english

PCA1000/6000D2
Sensor-control module for differential
pressure and volume
Operating Instructions

Keep for reference!

Software version: D4753A from version 1.00

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Operating Instructions PCA1000/6000D2

Content
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Structure of the operating instructions . . . . . . . . . . . . . . 4
1.2 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 EMC-compatible installation of control lines . . . . . . . . . 8
5.2 Connection Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Output voltage 0 - 10 V . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Input for switch over Setpoint 1/ 2 . . . . . . . . . . . . . . . . . . 9

6 Connection and operating elements . . . . . . . . . . . . . . . . . . . . 10

7 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Select operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.4 Display unit (metric / inch) . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.5 Parameter table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.6 Nozzle coefficient (K-Factor) . . . . . . . . . . . . . . . . . . . . . . . 16
7.7 Zero point adjustment (Autozero / Offset) . . . . . . . . . . . 16
7.8 Check sensor function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Operating Instructions PCA1000/6000D2

8.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.3 Dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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 Operating Instructions PCA1000/6000D2 General notes
1 General notes

1.1 Structure of the operating instructions

Before installation and start-up, read this manual carefully to
ensure correct use!
We emphasize that these operating instructions apply to specific
units only, and are in no way valid for the complete system!
Use these operating instructions to work safely with and on the
device. They contain safety instructions that must be complied
with as well as information that is required for failure-free operation
of the device.
Keep these operating instructions together with the device. It must
be ensured that all persons that are to work on the device can
refer to the operating instructions at any time.

1.2 Exclusion of liability

To allow for future developments, construction methods and tech-
nical data given are subject to alteration. We do not accept any
liability for possible errors or omissions in the information con-
tained in data, illustrations or drawings provided.
We accept no liability for damage caused by misuse, incorrect
use, improper use or as a consequence of unauthorized repairs or
modifications.

2 Safety instructions
Attention!
• Mounting, electrical connection, and start-up operation may only
be carried out by an electrical specialist in accordance with
electrotechnical regulations (e.g. DIN EN 50110 or
DIN EN 60204)!
• Persons entrusted with the planning, installation, commissioning
and maintenance and servicing in connection with the device
must have the corresponding qualifications and skills for these
jobs. In addition, they must be knowledgeable about the safety

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 Operating Instructions PCA1000/6000D2 Product overview

regulations, EU directives, rules for the prevention of accidents

and the corresponding national as well as regional and in-house
regulations.
• It is strictly forbidden for work to be carried out on any
components while they are connected to live voltage.
• The safe isolation from the supply must be checked using a two-
pole voltage detector.
• The owner is obliged to ensure that the device is operated in
perfect working order only.
• Inspect electrical equipment periodically: retighten loose con-
nections – immediately replace damaged lines and cables.
• Never clean electrical equipment with water or similar liquids.
• A separate fault and performance monitoring-system with an
alarm signal function is necessary in order to prevent personal
injuries and material damages during malfunctions and in case
the device fails. Substitute operation must be taken into
consideration!

Intended use
These devices are intended exclusively for measured value ac-
quisition of differential pressures (non-aggressive gases). Their
operation is only permitted under observance of the specifications
in these operating instructions.
Any other use above and beyond this will be considered as im-
proper use. The manufacturer will not be liable for any damage
resulting from this. The company using it bears the sole risk.

3 Product overview

3.1 Function
Sensor-control module with differential-pressure sensors in proven
ceramic-cantilever technology for climate and clean-room applica-
tion.

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 Operating Instructions PCA1000/6000D2 Product overview
The pressure range from 0 to 6000 Pa (24 in.wg) is covered with 2
types of device. With each type four measuring ranges are pro-
grammable.
Function when the pressure at the “Plus”- connection exceeds the
pressure at the “Minus”- connection.
Depending on the programmed Mode the device can be used
as sensor or as a control module for pressure or volume.
• For operation as pressure sensor the device supplies an output
signal (0...10 V) proportional to the measuring range.
• For operation as air volume sensor the device supplies an out-
put signal (0..10 V) proportional to the air volume measuring
range ( INFO / Range qV). Function in combination with cen-
trifugal fans and measuring device in the inlet ring. The control-
ler calculates the air volume of the fan from the “K-Factor” and
pressure differential between the suction side and the inlet duct.
• For operation as control module for pressure or volume the
purpose of the device is to reach and maintain the target value
set. To accomplish this, the measured actual value (sensor
value) is compared with the adjusted target value, and the con-
trolled value is deduced from this. Controlled output (0...10 V)
e.g. for activating a speed controller for fans or an EC-fan
directly.

