WIKA 831 User manual

GB
D
F
Operating Instructions
Betriebsanleitung
Mode d'emploi
Manual de Instrucciones
E
II 2 GD c TX TÜV 03 ATEX 2302 X
Model 432.50.100 with inductive
contact Model 831.12 per ATEX
Pressure gauges Model 4 with inductive contacts Model 831
per directive 94/9/EC (ATEX)
Druckmessgeräte Typ 4 mit Induktivkontakten Typ 831
nach Richtlinie 94/9/EG (ATEX)
Manomètres Type 4 avec contacts inductifs Type 831
selon directive 94/9/EG (ATEX)
Manómetros Modelo 4 con contacto inductivo Modelo 831
según la directiva 94/9/CE (ATEX)

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GB
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Operating instructions Model 4 with Model 831
per ATEX Page 3-27
Betriebsanleitung Typ 4 mit Typ 831
nach ATEX Seite 29-53
Mode d’emploi Type 4 avec Type 831
selon ATEX Page 55-66
Manual de instrucciones Modelo 4 con Modelo 831
según ATEX Página 67-78
© WIKA Alexander Wiegand SE & Co. KG 2009
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 posterior!

1. General information 4
2. Safety 5
3. Specifications 8
4. Design and function 9
5. Switch contacts 10
6. Transport, packaging and storage 11
7. Commissioning, operation 12
8. Maintenance and cleaning 14
9. Dismounting and disposal 14
Appendix 1: Declaration of conformity for Models 4XX
with inductive contacts Model 831 15
Appendix 2: EC-type examination certificate (Ex approval
for gases) for slot-type initiators types SJ
(WIKA-Model 831)
16-18
Appendix 3: EC-type examination certificate (Ex approval
for gases) for SN-sensors types SJ
(WIKA-Model 831-SN / S1N)
19-22
Appendix 4: EC-type examination certificate (Ex approval
for dust) for SN-proximity sensors types SJ
(WIKA-Model 831 and 831-SN / S1N)
23-27
WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX 3
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Contents
Contents

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WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX
1. General information
1. General information
The pressure gauge 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 certified to ISO 9001 and
ISO 14001.
These operating instructions contain important information on handling the
pressure gauge. Working safely requires that all safety instructions and work
instructions 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 instrument and must be kept in the
immediate vicinity of the instrument and readily accessible to skilled person-
nel at any time.
Skilled personnel must have carefully read and understood the operating
instructions, prior to beginning any work.
The manufacturer's liability is void in the case of any damage caused by
using the product contrary to its intended use, non-compliance with these
operating instructions, assignment of insufficiently qualified skilled personnel
or unauthorised modifications to the pressure gauge.
The general terms and conditions (AGB), contained in the sales documentati-
on, shall apply.
Subject to technical modifications.
Further information:
- Internet address: www.wika.de / www.wika.com
- relevant data sheet: PV 24.03, PM 04.02, PM 04.07, PM 04.08,
PM 04.09 and/or AC 08.01
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Explanation of symbols
WARNING!
… indicates a potentially dangerous situation, which can result
in serious injury or death, if not avoided.
Information
… points out useful tips, recommendations and information for
efficient and trouble-free operation.
WARNING!
… indicates a potentially dangerous situation in a potentially
explosive atmosphere, resulting in serious injury or death, if not
avoided.

