WIKA 821 User manual

EN
DE
Operating instructions
Betriebsanleitung
Mode d'emploi
Manual de instrucciones
FR
ES
Examples for pressure gauges with switch contacts
Model PGS23
Pressure gauges switch contact model 821, 851 or 830 E:
Magnetic snap-action, reed or electronic contact
Manometer mit Schaltkontakt Typ 821, 851 oder 830 E:
Magnetspring-, Reed- oder Elektronikkontakt
Manomètres avec contact électrique type 821, 851 ou 830 E:
Contact sec magnétique, contact Reed ou contact électronique
Manómetros con contacto eléctrico modelo 821, 851 o 830 E:
Contacto magnético de ruptura brusca, Reed o electrónico
Model PGS43 Model DPGS43 Model DPGS43HP

EN
DE
FR
ES
Operating instructions pressure gauges
with switch contact model 821, 851 or 830 E Page 3 - 28
Betriebsanleitung Manometer
mit Schaltkontakt Typ 821, 851 oder 830 E Seite 29 - 54
Mode d'emploi pour manomètres
avec contact électrique type 821, 851 ou 830 E Page 55 - 80
Manual de instrucciones para manómetros
con contacto eléctrico modelo 821, 851 o 830 E Página 81 -105
2
14057651.02 03/2018 EN/DE/FR/ES
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E
© 11/2017 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Lire le mode d‘emploi avant de commencer toute opération !
A conserver pour une utilisation ultérieure !
¡Leer el manual de instrucciones antes de comenzar cualquier trabajo!
¡Guardar el manual para una eventual consulta!

EN
Contents
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 3
14057651.02 03/2018 EN/DE/FR/ES
1. General information 4
2. Design and function 5
3. Safety 6
4. Transport, packaging and storage 9
5. Commissioning, operation 10
6. Faults 18
7. Maintenance and cleaning 19
8. Dismounting, return and disposal 20
9. Specications 22
Appendix: EU declaration of conformity 106
Contents
Declarations of conformity can be found online at www.wika.com.

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E4
14057651.02 03/2018 EN/DE/FR/ES
1. General information
■
The instrument described in the operating instructions has been designed and
manufactured using state-of-the-art technology. All components are subject to
stringent quality and environmental criteria during production. Our management
systemsarecertiedtoISO9001andISO14001.
■
These operating instructions contain important information on handling the
instrument. Working safely requires that all safety instructions and work instruc-
tions are observed.
■
Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.
■
The operating instructions are part of the product and must be kept in the im-
mediate vicinity of the instrument and readily accessible to skilled personnel at
any time. Pass the operating instructions on to the next operator or owner of the
instrument.
■
Skilled personnel must have carefully read and understood the operating
instructions prior to beginning any work.
■
The general terms and conditions contained in the sales documentation shall
apply.
■
Subjecttotechnicalmodications.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheets: Contact pressure gauges
PV 22.01 Models PGS21.100, PGS21.160
PV 22.02 Models PGS23.100, PGS23.160, PGS26.100, PGS26.160
PV 22.03 Model PGS23.063
PV 24.03 Models PGS43.100, PGS43.160
PV 27.05 Models DPGS43.100, DPGS43.160
PV 27.13 Models DPGS43HP.100, DPGS43HP.160
PM 02.11 Model 232.35
PV 24.07 Models 432.56, 432.36
PM 05.02 Models 532.52, 532.53 and 532.54
PM 06.06 Model 632.51
PM 07.08 Model 736.51
1. General information

