WIKA DELTA-comb DPGS40TA User manual

EN
DE
Operating instructions
Betriebsanleitung
Dierential pressure gauge with micro switches,
model DPGS40TA, with component testing
Dierenzdruckmanometer mit Mikroschaltern,
Typ DPGS40TA, mit Bauteilprüfung
Dierential pressure gauge with integrated working pressure indication
and up to two micro switches, model DPGS40TA
DELTA-comb

EN
DE
2
14106549.07 09/2020 EN/DE
WIKA operating instructions DPGS40TA with component testing
© 08/2015 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!
Operating instructions for dierential pressure gauge,
model DPGS40TA Page 3 - 30
Betriebsanleitung für Dierenzdruckmanometer,
Typ DPGS40TA Seite 31 - 57

EN
Contents
WIKA operating instructions DPGS40TA with component testing 3
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Contents
1. General information 4
2. Safety 5
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Additional instructions for operation as a flow limiter in accordance with
VdTÜV code of practice “Flow 100:2006” . . . . . . . . . . . . . 6
2.3 Functional safety of the SIL version . . . . . . . . . . . . . . . 7
2.4 Personnel qualification . . . . . . . . . . . . . . . . . . . 13
2.5 Special hazards. . . . . . . . . . . . . . . . . . . . . . 13
2.6 Product label and safety marks . . . . . . . . . . . . . . . . 14
3. Specifications 16
4. Design and function 18
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . 18
5. Transport, packaging and storage 19
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Packaging. . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Commissioning, operation 20
6.1 Mechanical connection . . . . . . . . . . . . . . . . . . . 20
6.2 Electrical connection . . . . . . . . . . . . . . . . . . . . 24
6.3 Commissioning . . . . . . . . . . . . . . . . . . . . . .27
7. Options and accessories 27
7.1 4-way valve manifold . . . . . . . . . . . . . . . . . . . . 27
7.2 Panel mounting flange . . . . . . . . . . . . . . . . . . . 28
8. Maintenance 29
9. Dismounting, return and disposal 29
9.1 Dismounting . . . . . . . . . . . . . . . . . . . . . . .29
9.2 Return . . . . . . . . . . . . . . . . . . . . . . . . .29
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 29
Annex 1: DNV GL approval 58
Annex 2: SIL certificate 60
Annex 3: VdTÜV certificate „Flow 100:2006“ 62
Annex 4: Declaration of conformity 63
Declarations of conformity can be found online at www.wika.com.

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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
immediate vicinity of the instrument and readily accessible to skilled personnel
at any time.
■Skilled personnel must have carefully read and understood the operating ins-
tructions 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 insuciently qualied skilled personnel or unautho-
rised modications to the instrument.
■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
- corresponding data sheets: PV 27.22
1. General information
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in
serious injury or death, if not avoided.
Information
... points out useful tips, recommendations and information for
ecient and trouble-free operation.

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2. Safety
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the
appropriate dierential pressure gauge has been selected in terms
of measuring range, design and specic measuring conditions.
Check the compatibility with the medium of the materials subjec-
ted to pressure!
In order to guarantee the measurement accuracy and long-term
stability specied, the corresponding load limits must be obser-
ved.
Only work on the gauge with the voltage disconnected.
Non-observance can result in serious injury and/or damage to the
equipment.
Further important safety instructions can be found in the individual
chapters of these operating instructions.
2.1 Intended use
The dierential pressure measuring instruments of the DELTA-line product family
are primarily used for the monitoring and control of low dierential pressures
where there are high requirements in terms of one-sided overpressure and static
pressure.
Typical markets for these products are the shipbuilding industry, process heating
technology, the heating, ventilation and air-conditioning industries, the water/
wastewater industry, and machine building and plant construction. For these, the
main function of the measuring instruments is the monitoring and control of lters,
compressors and pumps.
Classication per European pressure equipment directive
■Instrument type: Pressure accessory without safety function
■Media: Liquid or gaseous, group 1 (dangerous)
■Maximum permissible pressure PS, see chapter 2.6 “Product label and safety
marks”
■Volume: < 0.1 l
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.

