Pressure switches for gas DG

TECHNICAL INFORMATION
• Monitoring of gas and air pressures (positive, negative and differential
pressures)
• Certified for systems up to SIL 3 and PL e
• With approved isolating amplifier for Zone 1 and 2 hazardous areas
• EU certified pursuant to EN 1854 and class “S”
• DG..S: special version available for NH3 and O2

AGA EN
Edition 03.21
Safety manual for products complying with EN 61508-2 03250743


Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1 ProFi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 DG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.2 DG selection table . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 DG..T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.2.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.2 Mechanical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 Low gas pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . 6 4.3 DG..T selection table . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.2 Differential pressure monitoring . . . . . . . . . . . . . . . . . . . . . 6 4.3.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.3 Systems leak tightness check . . . . . . . . . . . . . . . . . . . . . . 6 4.3.2 Mechanical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.4 Negative pressure monitoring . . . . . . . . . . . . . . . . . . . . . . 6 5 Project planning information . . . . . . . . . . . . . . . . . . 20
1.3.5 Air line with minimum pressure and flow monitoring . . . . . 7 5.1 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3.6 Low and high gas pressure protection . . . . . . . . . . . . . . . 7
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.2.1 Pressure monitoring at high temperatures . . . . . . . . . . . 21
2.1 Overview of product approvals . . . . . . . . . . . . . . . . . . 9 5.3 Mechanical connection . . . . . . . . . . . . . . . . . . . . . . 22
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.3.1 DG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.2 DG..T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Vent limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Resetting pressure switches with manual reset . . . . 23
3.2 Positive pressure measurement . . . . . . . . . . . . . . . . . 11
3.3 Negative pressure measurement . . . . . . . . . . . . . . . . 11 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 Differential pressure measurement . . . . . . . . . . . . . . . 11 6.1 Fastening set with screws, U-shape bracket . . . . . . 24
3.5 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . 12 6.2 Connecting set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.1 Contact position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.3 External adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.2 Blue pilot lamp for 230 V AC or 110/120 V AC . . . . . . . . 12 6.4 Pressure equalization element . . . . . . . . . . . . . . . . . 25
3.5.3 Pilot lamp with plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.5 Restrictor orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.4 Red/green pilot LED for 24 V DC/AC or 110–230 V AC . . 12
3.5.5 Pilot LED with plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.6 Test key PIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.7 Filter pad set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6.1 DG 1,5I, DG 12I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.8 Tube set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.7 DG in Zone 1 (21) and 2 (22) hazardous areas . . . . . 14 6.9 Standard coupler plug set . . . . . . . . . . . . . . . . . . . . 25
3.7.1 Intrinsically safe circuit without monitoring for cable 6.10 Pilot lamp set, red or blue . . . . . . . . . . . . . . . . . . . . 26
faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.11 LED set, red/green . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7.2 Intrinsically safe circuit with monitoring for cable
discontinuities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.12 Weather protection cover . . . . . . . . . . . . . . . . . . . . 26
3.7.3 Intrinsically safe circuit with monitoring for cable faults 7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
and short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.8 DG in Zone 2 (22) hazardous areas . . . . . . . . . . . . . 15 7.2 Mechanical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.1 Recommended tightening torque . . . . . . . . . . . . . . . . . . 27

DG · Edition 03.21 · EN 2

7.3 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 12.2.3 Checking the switching point or function check by
7.4 DG adjusting range and switching hysteresis . . . . . . 29 rotating the hand wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5 DG..T adjusting range and switching hysteresis . . . . . 31 12.3 Accuracy of the tests . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.1 Examples for calculating the switch-on point when a
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 switch-off point of x mbar is required . . . . . . . . . . . . . . . . . . . 46
9 Converting units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 13 Maintenance cycles . . . . . . . . . . . . . . . . . . . . . . . . 47
10 Safety-specific characteristic values for SIL 14 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
and PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 14.1 Diagnostic coverage DC . . . . . . . . . . . . . . . . . . . . . 48
10.1 Determining the PFHD value, λD value and MTTFd 14.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . 48
value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.3 Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2 Designed lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
14.4 Common cause failure CCF . . . . . . . . . . . . . . . . . . 48
10.3 Use in safety-related systems . . . . . . . . . . . . . . . . . 35
14.5 Fraction of undetected common cause failures β . 48
11 Safety information in accordance with 14.6 B10d value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
EN 61508-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
14.7 T10d value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1 Scope of application . . . . . . . . . . . . . . . . . . . . . . . . 36
14.8 Hardware fault tolerance HFT . . . . . . . . . . . . . . . . . 48
11.2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . 36
14.9 Mean dangerous failure rate λD . . . . . . . . . . . . . . . 48
11.3 Reference documents . . . . . . . . . . . . . . . . . . . . . . . 36
14.10 Safe failure fraction SFF . . . . . . . . . . . . . . . . . . . . . 49
11.4 Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . 36
14.11 Probability of dangerous failure PFHD . . . . . . . . . . 49
11.5 Safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
14.12 Mean time to dangerous failure MTTFd . . . . . . . . 49
11.6 Safety instructions concerning operating limits . . . . 36
14.13 Demand rate nop . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.7 Installation and commissioning . . . . . . . . . . . . . . . . 36
14.14 Average probability of dangerous failure on
11.8 Operation and maintenance . . . . . . . . . . . . . . . . . . 36 demand PFDavg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.9.1 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 For more information . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.10 Safety instructions concerning design verification . 36
11.11 Characteristic safety data/SIL capability . . . . . . . . . 37
11.12 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12 Operation and maintenance . . . . . . . . . . . . . . . . . 38
12.1 Tightness test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
12.2 Function test on installed pressure switches . . . . . . 38
12.2.1 Checking the switching point by measuring the
process variable which is critical for safety . . . . . . . . . . . . . . 38
12.2.2 Checking the switching point by measuring when
installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DG · Edition 03.21 · EN 3
Application

1 Application

DG..-6, with fitted socket pursuant to DIN EN 175301-803

DG, adjustable switching point

DG..T, hand wheel with "WC and mbar scale. ½ NPT conduit for
DG..H, DG..N, adjustable switching point. Locks off once the electrical connection.
switching point is reached. Manual reset.
The gas pressure switch DG monitors extremely low pres-
sure differentials and triggers switch-on, switch-off or
switch-over operations if a set switching point is reached.
The switching point can be adjusted using a hand wheel.
It monitors positive and negative gas pressures on various
industrial gas and air appliances, such as boiler fan moni-

DG · Edition 03.21 · EN 4
Application
toring and differential pressure monitoring in firing, ventila-
tion and air-conditioning systems.
Pressure switches with manual reset lock off after switching.
Pressure switches (DG..T) with UL, FM approval are fitted
with a nozzle to limit the flow rate, see page 11 (Vent
limiter).
The TÜV-tested special-design pressure switch is used as
defined by VdTÜV Code of Practice “Druck 100/1” (Pres-
sure 100/1) in firing installations for steam and hot-water
generators in accordance with TRD 604, Para. 3.6.4, as
well as class “S” for DG..B, DG..U and DG..I pursuant to
EN 1854.

DG · Edition 03.21 · EN 5
Application

1.1 DG
Type Hand wheel setting/Switching properties Positive pressure Negative pressure
Hand wheel set to rising pressure/
DG..B Gas, air, flue gas or biogas –
DG switches with rising and falling pressure
Hand wheel set to rising pressure/
DG..U Gas, air, flue gas or biogas Air, flue gas
DG switches with rising and falling pressure
Hand wheel set to falling pressure/
DG..BN Gas, air, flue gas or biogas –
DG switches with rising and falling pressure
Hand wheel set to falling pressure/
DG..UN Gas, air, flue gas or biogas Air, flue gas
DG switches with rising and falling pressure
Hand wheel set to rising pressure/
DG..I Gas, air, flue gas Gas, air, flue gas or biogas
DG switches with rising and falling pressure
Hand wheel set to rising pressure/
DG..S NH3, O2, air –
DG switches with rising and falling pressure
Hand wheel set to rising pressure/
DG..H Gas, air, flue gas or biogas Air, flue gas
DG switches with rising pressure and locks off
Hand wheel set to falling pressure/
DG..N Gas, air, flue gas or biogas Air, flue gas
DG switches with falling pressure and locks off
Electrical connection: screw terminals and M16 cable gland or plug with socket.