EN
2. Design and function
2. Design and function
2.1 Description
The switch contacts permanently installed in the pressure gauge close or open
at set limit values, depending on the switching function. Switching functions are:
Normally closed, normally open, change-over contact.
Instruments with switch contact model 821
Model 821 magnetic snap-action contacts are auxiliary current switches which
open or close connected electric circuits via a contact arm which is moved by the
instrument pointer.
Instruments with switch contact model 851
Model 851 reed contacts are auxiliary current switches which open or close con-
nected electric circuits at the set limit values via a permanent magnet which is
moved by the instrument pointer.The reed contacts used are bistable switches,
which keep their condition after a signal change up to the next actuation.
Instruments with switch contact model 830 E
Theinductivecontactwithintegratedmodel830Eswitchingampliercanswitch
small loads directly. This is, for example, the case with applications with program-
mable logic controllers (PLCs).
The advantages of inductive contacts are the particularly fail-safe contact opera-
tion,nowearduetoproximitycontactoperationaswellasvirtuallynoeectonthe
measuring system.
No additional control unit is required.
The electronic contact is a 2- or 3-wire design with PNP output.
2.2 Scope of delivery
Cross-check scope of delivery with delivery note.
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 5
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EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E6
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3. Safety
3.1 Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in seri-
ous injury or death, if not avoided.
WARNING!
... indicates a potentially dangerous situation that can result in burns,
caused by hot surfaces or liquids, if not avoided.
Information
... points out useful tips, recommendations and information for ef-
cientandtrouble-freeoperation.
3.2 Intended use
Wherever the process pressure has to be indicated locally and, at the same time,
circuitsneedtobeswitched,theswitchGAUGEndsitsuse.
These instruments are used to control process values, to monitor plants and to
switch circuits in industrial applications.
This instrument is not permitted to be used in hazardous areas!
Only use the instrument in applications that lie within its technical performance
limits (e.g. max. ambient temperature, material compatibility, ...).
→Forperformancelimitsseechapter9“Specications”.
The instrument has been designed and built solely for the intended use described
here, and may only be used accordingly.
The manufacturer shall not be liable for claims of any type based on operation
contrary to the intended use.
3. Safety

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 7
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3.3 Improper use
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and
injuries.
▶ Refrainfromunauthorisedmodicationstotheinstrument.
▶ Do not use the instrument within hazardous areas.
▶ Do not use the instrument with abrasive or viscous media.
Anyusebeyondordierenttotheintendeduseisconsideredasimproperuse.
Do not use this instrument in safety or emergency stop devices.
3.4 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to
equipment.
▶ The activities described in these operating instructions may only
becarriedoutbyskilledpersonnelwhohavethequalications
described below.
3.5 Skilled personnel
Skilled personnel, authorised by the operator, are understood to be personnel
who, based on their technical training, knowledge of measurement and control
technologyandontheirexperienceandknowledgeofcountry-specicregula-
tions, current standards and directives, are capable of carrying out the work
described and independently recognising potential hazards.
3.6 Special hazards
WARNING!
Forhazardousmediasuchasoxygen,acetylene,ammableortoxic
gases or liquids, and refrigeration plants, compressors, etc., in ad-
dition to all standard regulations, the appropriate existing codes or
regulations must also be followed.
WARNING!
Residual media in dismounted measuring instruments can result in a
risk to persons, the environment and equipment.
Takesucientprecautionarymeasures.
3. Safety

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E8
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3.8 Explanation of symbols
Before mounting and commissioning the pressure gauge,
ensure you read the operating instructions!
Risk of burns!
Potentially dangerous situation caused by hot surfaces.
Protective earth
Instruments bearing this mark on the dial are safety pressure gauges
withsolidbaewallperEN837(S3).
3.7 Labelling / Safety marks
Product label (example)
Date of manufacturePin assignment
Switch contact model and switch-
ing function
821 Magnetic snap-action contact, model 821
851 Reed contact, model 851
830 E Electronic contact, model 830 E
3. Safety

EN
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4. Transport, packaging and storage
4. Transport, packaging and storage
4.1 Transport
Check the instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can
occur.
▶ When unloading packed goods upon delivery as well as during
internal transport, proceed carefully and observe the symbols on
the packaging.
▶ With internal transport, observe the instructions in chapter 4.2
“Packagingandstorage”.
4.2 Packaging and storage
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g.
change in installation site, sending for repair).
4.3 Storage
Permissible conditions at the place of storage
Storage temperature: -20 ... +70 °C
Humidity:≤80%relativehumidity(nocondensation)
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Hazardousenvironments,ammableatmospheres
WARNING!
Before storing the instrument, any residual media must be removed.
This is of particular importance if the medium is hazardous to health,
e.g. caustic, toxic, carcinogenic, radioactive, etc.

EN
5. Commissioning, operation
5.1 Mechanical connection
In accordance with the general technical regulations for pressure gauges (e.g.
EN837-2“Selectionandinstallationrecommendationsforpressuregauges”).
When screwing the instruments in, the force required for sealing must not be
appliedthroughthecase,butonlythroughthespanneratsprovidedforthis
purpose, and using a suitable tool.
Forparallelthreads,useatgaskets,lens-typesealingringsorWIKAprole
sealings at the sealing face .With tapered threads (e.g. NPT threads), sealing is
made in the threads , using a suitable sealing material (EN 837-2).
The torque depends on the sealing used. In order to orientate the measuring
instrument so that it can be read as well as possible, a connection with clamp
socketorunionnutshouldbeused.Whenablow-outdeviceisttedtoaninstru-
ment, it must be protected against being blocked by debris and dirt.
5.1.1 Installation
■
NominalpositionperEN837-3/9.6.6gure7:90°(⊥)
■
Process connection lower mount
■
Withlledversionstheventvalveatthetopofthecasemustbeopenedbefore
commissioning!
■
For outdoor applications, the selected installation location has to be suitable
forthespeciedingressprotection,sothattheinstrumentisnotexposedto
impermissible weather conditions.
Installation with open-
ended spanner
Sealing in the thread 
Spannerats
Sealing face 
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E10
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5. Commissioning, operation

