simex CCP-P-400 Electronic Pressure Switch User Manual

simex CCP-P-400 Electronic Pressure Switch

Product Information

The product is an Electronic Pressure Switch manufactured by SIMEX Ltd. The specific models are CCP-P-400, CCP-P-400P, and CCP-P-401. It is designed for applications that require absolute, vacuum, and overpressure measurement. The device is equipped with a 4-digit LED display to show the current system pressure. It is suitable for various areas of use depending on the device and mechanical connection.

Product Usage Instructions

1. Read the operating manual thoroughly before using the device and keep it for future reference.
2. Ensure that all persons involved in mounting, installation, putting into service, operation, maintenance, removal from service, and disposal of the device have read and understood the operating manual, especially the safety-related information.
3. Adhere to the current data sheet provided by accessing www.simex.pl or requesting it via info@simex.pl or phone: +48 58 7620777.
4. Observe the applicable accident prevention regulations, safety requirements, country-specific installation standards, and accepted engineering standards.
5. Pay attention to the symbols used in the manual which indicate the type and source of danger, as well as measures to avoid the danger.
6. Qualified persons should handle all aspects of the product, including mounting, installation, putting into service, operation, maintenance, removal from service, and disposal. Qualified persons are those who have knowledge and experience in metrology and automation technology, are familiar with the operation of measuring and automation systems, or have completed training for system repair and operation.
7. Only qualified persons should perform any work with this product.

General and safety-related information

General and safety-related information on this operating manual

This operating manual enables safe and proper handling of the product, and forms part of the device. It should be kept in close proximity to the place of use, accessible for staff members at any time.
All persons entrusted with the mounting, installation, putting into service, operation, maintenance, removal from service, and disposal of the device must have read and understood the operating manual and in particular the safety- related information.

• Complementary to this operating manual the current data sheet has to be adhered to.
• Download the data sheet by accessing www.simex.pl or request it: info@simex.pl | phone: +48 58 7620777

In addition, the applicable accident prevention regulations, safety requirements, and country-specific installation standards as well as the accepted engineering standards must be observed.

Symbols used

Warning word

• Type and source of danger
• Measures to avoid the danger

–     Non-compliance will result in

death or serious injury.

WARNING| –     Possible danger!

–     Non-compliance may result in death or serious injury.

CAUTION| –     Hazardous situation!

–     Non-compliance may result in

minor or moderate injury.

NOTE – draws attention to a possibly hazardous situation that may result in property damage in case of non-compliance.

• Precondition of an action

Staff qualification
Qualified persons are persons that are familiar with the mounting, installation, putting into service, operation, maintenance, removal from service, and disposal of the product and have the appropriate qualification for their activity.
This includes persons that meet at least one of the following three requirements:

• They know the safety concepts of metrology and automation technology and are familiar therewith as project staff.
• They are operating staff of the measuring and automation systems and have been instructed in the handling of the systems. They are familiar with the operation of the devices and technologies described in this documentation.
• They are commissioning specialists or are employed in the service department and have completed training that qualifies them for the repair of the system. In addition, they are authorized to put into operation, to ground, and to mark circuits and devices according to the safety engineering standards.

All work with this product must be carried out by qualified persons!

Intended use

• The electronic pressure sw itch CCP-P-400 has been developed, according to the type for applications, for absolute, vacuum and overpressure measurement. It is equipped with a 4-digit LED-display to show the current system pressure. Depending on the device and the mechanical connection it is suitable for various areas of use.
• Devices with 3-A and/or EHEDG certified process connection have been developed especially for applications in food and pharmaceutical industry. The process connection is hygienic and can be sterilized.
• Permissible measuring and cleaning media are gases or liquids, which are compatible with the media wetted parts of the device (according to data sheet) and your system. This must be ensured for the application.
• The device has to be used only for the described purpose, considering the following information.
• The user must check whether the device is suited for the selected use. In case of doubt, please contact our sales department: info@simex.pl | phone: +48 58 7620777
• The manufacturer assumes no liability for any wrong selection and the consequences th ereof!
• The technical data listed in the current data sheet are engaging and must absolutely be complied with. If the data sheet is not available, please order or download it from our homepage: http://www.simex.pl.