1.2 DG..T
Type Hand wheel setting/Switching properties Positive pressure Negative pressure
Hand wheel set to rising pressure/
DG..T Gas, air, flue gas or biogas Air, flue gas
DG switches with rising and falling pressure
Hand wheel set to falling pressure/
DG..FT Gas, air, flue gas or biogas Air, flue gas
DG switches with rising and falling pressure
Hand wheel set to rising pressure/ DG switches with rising
DG..HT Gas, air, flue gas or biogas Air, flue gas
pressure and locks off
Hand wheel set to falling pressure/ DG switches with falling
DG..NT Gas, air, flue gas or biogas Air, flue gas
pressure and locks off
Hand wheel set to rising pressure/
DG..ST NH3, O2, air –
DG switches with rising and falling pressure
Electrical connection: screw terminals and M16 cable gland or screw terminals and ½ NPT conduit or plug with socket.

DG · Edition 03.21 · EN 6
Application

1.3 Application examples 1.3.3 Systems leak tightness check

1.3.1 Low gas pressure monitoring

Electronic safety shut-off valve SSV with leak tightness

check of downstream devices
For monitoring the minimum gas inlet pressure
1.3.4 Negative pressure monitoring
1.3.2 Differential pressure monitoring

Monitoring the negative pressure ensures the correct posi-

Differential pressure switch for monitoring air filters tioning of the components during fully automatic assembly
of gas meters.

DG · Edition 03.21 · EN 7
Application
1.3.5 Air line with minimum pressure and flow 1.3.6 Low and high gas pressure protection
monitoring PI PI

PI

Min./Max. VAS..N VAS..L

PZL PDS
PZL PZH

KFM/RFM AKT GFK KFM GDJ KFM

1/min

If the pressure is either too low or too high, the min./max.

The air flow generated by the fan may be monitored as fol- pressure switch (PZL/PZH) switches in order to avoid start-
lows: up or to initiate a safety shut-down.
The static pressure is monitored by the pressure switch
(PZL) as long as it can be demonstrated that the display
consequently shows an adequate and secured flow of air,
or the pressure switch (PDS) checks the flow of air via the
differential pressure on the orifice.
If there is no air pressure supplied or if there is no differen-
tial pressure on the orifice, the system will be blocked.

DG · Edition 03.21 · EN 8
Certification

2 Certification DG..T: UL listed*

Certificates – see [Link] USA and Canada

Certified to SIL and PL

Underwriters Laboratories – UL 353 “Limit Controls”. www.

[Link]
AGA approved*

For systems up to SIL 3 pursuant to EN 61508 and PL e

AGA
pursuant to ISO 13849. See page 35 (Safety-specific
characteristic values for SIL and PL). Australian Gas Association, Approval No.: 5484. [Link].
[Link]
EU certified
Eurasian Customs Union*

• 2014/35/EU (LVD), Low Voltage Directive

• 2014/30/EU (EMC), Electromagnetic Compatibility Direc- The product DG meets the technical specifications of the
tive Eurasian Customs Union.
* Approval does not apply to DG..S. DG..S complies with the requirements
• 2011/65/EU, RoHS II of the Low Voltage Directive 2014/35/EU (LVD).
• 2015/863/EU, RoHS III
• (EU) 2016/426 (GAR), Gas Appliances Regulation
• EN 1854:2010
DG..T: FM approved*

Factory Mutual Research Class: 3510 Flow and pressure

safety switches. Designed for applications pursuant to NF-
PA 85 and NFPA 86. [Link]

DG · Edition 03.21 · EN 9
Certification

2.1 Overview of product approvals

DG..B, DG..U, DG..T, DG..HT,
DG..S
DG..H, DG..N, DG..I DG..NT

– –

–
2014/35/EU 2014/35/EU

– –
(EU) 2016/426 – GAR

– –
AGA

– –

– –

– –

DG · Edition 03.21 · EN 10
Function

3 Function DG..T
The pressure switch switches with rising or falling pressure.
Once the set switching point is reached, a micro switch is Manual 1/2" NPT
activated in the DG which is designed as a change-over Hand wheel reset Conduit/
contact. M16 x 1,5
The switching pressure is adjusted using a hand wheel.
Pressure switches which lock off after switching can only NC
be unlocked with a manual reset, see page 24 (Resetting NO COM
pressure switches with manual reset). Pilot
lamp
DG 4
Manual 2
reset Micro switch
Hand wheel Sealing plug, 1
1/4" NPT Measurement
M16 x 1,5 Filter pad/
nozzle point
NC
NO COM
Screw plug, 3.1 Vent limiter
Rp 1/4" 4
The flow on pressure switches DG 6..T to DG 500..T is
limited by the nozzle. In the event of a diaphragm tear, the
2 escape of gas is limited to less than 1.0 CFH of natural gas,
3 see max. inlet pressure, see page 28 (Technical data).
1 Micro switch
Nozzle
0.8 mm Measurement point

DG · Edition 03.21 · EN 11
Function

3.2 Positive pressure measurement 3.4 Differential pressure measurement

Positive pressure measurement is designed, for example, Differential pressure measurement is designed for safe-
for checking the fan function or measuring the min./max. guarding an air flow rate or for monitoring filters and fans,
gas pressure. for example.
4
Do not connect port 4 (or 3) to pipes carrying gas! For
further information, see “Project planning information”, “Me-
2
chanical connection”, page 23 (DG).
3
1
4
Gas, air, flue gas, biogas
2

The positive pressure is measured in the lower diaphragm

1 3
chamber, port 1 (or 2). The upper diaphragm chamber is
ventilated via port 4 (or 3).

3.3 Negative pressure measurement

Negative pressure measurement (air, flue gas) is designed, 4
for example, for monitoring a suction pressure blower.
2
4
Air, flue gas 3 1
2

1 3

The negative pressure is measured in the upper diaphragm The higher absolute pressure is connected to port 1 (or 2),
chamber, port4 (or 3). The lower diaphragm chamber is and the lower absolute pressure to port 4 (or 3). The re-
ventilated via port 1 (or 2). maining ports must be tightly plugged.
In the case of DG..I, the negative pressure (gas, air, flue gas Increasing
negative pressurea Increasing pressure
or biogas) is measured in the lower diaphragm chamber, Decreasing
port 1 or 2. The upper diaphragm chamber is ventilated via negative pressure Decreasing pressure
port 4 or 3.
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6

DG · Edition 03.21 · EN 12
Function

3.5 Connection diagrams 3.5.3 Pilot lamp with plug

N
L1
3.5.1 Contact position L1
NO 3 1
3
Contacts 3 and 2 close when subject to increasing pres- COM

sure.
Contacts 1 and 3 close when subject to falling pressure. NO
1 2 2
L1 N
1 3
2 NC COM
3 NO
COM
0
2
NO
1
NC
3.5.4 Red/green pilot LED for 24 V DC/AC or 110–
230 V AC
+ 1 3
2 NC COM
On pressure switches that switch with rising pressure: 3 COM NO
2 1 NC
The contact switches from NC 1 to NO 2. NO

On pressure switches that switch with falling pressure:

The contact switches from NO 2 to NC 1. –
N

3.5.2 Blue pilot lamp for 230 V AC or 110/120 V AC

L1
3.5.5 Pilot LED with plug
1 3
NO 2 NC COM –
3 NO +3 +
COM 3 1
2 1
COM
NO NC NC
NO
N
N
2 1 2
–
L1 NC 1 3
2 NC COM
3 NO
COM
2 1
NO NC

N
N

DG · Edition 03.21 · EN 13
Function

3.6 Wiring DG 18I, DG 120I, DG 450I

3
If the DG..G has switched a voltage > 24 V (> 30 V) and COM
a current > 0.1 A at cos φ = 1 or > 0.05 A at cos φ = 0.6 1 2 N
once, the gold plating on the contacts will have been burnt NC NO NC 1 3
COM
through. It can then only be operated at this power rating or NO 2

higher power rating. µ

When using silicone tubes, only use silicone tubes which Contacts 3 and 2 close when subject to increasing negative
have been sufficiently cured. Vapours containing silicone pressure. Contacts 1 and 3 close when subject to falling
can adversely affect the functioning of electrical contacts. negative pressure.
In the case of low switching capacities, such as 24 V, 8 mA,
for example, we recommend using an RC module (22 Ω, 3.6.1 DG 1,5I, DG 12I
1 μF) in air containing silicone or oil. The connection of DG 1,5I, DG 12I depends on the positive
C = 1 µF R = 22 Ω or negative adjusting range.
NO -12 7 6 - 1, .. 3
COM
5 5
2 100 P – 3 mba

..