EN
5. Commissioning, operation
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 11
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■
In order to avoid any additional heating, the instruments must not be exposed
to direct solar irradiation while in operation!
■
To ensure that the pressure can be safely vented in the case of failure, instru-
ments with blow-out device or blow-out back must keep a minimum distance of
20 mm from each object.
5.1.2 Requirements for the installation point
If the line to the measuring instrument is not adequately stable, an instrument
mounting bracket should be used for fastening. If vibrations cannot be avoided by
meansofsuitableinstallation,lledinstrumentsshouldbeused.Theinstruments
shouldbeprotectedagainstcoarsedirtandwideuctuationsinambienttempera-
ture.
5.1.3 Permissible vibration load at the installation site
The instruments should always be installed in locations free from vibration.
If necessary, it is possible to isolate the instrument from the mounting point, e.g.
byinstallingaexibleconnectionlinebetweenthemeasuringpointandtheinstru-
ment and mounting the instrument on a suitable bracket.
If this is not possible, the following limit values must not be exceeded:
Frequency range < 150 Hz
Acceleration < 0.5 g (5 m/s2)
5.1.4 Level check
Forlledinstruments,thelevelmustbecheckedonaregularbasis.
Theliquidlevelmustnotdropbelow75%oftheinstrumentdiameter.
5.1.5 Manual reset of reed switch, model 851
In rare cases an actuation of the reed switches can occur due to an impermissibly
high shock or vibration.To reset the reed switches, it is necessary to move the
instrument pointer over the set switch point of the reed switch.
5.1.6 Test connection
Inspecicapplications(e.g.steamboilers)theshut-ottingsmusthaveatest
connection, so that the instrument can be tested without being dismounted.

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E12
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5.1.7 Temperature load
The installation of the instrument should be made in such a way that the operat-
ingtemperature,alsoconsideringtheeectsofconvectionandthermalradiation,
neither exceeds nor falls below the permissible limits.Thus the instrument and the
shut-odevicemustbeprotectedbysucientlylongmeasuringlinesorsyphons.
Theinuenceoftemperatureontheindicationandmeasurementaccuracymust
be observed.
WARNING!
The actual maximum surface temperature depends not on the equip-
ment itself, but mainly on the operating conditions.With gaseous sub-
stances, the temperature may increase as a result of compression
warming. In these cases it may be necessary to throttle the rate of
change of pressure or reduce the permissible medium temperature.
5.1.8 Commissioning of pressure compensating valve
Instrumentswhicharettedwithapressurecompensating
valve must, following installation, be vented for internal pres-
sure compensation.
Tool:Open-endedspannerSW9
1. Remove plastic casing
2. Loosen the threaded connection above the valve body
3. Screwthevalvebodytight,turnedthrough180°,with≤4.5Nm
5.1.9 Protection of the pressure elements from overload
If the medium is subject to rapid changes in pressure, or pressure surges are ex-
pected, then these must not act directly on the pressure element.The action of the
pressuresurgesmustbedamped,forexamplewiththettingofathrottlesection
(reduction in cross-section in the pressure channel) or through the addition of an
adjustable throttling device.
5.1.10 Pressure tapping point
The pressure tapping point should be arranged with as large a bore as possible
(≥6mm)viaashut-odevice,sothatthepressuretapisnotdistortedbyaow
in the medium.The measuring line between the pressure tapping points and the
instrument should have a large enough internal diameter to prevent blockage and
lag in the pressure transmission.
5.1.11 Measuring line
The measuring lines must be as short as possible and should be arranged without
sharp radii in order to avoid any disruptive time lags.With the installation, a con-
tinuous inclination of approx. 1:15 is recommended.
5. Commissioning, operation
After commissioning
Before commissioning

