Inc Contact your local Setra Distributor
159 Swanson Road
Boxborough, MA 01719
Attn: Repair Department
RETURN TO FACTORY
PLEASE NOTE: To comply with Health and Safety requirements, the instrument must be clean and
safe to handle and accompanied by a formal statement to that effect duly signed by an authorised officer
of the Company.
Any instrument returned without certification will be quarantined and no action will occur until cleared. It
may ultimately be returned to you and subject to a transportation charge.

W A R N I N G
* IF INSTRUMENT IS SUBJECTED TO +400°C PLUS
Some instruments use Viton sealant. Above +400°C this material decomposes
producing (amongst others) Hydrofluoric Acid which is extremely corrosive
* DO NOT ALLOW CONTACT WITH SKIN
If it is suspected that an instrument has been subjected to temperatures in
excess of +400°C
* CONTACT OUR SALES OR SERVICE DEPARTMENT TO
ASCERTAIN IF THE INSTRUMENT CONTAINS VITON
W A R N I N G
ELECTRICAL REQUIREMENTS
SUPPLY VOLTS
MODEL
ELECTRI
CAL
CODE
MAX RATED OUTPUT +ve SUPPLY -ve SUPPLY +ve OUTPUT -ve OUTPUT CASE EARTH
540/541/5
42 B3 Pin A Pin D/E Pin B Pin C/F
541/542 N4 Red White Yellow Blue Shield
541/542 UA Red White Yellow Blue Shield
541 B4
15V
d.c. 10V d.c.
0-30mV
at rated
supply
Pin 1 Pin 4 Pin 2 Pin 3 Pin 5
B3 10-6 Bayonet Connector
N4 Weatherproof Cable
UA Molded Submersible Cable
B4 10-5 Bayonet, Screw lock connection
159 Swanson Road, Boxborough, MA 01719-1304
Tel: [phone]
OP540/541/542 Rev A 11/03