.
r 0,5 r

-1
a

2, 5 .
ba

4
NC 3 5;

. . -1
1
m

. . 2. . . .
=

,
3

= -1,5 – -0
1

-1 0

1m
-1; 1 – 7

. . . .- . .
2
bar
-9

0,5 .

ps
–
12

..
-8

-1

1
. . 1,5
- 00
Pa = mbar
7 ps =
In the case of high humidity or aggressive gas compo- - ..

-
1
-6

.
- 5 -4 -3 . . 0 ,5 1 ..
... . . ..
DG 12I DG 1,5I
nents (H2S), we recommend using a pressure switch with
gold contact due to its higher resistance to corrosion. In the negative adjusting range, the template which can be
Closed-circuit current monitoring is recommended under found in the unit displays the connection diagram.
difficult operating conditions. 3
COM
All DG models (except DG..I) 1
NO NC
2
NC 1
N
2 COM NO 3
3
COM
NC
NO 2
1
µ

Contacts 3 and 2 close when subject to increasing pres- In the positive adjusting range, remove the template and
sure. Contacts 1 and 3 close when subject to falling pres- wire the unit as shown in the engraved connection diagram.
sure. NO
COM
2
NC 3
1

DG · Edition 03.21 · EN 14
Function

3.7 DG in Zone 1 (21) and 2 (22) hazardous 3.7.1 Intrinsically safe circuit without monitoring for
areas cable faults

Pressure switch DG can be used in Zone 1 (21) and 2 (22) Isolating amplifier

hazardous areas if an isolating amplifier is installed up- NO

1+

stream in the safe area as “Ex-i” apparatus pursuant to 2+

EN 60079-11 (VDE 0170-7):2012. COM 3–

DG as “simple electrical equipment” pursuant to EN 60079-

11:2012 corresponds to the Temperature class T6, Group II. Zone 1 or 2 Safe area
The internal inductance/capacitance is Li = 0.2 μH/Ci = 8 pF.
The isolating amplifier transfers the DG’s signals from the 3.7.2 Intrinsically safe circuit with monitoring for
explosion-hazard area to the safe area. Depending on the cable discontinuities
design of the intrinsically safe circuit, the explosion-hazard
area can be monitored for cable faults, cable discontinuities
Isolating amplifier
or short-circuits. NO
1+
Ensure that standard-compliant wiring pursuant to 10 kΩ 2+

EN 60079 is used. COM 3–

When operating in Zones 21 and 22, the 1/8" connecting

thread or the tube connection for the surrounding air or me- Zone 1 or 2 Safe area
dium connection must be protected from dirt particles by a
separate filter.
3.7.3 Intrinsically safe circuit with monitoring for
cable faults and short-circuits

Isolating amplifier
NO
1+

10 kΩ 2+

COM 3–
400 Ω ≤ R ≤ 2 kΩ

Zone 1 or 2 Safe area

DG · Edition 03.21 · EN 15
Function

3.8 DG in Zone 2 (22) hazardous areas

Pressure switch DG can be connected to pipes/rooms in
which Zone 2 (22) explosive gases or dust are present with-
out an isolating amplifier.
The connection to Zone 2, Zone 22 must be implemented
via one of the two ¼" threads. Even in the unlikely event of
a break in the diaphragm, there is no danger of flashback
into the system. The pressure compensation holes on the
pressure switch (1/4" connections) have a defined ignition
protection, in terms of the safety measure for “enclosed
break devices for Group IIA gases and vapours”, pursuant
to IEC/EN 60079-15.
In the case of Zone 22, it must be ensured that dirt particles
do not block the pressure supply hole (Ø = 0.8 mm).

DG · Edition 03.21 · EN 16
Selection

4 Selection

4.1 ProFi
A web app selecting the correct product is available at
[Link].

4.2 DG selection table

DG..B, DG..
DG..H,
Option BN, DG..U, DG..S DG..I
DG..N
DG..UN
6, 10, 30, -1.5; -12;
Adjusting range 6, 10, 30, 50, 10, 50,
50, 150, -18; -120;
[mbar] 150, 400, 500 150, 500
400, 450 -450
Hand wheel set to ris-
DG..U, DG..B DG..H DG..S DG..I
ing pressure
Hand wheel set to DG..BN, DG..
DG..N – –
falling pressure UN
DG..H,
Lock-off – – –
DG..N
With gold-plated con- DG..B, DG..BN, DG..H,
DG..S DG..I
tacts DG..U, DG..UN DG..N
-3, -4, -5, -3, -4, -5, -3, -4, -5,
Electrical connection -3, -4, -5, -6, -9
-6, -9 -6, -9 -6, -9
K2, T, T2, K2, T, T2, K2, T, T2,
Pilot lamp K2, T, T2, N
N N N
DG..B, DG..BN, DG..H,
External adjustment DG..S DG..I
DG..U, DG..UN DG..N

Order example
DG 10U-3
Adjusting range and switching hysteresis, see page 28
(Technical data).

DG · Edition 03.21 · EN 17
Selection
4.2.1 Type code D Sealant
DG Pressure switch for gas -5 4-pin plug, without socket
15 Adjusting range 3-15 mbar -6 4-pin plug, with socket
17 Adjusting range 2-17 mbar S NO contact
30 Adjusting range 8-30 mbar W Change-over contact
35 Adjusting range 5-35 mbar G With gold-plated contacts
40 Adjusting range 5-40 mbar
45 Adjusting range 10-45 mbar
4.2.2 Mechanical connection
60 Adjusting range 10-60 mbar
DG..U, DG..H, DG..N, DG..I:
110 Adjusting range 33-110 mbar 2 Rp ¼"
150 Adjusting range 40-150 mbar 1 Rp ¼"
250 Adjusting range 70-250 mbar 3 4
Rp 1/8" Rp 1/8"
300 Adjusting range 100-300 mbar
Ports 1 and 2: Rp 1/4" (standard),
360 Adjusting range 100-360 mbar
Ports 3 and 4: Rp 1/8" (standard).
500 Adjusting range 150-500 mbar
DG..B, DG..S:
/60 2nd adjusting range 10-60 mbar
/150 2nd adjusting range 40-150 mbar 1 Rp ¼"
/300 2nd adjusting range 100-300 mbar 4
Rp 1/8"
V Switching point adjustable on hand wheel
Port 1: Rp 1/4" (standard).
C EU version, switches with falling pressure
1 Connection for valVario at the bottom, pressure tap on
the plug side
4 2 x Rp 1/4 internal thread, pressure test point
5 Rp 1/4 internal thread
6 R 1/8 external thread
8 R 1/4 external thread
9 Connection for valVario controls at the bottom, pressure
tap on the side opposite to the plug

DG · Edition 03.21 · EN 18
Selection

4.3 DG..T selection table 4.3.1 Type code

DG Pressure switch for gas
DG..T,
Option DG..FT DG..HT DG..NT 6 Adjusting range 0.2–2.4 “WC (0.5-6 mbar)
DG..ST
6, 10, 50, 6, 10, 50, 6, 10, 50, 6, 10, 50, 10 Adjusting range 0.4–4 “WC (1-10 mbar)
Adjusting range 6–500
150, 500 150, 500 150, 500 150, 500
Hand wheel set to ris- DG..T, DG.. 50 Adjusting range 1–20 “WC (2.5-50 mbar)
– DG..HT –
ing pressure ST 150 Adjusting range 12–60 “WC (30-150 mbar)
Hand wheel set to fall-
– DG..FT – DG..NT 500 Adjusting range 40–200 “WC (100-500 mbar)
ing pressure
Lock-off – – DG..HT DG..NT H Switches and locks off with rising pressure
With gold-plated con- DG..T, DG..
tacts ST
DG..FT DG..HT DG..NT N Switches and locks off with falling pressure
Electrical connection -2, -4, -9 -2, -4, -9 -2, -4, -9 -2, -4, -9 F Switches with falling positive pressure
Pilot lamp K2, T2, N K2, T2, N K2, T2, N K2, T2, N S Switches with rising and falling positive pressure; for O2,
DG..T, DG.. NH3 and air; without approval
External adjustment DG..FT DG..HT DG..NT
ST
T T-product
Adjusting range and switching hysteresis, see page 28
G With gold-plated contacts
(Technical data).
-2 Electrical connection via screw terminals, 1/2" NPT
Conduit, NEMA 4 (IP 65)
-4 Electrical connection via screw terminals, cable gland,
NEMA 4 (IP 65)
-9 Electrical connection via 4-pin plug, with socket, NEMA
4 (IP 65)
1 NPT connection 1x 1/4"
2 NPT connection 2x 1/4"
N Blue pilot lamp for 120 V AC
T2 Red/green pilot LED for 110 to 230 V AC
K2 Red/green pilot LED for 24 V DC/AC
A External adjustment
1) Letter omitted = DG..T switches with rising pressure

DG · Edition 03.21 · EN 19
Selection
4.3.2 Mechanical connection
DG..T:
¼" NPT 2
1 ¼" NPT
4
1/8 " NPT

Port 1: 1/4" NPT (standard) or

ports 1 and 2: 1/4" NPT (DG..T..2 available),
port 4: 1/8" NPT (standard).