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2. Safety
2.2 Additional instructions for operation as a flow limiter in accordance
with VdTÜV code of practice “Flow 100:2006”
The maximum permissible electrical loads of 250 V AC / 1.4 A or 30 V DC / 0.4 A
must not be exceeded. For this reason, a fuse must be provided in the current
circuit with a rated value that is smaller than 0.6 times the maximum permissible
current values.
The safety function is that, on falling dierential pressure, the switch contact will
open when the set limit value is reached.
The requirements on the interlocking and unlocking, as stipulated in the VdTÜV
code of practice 'Flow 100:2006' for limiters of “special design”, must be ensured
by external measures.
The measuring arrangement must be designed in accordance with DIN 19216. For
this arrangement with block valves it must be ensured that the dierential pressure
line between the block valve and the dierential pressure sensor, as a constituent
element of the switching element, is at least 500 mm long.
The requirements on the dierential pressure lines in accordance with VdTÜV
code of practice “Flow 100:2006” section 5.7.2.3 must be met.

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2. Safety
2.3 Functional safety of the SIL version
2.3.1 General information
History of the information on functional safety
Issue Remark
01/2016 First issue in January 2016
The following information on functional safety is valid in conjunction with the other
parts of these operating instructions and with the documents mentioned in chapter
2.3.2 “Other applicable instrument documentation”.
The operating instructions contain important information on handling the
DPGS40TA.100-xxS dierential pressure gauge. Working safely requires that all
safety instructions and work instructions are observed.
Only model DPGS40TA.100-xxS is suitable for operation in safety-
related applications!
The marking on the product label for the instruments with SIL
version is shown in the following illustrations.
2.3.2 Other applicable instrument documentation
In addition to this section, the other parts of these operating instructions,
14106549, for model DPGS40TA.100-xxS, the data sheet PV 27.22 and the
certicates V 495.01/15 and V 495.02/15 (see Annex 3) also apply.
2.3.3 Relevant standards
Standard Title
IEC 61508 edition 2.0 Functional safety of safety-related electrical/electronic/pro-
grammable electronic systems
IEC 61511 edition 1.0 Functional safety – Safety instrumented systems for the pro-
cess industry
ISO EN 13849-1:2008 Safety of machinery – Safety-related components of control
systems – Part 1: General principles for design

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2.3.4 Abbreviations
Abbreviation Description
λS + λDλS safe + λDdangerous
Sum of all mean failure rates for the system. A safe failure occurs
if, during this, the measuring system remains in a functioning state
or the failure detection is signalled by an alarm. A failure to danger
occurs if the measuring system, through this, can switch into a
dangerous or functionally inoperable condition.
λDD λDD dangerous detected
With detected failures to danger, the failure is detected by diagnostic
tests or proof testing, for example, where the system switches to the
safe state.
λDU λDU dangerous undetected
With undetected failures to danger, the failure is not detected
through diagnostic tests.
Operating mode
with low demand
rate
In this operating mode, the safety function of the safety system is
only carried out on request.The frequency of the request is no more
than once a year.
Operating mode
with high demand
rate
In this operating mode, the safety function of the safety system is
only carried out on request.The frequency of the request is more
than once a year.
DC Diagnostic coverage
Percentage of failures to danger that are detected by automatic
diagnostic online tests.
HFT Hardware fault tolerance
Capability of a functional unit to continue the execution of the
demanded function when faults or deviations exist.
SIL Safety integrity level
The international standard IEC 61508 denes four discrete safety
integrity levels (SIL 1 to SIL 4). Each level corresponds to a range of
probability with which a safety-related system performs the specied
safety functions in accordance with the requirements.The higher
the safety integrity level of the safety-related system, the greater the
probability that the safety function is executed.
2. Safety

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Abbreviation Description
PL Performance level;The international standard EN ISO 13849 1
denes ve discrete performance levels (PL a to PL e). Each level
corresponds to an ability of safety-related parts of control systems to
perform a safety function under foreseeable conditions.
MooN
(M out of N)
architecture
The architecture describes the specic conguration of hardware
and software in a system. N is the number of parallel channels and
M denes how many channels must be working correctly.
PFDavg Average probability of a dangerous failure on demand of the safety
function in the operating mode with low demand rate
Ti or Tproof Interval of the proof tests (in hours, typically one year (8,760 h)).
Following this interval, the proof test will be carried out.
PFHDAverage frequency of a dangerous failure on demand of the safety
function in the operating mode with high demand rate
SFF Safe failure fraction
MTTFDMean time to a failure to danger
B10d Number of cycles till 10 % of the components have failed
dangerously
nop Average number of operations per year
β factor Factor for failure due to common causes, in terms of the interaction
of several channels
2. Safety

