ITT Switch 801P5 User Manual

NEO-DYN  
801P5 SMART  
S
WITCHTM  
INSTALLATION AND  
OPERATION MANUAL  
PN 610-0002 Rev D  
ECO 71349  
 
TABLE OF CONTENTS  
PAGE  
CHAPTER 1 INTRODUCTION................................................. 1  
ABOUT THIS MANUAL......................................................... 4  
KEYS ........................................................................................ 4  
DISPLAY.................................................................................. 4  
CUSTOMER SERVICE............................................................ 4  
CHAPTER 2 INSTALLATION.................................................. 5  
MOUNTING............................................................................. 5  
PRESSURE CONNECTION .................................................... 5  
ELECTRICAL CONNECTIONS ............................................. 6  
CHAPTER 3 OPERATION & PROGRAMMING................... 11  
OPERATION MODE.............................................................. 11  
FRONT PANEL CONTROLS................................................ 12  
INPUT CONTROLS............................................................... 13  
DISPLAYING PRESSURE .................................................... 13  
DISPLAYING SET POINTS.................................................. 14  
STANDARD VS. WINDOW MODE..................................... 15  
PROGRAMMING MODE...................................................... 17  
ENTER PROGRAMMING MODE........................................ 17  
CHANGING THE SET POINTS............................................ 19  
ADDITIONAL FEATURES................................................... 20  
CHAPTER 4 ANALOG OPTION............................................. 25  
ANALOG OPTION WIRING................................................. 25  
TURNING ANALOG OUTPUT ON AND OFF(LOOP)...... 25  
4-20 MILLIAMPERE OUTPUT CALIBRATION (4CAL)... 26  
4-20 MILLIAMPERE OUTPUT SCALING .......................... 27  
CHAPTER 5 TROUBLESHOOTING ...................................... 29  
ERROR MESSAGES.............................................................. 29  
Page ii Installation and Operation Manual  
 
TABLE OF CONTENTS  
PAGE  
CHAPTER 6 SERIAL COMMUNICATIONS (Z Option) .......35  
GENERAL ..................................................................................35  
WIRING ......................................................................................35  
CHAPTER 7 SPECIFICATIONS..............................................37  
STANDARD ...........................................................................37  
OPTIONS ................................................................................40  
WARRANTY INFORMATION .................................................41  
801P5 Smart SwitchTM Page iii  
 
CHAPTER  
1  
INTRODUCTION  
The Neo-Dyn® 801P5 Smart-SwitchTM is a solid-state pressure  
switch designed for a wide range of applications in pneumatic and  
hydraulic systems up to 3,000 psig. Pressure indication, switch  
status and operational status are continually displayed on the front  
panel. The unit can be configured to display pressure readings in a  
variety of formats.  
The Smart-SwitchTM can be configured on-site, using the front  
panel keypad and 4 digit display, or remotely via the optional  
RS-232 connection. The 4-20 mA output option offers remote  
monitoring capabilities.  
A built-in password security system prevents unauthorized  
adjustments. When locked, pressure can be monitored and set  
points may be viewed, but no adjustments can be made without  
entering the correct password.  
The Smart-SwitchTM may be ordered to operate on 115 VAC  
50/60 Hz, 230 VAC 50/60 Hz, or 18-30 VDC input power.  
The external configuration of the Smart-SwitchTM is shown in  
Figure 1 on the next page.  
Page 1 801P5 Smart SwitchTM  
 
4-20 mA  
Output  
RS232  
COM Port  
Status  
Indicators  
Keypad  
Pressure  
Port  
1/4-18 NPT  
Std  
Conduit  
Connection  
1/2-14 NPT  
18” free leads  
#22 AWG  
Figure 1 Model 801P5 Smart-SwitchTM  
(Mounting Brackets not Shown)  
Page 2 Installation and Operation Manual  
 
The standard electrical interface is 22 AWG free leads exiting  
from a ½” - 14 NPT male conduit connection. The standard  
pressure connection is ¼” - 18 NPT female; a 7/16” - 20 SAE  
pressure connection is available as Option E.  
Output options available for the Smart-SwitchTM include a  
4-20 mA analog output (Option V), scalable display units  
(Option Q), and RS232 communications (Option Z).  
The RS232 option can be used to configure and monitor the unit  
remotely. This option includes Windows®-based software.  
Chapter 7 on page 37 contains complete specifications for the  
801P5 Smart-SwitchTM  
.
Page 3 801P5 Smart SwitchTM  
 
ABOUT THIS MANUAL  
The following paragraphs describe the format conventions used in  
this manual.  
KEYS  
Most of the instructions contain directions to press a key, which is  
one of the blue touchpads on the display surface of the  
Smart-SwitchTM. When included in instructions, the keys are  
shown in brackets, as [STORE].  
DISPLAY  
When shown in the text, the LED displays are formatted as  
279.3.  
CUSTOMER SERVICE  
If you have any questions about the 801P5 Smart-SwitchTM that  
are not covered in this manual, you can contact Neo-Dyn in several  
ways:  
The customer service phone number is (661) 295-4000. Our  
customer service department is open from 7:00 am to 3:30  
p.m. Pacific Time.  
Page 4 Installation and Operation Manual  
 