DG · Edition 03.21 · EN 20
Project planning information

5 Project planning information 5.2 Installation

The housing must not be in contact with masonry. Minimum
5.1 Installation position clearance 20 mm (0.8").
Installation in the vertical or horizontal position, or some- The DG..S is suitable for oxygen and ammonia only (dia-
times upside down, preferably with vertical diaphragm. If phragm made of IIR). Do not use for fuel gases – diaphragm
installed in a vertical position, the switching point pS will not resistant! In the case of oxygen, ensure grease-free
correspond to the scale value SK set on the hand wheel. installation.
If installed in another position, the switching point pS will Long-term use in the upper ambient temperature range ac-
change and no longer correspond to the set scale value SK. celerates the ageing of the elastomer materials and reduces
Switching point pS must be checked. the service life (please contact manufacturer).
Continuous operation with gases containing more than
0.1 %-by-vol. H2S or ozone concentrations exceeding
200 µg/m3 accelerate the ageing of elastomer materials and
All DG models (except DG..I) reduce the service life.
pS = SK - 0.18 mbar Vapours containing silicone can adversely affect the func-
pS = SK pS = SK + 0.18 mbar (0.8 "WC)
(0.8 "WC)
tioning of electrical contacts. When using silicone tubes,
DG 1,5I
pS = SK + 0.4 mbar
only use silicone tubes which have been sufficiently cured.
e.g. SK = 1.2: Condensation must not be allowed to get into the [Link]
pS = SK pS = 1.2 + 0.4 = 1.6 mbar
e.g. SK = -1.2:
possible, install pipework with an ascending gradient. Oth-
pS = -1.2 + 0.4 = -0.8 mbar erwise, there is a risk of icing of condensation at subzero
DG 12I temperatures, the switching point shifting or corrosion in
pS = SK + 0.5 mbar the device which can lead to malfunctions.
e.g. SK = 5:
pS = SK pS = 5 + 0.5 = 5.5 mbar Closed-circuit current monitoring is recommended if there
e.g. SK = -10: is a risk of contact corrosion (too humid or aggressive sur-
pS = -10 + 0.5 = -9.5 mbar rounding air) or foreign particles in the surrounding air.
DG 18I, DG 120I, DG 450I
DG 18I: pS = SK + 0.5 mbar
When installing outdoors, place the pressure switch in a
e.g. SK = -10: roofed area and protect from direct sunlight (even IP 65
pS = SK pS = -10 + 0.5 = -9.5 mbar version). To avoid condensation, the cover with pressure
DG 120I, DG 450I: pS = SK +
0.2 mbar equalization element can be used. See page 26 (Pres-
sure equalization element).

DG · Edition 03.21 · EN 21
Project planning information
The weather protection cover provides permanent protec- will not be enough time or volume available for cooling if the
tion when installed outdoors. See page 27 (Weather pro- media from the hot furnace and the tube volume are mixed.
tection cover).
In case of highly fluctuating pressures, install a restrictor ori-
fice. See page 26 (Restrictor orifice).

5.2.1 Pressure monitoring at high temperatures

If they are equipped with suitable supply lines, pressure
switches are able to monitor pressures in flue gas lines at
high temperatures. It is just necessary to ensure that the
hot medium does not enter the switch during a switching
operation.
For this, the switching volume of the pressure switch is to
be observed.
Volume per switching operation:
DG 6–50U, B, H, N, DL 5–50A, K = max. 9.5 cm3,
DG 150–500U, B, H, N, DL 150A, K = max. 2.5 cm3.
Requirement on the supply line
The volume of the supply line must be at least 1.2 times
greater than the switching volume to ensure that the hot
medium does not flow directly into the switching chamber.
This accelerates ageing of the diaphragm and possible con-
tact corrosion.
If there is a risk of condensation forming, the supply line
must be installed with an upward gradient towards the
pressure switch. Small line diameters are preferable (ID =
5 mm) to ensure that the humidity can condense in the long
line and flow back into the furnace/chimney.
In the case of high switching frequency (more than once
per minute), the volume of the line should be double that of
the switching operation. Otherwise, there is a risk that there

DG · Edition 03.21 · EN 22
Project planning information

5.3 Mechanical connection Differential

Connect Seal
pressure
5.3.1 DG for the higher for the lower
absolute pres- absolute pres-
2 Rp ¼" sure sure
1 Rp ¼" DG..U, DG..H, Seal ports that
4
1 or 2 3 or 4
3 DG..N, DG..UN are not in use
Rp 1/8" Rp 1/8"
Ports 3 and 4 are connected to the micro switch chamber.
DG..U, DG..H, DG..N, DG..UN
Pipes carrying gas must not be connected to port 3 or 4!
The port that is best protected against soiling (dust/humidi-
1 Rp ¼"
ty) is to be left open for ventilation (positive pressure meas-
4
Rp 1/8" urement) to the atmosphere. If dust exposure in the environ-
ment is high, a filter pad, see page 26 (Filter pad set), or a
DG..B, DG..BN, DG..S
filter is to be used in the open port.
Positive pres- In the case of high switching frequency (more than once per
Connect Seal Free*
sure minute), it is also recommended to use a filter pad since the
DG..U, DG..H, exchange of air with the environment considerably increas-
1 2 3 or 4
DG..N, DG..UN
es the risk of foreign particles entering the pressure switch
DG..U, DG..H,
2 1 3 or 4 and thus a malfunction can occur at low voltages and cur-
DG..N, DG..UN
DG..B, DG..BN, rents.
1 – 4
DG..S

Negative pres-
Connect Seal Free*
sure
DG..U, DG..H,
4 3 1 or 2
DG..N
DG..U, DG..H,
3 4 1 or 2
DG..N
DG..I 1 2 3 or 4
DG..I 2 1 3 or 4
* It is recommended that the port which is best protected from water and
dirt be left open.

DG · Edition 03.21 · EN 23
Project planning information
5.3.2 DG..T 5.4 Resetting pressure switches with manual
¼" NPT 2 reset
1 ¼" NPT
4
1/8 " NPT Manual reset

DG..T

Positive pres-
sure
Connect Seal Free Pressure switches locking off if the pressure drops to the
DG..T 1 2 4 set switching point:
DG..T 2 1 4 For resetting, the pressure must have risen to at least the
set switching point plus the pressure differential between
Negative pres-
Connect Seal Free* the switching pressure and possible reset.
sure Pressure switches locking off if the pressure rises to the set
DG..T 4 – 1 or 2
switching point:
DG..U, DG..H,
DG..N
3 4 1 or 2* For resetting, the pressure must have dropped to at least
the set switching point minus the pressure differential be-
* Port 2 only on DG..T..2 with 2 connections (¼" NPT).
tween the switching pressure and possible reset.
Differential pressure Connect
Pressure differential, see page 30 (DG adjusting range
for the higher abso- for the lower abso-
lute pressure lute pressure and switching hysteresis).
DG..T 1 or 2 4

Port 4 is connected to the micro switch chamber.

For this reason, pipes carrying gas must not be connected
to port 4!
If necessary, port 4 (1/8" NPT) can be used to connect the
venting line.
A filter pad at port 4 protects the electrical contacts in the
pressure switch from dirt particles in the surrounding air or
in the medium.
4
NEMA 4

If port 4 is at the top, NEMA 4 (IP 65) will not be satisfied.