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2.3.5 Intended use in safety applications
All safety functions relate exclusively to the switching function of the instrument.
The display of the dierential pressure is not part of the safety function.
The instrument is suitable for use in single-channel safety-related systems in ac-
cordance with IEC 61508 and IEC 61511 up to SIL 2. In a redundant conguration
(HFT ≥ 1), the instruments can be used in a redundant design up to SIL 3.
The instrument is suitable for use in single-channel safety-related systems in ac-
cordance with ISO 13849 up to PL d. In a redundant conguration (HFT ≥ 1), the
instrument can be used up to PL e, if a sucient external diagnosis is implement-
ed (DC low for PL d / medium for PL e).
WARNING!
The safety-related values of the instrument must be compared, for
the appropriate usage case, with the requirements of the applica-
tion.
The specic parameters should always be considered with respect
to the expected switching frequency.
2.3.6 Restrictions to operating mode
WARNING!
Under the following operating conditions, the safety function of the
instrument is not guaranteed:
■During the setting of the switch points
2.3.7 Safety function
The safety function of the instrument is that, on falling dierential pressure, the
respective switch(es) will open.The changeover contacts should always be used
so that the circuit opens on falling dierential pressure (observe the closed-circuit
principle).
2. Safety

EN
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2.3.8 Accuracy of the safe switching function
The following information on the total safety accuracy contains:
■Basic accuracy (measuring deviation, linearisation error)
■Inuence of the ambient temperature in the range -10 °C ... +70 °C
■Inuence of up to 259,835 load cycles
The total safety accuracy is -12 % ... +8 % of the measuring span for the dieren-
tial pressure.
2.3.9 Operating limits
Working pressure: see dial
Dierential pressure: see dial
Ambient temperature: -10 … +70 °C (operation)
Ambient temperature: -40 … +70 °C (storage)
Medium temperature: -10 … +90 °C
(The temperature at the instrument must not exceed 70 °C)
2.3.10 Configuration changes
The setting of the switch points is made in the factory in accordance with the
ordering information. Following any change by the operator, the switch points must
be checked.The marking must, for example, be updated via a suitable adhesive
label.The instrument should be secured against the switch points being changed
through the provided lead sealing of the setting elements.
WARNING!
The safety function must be checked by testing following any con-
guration procedure.
2. Safety

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2.3.11 Commissioning
All applications
The operability of the switching function of the DPGS40TA.100-xxS dierential
pressure gauge must be tested both during commissioning and at appropriate
intervals. Both the nature of the testing as well as the chosen intervals are the
responsibility of the user.
Additional for applications with low demand rate
The interval for the proof test usually conforms to the PFDavg value given in
the standard. Normally the proof test takes place every year, see certicates
V 495.01/15 and V 405.02/15.
2.3.12 Proof test of the safety function
Through a test of the entire safety function, check whether the switch is operating
correctly.
2.3.13 Information on the determination of safety-relevant parameters
The failure rates of the instruments were determined through the use of statis-
tical methods in accordance with IEC 61508 on the basis of a type test for the
DPGS40TA.100-xxS.
The instrument is designed for applications with low or high demand rates.
WARNING!
The maximum operating life of a safety-related system is 5 years,
plus a 1.5 year reserve. Any longer operating life is the responsibility
of the operator.
2.3.14 Instrument-specific safety-related parameters
The safety-related parameters for the operation in safety integrated systems in
accordance with IEC 61508 and IEC 61511 are to be taken from the certicate
V 495.01/15, see Annex 3 of these operating instructions.
The safety-related parameters for the operation in safety integrated systems in
accordance with ISO 13849 are to be taken from the certicate V 495.02/15, see
Annex 3 of these operating instructions.
2. Safety