Incorrect use

WARNING

Danger through incorrect use

• Only use the device in permissible media and in accordance with its intended use.
• Do not use the device as a ladder or climbing aid.
• The device must not be altered or modified in any way.
• The manufacturer is not liab le for dama-ge caused by improper or incorrect use.

Limitation of liability and warranty
Failure to observe the instructions or technical regulations, improper use and use not as intended, and alteration of or damage to the device will result in the forfeiture of warranty and liability claims.

Safe handling

• NOTE – Do not use any force when installing the device to prevent damage of the device and the plant!
• NOTE – Treat the device with care both in the packed and unpacked condition!
• NOTE – Do not throw or drop the device!
• NOTE – Excessive dust accumulation and complete coverage with dust must be prevented!
• NOTE – The device is state-of-the-art and is operationally reliable. Residual hazards may originate from the device if it is used or operated improperly.

Scope of delivery
Check that all parts listed in the scope of delivery are included free of damage, and have been delivered according to your purchase order:

• electronic pressure switch
• for mechanical pressure ports DIN 3852: O- Ring (pre-mounted)
• mounting instructions or operating manual

UL approval (for devices with UL Marking)
The UL approval was effected by applying the US standards, which also conform to the applicable Canadian standards on safety.

Observe the following points so that the device meets the requirements of the UL approval:

• only indoor usage
• maximum operating voltage: according to data sheet
• The device must be operated via a supply with energy limitation (acc. to UL 61010) or an NEC Class 2 energy supply.

Product identification

The device can be identified by means of the manufacturing label with ordering code. The most important data can be gathered therefrom. The version of the firmware, (e. g. P07) will appear for about 1 second in the display after starting up the device. Please hold it ready for inquiry calls.

Fig. 1 example of manufacturing label

NOTE – The manufacturing label must not be removed!

Mounting

Mounting and safety instructions

DANGER

| Danger of death from airborne parts, leaking fluid, electric shock

– Always mount the device in a depressurized and de-energized

condition!

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DANGER

| Danger of death from improper installation

– Installation must be performed only by appropriately qualified persons who

have read and understood the operating manual.

• NOTE – Do not remove the packaging or protective caps of the device until shortly before the mounting procedure, in order to exclude any damage to the diaphragm! Protective caps must be kept! Dispose of the packaging properly!
• NOTE – If there is increased risk of damage to the device by lightning strike or overvoltage, increased lightning protection must additionally be provided!
• NOTE – Treat any unprotected diaphragm with utmost care; this can be damaged very easily.
• NOTE – The operating and display module as well as the housing are equipped with rotation limiters. Please do not attempt to overtighten it by applying increased force.
• NOTE – Provide a cooling line when using the device in steam piping and and clarify the material compatibility.
• NOTE – The measuring point must be designed in such a way that cavitation and pressure surges are avoided.
• NOTE – When installing the device, avoid high mechanical stresses on the pressure port! This will result in a shift of the characteristic curve or to damage, in particular in case of very small pressure ranges.
• NOTE – In hydraulic systems, position the device in such a way that the pressure port points upward (ventilation).
• NOTE – The permissible tightening torque depends on the conditions on site (material and geometry of the mounting point). The specified tightening torques for the pressure switch must not be exceeded!
• NOTE – If the device is installed with the pressure port pointing upwards, ensure that no liquid drains off on the device. This could result in humidity and dirt blocking the gauge reference in the housing and could lead to malfunctions.
• Dust and dirt must be removed from the edge of the screwed joint of the electrical connection.
• NOTE – Please check the conditions of use and operation of the device at regular intervals. If the properties are changed, initiate appropriate measures.
• NOTES – for mounting outdoors / in a humid environment and for cleaning:
  • Please note that your application does not show a dew point, which causes condensation and can damage the device. There are specially protected devices for these operating conditions. Please contact us in such case.
  • Connect the device electrically straightaway after mounting or prevent moisture penetration, e.g. by a suitable protective cap. (The ingress protection specified in the data sheet applies to the connected device.)
  • For devices with gauge reference in the housing (small hole next to the electrical connection), install the device in such a way, that the gauge reference is protected from dirt and moisture. Should the device be exposed to fluid admission, the functionality will be blocked by the gauge reference. An exact measurement in this condition is not possible. Furthermore, this can lead to damages on the device.
• Select the mounting position such that splashed and condensed water can drain off. Stationary liquid on sealing surfaces must be excluded!
• If the device has a cable outlet or cable gland, the outgoing cable must be routed downwards. If the cable needs to be routed upwards, this must be done in an initially downward curve.
• Mount the device such that it is protected from direct solar radiation. In the most unfavourable case, direct solar radiation leads to the exceeding of the permissible operating temperature, which can then damage the device or affect its ability to function correctly. If the internal pressure in the device rises, this could also cause temporary measurement errors.