3.2 Storage
• The device must be stored in its original packaging in a dry and
weather-proof room.
• Avoid exposure to extreme heat and cold.
• Avoid over-long storage periods (we recommend a maximum of
one year).

3.3 Disposal / recycling

Disposal must be carried out professionally and in an environ-
mentally friendly way in accordance with the respective national
legal stipulations.

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Operating Instructions PCA1000/6000D2 Mounting
"Separate the materials by type and in an environmentally
friendly way.
"If necessary, commission a specialist company with the waste
disposal.

4 Mounting
• Before installation remove the device from the packing and
check for any possible shipping damage!
• Assemble the device on a clean and stable base. Do not distort
during assembly! Use the appropriate mounting devices for
proper installation of the unit!
• Use the templates printed on the device packing to mark the
fastening bore holes.
• The pressure measuring depends on position, therefore the
mounting must be made vertical and as possible on a vibration-
free place (cable inlet and pressure connections down).
• The pressure line´s connection should be with plastic-hose (in
building), inside diameter 4 / 5 mm. For a firm hold of the hose,
its inside diameter must be 1 mm smaller than the outside
diameter of the hose nozzle (step spigot 5 / 6 mm).
• Remove the connection cover for mounting, electrical connec-
tion and setting of the measuring range. Close the lid again
carefully before start-up (tightening torque of the lid screws
1.1 Nm).
11 mm

Bohrschablone
drilling template
Gehäuse
housing
111 mm

83 mm

Schraube
max 4,5 mm
screw max
4,5 mm

91 mm
Gehäuse / housing
106 mm

Vertical mounting Drilling template on packing

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 Operating Instructions PCA1000/6000D2 Electrical installation
5 Electrical installation

5.1 EMC-compatible installation of control lines

Pay attention to maintain sufficient distance from powerlines and
motor wires to prevent interferences.
When using a shielded cable the shield must be connected (as
short and with as low an induction as possible!) to the PE conduc-
tor on one side at the signal input (of the evaluation unit).

5.2 Connection Voltage supply

Connection Voltage supply at terminals: “+US” and “GND”. Here, it
must be strictly observed that the mains voltage lies within the
allowable tolerance specifications ( Technical data and name-
plate affixed to the side).

Danger due to electric current

Only PELV current sources which ensure safe electrical isolation
of the operating voltage in accordance with IEC/DIN EN 60204-1
must be used.
There is no potential isolation between supply voltage and output
signal.

5.3 Output voltage 0 - 10 V

Connection to Terminals “A” - “GND” (Imax Technical data).
It is not permissible to connect outputs of several devices to each
other!

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 Operating Instructions PCA1000/6000D2 Electrical installation
5.4 Input for switch over Setpoint 1/ 2
Via voltage at terminals “1” and “2” (10... 24 V DC) a switchover
between Setpoint 1 and Setpoint 2 is possible (note polarity
connection diagram).
• Voltage OFF => Setting “Setpoint 1” active
• Voltage ON => Setting “Setpoint 2” active
Setpoint 1active Setpoint 2 active
100 Pa The active Setpoint is indicated in the 80 Pa
(0.401 in.wg) menu INFO, an active “Setpoint 2” is (0.321 in.wg)
Δp signalized by the moon symbol. Δp

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Operating Instructions PCA1000/6000D2 Connection and operating elements
6 Connection and operating elements
Voltage supply
+US/ GND
Output signal 0...10 V
A / GND

Voltage input for switch over Set-

1/2
point 1 / 2
“Minus”- connection in area with
- lower pressure
+ “Plus”- connection in area with
higher pressure

Multipurpose LC display and keyboard

100 Pa Text line 1: 16 figures for display of actual and desired values
Δp Text line 2: 16 figures for display of menu text

P Program key and open menu

▼ Menu selection, reduce value
▲ Menu selection, increase value
▼+▲ ESC-key combination, Escape = leave menu

Messages on the display

! Exceeding measuring range

Moon symbol = Adjustment for Setpoint 2 active

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 Operating Instructions PCA1000/6000D2 Programming
7 Programming

7.1 Select operation mode

Information
Simple installation is possible through the selection of the preprog-
rammed mode of operation.
This determines the basic function of the device, factory set 4.01 .