DG · Edition 03.21 · EN 24
Accessories

6 Accessories Order No.: 74915387

6.1 Fastening set with screws, U-shape 6.2 Connecting set

bracket
47,5
.95") (1.8
75 (2 7")

For monitoring a minimum and maximum inlet pressure

40 (1.57")
with two pressure switches attached to one another.
Order No.: 74912250

20
(0.79
M4 x 12 6.3 External adjustment
")
50 (1.97")
30 (1.18") M4 x 10

20 ")
(0.7
9 In order to set the switching pressure from the outside, the
cover for external adjustment (6 mm Allen key) for DG can
be retrofitted.
45 (1.77") Order No.: 74916155
25 (0.98")
(0.4")
(0.2") 10
5,2

39 (1.53")
6 (0.24")

(0.63")
16

4,20 +0,1
(0.17")

24 (0.94")
43 -0,3 (1.69")
64 (2.52")

DG · Edition 03.21 · EN 25
Accessories

6.4 Pressure equalization element To test the min. pressure switch, the DG can be vented in its
switched state using the PIA test key (contains non-ferrous
metals).
Order No.: 74329466

For CE certified pressure switches.

6.7 Filter pad set
To protect the electrical contacts in the DG from dirt parti-
To avoid the formation of condensation, the cover with pres- cles in the surrounding air or in the medium, use a filter pad
sure equalization element can be used. The diaphragm in at the 1/8" negative pressure port. As standard on IP 65
the screw connector is designed to ventilate the cover, with- units.
out allowing water to enter. 5-piece filter pad set, Order No.: 74916199
Order No.: 74923391
6.8 Tube set
6.5 Restrictor orifice
Rp ¼
R¼

To be used with air only.

For CE certified pressure switches. Tube set with 2 m PVC tube, 2 duct connection flanges with
screws, R 1/4 and R 1/8 connecting nipples.
In the case of high pressure fluctuations, we recommend
using a restrictor orifice (contains non-ferrous metals). Order No.: 74912952
Hole diameter 0.2 mm, Order No.: 75456321
Hole diameter 0.3 mm, Order No.: 75441317 6.9 Standard coupler plug set

6.6 Test key PIA

R¼ Click

TEST
Rp ¼ For CE certified pressure switches, Order No.: 74915388
For FM, UL certified pressure switches, Order No.: 75459526

DG · Edition 03.21 · EN 26
Accessories

6.10 Pilot lamp set, red or blue When the DG is installed outdoors, the weather protection
cover provides permanent protection against condensation
and weathering of housing parts.
The weather protection cover is made of 1 mm-thick stain-
less steel.
The enclosed filter pad is designed to protect the open 1/8"
For DG port from the ingress of dirt or insects.
Pilot lamp, red: Scope of delivery:
110/120 V AC, I = 1.2 mA, Order No.: 74920430. A 2 x covers, 100 x 100 x 100 mm
230 V AC, I = 0.6 mA, Order No.: 74920429. B 2 x M4 x 16 screws
Pilot lamp, blue: C 4 x nuts
110/120 V AC, I = 1.2 mA, Order No.: 74916121. D 2 x washers
230 V AC, I = 0.6 mA, Order No.: 74916122. E 2 x cap nuts
F 1 x filter pad (1/8" port)
6.11 LED set, red/green Order No.: 74924909
For DG Installation position: vertical, with the cable gland pointing
downwards.

24 V DC, I = 16 mA; 24 V AC, I = 8 mA, Order No.:

74921089.
110 to 230 V AC, Order No.: 74923275

6.12 Weather protection cover

E
A D
C
B
F

DG · Edition 03.21 · EN 27
Technical data

7 Technical data 7.2 Mechanical data

Gas type: natural gas, town gas, LPG (gaseous), flue gas,
7.1 Ambient conditions biogas (max. 0.1 %-by-vol. H2S) and air.
Maximum medium and ambient temperatures: Max. inlet pressure pmax. = withstand pressure.. See page
DG..B, DG..U, DG..I: -20 to +80°C (-4 to +176°F), 30 (DG adjusting range and switching hysteresis).
DG..S, DG..ST: -15 to +60°C (5 to 140°F), Max. test pressure for testing the entire system: temporarily
DG..H, DG..N: -15 to +60°C (5 to 140°F), < 15 minutes 2 bar (29 psig).
DG..T, DG..FT, DG..HT, DG..NT: Housing: glass fibre reinforced PBT plastic with low gas
-40 to +60°C (-40 to +140°F). release.
Transport temperature = medium and ambient tempera- Diaphragm pressure switch, silicone-free.
tures Diaphragm: NBR.
Long-term use in the upper ambient temperature range ac- Lower housing section: AlSi 12.
celerates the ageing of the elastomer materials and reduces Diaphragm: IIR for DG..S, DG..ST.
the service life (please contact manufacturer). Weight:
The set switching point may palpably change in media and 270 to 320 g (9.5 to 11.3 oz) depending on equipment.
ambient temperatures below -22°F (-30°C).
7.2.1 Recommended tightening torque
Storage temperature:
Tightening torque
DG, DG..T: -20 to +40°C (-4 to +104°F). Component
[Ncm]
Enclosure: Cover screws 65
DG: IP 54 or IP 65, safety class: 1. M16 x 1.5 cable gland 50
DG..T: NEMA 4 (IP 65), safety class: 1. ½" NPT conduit 170 (15 lb")
Rp 1/8 pipe connection on aluminium lower section 250
Rp 1/4 connection (1/4” NPT) on aluminium lower
1300
section
Rp 1/8 connection on upper housing section 250
Clamping terminal screws 80
T15 test point screw 150

DG · Edition 03.21 · EN 28
Technical data

7.3 Electrical data

Switching capacity:
I I
U
(cos φ = 1) (cos φ = 0.6)
DG 24–250 V AC 0.05–5 A 0.05–1 A
DG..G 5–250 V AC 0.01–5 A 0.01–1 A
DG..G 5-48 V DC 0.01–1 A 0.01–1 A
DG..T max. 240 V AC max. 5 A max. 0.5 A
DG..TG < 30 V AC/DC max. 0.1 A max. 0.05 A

If the pressure switch has switched a voltage > 24 V

(> 30 V) and a current > 0.1 A at cos φ = 1 or > 0.05 A at
cos φ = 0.6 once, the gold plating on the contacts will have
been burnt through. It can then only be operated at this
power rating or higher power rating.
Conductor diameter:
AWG 24 to AWG 13,
0.5 to 1.8 mm (0.02 to 0.07").
DG..T, DG..FT, DG..HT, DG..NT, DG..ST:
½" NPT conduit cable gland.
Electrical connection type: screw terminals.

DG · Edition 03.21 · EN 29
Technical data

7.4 DG adjusting range and switching hysteresis

Switching properties, see “Selection”, page 6 (DG).
Difference be-
Mean switching Max. inlet pres-
tween switching Deviation from the switching point dur-
Type Adjusting range* differential at min. sure pmax. = with-
pressure and pos- ing testing pursuant to EN 1854
and max. setting stand pressure
sible reset
Gas pressure Air pressure
mbar mbar mbar mbar
switches switches
DG 6U, DG 6B,
0.5–6 0.2–0.3 100 – ± 15% ± 15% or 0.1 mbar
DG 6S
DG 10U, DG 10B,
1–10 0.25–0.4 500 – ± 15% ± 15%
DG 10S
DG 30U,
2.5–30 0.35–0.9 500 – ± 15% ± 15%
DG 30B,DG 30S
DG 50U, DG 50B,
2.5–50 0.8–1.5 500 – ± 15% ± 15%
DG 50S
DG 150U, DG 150B,
30–150 3–5 600 – ± 15% ± 15%
DG 150S
DG 400U, DG 400B,
50–400 5–15 600 – ± 15% ± 15%
DG 400S
DG 500U, DG 500B,
100–500 8–17 600 – ± 15% ± 15%
DG 500S

DG 10H, DG 10N 1–10 – 600 0.4–1 ± 15% ± 15%

DG 50H, DG 50N 2.5–50 – 600 1–2 ± 15% ± 15%
DG 150H, DG 150N 30–150 – 600 2–12 ± 15% ± 15%
DG 500H, DG 500N 100–500 – 600 5–18 ± 15% ± 15%
* Adjusting tolerance = ± 15% of the scale value.