CHAPTER  
2  
INSTALLATION  
Installation of the Smart-SwitchTM is relatively straightforward.  
However, the Smart-SwitchTM must be installed by a qualified  
electrician, in compliance with all local and national electrical codes.  
Electrical Hazard  
WARNING  
WARNING Do not make electrical connections while power is on.  
WARNING Always check for multiple circuits.  
Always make sure grounding is adequate.  
MOUNTING  
WARNING  
The Smart-SwitchTM can be mounted directly to the pressure  
connection, or it can be attached to a flat surface, such as a wall,  
near the connection to be monitored. For surface mounting, slide  
the two mounting brackets into the slots on the back of the  
Smart-SwitcTM and use #10 (.190 in. dia.) fasteners.  
PRESSURE CONNECTION  
The standard pressure connection for the 801P5 Smart-SwitchTM  
is a ¼”- 18 NPT female pipe thread. A 7/16” - 20 SAE boss is  
also available as Option E. When installing the Smart-SwitchTM  
always:  
,
Make sure that the unit and your system have the same fittings.  
Use the wrench flats provided.  
Seal all joints with pipe joint sealing compound.  
Avoid excessive torque on all threaded connections.  
CAUTION  
Page 5 801P5 Smart SwitchTM  
 
ELECTRICAL CONNECTIONS  
Units are supplied with 22 AWG free leads exiting from a ½”-14  
NPT male conduit connection. The leads are-color coded and  
marked. See Figure 2 for AC operation and Figure 3 for DC  
operation.  
4-20 mA output (option letter V) is connected to the 2-pin  
connector on the top-right of the unit per Figure 4, using the  
supplied mating connector. This mating connector has solder cups  
that will take wires as large as #18 AWG. See Chapter 4 for  
operating instructions.  
The RS232 communications (option letter Z) are connected to the  
3-pin connector on the top-left of the unit (See Figure 5), using  
the supplied mating connector. This mating connector has solder  
cups that will take wires as large as #18 AWG. Cable length must  
not exceed 50 feet. See Chapter 6 for operating instructions.  
All field wiring for the 801P5 must comply with requirements of  
the NEC or applicable local electrical codes.  
Page 6 Installation and Operation Manual  
 
Figure 2 - Schematic for AC Operation  
Page 7 801P5 Smart SwitchTM  
 
Figure 3 - Schematic for DC Operation  
Page 8 Installation and Operation Manual  
 
+ 4-20 Ma  
A
B
RETURN  
Figure 4 - Wiring for 4-20 mA Analog Output  
Page 9 801P5 Smart SwitchTM  
 
DATA SEND  
A
DATA RECEIVE  
SIGNAL GROUND  
B
C
Figure 5 - Wiring for RS-232 Communications  
Page 10 Installation and Operation Manual  
 
CHAPTER  
3  
OPERATION & PROGRAMMING  
This section describes the regular (normal) operation of the  
Smart-SwitchTM as it monitors pressure after installation and  
initial setup, and the Programming Mode for changing the  
settings.  
Both modes rely on the front panel for information and input. See  
Figure 6 on the next page.  
OPERATION MODE  
To begin operation, apply correct power to the appropriate free  
leads (there is no on-off switch).  
In normal operation mode, the display shows:  
Online LED (green) indicates operation mode  
S1 and S2 LED's (red) indicate the switch status (illuminated  
when the relay coil is energized or the solid-state switch is  
actuated)  
System pressure is displayed  
You can also check the set points in operating mode; all other  
actions are done in programming mode. However, If you have the  
RS232 option, you can program the unit remotely using its  
Windows® software on a personal computer; see Chapter 6.  
Page 11 801P5 Smart SwitchTM  
 
FRONT PANEL CONTROLS  
Figure 6 The Front Panel,  
with Function Keys Below the Display  
Indicators  
Display  
The display shows the actual system pressure in normal  
operation.  
S1 and S2 (Switch) Indicators  
The S1 and S2 (red LED's) indicate switch status (illuminated  
with the relay coil energized or the solid-state switch actuated).  
Online Indicator  
The Online indicator (green LED) is lit when the unit is  
online and active. If the indicator is not lit, the unit is offline.  
Page 12 Installation and Operation Manual  
 
INPUT CONTROLS  
S1 and S2 INCR/DECR  
Push the [S1] and [S2] [INCR] and [DECR] keys to see what  
values the set points are configured for.  
MENU  
Use the [MENU] key to enter program mode.  
UP/DOWN ARROW  
The [UP/DOWN ARROW] keys are used to move through  
the list of submenus.  
SELECT  
The [SELECT] key is used to move into the desired submenu.  
STORE  
The [STORE] key is used to temporarily save changes made  
to the current submenu and return to the main menu.  
RUN  
The [RUN] key is used to lock in the programming changes  
made.  
NOTE  
After pressing [RUN], to return to operation mode (go back  
online), you must press [SELECT]. Otherwise, any programming  
changes will be lost after 2 minutes.  
DISPLAYING PRESSURE  
When the Smart-SwitchTM is in operation mode, system pressure  
is displayed on the front panel.  
Page 13 801P5 Smart SwitchTM  
 