Conditions for devices with 3-A symbol

• The device or its connecting piece must be installed in such a way that the surfaces are self-draining (permissible installation position 273° … 87°).
• Make sure that the welding socket is mounted flush inside the tank.

The user is responsible for:

• the correct size of the seal and the choice of an elastomeric sealing material that complies with the 3- A standard
• an easy to clean installation position of the pressure transmitter with little dead space, as well as definition / verification / validation of a suitable cleaning process
• defining adequate service intervals

Conditions for devices, with EHEDG certificate
Install the device according to the requirements given in EHEDG Guidelines 8, 10 and 37. That is to mount the device in a self-draining orientation. The device should be installed flush to the process area. If mounting in a T-piece, the ratio between the depth of the upstand (L) and the diameter (D) of the upstand shall be L/D<1. If welded adapters are used, the food contact surface must be smooth, and the welding has to be done according to EHEDG Guideline 9 and 35. Suitable pipe couplings and process connections must be applied according to the EHEDG Position Paper. (List the available ones.)

Conditions for oxygen applications

DANGER
Danger of death from explosion – when used improperly

• Make sure that your device was ordered for oxygen applications and delivered accordingly. (see manufacturing label – ordering code ends with the numbers “007”)
• Unpack the device directly prior to the installation.
• Skin contact during unpacking and installation must be avoided to prevent fatty residues remaining on the device.

Wear safety gloves!

• The entire system must meet the requirements of BAM (DIN 19247)!
• For oxygen applications > 25 bar, devices without seals are recommended.
• Device with o-rings of FKM (Vi 567): permissible maximum values: 25 bar / 150° C (BAM approval)

Mounting steps for connections according to DIN 3852

NOTE
Do not use any additional sealing material such as yarn, hemp or Teflon tape!

• The O-ring is undamaged and seated in the designated groove.
• The sealing face of the mating component has a flawless surface. (RZ 3.2)

1. Screw the device into the corresponding thread by hand.
2. Devices with a spanner flat must be tightened using a suitable open-end wrench. Permissible tightening torques for pressure switch:
   • G1/4″: approx. 5 Nm
   • G3/4″: approx. 15 Nm
   • G1 1/2″: approx. 25 Nm
   • G1/2″: approx. 10 Nm
   • G1″: approx. 20 Nm

Mounting steps for connections according to EN 837

• A suitable seal for the medium and the pressure to be measured is available. (e.g. a copper seal)
• The sealing face of the mating component has a flawless surface. (RZ 6.3)

1. Screw the device into the corresponding thread by hand.
2. Then tighten it using an open-end wrench. Permissible tightening torques for pressure switch:
   • G1/4″: approx. 20 Nm; G1/2″: approx. 50 Nm

NOTE – note the permitted pressure according to EN 837:

G1/4″ EN 837| p ≤ 600 bar| Counterpart has to be of steel according to

DIN 17440 with strength Rp 0.2 ≥ 190 N/mm2

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G1/2″ EN 837| p ≤ 1000 bar

NOTE
Please refer to data sheet or contact sales department at Simex regarding max. permitted pressure of device.