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 13
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5. Commissioning, operation
The measuring line should be designed and installed so that the loads occurring
duetoexpansion,vibrationandthermaleectscanbeabsorbed.Withgaseous
media, a drain should be provided at the lowest point; with liquid media, a vent
should be provided at the highest point.
The measuring instruments must be mounted in the common mounting position
per EN 837-1, with a max. permissible incline of 5° on all sides.
5.1.12 Measuring assemblies
Proven measuring assemblies for various types of media.
Liquid media Gaseous media
Filling of the
measuring
line
liquid liquid
with
vapour
com-
pletely
vapour-
ised
gase-
ous
partially
condensed
(damp)
complete-
ly con-
densed
Examples conden-
sate
boiling
liquids
“liquid
gases”
dry air moist air
uegases
Steam
Pressure
gauge above
the tapping
point
Pressure
gauge below
the tapping
point

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E14
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5.2 Electrical connection
Theelectricalconnectionmustonlybemadebyqualiedskilledpersonnel.Con-
nection details and switching functions are given on the product label. Connection
terminals and ground terminal are appropriately marked.
Forpowerratings(see“Specications”)andforcircuitprotectionforinductiveand
capacitiveloadsseechapter5.3“Contactprotectionmeasures”.
Safety instructions for installation
■
Install instruments in accordance with the manufacturer's instructions and the
valid standards and regulations.
■
Only connect circuits with the same voltage and type of protection to the switch
contacts and connecting cables.
■
Only for switch contact models 821 and 851: Limit the maximum current, using
externalmeasures,toavalueof≤1Apercircuit.
■
Size the connecting cables for the largest current strength in the circuits and
ensuresucientUVresistanceandmechanicalstability.
■
Voltages greater than AC 50 V or DC 120 V:
- Do not connect circuits simultaneously with extra-low voltage circuits or with
safety extra-low voltage (SELV) or protected extra-low voltage (PELV).
-Circuitsmustoeradevice,externaltothemeasuringinstrument,that
enables the instrument to be isolated from the electrical supply. This must be
easily accessible and be marked as the isolation device for the instrument.
-Cablesforthecircuitmustfulltheisolationrequirementsandconformto,for
example, IEC 60227 or IEC 60245.
- For protection against electric shock, connect the protective conductor con-
nection to the protective earth.
■
Withexibleconnectingcables,useisolatedendsplices.Max.permissible
conductor cross-section 1.5 mm².
■
Connecting cables must be suited to the ambient temperature range of the
application.
■
The connecting cables must also be suitable for the supplied cable gland (for
diameter range, see below).
5. Commissioning, operation

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 15
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5. Commissioning, operation
■
Seal the cable entry with the appropriate approved cable glands.
■
Install the connection cables securely.
5.3 Contact protection measures
Mechanicalcontactsmustnotexceedthespeciedelectricalvaluesforswitching
current, switching voltage and switching power independent of each other, not
even for a short time only.
For capacitive or inductive loads we recommend one of the following protective
circuits:
Inductive load with DC voltage
With DC voltage the contact protection can be achieved via a free-wheeling di-
ode, connected in parallel to the load. The polarity of the diode must be arranged
so that it closes when the operating voltage is on.
Only use
cable with a
diameter of
7 ... 13 mm
Standard Instruments > 4 kg
Only use
cable with a
diameter of
5 ... 10 mm
1346210y 14062234.01
Cable gland design
Example:
Contact protec-
tion measure with
free-wheeling
diode
Contact
Diode Load

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E16
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Contact
Contact
Inductive load with AC voltage
With AC voltage two protection measures are possible:
Example:
Contact protec-
tion measure
with voltage-de-
pendent resistor
VDR
Example:
Contact protec-
tion measure
with RC element
Load
Load
Contact Contact
Capacitive load
With capacitive loads elevated make currents arise.These can be reduced by
series-connecting resistors in the supply line.
Examples: Contact protection measure with current-limiting resistor
Load Load
U
B
R1
U
B
R1
5. Commissioning, operation

EN
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5. Commissioning, operation
5.4 Adjusting the set pointers of contact model 851
The adjustment of the set points is achieved using the adjustment lock in the
window with the aid of the adjustment key (included in delivery; found in standard
instruments on the side of the cable socket).
Instruments with switch contact model 821 or 830 E
The set pointers for the limit switches are freely adjustable over the full scale
range. For reasons of switching accuracy, switching reliability and service life of
themechanicalmeasuringsystems,theswitchpointsshouldbebetween10%
and90%ofthemeasuringspan.
Instruments with switch contact model 851
Thesetpointersofthelimitswitchesarefreelyadjustablebetween10%and90%
ofthescalerange;thedistancebetweenthetwosetpointersisapprox.10%of
thescalerange(correspondstoapprox.30∢°).Withnominalsize160measuring
instruments it has to be ensured that the adjusting arm is pushed down exclusively
in the area of the set pointer to be adjusted. Otherwise damage to the instrument
pointer or a misadjustment of the zero point cannot be excluded.
5.5 Commissioning
Pressuresurgesmustbeavoidedatallcosts,opentheshut-ovalvesslowly.
Set pointer
Removable
adjustment key
Adjustment lock
(to adjust the set pointer, place the
adjustment key here, press it in and set
the required set point)
Set pointer
Removable
adjustment key
Adjustment lock
(to adjust the set pointer, place the
adjustment key here, press it in and set
the required set point)
Adjusting arm
Pressure compensating valve