DISPLAYING SET POINTS.  
Programmed set points can be viewed on the front panel display  
by pressing the corresponding [S1] or [S2] key. To view the  
increasing value for Switch 1, press [S1 INCR]. To view the  
decreasing value for Switch 2, press [S2 DECR].  
Figure 7 Press the Incr / Decr Buttons  
to Display Set Points for S1 / S2  
After 5 seconds of keypad inactivity, the display automatically  
changes back to the system pressure display. While viewing set  
points, the output functions remain active.  
NOTE  
Page 14 Installation and Operation Manual  
 
STANDARD VS. WINDOW MODE  
The terms “Standard” and “Window” describe two methods for  
setting up the Smart-SwitchTM to monitor pressure.  
Standard Mode  
In Standard Mode, illustrated in Figure 8, the SP1i (or SP2i) set  
point actuates when the pressure being monitored goes above the  
set value. At this point, the Smart-SwitchTM might turn off  
whatever electrical power is being applied to a pump, for  
example, which is increasing or maintaining the pressure. The  
switch de-actuates, or resets, when the pressure drops below the  
preset decreasing set point (SP1d or SP2d). At this time, the  
electrical power to the pump would be turned back on.  
SWITCH  
ACTUATES  
INCREASING SET POINT  
DEADBAND  
SWITCH  
DEACTUATES  
DECREASING SET POINT  
Figure 8 Standard Mode  
Page 15 801P5 Smart SwitchTM  
 
Deadband  
The deadband is the separation between the increasing set point  
and the decreasing set point, as shown in Figure 8. The deadband  
can be anywhere from 1% to 99% of Full-Scale Output (F.S.O.).  
In the case above where the Smart-SwitchTM is controlling a  
pump, a wider deadband reduces the frequency at which the pump  
cycles on and off.  
Window Mode  
This mode is useful when you want to maintain pressure within a  
certain range, and want to be notified when pressure either goes  
above or falls below that range. In Window Mode, the Smart-  
Switch® starts out actuated, then deactuates when it reaches its  
lower set-point (SP1d or SP2d). As pressure continues to  
increase, the switch actuates again when it reaches the upper  
set-point (SP1i or SP2i). This range between the lower and upper  
set-points is the "window". When pressure decreases, the  
sequence reverses, with a deadband of 1% of F.S.O. at each of the  
set-points. See Figure 9.  
In this mode, the Smart SwitchTM might be wired to, say, an alarm  
bell, which would sound if the pressure either rose above SP1i or  
fell below SP1d.  
NO = CLOSED  
UPPER BOUNDARY  
(INCREASING SET POINT)  
WINDOW  
NO = OPEN  
LOWER BOUNDARY  
(DECREASING SET POINT)  
NO = CLOSED  
Figure 9 Window Mode  
Page 16 Installation and Operation Manual  
 
PROGRAMMING MODE  
In Programming Mode, you can:  
Change the set points  
Perform field pressure calibration  
Program Window or Standard Mode  
Change the password  
Program display update time  
Program delays for both switches  
Scale the readout  
Reset the Smart-SwitchTM to factory defaults  
If your unit includes the 4-20 mA option, you can:  
Activate 4-20 mA mode  
Calibrate the 4-20 mA  
Scale the 4-20 mA output  
If your unit includes the RS232 option, you can:  
Set the BAUD rate  
The unit will not function as a switch while in programming  
mode.  
NOTE  
ENTER PROGRAMMING MODE  
To access the programming mode, press the [MENU] key (See  
Figure 7). On the initial startup, no password is required. If you  
have previously set up a password, you must enter it at this time:  
1. When the displays show ---O, press the [UP/DOWN  
ARROW] keys to set the first digit.  
2. Press [SELECT] to move to the next digit.  
3. Repeat this process until display shows the correct password.  
4. Press [STORE] to enter programming mode.  
Page 17 801P5 Smart SwitchTM  
 
You can now use the arrow keys to move throughout the menu  
system. Then:  
1. When the menu item you want to change is displayed, press  
[SELECT].  
2. After changing the value, use the [STORE] key to temporarily  
save the changes. If you make a mistake while entering  
values, press the [MENU] key to return to the menu system  
and restart.  
3. To change another item, press the [UP/DOWN ARROW]  
keys to display that item, and repeat steps 1 and 2.  
4. After you are done, press the [RUN] key to lock in the  
changes. Then press the [SELECT] key to return online.  
You must press the [SELECT] key when RUN is displayed to  
permanently save any changes you have made. If you do not, all  
changes will be lost after two minutes of inactivity.  
NOTE  
When RUN is displayed, you have two additional choices, REDO  
and UNDO. Use the [UP/DOWN ARROW] keys to scroll  
through the menu. Press the [SELECT] key to make your choice.  
REDO puts the unit back into program mode to allow  
further changes.  
UNDO returns the unit online without making the changes  
you may have entered.  
RUN returns the unit online, saving all changes.  
Page 18 Installation and Operation Manual  
 