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2. Safety
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that
the appropriate pressure gauge has been selected in terms of
measuring range, design and specific measuring conditions.
In order to guarantee the accuracy and long-term stability
specified, the corresponding load limits are to be observed.
Only work on the gauge with the voltage disconnected.
Serious injuries and/or damage can occur should these not be
observed.
Further important safety instructions can be found in the indivi-
dual chapters of these operating instructions.
2.1 Intended use
The Model 4 pressure gauges per Directive 94/9/EC (ATEX) with Model 831
inductive contacts are used to control industrial processes, to monitor plants
and to switch electrical circuits.
The pressure gauge 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.
2.2 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient!
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 qualifi-
cations described below.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical
training, knowledge of measurement and control technology and on their experi-
ence and knowledge of country-specific regulations, current standards and
directives, are capable of carrying out the work described and independently
recognising potential hazards.
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Temperature Class of the
ambient atmosphere
(ignition temperature)
Maximum permissible medium
temperature (in the pressure system)
Models 42X.12
and 42X.20
Models 43X.50,
43X.30 and 43X.X6
Model 43X.55
T 6 (> 85 °C) +70 °C +70 °C +70 °C
T 5 (> 100 °C) +85 °C +85 °C +85 °C
T 4 (> 135 °C) +100 °C +100 or +120 °C 2) +100 °C
T 3 (> 200 °C) +100 °C +100 or +185 °C 2) +100 °C
T 2 (> 300 °C) +100 °C +100 or +200 °C 2) +100 °C
T 1 (> 455 °C) +100 °C +100 or +200 °C 2) +100 °C
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WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX
2.3 Safety instructions for pressure gauges with ATEX approval
WARNING!
Non-observance of these instructions and their contents may
result in the loss of explosion protection.
It is imperative that the application conditions and safety
requirements of the EC-type examination certificate are
followed.
Technical data
Operating Temperature
Ambient: -20 … +60 °C (with inductive contacts in safety pattern version
Models 831.XX-SN up to -40 °C)
Attention: Footnote 1) under table 1 must be absolutely taken into account!
Medium: see table 1
Attention! In the case of gaseous substances, the temperature may increase due
to compression warming. In these cases it may be necessary to throttle the rate of
change of pressure or reduce the permissible temperature of the pressure medium.
Table 1: Permissible medium temperature (only mechanical part)
2. Safety
1) The permissible upper ambient temperature for the electrical components is determined by the
electrical connection values and the ignition temperature of the ambient gases, vapours and dusts.
Therefore the maximum permissible ambient temperatures specified in the EC-type examination
certificates for slot-type sensors and SN sensors must be observed as well. The lower of these two
values is to be considered the maximum permissible ambient temperature!
2) The higher values apply only to special versions with higher permissible media temperatures.

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2.4 Special hazards
WARNING!
Observe the information given in the applicable type exami-
nation certificate and the relevant country-specific regulations
for installation and use in potentially explosive atmospheres
(e.g. IEC 60 079-14, NEC, CEC). Non-observance can result in
serious injury and/or damage to equipment.
Dangerous pressure media such as Oxygen, Acetylene, flammable gases or liquids, toxic
gases or liquids as well as for refrigeration plants or compressors requires attention above
the standard regulations. Here the specific safety codes or regulations must be consi-
dered.
For additional important safety instructions see chapter 2.3 "Safety instructions
for instruments with ATEX approval".
WARNING!
Residual media in dismounted pressure gauges may result in a
risk to people, the environment and the system. Take sufficient
precautionary measures.
2.5 Labelling / safety marks
Product label
2. Safety
Wiring details Date of manufacture
Month/year
(here October 2009)

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WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX
3. Specifications
Pressure limitation
Steady: full scale value
Fluctuating: 0.9 x full scale value
Overpressure safety: see respective data sheet
Temperature effect
When the temperature of the measuring system deviates from the reference
temperature (+20 °C): max. ±0.8 %/10 K of full scale value
IP Ingress protection
IP 54 per EN 60 529 / IEC 60 529
(with liquid filling IP 65)
For further specifications see WIKA Data Sheet PV 24.03, PM 04.02, PM 04.07,
PM 04.08, PM 04.09 and the order documentation.
2. Safety / 3. Specifications
Explanation of symbols
CE, Communauté Européenne
Gauges bearing this mark comply with the relevant European
directives.
ATEX European Explosion Protection Directive
(Atmosphère = AT, explosible = Ex)
Gauges bearing this mark comply with the requirements of the
European Directive 94/9/EC (ATEX) on explosion protection.
Gauges bearing this mark on the dial are safety pressure
gauges with solid baffle wall per EN 837 (S3).