Mounting steps for NPT connections

• Suitable fluid-compatible sealing material, e.g. PTFE tape, is available.

1. Screw the device into the corresponding thread by hand
   Then tighten it using an open-end wrench. Permissible tightening torques for pressure switch: 1/4″ NPT: approx. 30 Nm; 1/2″ NPT: approx. 70 Nm

Mounting steps for G1″ cone connection

1. Screw the device into the mating thread by hand (seal produced metallically)
2. Then tighten it using an open-end wrench. Permissible tightening torques for pressure switch: pN < 10 bar: 30 Nm; pN ≥ 10 bar: 60 Nm

Mounting steps for dairy pipe connections

• The O-ring is undamaged and seated in the designated groove.
• Chapter “3.2 and/or 3.3” have been noticed.
  EHEDG conformity is only ensured in combination with an approved seal for codes M73, M75, M76. This is e.g.: ASEPTO-STAR k-flex upgrade seal by Kieselmann GmbH

1. Centre the dairy pipe connection in the counterpart.
2. Screw the cup nut onto the mounting part.
3. Then tighten it using a hook wrench.

Mounting steps for Clamp and Variventâ connections

• A suitable seal for the measured fluid and the pressure to be measured is available.

• Chapter “3.2 and/or 3.3” have been noticed.
  EHEDG conformity is only ensured in combination with an approved seal. This is e.g.: for Clamp connections – codes C61, C62, C63:

• T-ring seal from Combifit International B.V.

for Variventâ connections – codes P40, P41: EPDM-O-ring which is FDA-listed

Note, that P40 can only be used for tank flanges.

1. Place the seal onto the corresponding mounting part.
2. Centre the clamp connection or Variventâ connection above the counterpart with seal.
3. Then fit the device with a suitable fastening element (e. g. semi-ring or retractable ring clamp) according to the supplier’s instructions

Positioning of the display
In order to ensure easy readability even when the device is installed in an awkward location, the display and operating module as well as the housing can be rotated into the desired position. Note rotation limits.

To rotate the display and operating module proceed as follows to change the position:

• Unscrew the housing cap by hand.
• Rotate the display and operating module carefully by hand into the desired position. The module is equipped with a turning limiter.
• Before screwing on the cap again, the o-ring and sealing surfaces of the housing have to be checked for damage and if necessary, have to be changed!
• Afterwards screw the housing cap on by hand and make sure that the housing is firmly locked again.

NOTE
Ensure that moisture cannot enter the device! The seals and sealing surfaces must not get dirty, as (depending on application and location) fouling can cause a reduced degree of protection and therefore lead to device failure or irreparable damage to the device.

Electrical connection

Connection and safety instructions

DANGER| Danger of death from electric shock

– Always mount the device in a depressurized and de-energized condition!

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• The supply corresponds to protection class III (protective insulation).

NOTE For the electrical connection a shielded and twisted multicore cable is recommended.

NOTE for devices with cable outlet

• When routing the cable, following bending radiuses have to be complied with:
• cable without ventilation tube:
  • static installation: 8-fold cable diameter
  • dynamic application: 12-fold cable diameter cable with ventilation tube:
  • static installation: 10-fold cable diameter
  • dynamic application: 20-fold cable diameter
• In case of devices with cable outlet and integrated ventilation tube, the PTFE filter located at the cable end on the ventilation tube must neither be damaged nor removed! Route the end of the cable into an area or suitable connection box which is as dry as possible and free from aggressive gases, in order to prevent any damage.