CHANGING THE SET POINTS  
To change the set points, press the [MENU] key (See Figure 7).  
The first menu item is SP1i, for Set point 1, increasing. To change  
a set point:  
1. If you want to change a set point other than SP1i, select the  
set point by pressing the arrow keys, then press [SELECT].  
The furthest right digit will blink.  
2. Use the [SELECT] key to move to the digit you want to  
change.  
3. Use the [UP/DOWN ARROW] keys to change the value of  
the digit.  
4. When the value is correct, press the [SELECT] key to move to  
another digit. Repeat this until you have the correct value for  
this set point.  
5. Use the [STORE] key to temporarily save the changes and  
return to the main menu.  
6. Press [RUN]and then [SELECT] to permanently save the  
setting and return to On-Line operation.  
If you have set an invalid set point, the error message EROR will  
be displayed. Possible causes for errors are:  
INCREASE value is equal to or lower than DECREASE value.  
Values exceed range limits  
Deadband is less than 1% of F.S.O.  
Page 19 801P5 Smart SwitchTM  
 
ADDITIONAL FEATURES  
To alter the settings of the Smart-SwitchTM, press the [MENU] key  
and use the [UP/DOWN ARROW] keys to move through the  
menu.  
Mode (MOD)  
Mode allows you to choose between Standard and Window  
Mode. After MOD is displayed, use the [SELECT] key to  
enter the Mode submenu and use the [UP/DOWN ARROW]  
keys to toggle between STD and WIN. Press the [STORE]  
key to temporarily save your setting.  
Delay (DELY)  
This menu item allows you to delay the actuation and  
deactuation of the relay switches controlled by the set points.  
After DELY is displayed, use the [SELECT] key to enter the  
submenu. Use the [UP/DOWN ARROW] keys to cycle  
through the available delay times. Your choices are 0, 40,  
100, 300, 1000, 3000 or 5000 mSec. Press the [STORE]  
key to temporarily save your settings.  
Display (DISP)  
This item sets how often the pressure display is updated.  
This can be useful when there is a lot of fluctuation in the  
pressure reading. After DISP appears, use the [SELECT] key  
to enter the submenu. Use the [UP/DOWN ARROW] keys  
to cycle through the available display settings. This option  
can be set at OFF, 0.5, 1.0, 2.0, 3.0, 4.0, or 5.0 seconds.  
Press the [STORE] key to temporarily save your setting.  
Password (PASS)  
The Password function allows you to set a password to limit  
access to all menu functions. After PASS is displayed, use  
the [SELECT] key to enter the submenu. Use [SELECT] to  
find the digit of the value you want to change. The digit will  
blink. Use the [UP/DOWN ARROW] keys to change the  
value of the digit. When the value is correct, press the  
[SELECT] key. Use this procedure until all digits of the  
password are changed to the correct values. Then press the  
[STORE] key to temporarily save your setting.  
Page 20 Installation and Operation Manual  
 
Scalable Readout: Option Q  
With this option installed, you can change the scale factor of  
the display to read in different units of pressure, or in  
arbitrary numbers that you choose.  
If your system is set up with pressures in bars, for example,  
you might want the Smart-SwitchTM display to show bars  
instead of psig.  
The r-Hi, r-Lo and .Loc menu functions allow you to scale  
the readout to your preference. In the following example,  
millibars are used:  
You have a scalable 801P5 with the 15psig sensor. You  
want to represent the pressure in millibars. The standard  
conversion unit is 1 psi = 68.95 millibars.  
You want to read zero for zero pressure, therefore,  
r-Lo = 0.  
Full-scale output pressure for the 801P5 for this example  
is 15 psig. So, r-Hi = 68.95 x 15 = 1034.25 millibars,  
which rounds to 1034. Therefore r-Hi should be set to  
1034.  
The unit now reads from 0 to 1034 millibars for 0 to  
15 psig pressure. The accuracy is ± 2 millibars, which is  
± 0.2% of 1034.  
You can use the scalable readout to set the display to read  
whatever units are most familiar to you, or arbitrary numbers  
such as 0 to 10. With the 4-digit display, you can use  
positive numbers to 9999, and negative numbers to -999 (for  
fewer digits, use leading zeros).  
Page 21 801P5 Smart SwitchTM  
 