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2.3.15 Decommissioning the instrument
WARNING!
Ensure instruments that have been taken out of service are not
accidentally recommissioned (e.g. through marking the instrument).
After exchanging the instrument, a functional test of the entire safe-
ty function (safety loop) should be initiated, in order to test whether
the safety function of the system is still guaranteed. Function tests
are intended to demonstrate the correct function of the whole
safety-related system, including all instruments (sensor, logic unit,
actuator).
2. Safety
2.4 Personnel qualification
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.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical
training, knowledge of measurement and control technology and on their ex-
perience and knowledge of country-specic regulations, current standards and
directives, are capable of carrying out the work described and independently
recognising potential hazards.
2.5 Special hazards
WARNING!
For hazardous media such as ammable or toxic gases or liquids,
and refrigeration plants, compressors, etc., in addition to all stan-
dard 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.
WARNING!
The maximum surface temperature of the instrument may
not exceed the ignition temperature of ammable media.
Take sucient precautionary measures.

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2.6 Product label and safety marks
Product label
Dial (example)
Model DPGS40TA
Code 1st digit: E = Single micro switch 850.3
D = Double micro switch 850.3.3
2nd digit: S = VdTÜV “Flow 100”
3rd digit: S = SIL version
Date of manufacture
Pin assignment
Contact type
Article number
Maximal permissable pressure PS per European Pressure Equipment Directive
 





2. Safety

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2. Safety
Explanation of symbols
Before mounting and commissioning the instrument, ensure
you read the operating instructions!
Risk of burns!
Potentially dangerous situation caused by hot surfaces.
Due to the maximum permissible process temperature of 90 °C,
measuring cells, adapters, valves or other attachment parts can
reach a temperature of 90 °C.

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3. Specications
3. Specifications
The insulation values (air gaps and creepage distances) are sized for the fo-
llowing ambient conditions in accordance with EN 61010-1:2010:
■Altitude up to 2,000 m
■Overvoltage category II
■Pollution degree 2
■Relative humidity 0 ... 95 % non-condensing (per DIN 40040)
The strength of the measuring instruments (enclosing non-metallic compo-
nents) was tested with a reduced impact energy of 2 J corresponding to IK07
per EN 61010-1:2010.The IK code is included on the respective product label.
Specications
Nominal size Dierential pressure indication: Ø 100 mm
Working pressure indication: Ø 22 mm
Accuracy Dierential pressure indication: ≤ 2.5 % of span
(option ≤ 1.6 %)
Working pressure indication: ≤ 4 % of span
Scale ranges
(EN 837)
Dierential pressure: 0 ... 0.25 up to 0 ... 10 bar
Working pressure: 0 ... 25 bar
Max. working pressure
(stat.)
25 bar
Overload safety Max. 25 bar
On one, both and alternatingly on the ⊕ and ⊖ side
Permissible
temperatures
Ambient: -10 ... +70 °C, medium: -10 ... +90 °C
Storage: -40 ... +70 °C
Ingress protection IP65 per IEC/EN 60529
Media chamber (wetted) Aluminium, EN AC–Al Si9Cu3(Fe), black lacquered
(option: stainless steel)
Process connections
(wetted)
2 x G 1/4 female, lower mount (LM), in-line, centre distance
26 mm
Pressure elements
(wetted)
Dierential pressure: Compression springs from stainless
steel 1.4310 and separating diaphragm from FPM/FKM
(option: NBR)
Working pressure: Bourdon tube from Cu-alloy
Transmission parts
(wetted)
Stainless steel 1.4301, 1.4305, 1.4310, FPM/FKM
(option: NBR)
Sealings (wetted) FPM/FKM (option: NBR)
Movement Copper alloy