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4. Design and function
4. Design and function
Description
The pressure gauges measure the pressure by means of resilient diaphragm
measuring elements
The measuring characteristics are in accordance with the EN 837-3 and
DIN 16 085 standards
In addition the Models 43X.30 and 43X.36 also meet the requirements,
relating to safety pattern pressure gauges, outlined in the EN 837 (user
protection) standard
The built-in electrical switch contacts are non-contact slot-type inductive
proximity sensors, which are powered from switching amplifiers with certified
intrinsically safe circuits. When any of the adjustable set points is reached, the
associated output circuits will either open or close.
As standard Model 831 slot sensors, to EC-type examination certificate
PTB 99 ATEX 2219 X (see Appendix 2) and ZELM 03 ATEX 0128 X (see
Appendix 4), are used
Model 831-SN and -S1N SN sensors, to PTB 00 ATEX 2049 X (see Appen-
dix 3) and ZELM 03 ATEX 0128 X (see Appendix 4), are special designs with
safety features (that are not relevant to explosion protection) for special
applications
The connected loads for the switches are in accordance with EN 60 947-5-6
("NAMUR").
Scope of delivery
Cross-check scope of delivery with delivery note.
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WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX
5. Switch contacts
5. Switch contacts
EC-type examination certificates
Standard version Model 831.XX
PTB 99 ATEX 2219 X (Appendix 2) and ZELM 03 ATEX 0128 X (Appendix 4)
Depending on the number of switches and on the case diameter either
Model SJ2-N... or Model SJ3.5-...-N... is used.
Safety pattern version Models 831.XX - SN or - S1N
PTB 00 ATEX 2049 X (Appendix 3) and ZELM 03 ATEX 0128 X (Appendix 4)
Depending on the number of switches and on the case diameter either
Models SJ 2-SN..., SJ 2-S1N..., SJ 3.5-SN.. or SJ 3.5-S1N... are used.
The built-in sensor type is stated on the product label of the pressure gauge.
Wiring details
The electrical connections must only be made by qualified skilled personnel
Connection of the switches via screw terminals in the terminal box
Conductor cross section max. 1.5 mm2
The terminal assignment is stated on the product label of the pressure gauge
The gauges must be connected to the equipotential bonding of the plant
The permissible limits of Ui, Iiand Pifor the intrinsically safe supply circuits
depend on the sensor type. They can be taken from the corresponding EC-type
examination certificates. (The sensor type is stated on the connection plate of
the pressure gauge.)
Suitable switch amplifiers are e.g.:
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Electromagnetic compatibility
EMC to EN 60 947-5-2.
The instruments are to be protected against strong electromagnetic fields.
Circuit Sensor type Model designation EC-type exami- WIKA-
(s. Ex-certific.) Fa. Pepperl & Fuchs nation certificate Model
Model 1 standard KFD2-SR2-Ex1 PTB 00 ATEX 2080 904.31
standard KFD2-SR2 Ex2 PTB 00 ATEX 2080 904.32
Model 2 standard KFA6-SR2-Ex1 PTB 00 ATEX 2081 904.28
standard KFA6-SR2-Ex2 PTB 00 ATEX 2081 904.29
SN-sensors KFD2-SH-Ex1 PTB 00 ATEX 2042 904.33
SN-sensors KHA6-SH-Ex1 PTB 00 ATEX 2043 904.30

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5. Switch contacts / 6. Transport, packaging and storage
Adjusting red set pointers
The setting of the set point is achieved using the adjustment lock in the window
with the aid of the adjustment key (part of the scope of supply; found in
standard instruments on the side of the terminal box).
The set point indicators for the switch contacts are freely adjustable over the full
scale range. For reasons of switching accuracy and long life of the mechanical
measuring system, the switching points should be between 10 % and 90 % of
the measuring range.
6. Transport, packaging and storage
6.1 Transport
Check pressure gauge for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
6.2 Packaging
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).
6.3 Storage
Permissible conditions at the place of storage
Storage temperature: -20 ... +70 °C
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Red set pointer
Adjustment
lock
Removable
adjustment key