To change the (r-Lo)and (r-Hi):  
1. Press the [MENU] key and use the [UP/DOWN ARROW]  
keys to move through the menu selections to r-Lo.  
2. Press [SELECT]. The furthest right digit will blink.  
3. Change the digit’s value with the [UP/DOWN ARROW] keys.  
4. When the value is correct, press the [SELECT] key to move to  
the next digit and repeat step 3. Repeat for each digit until  
you have the correct value for r-Lo.  
5. Use the [STORE] key to temporarily save the changes and  
return to the main menu.  
6. Press [RUN]and then [SELECT] to permanently save the  
setting and return to On-Line operation.  
7. Repeat steps 1 through 6 for r-Hi. The setting should be at  
least 2 display counts higher than r-Lo.  
Decimal Location (.Loc)  
You can change the location of the decimal point, thereby  
changing the scale of the display, by using this function.  
After .Loc displays, press [SELECT] to move the location  
one digit left. When the correct location has been reached,  
press [STORE] to temporarily save your setting.  
When the decimal point is in the far right location, no decimal is  
displayed during operation.  
NOTE  
Page 22 Installation and Operation Manual  
 
Pressure Calibration (PCAL)  
You can do a field pressure calibration using this function.  
After PCAL is displayed, use the [SELECT] key to enter the  
submenu. LO-P will be displayed for one second, and then  
the switch’s interpretation of the actual pressure will be  
displayed. Apply 0.0 psig to the unit. Use the [UP/DOWN  
ARROW] keys to adjust the pressure display to zero psig.  
Press the [STORE] key. The display will show HI-P for one  
second, followed by the switch’s interpretation of the actual  
pressure applied. Apply Full- Scale pressure to the unit. Use  
the [UP/DOWN ARROW] keys to set the display equal to  
Full- Scale pressure. Press the [STORE] key to return to the  
main menu.  
A pressure source is required for this operation. In addition,  
calibration equipment used must have an accuracy of at least  
± 0.02% F.S.O. of the switch being calibrated.  
NOTE  
NOTE  
If re-calibration results in zero or Full-Scale readings that have  
shifted by 4% F.S.O. or more from the factory calibration, an  
error code of EROR will be displayed.  
Reset (rSET)  
This command resets the Smart-SwitchTM to factory default  
settings. After rSET appears, press [SELECT], [STORE],  
[RUN] and [SELECT] to reset the unit to factory defaults.  
These are as follows:  
r-Hi returns to factory F.S.O.  
r-Lo is set to zero  
Spli is set to 60% of the full range.  
SPld is set to 40% of the full range.  
SP2i is set to 70% of the full range.  
SP2d is set to 30% of the full range.  
Switch delay is set to 0 mSec.  
Display update time is set to 0.5 seconds.  
Page 23 801P5 Smart SwitchTM  
 
If you have the 4-20 mA analog option, there are three additional  
menu items that are reset. These are:  
NOTE  
LooP is set to on.  
ScHi is set to F.S.O.  
ScLo is set to zero.  
These three menu items are discussed in Chapter 4, Analog  
Option.  
Page 24 Installation and Operation Manual  
 
CHAPTER  
4  
ANALOG OPTION  
The analog option (V option) for the 801P5 allows you to equate  
pressure with electrical current. If your Smart-SwitchTM includes  
this option, the 4-20 mA output can be scaled; see page 27.  
ANALOG OPTION WIRING  
The 4-20 mA output connections are provided by the two pin  
connector located on the top right of the unit:  
Pin A is the + (positive) output  
Pin B is the – (negative) output  
The 801P5 generates its own loop power and it can operate with a  
load resistance of 600 ohms maximum.  
NOTE  
TURNING ANALOG OUTPUT ON AND OFF(LOOP)  
Current Loop (LOOP)  
This menu item enables or disables the current (4-20 mA) output.  
To use this item:  
1. Press [MENU]  
2. Press the [UP/DOWN ARROW] key until LOOP displays,  
the press the [SELECT] key to enter the submenu.  
3. Press either [ARROW] key to change the display from OFF  
to ON, and vice versa.  
4. Press [STORE] to temporarily save your changes, then press  
[RUN] followed by [SELECT] to lock in changes and return online.  
Page 25 801P5 Smart SwitchTM  
 
4-20 MILLIAMPERE OUTPUT CALIBRATION (4CAL)  
The 801P5 is factory calibrated to generate 4 mA when the  
pressure sensor is at 0 psig, and 20 mA when rated pressure is  
applied. Tolerances in your signal conditioning equipment may  
result in readings varying from these values, so you can calibrate  
the 4-20 mA output as follows to correct these readings.  
1. Connect a calibrated milliammeter to the 4-20 mA output.  
2. Press [MENU], then press the [UP/DOWN ARROW] key  
until 4CAL is displayed.  
3. Press [SELECT]. The display will show LO-C.  
4. While reading the milliammeter, use the [UP/DOWN  
ARROW] keys to adjust the output to 4 milliamperes.  
5. Press the [STORE] key. The display will read HI-C.  
6. Use the [UP/DOWN ARROW] keys to adjust the output to  
20 mA, then press the [STORE] key to temporarily save the  
calibration data and return to the main menu.  
7. Press [RUN] and [SELECT] to save the changes and return  
online.  
If the 0 or Full Scale output has shifted by 4% of F.S.O. or more  
NOTE  
from the factory calibration, EROR will be displayed.  
Page 26 Installation and Operation Manual  
 