NOTE
If a transition is desired from a transmitter cable with gauge tube to a cable without gauge tube, we recommend our terminal box KL 1 or KL 2.

Electrical installation
Establish the electrical connection of the device according to the technical data shown on the manufacturing label, the following table and the wiring diagram.

Pin configuration:

(green / yellow)

Wiring diagrams:
2-wire-system (current)

3-wire-system (current/voltage)

Commissioning

DANGER

| Danger of death from airborne parts, leaking fluid, electric shock

– Operate the device only within the specification! (according to data sheet)

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• The device has been installed properly.
• The device does not have any visible defect.

Operation

Control and display elements

Fig. 2 touch pad (example with two contacts)

The device has, according to the order max. two LEDs which are allocated to the resp. contacts. The LEDs will light up when the respective set point has been reached and the contact is active. The display of the measured value as well as the configuration of the individual parameters occurs menu-driven via the sevensegment display.

To configurate the device, unscrew the housing cap by hand. execution of configuration:

• set the desired menu item by pushing the ▲- or ▼-button
• activate the set menu item by pushing both buttons simultaneously
• set the desired value or select one of the offered settings by using the ▲- or ▼-button
• store / confirm the set value/selected setting and exit the menu by pushing both buttons simultaneously

Before screwing on the cap again, the o-ring and sealing surfaces of the housing have to be checked for damage and if necessary, have to be changed! Afterwards screw the housing cap on by hand and make sure that the housing is firmly locked again.

NOTE
Ensure that moisture cannot enter the device! The seals and sealing surfaces must not get dirty, as (depending on application and location) fouling can cause a reduced degree of protection and therefore lead to device failure or irreparable damage to the device.

Configuration
The menu system is a closed system allowing you to scroll both forward and backward through the individual set-up menus to navigate to the desired setting item. All settings are permanently stored in an EEPROM and therefore available again even after disconnecting from the supply voltage. The structure of the menu system is the same for all types of devices, regardless of the number of contacts. However, they only differ by the number of menus. Following figure and the menu list shows all possible menus. On devices with 3-wire output 4 … 20 mA and 0 … 20 mA, the menus ZP and EP have special functions. The menu DP is not applied, as the decimal point is already factory set during production.

Please follow the manual meticulously and remember that changes of the adjustable parameters (switch-on point, switchoff point, etc.) become only effective after pushing both buttons simultaneously and leaving the menu item.

Password system
To avoid a configuration by unautho rized persons, the possibility is given to lock the device by an access protection. More information is given in menu 1 of the menu list.

Configuration example of the analogue output for 4 … 20 mA / 3-wire adjustable
By the menus ZP and EP, the analog ue output can be configured. In the following, the function of these menus shall be made clear by an example. Assuming you have a device with a nominal pressure range 0 … 400 bar by factory the following performance is set:

• 0 bar = 4.00 mA
• 200 bar = 12.00 mA
• 400 bar = 20 mA

If you change the value in the me nu ZP from 0 to 20 and the value in the menu EP from 400 to 300, the following performance will appear:

• 20 bar = 4.00 mA
• 160 bar = 12.00 mA
• 300 bar = 20 mA

The values of ZP and EP are adjustable up to 1:5 of the nominal pressure range.

Description of hysteresis and compare mode
To invert the respective modes, you have to exchange the values for the switch-on and switch-off points.

Menu list

Button functions are well known (see ″6.1 Control and display elements″)

Structure of the menu system

2-wire-version (P07)

3-wire-version (P07):

Maintenance

DANGER

| Danger of death from airborne parts, leaking fluids, electric shock

– Always service the device in a depressurized and de-energized condition!

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WARNING

| Danger of injury from aggressive fluids or pollutants

–   Depending on the measured medium, this may constitute a danger to the operator.