Mode Function
Pressure sensor output 0...10 V proportional to measuring range
4.00
Pressure controller (PID): output 0...10 V depending on adjusted
4.01 Setpoint and measured actual value.

Air volume sensor: Output 0...10 V propotional to measuring range

5.00 (depending on setting for K-Factor)
Air volume controller (PID): Output 0...10 V depending on adjusted
5.01 Setpoint and measured actual value

7.2 Start-up

Procedure
1. You must mount and connect the device in accordance with
the operating instructions.
2. Double check that all connections are correct.
3. The supply voltage must match the information on the rating
plate.
4. Set the mode, unit and measuring range and adjust the sensor
in the BASE SETUP.
5. Set the parameters for control operation for the modes 4.01
and 5.01 under SETTING.
Information
When saving the Operating Mode, the factory settings are stored.
Therefore all the settings you have made, are lost.

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 Operating Instructions PCA1000/6000D2 Programming
7.3 Menu structure
100 Pa Display after turning on the voltage supply.
Δp Switch over between actual value display and INFO
“INFO” with the key shortcut for Escape (Esc
= ▼ + ▲).

Selection of the menu group (e.g. BASE SETUP) to the right

through the ▼-key, to the left through the ▲-key.
Youcangotothemenuitemsinthemenugroups (e.g. mode) by using
the P key. Use the arrow keys to move up and down within the
menu group.
To make adjustments, press the P key after selecting the menu
item. If the previously set value starts to flash, it can be adjusted
with the ▼ + ▲ keys and then saved with the P key. To exit the
menu without making any changes, use the “Esc” short-key, i.e.,
the originally set values remain.

Example for Mode 4.01 (Factory setting)

▼ ▼
INFO ▲ SETTING ▲ BASE SETUP
P↓ ↑ Esc P↓ ↑ Esc P↓ ↑ Esc
100 Pa 100 Pa 4.01
Δp Setpoint 1 Mode
▲▼ ▲▼ ▲▼
100 Pa 100 Pa 1: metric
Setpoint 1 Setpoint 2 Units
▲▼ ▲▼ ▲▼

Reprogramming Mode 4.01 to 5.00 in “BASE SETUP”

1 2 3 4 5 6 7
4.01 «4.01» «5.00» 5.00
Mode P Mode ▲ Mode P Mode

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 Operating Instructions PCA1000/6000D2 Programming
7.4 Display unit (metric / inch)
The display can be switched between SI units (factory setting) and
imperial (US) units BASE SETUP / Units.
Conversion factors
• Pressure: 1.0 in.wg = 254 Pa3
• Air flow: 1.0 cfm = 0.5885 m /h
inlet ring: K-Factor US = 9.3 x K-Factor SI

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 Operating Instructions PCA1000/6000D2 Programming
7.5 Parameter table
Example for PCA1000D2

Parameter Display / factory setting Funktion

Mode 4.00 4.01 5.00 5.01 Mode

INFO Information
0 Pa 0 Pa
Display actual value for
Δp (0.000 (0.000 - -
differential pressure
in.wg) in.wg)
0 m3/h 0 m3/h Display actual value for
qV - -
(0 cfm) (0 cfm) airflow
500 Pa
1185 m3/h
Setpoint 1 - (2.000 - Display active Setpoint
(697 cfm)
in.wg)
Air volume measuring
2371 m3/h 2371 m3/h range depending on
Range qV - -
(1394 cfm) (1394 cfm) sensor measuring
range and K-Factor
Magnitude of the out-
Uout 0.0 V 9.9 V 0.0 V 9.9 V
put voltage 0...10 V
UNIcon 1.00 1.00 1.00 1.00 Software version
0 Pa 0 Pa Display actual value for
Δp - - (0.000 (0.000 volume measurement
in.wg) in.wg)
SETTING 4.01 + 5.01 Setting
500 Pa
1185 m3/h
Setpoint 1 - (2.000 - Setpoint 11
(697 cfm)
in.wg)
500 Pa Setpoint 21
- 1185 m3/h
Setpoint 2 - (2.000 (active if voltage at ter-
(697 cfm)
in.wg) minals 1, 2)
500 Pa
1185 m3/h
Pband - (2.000 - Pband1, 2
(697 cfm)
in.wg)
Min. output voltage:
Min. Uout - 0.0 V - 0.0 V 0.0...10.0 V (priority
over “Max. Uout”)