4-20 MILLIAMPERE OUTPUT SCALING  
The 4-20 mA output is scaleable, allowing 4 mA to represent any  
pressure between 0% and 66% F.S.O., and 20 mA to represent  
any pressure between 33% and 100%F.S.O. This feature is helpful  
in systems where the normal operating pressure falls within the  
pressure range of the unit. For example, let’s assume that the  
Smart-SwitchTM has a pressure range of 0 to 100 PSIG, and the  
process that it is monitoring operates between 20 and 80 PSIG.  
The equipment that is monitoring the 4-20 mA output expects 4  
mA to represent 20 PSIG, and 20 mA to represent 80 PSIG. Using  
the following instructions, by setting SCLO to 20 PSIG and SCHI  
to 80 PSIG, these conditions will be met.  
Scale Low (SCLO)  
To set the pressure at which the output equals 4 mA, press the  
[UP/DOWN ARROW] keys until SCLO is displayed. Press  
[SELECT] to enter the submenu. Use the [SELECT] key to move  
from digit to digit and use the [UP/DOWN ARROW] keys to  
adjust each digit. Once you have set the pressure, press [STORE]  
to save your setting. The range of adjustment for this function is  
zero psig to 66% of F.S.O.  
The difference between the SCLO setting and the SCHI setting  
NOTE  
must be at least 33% of F.S.O.  
Scale High (SCHI)  
To adjust the pressure, at which the output equals 20 mA, use the  
[UP/DOWN ARROW] keys until SCHI is displayed. Use the  
[SELECT] key to enter the submenu. Use the [SELECT] key to  
move from digit to digit and use the [UP/DOWN ARROW] keys  
to adjust each digit. Once you have set the pressure that should  
equal 20 mA output, press the [STORE] key to save your setting.  
The range of adjustment for this function is 33% F.S.O to 100%  
of F.S.O.  
The difference between the SCLO setting and the SCHI setting  
NOTE  
must be at least 33% of F.S.O.  
Page 27 801P5 Smart SwitchTM  
 
Page 28 Installation and Operation Manual  
 
CHAPTER  
5  
TROUBLESHOOTING  
It is unlikely that you’ll have any problems with the  
Smart-SwitchTM. However, just in case, this chapter contains  
information to help diagnose and correct any error messages you  
may see.  
ERROR MESSAGES  
Below are error messages that you may see during operation or  
programming, along with brief descriptions of how to correct  
them. If you see an error that is not listed here, contact Neo-Dyn  
Customer Service. The contact information is located in  
Chapter 1.  
Display Shows ---0  
The [MENU] key has been pressed and the unit has a password  
other than 0000. Use the [UP/DOWN ARROW] keys to set the  
first digit at the correct value. Use the [SELECT] key to move to  
the next digit. Repeat this process until the display shows the  
correct password. Press the [STORE] key to enter the  
programming menu.  
Page 29 801P5 Smart SwitchTM  
 
Display Shows EROR  
This message might appear while programming the 801P5  
Smart-SwitchTM. The meaning depends on what is being  
programmed. Following are the possible causes and solutions.  
Incorrect password entered  
You have entered an incorrect password. Re-enter the  
correct password. If you have lost or forgotten the password,  
contact Neo-Dyn Customer Service for assistance.  
Incompatible switch set points.  
You have entered incompatible set points. Switch 1 and  
Switch 2 are independent of each other; however, the  
following rules apply to each switch:  
The increasing set point must be at or below the Full Scale  
Output (F.S.O.) value; it cannot be less than 2% of F.S.O.,  
and it must be at least 1% of F.S.O. above the decreasing set point.  
The decreasing set point must be no lower than 1% of  
F.S.O.; it can be no higher than 99% of F.S.O.; and it must  
be at least 1% of F.S.O. below the increasing set point.  
The minimum deadband is 1% of F.S.O.  
Re-enter the set points to conform to the requirements.  
Page 30 Installation and Operation Manual  
 
Pressure Calibration (PCAL) or Analog Output  
Calibration (4Cal) is incorrect.  
If you change the value for pressure or analog output  
calibration more than 4% of the F.S.O. from the original  
factory values, this error occurs. Contact Neo-Dyn Customer  
Service for assistance.  
If the power to the unit is turned off and then back on, the unit  
will function using the new values. However, this is not  
recommended, as a calibration error this large indicates imminent  
component failure.  
NOTE  
Display shows HHHH  
This indicates that the unit is online and monitoring pressure, but  
the pressure is at or greater than 110% of F.S.O. When the  
pressure returns to less than 110% of F.S.O., the display will  
return to its normal pressure display.  
Display shows LLLL  
This indicates that the unit is online and monitoring pressure, but  
the pressure is less than 4% of the F.S.O. below zero psig (pulling  
a vacuum). When the pressure returns to greater than 4% of the  
F.S.O. below zero psig, the display will return to its normal  
pressure display.  
An unlikely possibility is that the pressure transducer's connector  
has been dislodged from the internal circuit card. Check to insure  
that the transducer connector is indeed connected. Contact  
Neo-Dyn Customer Service for assistance.  
NOTE  
Page 31 801P5 Smart SwitchTM  
 