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E18
14057651.02 03/2018 EN/DE/FR/ES
6. Faults
CAUTION!
Physical injuries and damage to property and the environment
If faults cannot be eliminated by means of the listed measures, the
instrument must be taken out of operation immediately.
Ensure that pressure or signal is no longer present and protect
against accidental commissioning.
Contact the manufacturer.
If a return is needed, please follow the instructions given in chapter
8.2“Return”.
WARNING!
Physical injuries and damage to property and the environment
caused by hazardous media
Uponcontactwithhazardousmedia(e.g.oxygen,acetylene,amma-
ble or toxic substances), harmful media (e.g. corrosive, toxic, carci-
nogenic, radioactive), and also with refrigeration plants and compres-
sors, there is a danger of physical injuries and damage to property
and the environment.
Should a failure occur, aggressive media with extremely high tem-
perature and under high pressure or vacuum may be present at the
instrument.
For these media, in addition to all standard regulations, the appropri-
ate existing codes or regulations must also be followed.
Weartherequisiteprotectiveequipment(seechapter3.6“Personal
protectiveequipment”).
Forcontactdetailsseechapter1“Generalinformation”ortheback
page of the operating instructions.
6. Faults

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E 19
14057651.02 03/2018 EN/DE/FR/ES
Faults Causes Measures
Contact is no longer
switching in line with
the specication.
Electrical connection is
interrupted.
Carry out a continuity test on the
electrical connection lines.
Electrical load unsuita-
ble for the switch contact
model.
Maintain the permissible electrical
loads for the switch contact model.
Contact contaminated.
Residual current pro-
tection device for the
circuit is tripped.
Insulation failure Replace instrument
Contact chatter (re-
peated, short-duration
opening and closing).
Vibrations Decouple the instrument
mechanically.
Switching state
remains unchanged
despite reaching the
switch point/reset
point.
Contacts defective (e.g.
fused contact zone).
Replace instrument Before recom-
missioning the new instrument,
provide a protective circuit for the
contact.
No pointer movement
despite change in
pressure.
Movement blocked. Replace instrument
Fortheexchangeoftheinstrumentchapters8“Dismounting,returnanddisposal”and5
“Commissioning,operation”mustbeobserved.
7. Maintenance and cleaning
The instruments are maintenance-free.
The indicator and switching function should be checked once or twice every year.
For this the instrument must be disconnected from the process to check with a
pressure testing device.
Repairs must only be carried out by the manufacturer.
Clean the instrument with a moist cloth.
6. Faults / 7. Maintenance and cleaning

EN
Operating instructions pressure gauges with switch contact models 821, 851 or 830 E20
14057651.02 03/2018 EN/DE/FR/ES
8. Dismounting, return and disposal
8. Dismounting, return and disposal
WARNING!
Physical injuries and damage to property and the environment
through residual media
Residual media in the dismounted instrument can result in a risk to
persons, the environment and equipment.
▶ Weartherequisiteprotectiveequipment(seechapter3.6“Per-
sonalprotectiveequipment”).
▶ Observe the information in the material safety data sheet for the
corresponding medium.
▶ Wash or clean the dismounted instrument, in order to protect per-
sons and the environment from exposure to residual media.
8.1 Dismounting
WARNING!
Risk of burns
During dismounting there is a risk of dangerously hot media escap-
ing.
▶ Lettheinstrumentcooldownsucientlybeforedismountingit!
DANGER!
Danger to life caused by electric current
Upon contact with live parts, there is a direct danger to life.
▶ The dismounting of the instrument may only be carried out by
skilled personnel.
▶ Remove the instrument once the system has been isolated from
power sources.
WARNING!
Physical injury
When dismounting, there is a danger from aggressive media and
high pressures.
▶ Observe the information in the material safety data sheet for the
corresponding medium.
▶ Dismount the instrument when there is no pressure.
If necessary, the measuring line must have strain relief. For diaphragm pressure
gauges,theclampingboltsoftheupperandlowerangemustnotbeloosened.