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3. Specications
For further specications see the corresponding product label, WIKA data sheet
and order documentation.
For models with optional explosion protection read the “Additional information
for hazardous areas (Ex i), models DPS40, DPGS40, DPGS40TA und DPGT40”,
article number 14110818.
Specications
Dial Dierential and working pressure indication: White dial, black
lettering
Pointer Dierential and working pressure indication: Blue pointer
Zero adjustment for
dierential pressure
indication
Via screw in the dial
Case Aluminium, EN AC–Al Si9Cu3(Fe), black lacquered
Window Plastic, with plug screw for zero and switch point adjustment
(option: Lead sealing of the settings)
Weight approx. 1.3 kg
Electrical contact
Type of contact Micro switch
Contact function
Single change-over
Double change-over
Contact type 850.3
Contact type 850.3.3
Load data
U max., I max., P max. AC 250 V, 5 A 1), 250 VA DC 30 V, 0.4 A, 10 W
Switch point setting from the outside at assistant scale by means of adjustment
screw(s)
Setting range from 10 % to 100 % of the full scale value
Switch point
reproducibility
≤ 1.6 %
Switch hysteresis max. 5 % of the full scale value (option: max. 2.5 %)
Electrical connection Cable gland M20 x 1.5 with 1 m free cable
1) I max. = 1.4 A for designs in accordance with VdTÜV code of practice "Flow 100"

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4. Design and function
4.1 Description
4. Design and function
Pressures p1and p2 act on the media chambers ⊕ and ⊖, which are separated by
an elastic diaphragm (1).
The dierential pressure (∆p = p1- p2) leads to an axial deection of the dia-
phragm against the measuring range springs (2).
The deection, which is proportional to the dierential pressure, is transmitted to
the movement (4) in the indicating case and to the leaf springs of the micro swit-
ches (5) via a pressure-tight and low friction rocker arm (3).
Overpressure safety is provided by metal bolsters (6) resting against the elastic
diaphragm.
The setting of the switch point is made by the adjustment screws accessible from
the front (7).The assistant scales (8) simplify the setting of the switch points.
14077593.01
⊖ ⊕








4.2 Scope of delivery
Cross-check scope of delivery with delivery note.

EN
5. Transport, packaging and storage
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5. Transport, packaging and storage
5.1 Transport
Check the dierential pressure gauge for any damage that may have been
caused by transport. Obvious damage must be reported immediately.
5.2 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).
5.3 Storage
Permissible conditions at the place of storage
Storage temperature: -40 ... +70 °C
In order to prevent damage, the following points should be noted for the
storage of the instruments:
■Leave the instruments in their original packaging
■Following any possible removal of the measuring instruments, e.g. for testing,
the instrument should again be stored in its original packaging
Avoid exposure to the following factors:
■Direct sunlight or proximity to hot objects
■Mechanical vibration, mechanical shock (putting it down hard)
■Soot, vapour, dust, humidity and corrosive gases
■Hazardous environments, ammable atmospheres
WARNING!
Before storing the instrument, any residual media must be remo-
ved.This is of particular importance if the medium is hazardous to
health, e.g. caustic, toxic, carcinogenic, radioactive, etc.

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6. Commissioning, operation
6. Commissioning, operation
6.1 Mechanical connection
■In accordance with the general technical regulations for pressure gauges (e.g.
EN 837-2 “Selection and installation recommendations for pressure gauges”).
■Mounting of the pressure connections according to axed symbols, ⊕ high
pressure, ⊖ low pressure
■Mounting by means of:
- rigid measuring line or
- wall mounting with available mounting links
■Process connections 2 x G 1/4 female, lower mount (LM), in-line, centre
distance 26 mm, operating position NL 90 (nominal position) per DIN 16257
(i.e. vertical dial), design the threads of the connection shanks in accordance
with EN 837-3 (section 7.3.2).
■Prior to the installation of the instrument, clean the measuring lines thoroughly
by tapping and blowing or ushing.
■Protect measuring instruments from contamination and high temperature
changes!
■The pressure gauge must be mounted free from vibration and should be
aligned so that it is easy to read. It is recommended that an isolation device is
interposed between the pressure tapping point and the instrument, which will
enable the replacement of the instrument and a zero point check while the plant
is running.The instruments should be protected against coarse dirt and wide
uctuations in ambient temperature.
■For sealing the connections, use at gaskets, lens-type sealing rings or WIKA
prole sealings. In order to orientate the gauge so that the on-site display can
be read as well as possible, a connection with clamp socket or union nut should
be used. When screwing on and unscrewing the instruments they should not be
gripped by the case, but rather only on the spanner ats of the connection!
Wall mounting
Mounting using three integrally cast mounting lugs