Display alternates between OPEN and LOOP and the  
pressure reading  
The OPEN LOOP message is displayed with the V option  
(4-20 mA analog output) in the following circumstances:  
The analog loop is turned on, but nothing is connected to the  
analog output connector. In this case, press the [MENU] key  
to enter the programming mode. Use the [UP/DOWN  
ARROW] keys to set this option to OFF. Press the [STORE]  
key to temporarily save the change. Press the [RUN] key,  
followed by the [SELECT] key to save the change  
permanently and return on-line.  
The analog loop is turned on and connected, but the  
connection has been broken. In this case, repair the broken  
connection, or turn the loop off using the method described  
in the previous paragraph.  
Load resistance exceeds 600 ohms. In this case, reduce the  
resistance.  
Display is blank  
Press the [S1 INCR] key. If the display illuminates and displays  
the increasing set point for Switch 1, then the Disp display update  
option has been set to OFF.  
If the display does not react, there has been an internal component  
failure. Contact Neo-Dyn Customer Service for assistance.  
Display shows E-95  
This code indicates that the internal manufacturing data, which is  
saved in the nonvolatile RAM, has become corrupt.  
Power down the unit and then turn the power back on. If the unit  
continues to show E-95, contact Neo-Dyn Customer Service for  
assistance.  
Page 32 Installation and Operation Manual  
 
Display shows E-96  
This code indicates an internal A/D reading that is out of its  
allowable tolerance. Although this can indicate an internal  
component failure, the most common cause of this error is  
vacuum applied to the pressure port of the unit. If the cause is  
vacuum, once the pressure returns to near zero, the unit will return  
to monitoring and controlling. If the cause is internal component  
failure, contact Neo-Dyn Customer Service for assistance.  
Display shows E-97  
This error indicates that the internal user data, saved in the  
nonvolatile RAM, has become corrupt. Press the [SELECT] key to  
cause the unit to reboot. If the unit continues to show E-97,  
contact Neo-Dyn Customer Service for assistance.  
Page 33 801P5 Smart SwitchTM  
 
Page 34 Installation and Operation Manual  
 
CHAPTER  
6  
SERIAL COMMUNICATIONS  
(Z Option)  
GENERAL  
The Smart SwitchTM with the Z Option installed is capable of  
RS232 communications with an IBM compatible computer. This  
option includes Windows 3.x / 95 / 98 / Me / 2000 compatible  
software, which allows remote monitoring and programming of  
the Smart Switch, as well as data tracking functions.  
To install the software, follow the Setup instructions on the  
diskette label. Once it is installed, the Help menu provides  
detailed operating instructions.  
The default BAUD rate is 9600, but it may be set to 2400 BAUD  
for noisy environments.  
WIRING  
Smart Switch  
Connector (Pin)  
Function  
DB9 Connection  
(Pin)  
DB25  
Connection  
(Pin)  
A
B
Transmit  
Receive  
2
3
3
2
Page 35 801P5 Smart SwitchTM  
 
Page 36 Installation and Operation Manual  
 
CHAPTER  
7  
SPECIFICATIONS  
This section shows the standard specifications and available  
options for the Neo-Dyn® 801P5 Smart-SwitchTM  
.
STANDARD  
Interface  
The Smart-SwitchTM weighs approximately 6 pounds (2.7 kg).  
½” - 14 NPT Conduit Connection with 22 AWG Free Leads  
¼” - 18 NPT Female Pressure Port  
Two independent Solid State or Relay Switches  
Temperature Range  
Operating:  
Storage:  
-15°F (-26°C) to +140°F (+60°C)  
-30°F (-34°C) to +170°F (+72°C)  
Input power  
115 VAC, 50/60 Hz  
230 VAC, 50/60 Hz  
18-30 VDC  
Page 37 801P5 Smart SwitchTM  
 
Part Number  
The part number contains information about which configurations  
and options are included in your Smart-SwitchTM. To determine  
the pressure range, electrical rating, and options, compare the part  
number of your unit with the information below.  
801P 5  
##  
X
X
X
Model Series  
Wetted Material  
Range Number  
Input Power  
Switch Type  
Options  
Figure 10 Part Number Breakdown  
Pressure Rating Information  
Range Operating IncreasingDeadband Minimum  
Max  
DecreasingOperating Pressure  
Percent of Setpoint Pressure  
Proof  
No. Range  
Range  
psig  
psig Full Scale psig  
psig  
12.5  
37.5  
75  
psig  
02  
04  
05  
07  
09  
11  
0 - 5  
0 - 15  
0 - 30  
.10 - 5  
.30 - 15  
.60 - 30  
1-99  
1-99  
1-99  
1-99  
1-99  
1-99  
.05  
.15  
.30  
1
25  
75  
150  
500  
750  
1500  
3000  
7500  
0 - 100 2 - 100  
0 - 250 5 - 250  
0 - 500 10 - 500  
250  
2.5  
5
625  
1250  
2500  
3000  
12 0 - 1000 20 - 1000 1-99  
14 0 - 3000 60 - 3000 1-99  
10  
30  
Page 38 Installation and Operation Manual  
 