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 Operating Instructions PCA1000/6000D2 Programming
Parameter Display / factory setting Funktion
Max. output voltage:
Max. Uout - 10.0 V - 10.0 V
10.0...0.0 V
BASE SETUP Base setup
Mode 4.00 4.01 5.00 5.01 Mode
metric: Pa, m3/h, K-Factor SI units or Imperial
Units units (US)
inch: in.wg, cfm, K-Factor US
1: 0...1000 Pa (0...4.0 in.wg) PCA1000D2
2: 0...500 Pa (0...2.0 in.wg) Adjustable measuring
3: 0...300 Pa (0...1.2 in.wg) range
Measuring 4: 0...200 Pa (0...0.8 in.wg)
Range 1: 0...6000 Pa (0...24.0 in.wg) PCA6000D2
2: 0...4000 Pa (0...16.0 in.wg) Adjustable measuring
3: 0...3000 Pa (0...12.0 in.wg) range
4: 0...2000 Pa (0...8.0 in.wg)
Nozzle coefficient (K-
K-Factor 75 75 Factor) following
- -
K-Factor US (697) (697) table
Autozero OFF => ON Automatic “0” offset
Sensor offset (auto-
matically when “Auto-
0 Pa zero”)
Offset
(0.000 in.wg) Setting range: +/ -
1000 Pa (+/- 4.000
in.wg)

1 Setting range 4.01 : 0..100 % sensor measurung range, 5.01 : 0...Max. Range qV (depending
on K-Factor and sensor measuring range)
2 small value = quick regulation, great value = slow regulation (high stability)
- Parameter for selected mode not available
(xxx) Values for Imperial units (US)

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 Operating Instructions PCA1000/6000D2 Programming
7.6 Nozzle coefficient (K-Factor)
Maximum K-Factor depending on the measuring range of the pressure sensor
Range
[Pa] 200 300 500 1000 2000 3000 4000 6000
[in.wg] 0.8 1.2 2.0 4.0 8.0 12.0 16.0 24.0
Max.
K-Factor 4596 3752 2906 2055 1453 1186 1027 839
US 32767 32767 32767 32500 22980 18763 16250 13268

Air volume measuring range [m3/h], [cfm] depends on selected

measuring range of pressure senosr [Pa], [in.wg] and selected “K-
Factor (US)”. In menu “INFO” display for “Range qV”. Maximum
measuring range at input of each possible maximum “K-Factor
(US)”.
Air flow measuring range: max. 65000 m3/h (38257 cfm) depend-
ing on setting of measuring range and K-Factor.

7.7 Zero point adjustment (Autozero / Offset)

A zero-point adjustment is possible if the actual value is not “0 Pa
Δp” or “0 m3/h qV” in pressureless state. A zero point calibration is
possible with the function “Autozero”.
This may be necessary, for example, in case of heavy thermal
fluctuations in the sensor environment or non-vertical mounting.
Procedure
1. Pull off the pressurised hoses.
2. Switch function “Autozero” in BASE SETUP to “ON” .
3. The display switches to the actual value display and the value
“0” is displayed after zero point calibration has taken place.
4. The necessary difference up to “0” is displayed in the BASE
SETUP under “Offset”.

Alternatively to the automatic zero point calibration, the offset

value can also be set manually BASE SETUP / Offset.