–   Wear suitable protective clothing e.g. gloves, safety goggles.

If necessary, clean the housing of the device using a moist cloth and a non- aggressive cleaning solution. During the cleaning processes, note the compatibility of the cleaning media used in combination with the media-wetted materials of the pressure measuring devices. Permissible concentrations and temperatures must be observed. Verification/ validation by the user is essential. For EHEDG certified devices in tanks, the cleaning device must be positioned in such a way that the sensor is directly assessed and wetted for cleaning. The device has been developed for Cleaning in Place (CIP) applications and must not be dismantled for cleaning.

Deposits or contamination may occur on the diaphragm/ pressure port in case of certain media. Depending on kind and quality of the process, suitable cyclical maintenance intervals must be specified by the operator. As part of this, regular checks must be carried out regarding corrosion, damage of diaphragm/seal(s) and signal shift. A periodical replacement of the seal(s) may be necessary. If the diaphragm is calcified, it is recommended to send the device to the manufacturer for decalcification. Please note the chapter ″Service / repair″ below.

NOTE
Wrong cleaning or improper touch may cause an irreparable damage on the diaphragm. Therefore, never use pointed objects or pressured air for cleaning the diaphragm.

Removal from service

DANGER| Danger of death from airborne parts, leaking fluids, electric shock

– Disassemble the device in a depressurized and de-energized condition!

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WARNING| Danger of injury from aggressive media or pollutants

–   Depending on the measured medium, this may constitute a danger to the operator.

–   Wear suitable protective clothing e.g. gloves, goggles.

NOTE
After dismounting, mechanical connections must be fitted with protective caps.

Service/repair

Information on service/repair:

• www.simex.pl
• info@simex.pl
• Service phone: +48 58 7620777

Recalibration
During the life-time of a device, the value of offset and span may shift. As a consequence, a deviating signal value in reference to the nominal pressure range starting point or end point may be transmitted. If one of these two phenomena occurs after prolonged use, a recalibration is recommended to ensure furthermore high accuracy.

Return

WARNING| Danger of injury from aggressive media or pollutants

–   Depending on the measured medium, this may constitute a danger to the operator.

–   Wear suitable protective clothing e.g. gloves, goggles.

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Before every return of your device, whether for recalibration, decalcification, modifications or repair, it has to be cleaned carefully and packed shatter- proofed. You have to enclose a notice of return with detailed defect description when sending the device. If your device came in contact with harmful substances, a declaration of decontamination is additionally required.

Appropriate templates can be found on our homepage. Download these by accessing www.simex.pl. or request them: info@simex.pl | phone: +48 58 7620777

In case of doubt regarding the fluid used, devices without a declaration of decontamination will only be examined after receipt of an appropriate declaration!

Disposal

WARNING

Danger of injury from aggressive media or pollutants

• Depending on the measured medium, this may constitute a danger to the operator.
• Wear suitable protective clothing e. g. gloves, goggles.

The device must be disposed of according to the European Directive 2012/19/EU (waste electrical and electronic equipment). Waste equipment must not be disposed of in household waste!

NOTE Dispose of the device properly!

Warranty terms

The warranty terms are subject to the legal warranty period of 24 months, valid from the date of delivery. If the device is used improperly, modified or damaged, we will rule out any warranty claim. A damaged diaphragm will not be accepted as a warranty case. Likewise, there shall be no entitlement to services or parts provided under warranty if the defects have arisen due to normal wear and tear.

EU declaration of conformity/CE

The delivered device fulfils all legal requirements. The applied directives, harmonised standards and documents are listed in the EC declaration of conformity, which is available online at: http://www.simex.pl.

Additionally, the operational safety is confirmed by the CE sign on the manufacturing label.

SIMEX Ltd., Wielopole 11, 80-556 Gdańsk, Poland, tel. (+48) 58 762-07-77, www.simex.pl.

References

• Simex - Pomiar i Sterowanie

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