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Sealing of
the thread 
Wrench surface
Sealing area 
Installation with
spanner
Flange connection 1)
1) The screw connection of the
flange must not be opened
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WIKA Operating instructions pressure gauges Model 4 with 831 per ATEX
7. Commissioning, operation
Mechanical connection
In according with the general technical regulations for pressure gauges (i.e.
EN 837-2 "Selection and installation recommendations for pressure gauges").
When screwing gauges in, the force required for this must not be applied
through the case, but rather through the spanner flats (using a suitable tool)
provided for this purpose on the square shaft of standard connections.
Correct sealing of pressure gauge connections with parallel thread shall
be means of a suitable sealing ring, sealing washer or WIKA profile seals. The
sealing of tapered threads (e.g. NPT threads) is made by providing the thread ,
with additional sealing material like, for example, PTFE tape (EN 837-2).
The torque depends on the seal used. With standard G-type pipe thread, gauge
connection by means of a union nut or a LH-RH adjusting nut is recommended
to simplify correct orientation of the gauge. When a blow-out device is fitted to a
pressure gauge it shall be resistant to blocking by debris and dirt.
With safety pattern gauges (see dial symbol k) you need to pay attention to the
fact that the free space behind the blow-out back will be at least 15 mm.
Requirements for the installation point
If the measuring point is not adequately stable a measuring instrument support
such as a bracket or flange should be used for fastening (and possibly via a
flexible capillary line). If the pressure gauge is exposed to vibration or pulsating
pressure or both, then a liquid filled pressure gauge may provide considerably
better performance and readability. Instruments should be protected against
coarse dirt and wide fluctuations in ambient temperature.
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7. Commissioning, operation

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Installation
In order to ensure that with both models 43X.30 and 43X.36 pressure can
be safely and reliably vented through the case back, a distance of at least
25 mm must be left free behind the case!
After installation, instruments with liquid filling must be operated in a vented
condition by turning the pressure equalising valve.
In order to avoid any additional heating, the instruments must not be exposed
to direct solar irradiation while in operation!
Admissible ambient and working temperatures
When installing the pressure gauge it has to be ensured that, taking the influ-
ence of convection and heat radiation into consideration, no upper or lower
deviation from the permissible ambient and medium temperatures can occur.
The influence of temperature on the class accuracy is to be observed.
Permissible vibration load at the mounting point
The instruments should always be installed in locations free from vibration.
If necessary, it is possible to isolate the instrument from the mounting point
by installing a flexible connection line between the measuring point and the
pressure gauge and mounting the instrument on a suitable bracket.
If this is not possible, the following limit values must not be exceeded:
Dry gauges: Frequency range < 150 Hz
(Model 432) Acceleration < 0.7 g (7 m/s2)
Liquid-filled gauges: Frequency range < 150 Hz
(Model 433) Acceleration < 4 g (40 m/s2)
The liquid filling must be checked on a regular basis.
The liquid level must not drop below 75 % of the gauge diameter.
Commissioning
During the commissioning process pressure peaks must be avoided at all costs.
Open the shut-off valves slowly.
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7. Commissioning, operation

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8. Maintenance and cleaning
8.1 Maintenance
The instruments require no maintenance or servicing.
The indicator and switching function should be checked once or twice every
12 months. The gauge must be disconnected from the process to check with
a pressure testing device.
Repairs are only to be carried out by the manufacturer or appropriately
trained skilled personnel.
8.2 Cleaning
CAUTION!
Before cleaning, correctly disconnect the pressure gauge
from the pressure supply, switch it off and disconnect it from
the mains.
Clean the pressure gauge with a moist cloth.
Electrical connections must not come into contact with
moisture.
Wash or clean the dismounted pressure gauge before retur-
ning it, in order to protect staff and the environment from
exposure to residual media.
9. Dismounting and disposal
WARNING!
Residual media in dismounted pressure gauges can result in a
risk to persons, the environment and equipment. Take sufficient
precautionary measures.
9.1 Dismounting
Only disconnect the pressure gauge once the system has been depressurised!
9.2 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmen-
tally compatible way and in accordance with the country-specific waste dispo-
sal regulations.
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8. Maintenance and cleaning / 9. Dismounting and disposal

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Appendix 1: Declaration of conformity

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Appendix 2: EC-type examination certificate

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Appendix 2: EC-type examination certificate

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Appendix 2: EC-type examination certificate

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Appendix 3: EC-type examination certificate

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Appendix 3: EC-type examination certificate