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 Operating Instructions PCA1000/6000D2 Enclosure
7.8 Check sensor function
1. Program Mode 4.00 for pressure sensor.
2. Connect the voltage supply (+US / GND), disconnect output
0 ...10 V (A / GND).
3. Remove pressure hoses and measure output signal, nominal
= 0 V.
4. Create pressure at the "+" connection against the "-" connec-
tion (e. g. by carefully blowing in), measure the output signal
(0...10 V measuring range).
5. If the sensor works, reconnect the pressure hoses and check
these if necessary.

8 Enclosure

8.1 Technical data

Type PCA1000D2 PCA6000D2
Part-No. 76739 76740
(320064-42) (320065-42)
Voltage supply 10...24 V DC (+20 %)
Protected against reverse polarity

@ US 10 V DC @ US 13...24 V DC
Max. load output 0...10 V 0.3 mA 10 mA
(short-circuit-proof)
Max. current consumption ca. 6 mA 14 mA

Pressure connections “+, -” Hose connectors d = 5 / 6 mm (0.20 / 0.24 inch)

Housing PC (polycarbonate)
Fire protection classification UL94V0
Use position vertical (measuring depends on position)
Protection class IP54 according EN 60529
Weight approx. 230 g (0.50 lb)

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 Operating Instructions PCA1000/6000D2 Enclosure
Permissible temperature range for op- -10...50 °C (14...122 °F)
eration
Permissible temperature range for -30...50 °C (-22...122 °F)
storage and transport
Permissible rel. humidity 85 % no condensation
One-sided permissible overload 0.1 bar (80 in.wg)
Burst prssure at room temperature: 0.2 bar (80 in.wg)
at 70 °C (158 °F): 0.15 bar (60 in.wg)
Maximum cross section of terminals 1.5 mm2 / AWG16
Interference emission according EN 61000-6-3 (domestic household
applications)
Interference immunity according EN 61000-6-2 (industrial applica-
tions)

Accuracy and measuring ranges

Type PCA1000D2 PCA6000D2
Pressure measuring range max. 0...1000 Pa 0...6000 Pa
(0...4.0 in.wg) (0...24.0 in.wg)
*)
Tolerance zero point max. % +/- 0.9 +/- 0.9
Tolerance full scale max. % +/- 1.3 +/- 0.7
Resolution % 0.1 0.1
Total of linearity, hysteresis and repeatability max. % 0.6 0.6
Long term stability according to DIN EN 60770 % +/- 1.0 +/- 1.0
Temperature coefficient typical %/
10K +/- 0.2 +/- 0.2
Temperature coefficient max. %/
10K +/- 0.4 +/- 0.4
Temperature coefficient sensitivity typical %/
10K +/- 0.2 +/- 0.2
Temperature coefficient sensitivity max. %/
10K +/- 0.4 +/- 0.4
The accuracy data are percentages and refer to the maximum possible measuring
range of the respective type.
Test conditions: 25 °C, 45 % RH, voltage supply 12 VDC

*) Calibration is possible to reduce the zero point error zero point calibration

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 Operating Instructions PCA1000/6000D2 Enclosure
8.2 Connection diagram
PCA 1000/6000D2

p Ri = 4 kΩ
PI
V

+US GND A GND 1(+) 2( )

+ ∆p -
+ US
3 01
Spannungsversorgung
Voltage supply
10...24 V DC +
(10 V: Imax = 6 mA)
10...24 V DC -
(13...24 V: Imax = 14 mA)
1 0 = Setpoint 1
4
+ Uout 1 = Setpoint 2
Ausgang
Output
MCDU05K2
0...10 V 16.12.2015
(Imax = 0.3 mA @ US 10 V)
(Imax = 10 mA @ US 13...24 V)
2

1 Voltage supply 10...24 V DC

2 Output 0...10 V
3 Pressure connections
4 Voltage input for switch over Setpoint 1 / Setpoint 2

8.3 Dimensions [mm]

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 Operating Instructions PCA1000/6000D2 Enclosure
8.4 Manufacturer reference
Our products are manufactured in accordance with the relevant
international regulations. If you have any questions concerning the
use of our products or plan special uses, please contact:
Systemair
Industrievägen 3
73930 Skinnskatteberg
Telefon:+46 (0) 222 440 00
Telefax:+46 (0) 222 440 99
[email protected]
www.systemair.se

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