DG · Edition 03.21 · EN 30
Technical data

Mean switching differ- Max. inlet pressure

Deviation from the switching point during test-
Type Adjusting range* ential at min. and max. pmax. = withstand
ing pursuant to EN 1854
setting pressure
Gas Air
mbar mbar mbar
pressure switches pressure switches
-1.5 to -0.5 and
DG 1,5I 0.2–0.5 ± 100 ± 15% ± 15% or 0.4 mbar
+0.5 to +3
-12 to -1 and
DG 12I 0.5–1 ± 100 ± 15% ± 15% or 0.5 mbar
+1 to +7
DG 18I -2 to -18 0.5–1.5 ± 100 ± 15% ± 15% or 0.5 mbar
DG 120I -10 to -120 4–11 ± 600 ± 15% ± 15%
DG 450I -80 to -450 10–30 ± 600 ± 15% ± 15%
* Adjusting tolerance = ± 15% of the scale value.

DG · Edition 03.21 · EN 31
Technical data

7.5 DG..T adjusting range and switching hysteresis

Switching properties, see “Selection”, page 6 (DG..T).
Mean switching Difference be-
Adjusting differential at tween switching Deviation from the switching point
Type Max. inlet pressure
range1) min. and max. pressure and during testing pursuant to EN 1854
setting possible reset
with venting without venting
Gas pressure Air pressure
"WC (mbar) "WC (mbar) line2) line2) "WC (mbar)
switches switches
psi (mbar) psi (mbar)
DG 6T, DG 6FT, 0.2–2.4 0.08–0.12 8.5 2.4 ± 15% or 0.04
– ± 15%
DG 6ST (0.5–6) (0.2–0.3) (600) (165) "WC
DG 10T, DG 10FT, 0.4–4 0.1–0.16 8.5 7 ± 15% or 0.04
– ± 15%
DG 10ST (1–10) (0.25–0.4) (600) (480) "WC
DG 50T, DG 50FT, 1–20 0.3–0.6 8.5 7
– ± 15% ± 15%
DG 50ST (2.5–50) (0.8–1.5) (600) (480)
DG 150T,
12–60 1.2–2 8.5 7
DG 150FT, – ± 15% ± 15%
(30–150) (3–5) (600) (480)
DG 150ST
DG 500T,
40–200 3.2–6.8 8.5 7
DG 500FT, – ± 15% ± 15%
(100–500) (8–17) (600) (480)
DG 500ST

DG 10HT, 0.4–4 8.5 7 0.16–0.4

– ± 15% ± 15%
DG 10NT (1–10) (600) (480) (0.4–1)
DG 50HT, 1–20 8.5 7 0.4–0.8
– ± 15% ± 15%
DG 50NT (2.5–50) (600) (480) (1–2)
DG 150HT, 12–60 8.5 7 0.8–4.8
– ± 15% ± 15%
DG 150NT (30–150) (600) (480) (2–12)
DG 500HT, 40–200 8.5 7 2–7.2
– ± 15% ± 15%
DG 500NT (100–500) (600) (480) (5–18)
1) Adjusting tolerance = ± 15% of the scale value.
2) Venting line connected to port 4, see “Project planning information”, “Mechanical connection”, page 24 (DG..T).

DG · Edition 03.21 · EN 32
Dimensions

8 Dimensions
13,1 70 43 (1.7")
(0.52") Rp ¼

(0.1")
(2.76") 11 (¼" NPT) 30 (1.2")

2,5
ø 4,2 (0.43")
(ø 0.17") 4 x ø 3,6 1)

(ø 0.14")

64 (2.52")
10,5 (0.41")

17 (0.7")
76 (3")

36 Rp 1/8 2)

(1.12")
(1.4

28,5
2")
Rp 1/8 50
(2")
(1/8" NPT) M16 x 1,5 13 (0.51")
(½" NPT Conduit)
30,5 (1.2")

1) Holes 10 mm (0.4") deep, for self-tapping screws.

2) For DG..U, DG..H, DG..N, DG..I.

DG · Edition 03.21 · EN 33
Converting units

9 Converting units
See [Link]

DG · Edition 03.21 · EN 34
Safety-specific characteristic values for SIL and PL

10 Safety-specific characteristic Relationship between the Performance Level (PL)

and the Safety Integrity Level (SIL)
values for SIL and PL
PL SIL
Certificates – see [Link].
a –
For a glossary of terms, see page 49 (Glossary). b 1
For SIL c 1
Suitable for Safety Integrity Level SIL 1, 2, 3 d 2
Diagnostic coverage DC 0 e 3
Type of subsystem Type A to EN 61508-2, [Link].2
High demand mode pursuant to
Mode of operation
EN 61508-4, 3.5.12 10.1 Determining the PFHD value, λD value
For PL and MTTFd value
Suitable for Performance Level PL a, b, c, d, e
Category B, 1, 2, 3, 4
1 0,1
Common cause failure CCF > 65 PFHD = λD = = x nop
Application of essential safety require-
MTTFd B10d
Satisfied
ments
Application of tried-and-tested safety
Satisfied
requirements PFHD = Probability of dangerous failure (HDM = high de-
For SIL and PL mand mode) [1/hour]
B10d value of VAS 1 15,845,898 operating cycles
B10d value
PFDavg = Average probability of a dangerous failure of the
U = 24 V DC, I = 10 mA; 6,689,477 operating cycles safety function on demand (LDM = low demand mode)
U = 230 V AC, I = 4 mA
λD = Mean dangerous failure rate [1/hour]
B10d value
U = 24 V DC, I = 70 mA; 4,414,062 operating cycles MTTFd = Mean time to dangerous failure [hours]
U = 230 V AC, I = 20 mA
nop = Demand rate (mean number of annual operations) [1/
B10d value
U = 230 V AC, I = 2 A
974,800 operating cycles hour]
Hardware fault tolerance (1 compo-
0
nent/switch) HFT
Hardware fault tolerance (2 compo-
nents/switches, redundant operation) 1
HFT
Safe failure fraction SFF > 90%
Fraction of undetected common
≥ 2%
cause failures β

DG · Edition 03.21 · EN 35
Safety-specific characteristic values for SIL and PL

10.2 Designed lifetime

Max. service life under operating conditions in accordance
with EN 13611, EN 1854 for DG..U, DG..H, DG..N, DG..I:
designed lifetime after date of production, plus max. ½ year
in storage prior to first use, or once the given number of
operating cycles has been reached, depending on which is
achieved first:
Medium Designed lifetime
Switching cycles Time (years)
Gas 50,000 10
Air 250,000 10

10.3 Use in safety-related systems

For systems up to SIL 3 pursuant to EN 61508 and PL e
pursuant to ISO 13849.
The devices are suitable for single-channel systems
(HFT = 0) up to SIL 2/PL d, and up to SIL 3/PL e when two
redundant devices are installed in a double-channel archi-
tecture (HFT = 1), provided that the complete system com-
plies with the requirements of EN 61508/ISO 13849.

DG · Edition 03.21 · EN 36
Safety information in accordance with EN 61508-2

11 Safety information in accordance 11.6 Safety instructions concerning

with EN 61508-2 operating limits
The function is only guaranteed when used within the spec-
11.1 Scope of application ified limits – see page 28 (Technical data) or operating
instructions at [Link].
The gas pressure switch triggers switch-on, switch-off or
switch-over operations if a set switching point is reached.
11.7 Installation and commissioning
11.2 Product description Installation and commissioning procedures are described in
the operating instructions.
See page 11 (Function) and page 4 (Application). for
information about the product description and the device
functions. 11.8 Operation and maintenance
Operation and maintenance, see page 39 (Operation and
11.3 Reference documents maintenance).
Maintenance cycles, see page 48 (Maintenance cycles).
Operating instructions, see [Link].
Certificate, see [Link].
11.9 Troubleshooting
A web app for spare parts is available at [Link].
In the event of faults after maintenance work or function
A web app selecting the correct product is available at
checks: remove the unit and return it to the manufacturer
[Link].
for inspection.

11.4 Applicable standards 11.9.1 Repairs

Standards used for certification, see [Link]. If the test reveals that the pressure switch does not switch
properly or is leaking, the device must be replaced. Repairs
are not permitted.
11.5 Safety function
The safety function involves the safe closing and opening 11.10 Safety instructions concerning design
of the circuits COM-NO and COM-NC, depending on the
verification
available pressure, and ensuring external tightness.
A Failure Mode and Effects Analysis has been carried out to
assess possible design-related failures and to classify these
into safe and dangerous failures.

DG · Edition 03.21 · EN 37
Safety information in accordance with EN 61508-2

11.11 Characteristic safety data/SIL

capability
See page 35 (Safety-specific characteristic values for SIL
and PL) and page 28 (Technical data).