Range Operating IncreasingDeadband Minimum  
Max  
DecreasingOperating Pressure  
Percent of Setpoint Pressure  
Proof  
No. Range  
Range  
bar  
bar  
Full Scale  
bar  
bar  
bar  
22  
0 - 350 7 - 350  
mB mB  
1-99  
3.5 mB  
0.86  
1.7  
24 0 - 1000 20 - 1000 1-99  
10 mB  
2.6  
5.1  
mB  
mB  
25  
27  
29  
31  
32  
34  
0 - 2  
0.04 - 2  
1-99  
0.02  
0.065  
0.17  
0.35  
0.65  
2
5.2  
17.2  
43.1  
103  
172  
206  
10.3  
34.4  
51.7  
103  
206  
344  
0 - 6.5 0.013 - 6.5 1-99  
0 - 17 0.34 - 17  
1-99  
1-99  
1-99  
1-99  
0 - 35  
0 - 65  
0.7 - 35  
1.3 - 65  
0 - 200 4 - 200  
Range Operating Increasing Deadband Minimum  
Max  
Proof  
No.  
Range  
Range  
Decreasing Operating Pressure  
Percent of Setpoint Pressure  
inH2O  
inH2O FullScale inH2O  
psig  
12.5  
37.5  
psig  
72  
74  
0 - 100 2 - 100  
0 - 415 8.3 - 415  
1-99  
1-99  
1
25  
4.15  
75  
Total Accuracy  
± 0.2% F.S.O., including linearity, hysteresis, repeatability, and  
temperature  
Page 39 801P5 Smart SwitchTM  
 
Standard Electrical Ratings are:  
Electrical Rating Code  
Input Power  
A
E
90 - 130 VAC 50/60 Hz  
180 - 260 VAC 50/60 Hz  
18 - 30 VDC  
D
The Switch Types are:  
Switch Code Switch Type Switch Rating LeakageCurrent  
A
D
R
Solid State  
SPDT  
12-140 VAC  
3 Amp Resistive  
5 mA max  
1 mA max  
N/A  
Solid State  
SPDT  
5-60 VDC  
3 Amp Resistive  
Relay SPDT  
115 VAC  
24 VDC  
3 Amp Resistive  
OPTIONS  
The 801P5 options are listed below. You can combine these  
options, but every option ordered should be indicated in the part  
number of the unit.  
Option  
Description  
7/16"-20 SAE Pressure Port  
Scalable Readout  
E
Q
V
Z
Analog Output, 4 - 20 mA  
RS232 Communications  
Page 40 Installation and Operation Manual  
 
WARRANTY INFORMATION  
A. Warranty:  
ITT Industries (ITT) warrants that at the time of shipment, the  
products manufactured by ITT Neo-Dyn and sold hereunder, will  
be free from defects in material and workmanship and will  
conform to the specifications furnished or approved by ITT.  
B. Warranty Adjustment:  
If any defect within this warranty appears, the Buyer shall notify  
ITT immediately.  
ITT agrees to repair or furnish a replacement for, but not install,  
any product which, within one (1) year from the date of shipment  
by ITT shall, upon test and examination by ITT, prove defective  
within the above warranty.  
No product will be accepted for return or replacement without the  
written authorization of ITT. Upon such authorization, and in  
accordance with instructions by ITT, the product will be returned  
with shipping charges prepaid by the Buyer. Replacements made  
under this warranty will be shipped prepaid.  
C. Exclusion from Warranty:  
THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES  
ALL OTHER EXPRESSED OR IMPLIED WARRANTIES OF  
MERCHANTABILITY, OR FITNESS, OR OTHERWISE.  
Components manufactured by any supplier other than ITT shall  
bear only the warranty made by the manufacturer of that product,  
and ITT assumes no responsibility for the performance or  
reliability of the unit as a whole.  
“In no event shall ITT be liable for indirect, incidental or  
consequential damages nor shall the liability of ITT arising in  
connection with any products sold hereunder (whether such  
liability arises from a claim based on contract, warranty, tort or  
otherwise) exceed the actual amount paid by Buyer to ITT for the  
products delivered hereunder.”  
The warranty does not extend to any product manufactured by  
ITT which has been subject to misuse, neglect, accident, improper  
installation, or to use in violation of instructions furnished by ITT.  
The warranty does not extend to or apply to any unit which has  
been repaired or altered at any place other than at ITT’s factory or  
service locations, by persons not expressly approved by ITT.  
801P5 Smart SwitchPage 41  
 

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