11.12 Mode of operation

The pressure switches are suitable for a 100% duty cycle.

DG · Edition 03.21 · EN 38
Operation and maintenance

12 Operation and maintenance System parameters: operating pressure is not measured

(not important for this method), signal between COM and
NO.
12.1 Tightness test
Test: measure the O2 content in the flue gas, then slowly
reduce the gas flow (manual valve). If there is too much O2
(air excess), the DG should have switched off the system
beforehand.
Flue gas differential pressure switch on the chimney
Safety-relevant function: the DG should prevent it being
impossible to discharge the flue gases into the open air and
should avoid incomplete combustion.
Apply pressure to device and test the joints using leak de- Device used: DG 6U-3, hand wheel setting: 5 mbar, was
tection spray. No bubbles should form. determined during commissioning of the system.
System parameters: operating pressure is not measured
(not important for this method), signal between COM and
12.2 Function test on installed pressure
NO.
switches
Test: measure the CO content in the flue gas, then slowly
There are three ways of testing installed pressure switches close off the chimney. The DG should have switched off be-
for correct functioning. Ensure that the measuring instru- fore incomplete combustion occurs.
ments used comply with the accuracy defined for the pro-
cess variable which is critical for safety.

12.2.1 Checking the switching point by measuring

the process variable which is critical for safety
Examples:
Gas min. pressure switch
Safety-relevant function: should prevent the gas pres-
sure from dropping so low that an unwanted air excess is
generated during combustion.
Device used: DG 30B-3, hand wheel setting: 15 mbar.

DG · Edition 03.21 · EN 39
Operation and maintenance
12.2.2 Checking the switching point by measuring
when installed
Gas max. pressure switch
Safety-relevant function: should prevent gas pressure
from increasing and exceeding pmax. of the other compo-
nents used and thus impairing/preventing correct function-
ing.
Device used: DG 150B-3, hand wheel setting: 100 mbar.
System parameters: operating pressure is not measured
(not important for this method), signal between COM and
NC.
Test: connect the pressure gauge to the DG pressure test
point, slowly adjust the regulator upstream of the DG so
that the gas pressure increases. The DG switch-on point
(COM-NO) should be reached before attaining pmax. of the
downstream components.

DG · Edition 03.21 · EN 40
Operation and maintenance
Gas min. pressure switch
Safety-relevant function: should prevent the gas pres-
sure from dropping so low that incomplete combustion (for-
mation of CO) occurs. A minimum of 40 bar is required to
ensure proper functioning of the burners according to the
information provided by the manufacturer.
Device used: DG 150U-3, hand wheel setting: 41.4 mbar.
Hand wheel setting for the switch-off point is calculated as follows: SPHE = SPA + (Smin. + (Smax. - Smin.) / (Emax. - Emin.) x
(SPA - Emin.)) = 41.35 mbar
Type Hand wheel adjusting range Example
HS switching differen-
Switch-off SPHE hand wheel
Switch-on point Switching differential tial for hand wheel
point switch-on point
setting
Emin. Emax. Smin. Smax. STP
DG 50 2.5 50 0.8 1.5 40 1.35 41.35
All specifications in mbar
System parameters: the operating pressure is 55 mbar.
Test: 40 mbar), the DG should switch off (COM-NC) and the sys-
tem should shut down.
NC
COM NO

The pressure is measured at the test point. In this exam-

ple, it is 55 mbar. Then the open 1/8" port, which is usually
used to measure atmospheric pressure, is attached to a
syringe and connected measuring instrument. The plunger
is then pushed in slowly and the reaction of the system is
observed. If the pressure is around 15 mbar (ps = 55 - 15 =

DG · Edition 03.21 · EN 41
Operation and maintenance
Flue gas differential pressure switch on the chimney
Safety-relevant function: the DG should stop it being
impossible to discharge the flue gases into the open air
(bird’s nest on chimney) and prevent incomplete combus-
tion (formation of CO). A minimum pressure differential of
5 mbar is required according to the information provided by
the manufacturer.
Device used: DG 10U-3, hand wheel setting: 5.3 mbar for
a switch-off point of 5 mbar.
System parameters: in normal operation, the pressure
drops by 22 mbar due to the orifice, signal between COM
and NO.
Test: a pressure of 22 mbar is measured at the test point.
In this case, the line which leads to one of the 1/8" ports
must be dismantled. The syringe and measuring instrument
are connected to this port. The plunger is pushed in slowly
and the DG should switch off at around 17.3 mbar. Signal
between COM and NC.
Pressure switch for monitoring the fan pressure
Safety-relevant function: pre-purge to remove any air/
gas mixture from the combustion chamber before ignition,
then safeguarding of the combustion air. For this, the manu-
facturer specifies a switch-on point of 18 mbar.
Device used: DG 30B-3, hand wheel setting: 18 mbar.
System parameters: in normal operation, the fan gener-
ates a pressure of 28 mbar. In this case, the burner is not
operating. It should only be checked whether the actual
switching pressure is 18 mbar.
Test: connect pressure gauge to open 1/8" port. Then
slowly pull out the plunger of the syringe (a vacuum is cre-
ated in the blue area). The device should switch at around
18 mbar.

DG · Edition 03.21 · EN 42
Operation and maintenance
12.2.3 Checking the switching point or function
check by rotating the hand wheel
This is the least precise method, see example at the end
of the chapter. It only works if the operating pressure and
switching point are within the setting range of the hand
wheel.
Gas min. pressure switch
Safety-relevant function: should prevent the gas pres-
sure from dropping so low that incomplete combustion (for-
mation of CO) occurs. A minimum of 25 bar is required to
ensure proper functioning of the burners according to the
information provided by the manufacturer.
Device used: DG 50U-3, hand wheel setting: 26 mbar,
switch-off point: 25 mbar.

Type Hand wheel adjusting range Example

HS switching differen-
Switch-off SPHE hand wheel
Switch-on point Switching differential tial for hand wheel
point switch-on point
setting
Emin. Emax. Smin. Smax. STP
DG 50 2.5 50 0.8 1.5 25 1.13 26.13
All specifications in mbar
System parameters: a pressure gauge installed in the
system indicates a pressure of 40 mbar. Signal at COM-NC.
Test: the hand wheel is set to 50 mbar. The pressure
switch should switch off (COM-NC). The hand wheel is then
turned slowly in the “min.” direction. The DG should switch
on at around 40 mbar.

DG · Edition 03.21 · EN 43
Operation and maintenance
Gas vacuum sensor DG..I count the entire system. The measuring method must also
Safety-relevant function: should prevent the biogas be based on this. The measuring accuracy that can be
pressure in the digester from dropping below -0.8 mbar, achieved will be shown in the following examples.
otherwise the hood will be damaged and air can enter the
system.
Device used: DG 1,5I-3, hand wheel setting: -0.8 mbar.
Contact assignment, see template.
System parameters: a pressure gauge installed in the
system indicates a pressure of 1.1 mbar. Signal at COM-NC.
3
COM
1
NC
2
NC 1
N
NO 3
COM
NO 2
µ

5
-1, .. 3
– 3 mba
..

0,5 r
2, 5 .

5;
. . -1

. . 2. . . .
,
= -1,5 – -0
. . . .- . .
0, 5 .

ps

..
1
. . 1 ,5

00
Pa = mbar
..
1
.

. . 0,5 1 ..
... .. ..
DG 1,5I

Test: turn hand wheel in the “plus” direction as far as it will

go (signal at COM-NO), then turn the hand wheel in the “mi-
nus” direction until the signal changes to COM-NC (accord-
ing to details on template). When simulated in a laboratory,
this test produces the following results: signal at COM-NC
(switch-off point) = 1.2 mbar, turn hand wheel back, switch-
on point = 1.5 mbar.
Note: the contact assignment changes from the negative
to the positive range, thus the switch-off point corresponds
to the operating pressure in this test.
The switching point accuracy required can only be deter-
mined by the operator/project developer taking into ac-

DG · Edition 03.21 · EN 44
Operation and maintenance

12.3 Accuracy of the tests

Example:
Gasmin. pressure switch, 3 pressure ranges which illustrate the varying accuracy of the methods compared to measure-
ment to EN 1854.
Gasmin. pressure switch, switch-off point should be 2 mbar, hand wheel setting = 2.2*, operating pressure = 5 mbar
Hand wheel in Testing using test rig pursuant to Measurement using syringe meth- Estimation with hand wheel meth-
DG 6U-3
mbar EN 1854 od, operating pressure: 5 mbar od, value read off on hand wheel
On Off (actual) Off1) Off (actual) On2) Off2)
1st measurement 2.2 2.25 2.04 2.9 2.1 4.8 5.6
2nd measurement 2.2 2.24 2.04 3.2 1.8 4.8 5.6
3rd measurement 2.2 2.24 2.03 3.1 1.9 4.8 5.5

Gasmin. pressure switch, switch-off point should be 30 mbar, hand wheel setting = 31.2*, operating pressure = 40 mbar
Hand wheel in Testing using test rig pursuant to Measurement using syringe meth- Estimation with hand wheel meth-
DG 50U-3
mbar EN 1854 od, operating pressure: 40 mbar od, value read off on hand wheel
On Off (actual) Off1) Off (actual) On2) Off2)
1st measurement 31 33.0 32 8.9 31.1 39.0 40
2nd measurement 31 32.8 32 8.8 31.2 38.8 40
3rd measurement 31 32.9 32 8.9 31.1 39.0 40.5
* Hand wheel setting = 2.2 or hand wheel setting = 31.2, see page 47 (Examples for calculating the switch-on point when a switch-off point of x mbar is re-
quired)
Gasmin. pressure switch, switch-off point should be 100 mbar, hand wheel setting = 104, operating pressure = 130 mbar
Hand wheel in Testing using test rig pursuant to Measurement using syringe meth- Estimation with hand wheel meth-
DG 150U-3
mbar EN 1854 od, operating pressure: 130 mbar od, value read off on hand wheel
On Off (actual) Off1) Off (actual) On2) Off2)
1st measurement 104 108.5 103.1 34 96 135 142
2nd measurement 104 108.5 103.1 34 96 136 143
3rd measurement 104 108.5 103.2 35 95 135 142

Gasmin. pressure switch, switch-off point should be 300 mbar, hand wheel setting = 310, operating pressure = 400 mbar

DG · Edition 03.21 · EN 45
Operation and maintenance

Hand wheel in Testing using test rig pursuant to Measurement using syringe meth- Estimation with hand wheel meth-
DG 500U-3
mbar EN 1854 od, operating pressure: 400 mbar od, value read off on hand wheel
On Off (actual) Off1) Off (actual) On2) Off2)
1st measurement 313 320.0 309.0 98 302 395 410
2nd measurement 313 320.4 308.9 98 302 395 410
3rd measurement 313 320.0 309.0 99 301 393 408

Gasmax. pressure switch, switch-on point should be 25 mbar, hand wheel setting = 25 mbar, operating pressure = 15 mbar
Hand wheel in Testing using test rig pursuant to Measurement using syringe meth- Estimation with hand wheel meth-
DG 50U-3
mbar EN 1854 od, operating pressure: 15 mbar od, value read off on hand wheel
On Off (actual) On3) On (actual) On4) Off4)
1st measurement 25 25.98 24.97 10.9 25.9 15 16.5
2nd measurement 25 25.96 24.99 11 26 15 16.5
3rd measurement 25 26.05 24.98 10.9 25.9 15 16.5
1) Min. pressure switch: connect syringe with pressure gauge to the upper chamber, push plunger in slowly, read off pressure at switching instant. The pres-
sure read off must now be deducted from the operating pressure (previously measured at the pressure test point) in order to determine the actual switch-
off point.
2) Min. pressure switch: only the switching point in the operating pressure range can be tested using this method. In this case, the DG 6U is switched on. Turn
the hand wheel to the min. position (as far as it will go), then slowly turn it in the direction of the max. position until the switch-off point is reached. Then
turn the hand wheel in the direction of the min. position and make a note of the switch-on point. The switch-on point corresponds to the operating pres-
sure.
3) Max. pressure switch: connect syringe with pressure gauge to the upper chamber, pull plunger out slowly, read off negative pressure at switching instant.
The pressure read off must be added to the operating pressure measured at the test point without a sign in order to determine the switching point.
4) Max. pressure switch: only the switching point in the operating pressure range can be tested using this method. In this case, the DG 50U is switched off
(signal at COM-NC). Turn the hand wheel slowly to the min. position until the pressure switch switches on (COM-NO). The switch-on point corresponds
to the operating pressure.

DG · Edition 03.21 · EN 46
Operation and maintenance
12.3.1 Examples for calculating the switch-on point when a switch-off point of x mbar is required
Type Hand wheel adjusting range Examples
HS switching
SPHE hand
differential for
Switch-on point Switching differential Switch-off point wheel switch-on
hand wheel set-
point
ting
Emin. Emax. Smin. Smax. STP
DG 6 0.4 6 0.2 0.3 3 0.25 3.25
DG 10 1 10 0.25 0.4 5 0.32 5.32
DG 30 2.5 30 0.35 0.9 15 0.60 15.60
DG 50 2.5 50 0.8 1.5 40 1.35 41.35
DG 150 30 150 3 5 100 4.17 104.17
DG 400 50 400 5 15 200 9.29 209.29
DG 500 100 500 8 17 300 12.50 312.50
All specifications in mbar
SPHE = SPA + (Smin. + (Smax. x - Smin.) / (Emax. - Emin.) x (SPA - Emin.))

DG · Edition 03.21 · EN 47
Maintenance cycles

13 Maintenance cycles
At least once a year, at least twice a year in the case of bio-
logically produced methane.

DG · Edition 03.21 · EN 48
Glossary

14 Glossary see EN ISO 13849-1

14.5 Fraction of undetected common cause

14.1 Diagnostic coverage DC
failures β
Measure of the effectiveness of diagnostics, which may be
determined as the ratio between the failure rate of detected Fraction of undetected failures of redundant components
dangerous failures and the failure rate of total dangerous due to a single event, whereby these failures are not based
failures on mutual causes
NOTE: Diagnostic coverage can exist for the whole or parts NOTE: β is expressed as a fraction in the equations and as
of a safety-related system. For example, diagnostic cover- a percentage elsewhere.
age could exist for sensors and/or logic system and/or final see EN 61508-6
elements. Unit: %
see EN ISO 13849-1 14.6 B10d value
Mean number of cycles until 10% of the components fail
14.2 Mode of operation dangerously
High demand mode or continuous mode see EN ISO 13849-1

Operating mode, where the frequency of demands for op-

eration made on a safety-related system is greater than one 14.7 T10d value
per year or greater than twice the proof-test frequency Mean time until 10% of the components fail dangerously
see EN 61508-4 see EN ISO 13849-1

14.3 Category 14.8 Hardware fault tolerance HFT

Classification of the safety-related parts of a control system A hardware fault tolerance of N means that N + 1 is the
in respect of their resistance to faults and their subsequent minimum number of faults that could cause a loss of the
behaviour in the fault condition, and which is achieved by safety function
the structural arrangement of the parts, fault detection see IEC 61508-2
and/or by their reliability
see EN ISO 13849-1 14.9 Mean dangerous failure rate λD
Mean rate of dangerous failures during operation time (T10d).
14.4 Common cause failure CCF Unit: 1/h
Failures of different items, resulting from a single event, see EN ISO 13849-1
where these failures are not consequences of each other

DG · Edition 03.21 · EN 49
Glossary

14.10 Safe failure fraction SFF

Fraction of safe failures related to all failures, which are as-
sumed to appear
see EN 13611/A2

14.11 Probability of dangerous failure PFHD

Value describing the likelihood of dangerous failure per
hour of a component for high demand mode or continuous
mode. Unit: 1/h
see EN 13611/A2

14.12 Mean time to dangerous failure MTTFd

Expectation of the mean time to dangerous failure
see EN ISO 13849-1:2008

14.13 Demand rate nop

Mean number of annual operations
see EN ISO 13849-1

14.14 Average probability of dangerous

failure on demand PFDavg
(LDM = 1 – 10 switching cycles/year)
Average probability of a dangerous failure of the safety func-
tion on demand (LDM = low demand mode)
see EN 61508-6

DG · Edition 03.21 · EN 50
For more information

The Honeywell Thermal Solutions family of products includes Honeywell

Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and
Maxon. To learn more about our products, visit [Link]-
[Link] or contact your Honeywell Sales Engineer.
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Strotheweg 1, D-49504 Lotte
T +49 541 1214-0 We reserve the right to make tech-
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DG · Edition 03.21 · EN