Bulletin P-616W-1

Series 616W Differential Pressure Transmitter

®

Specifications - Installation and Operating Instructions

3-1/8
[79.38] Ø3/16 [4.76]
MOUNTING HOLES
1-1/4 TYP 4 PLACES
[31.75]
4-1/2
[114.30]
4-17/32
[115.09]
5-1/8 1-5/16 [33.32] TYP
[130.18] 7/16 OR 5/8
[11.13 OR 15.88]
TYP
1/8 AND 3/16
[3.18 AND 4.76]
I.D. TUBING 3-1/8
1-3/16 [79.38]
1-1/4 3/4 [19.05] TYP
[30.18] [31.75]
2-1/8
3-3/4 [95.25] [53.98]

The Series 616W Differential Pressure Transmitter senses the pressure of air and SPECIFICATIONS
non-combustible, compatible gases and sends a standard 4-20 mA or selectable 0 to Service: Air and non-combustible, compatible gases.
5/0 to 10 VDC output signal. All models, including those featuring an LCD, are factory Wetted Materials: Consult factory.
calibrated to specific ranges. Positive, negative, and differential pressures can be Accuracy: 0.25% FS @ 77°F (25°C), display accuracy ±0.5%.
measured within a full-scale accuracy of ±0.25%. This weatherproof unit is enclosed in Thermal Effect: ±0.02% FS/°F (±0.036% FS/°C).
a polycarbonate case, rated NEMA 4X (IP66). The span and zero controls are for use Stability: ±1% FS/yr.
when checking calibration, and are not intended for re-ranging. Temperature Limits: -4 to 158°F (-20 to 70°C).
Pressure Limits: See chart.
Power Requirements: 10-36 VDC (2-wire), 17-36 VDC, or isolated 21.6-33 VAC
(3-wire).
Output Signal: 4-20 mA (2-wire), 0-5 VDC, or 0-10 VDC (3-wire).
Zero and Span Adjustments: Digital push-button.
MODEL CHART Response Time: Instantaneous (default) or 3 s (selectable).
Model Range Max. Pressure Digital Display Loop Resistance: Current output: 0-1250 Ω max.; Voltage output: Min. load
616W-2 0 to 6 in w.c. 4.5 psig – resistance 1 kΩ.
616W-3 0 to 10 in w.c. 4.5 psig – Current Consumption: 21 mA max. continuous.
616W-4 0 to 20 in w.c. 6 psig – Electrical Connections: 4-wire removable European style terminal block for 16 to
616W-5 0 to 40 in w.c. 25 psig – 26 AWG.
616W-6 0 to 100 in w.c. 25 psig – Process Connections: Barbed, dual size to fit 1/8˝ and 3/16˝ (3.12 and 4.76 mm)
616W-2-LCD 0 to 6 in w.c. 4.5 psig 0 to 6.00 I.D. rubber or vinyl tubing.
616W-3-LCD 0 to 10 in w.c. 4.5 psig 0 to 10.00 Enclosure Rating: NEMA 4X (IP66).
616W-4-LCD 0 to 20 in w.c. 6 psig 0 to 20.0 Mounting Orientation: Any orientation.
616W-5-LCD 0 to 40 in w.c. 25 psig 0 to 40.0 Weight: Without LCD: 8.9 oz (253 g); With LCD: 9.5 oz (269 g).
616W-6-LCD 0 to 100 in w.c. 25 psig 0 to 100.0 Compliance: CE.
616W-6B-LCD 3-0-3 in w.c. 3.6 psig -3.00-0-3.00
616W-10B-LCD 5-0-5 in w.c. 3.6 psig -5.00-0-5.00
616W-20B-LCD 10-0-10 in w.c. 4.5 psig -10.00-0-10.00
616W-2M-LCD 0 to 1.5 kPa 31.0 kPa 0 to 1.50
616W-3M-LCD 0 to 2.5 kPa 31.0 kPa 0 to 2.50
616W-4M-LCD 0 to 5 kPa 41.2 kPa 0 to 5.00
616W-5M-LCD 0 to 10 kPa 172.3 kPa 0 to 10.0

DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/872-9057 e-mail: info@dwyermail.com
INSTALLATION 3-Wire 0-10 V and 0-5 V Voltage Output
1. Location: Select a clean, dry mounting location free from excess vibration where
CAUTION DO NOT EXCEED SPECIFIED SUPPLY VOLTAGE RATINGS.
the temperature will remain between -4 to 158°F (-20 to 70°C). Distance from the
PERMANENT DAMAGE NOT COVERED BY WARRANTY WILL
receiver is limited only by total loop resistance. See Electrical Connections below.
RESULT.
The tubing supplying pressure to the instrument can be practically any length
required, but long lengths will increase response time slightly. The terminal block is removable and each of the terminals are labeled next to the
terminal block on the circuit board. Positive polarity is indicated by VOUT. AC/DC
2. Position: A vertical position, with the pressure connection pointing down, is selection is made via the terminal block. If the polarity of the transmitter is inadvertently
recommended. That is the position in which all standard models are spanned and reversed, the unit will not function properly, but no damage will be done to the
zeroed at the factory. They can be used at other angles, but final spanning and transmitter.
zeroing must be done while the transmitter is in that alternate position.
Selection of using a DC or AC power supply is made via the terminal block.
3. Pressure Connections: Two integral barbed tubing connections are provided. See Figure 2 for DC Wiring.
They are dual-sized to fit both 1/8˝ and 3/16˝ (3.12 and 4.76 mm) I.D. tubing. Be See Figure 3 for AC Wiring.
sure the pressure rating of the tubing exceeds that of the operating range. On
ranges over 20 psi, we recommend use of a suitable hose clamp to assure the

VOUT
COM
VDC
VAC
integrity of the connection.

ELECTRICAL CONNECTIONS
The 616W transmitter utilizes a 2-wire 4-20 mA Current Output, or a 3-wire 0-5 V
/ 0-10 V Voltage Output. It is also capable of Simultaneous Current and Voltage
Output. The power and signals interconnect via a removable European-style four
conductor terminal block, or optionally, via the included tooless terminal block.

NOTICE If equipped, the LCD must be removed before wiring. Pull the LCD
directly away from the product to remove. Reinstall the LCD after
DC POWER VOLTAGE
wiring is completed. SUPPLY - - +
+ RECEIVER
17-36 VDC
2-Wire 4-20 mA Current Output

CAUTION DO NOT EXCEED SPECIFIED SUPPLY VOLTAGE RATINGS.

Figure 2: DC wiring
PERMANENT DAMAGE NOT COVERED BY WARRANTY WILL
RESULT. SIMULTANEOUS OUTPUTS ARE NOT DESIGNED FOR AC VOLTAGE
OPERATION.

VOUT
COM
VDC
VAC
The connections to the transmitter are made through terminals VDC and COM on
the terminal block as shown in Figure 1. The terminal block is removable and each
of the terminals are labeled next to the terminal block on the circuit board. Polarity is
indicated by VDC and COM. See Figure 1.
VOUT
COM
VDC
VAC

AC POWER VOLTAGE
SUPPLY - +
RECEIVER
21.6-33 VAC

Figure 3: AC wiring

The minimum receiver load is 1 kΩ. The resistance due to the wire should be low
DC POWER compared to the receiver load resistance. While the voltage at the terminal block
SUPPLY - - CURRENT +
+ RECEIVER remains unchanged with a 10 mA current flow, resistive losses in the wiring do cause
10-36 VDC
errors in the voltage delivered to the receiver. For a 1% accurate gage, the resistance
of the wires should be less than 0.1% of the value of the receiver load resistance. This
will keep the error caused by the current flow below 0.1%.
Figure 1
The output across VOUT and COM will be either 0-5 V, 0-10 V depending on the DIP
switch setting. See DIP Switch Settings Section for more information.
The maximum receiver load resistance (RL) for a given power supply voltage (Vps) is
defined by the formula:
Vps - 10.0
RL =
20 mA DC

Shielded 2-wire cable is recommended for control loop wiring. Ground the shield at the
power supply end only.

The receiver may be connected to either the negative or positive side of the loop,
whichever is most convenient. Should polarity of the transmitter or receiver be
inadvertently reversed, the loop will not function properly but no damage will be done
to the transmitter.

The maximum length of connecting wire between the transmitter and the receiver is
a function of wire size and receiver resistance. That portion of the total current loop
resistance represented by the resistance of the connecting wires themselves should
not exceed 10% of the receiver resistance. For extremely long runs (over 1,000 feet), it
is desirable to select receivers with lower resistances in order to keep the size and cost
of the connecting leads as low as possible. In installations where the connecting run
is no more than 100 feet, you can use a connecting lead wire as small as No. 22 ga.
3-Wire 0 to 10 V and 0 to 5 V Voltage Operation Power Supply
Simultaneous Current and Voltage Output Refer to the following tables for the required supply rating.

CAUTION DO NOT EXCEED SPECIFIED SUPPLY VOLTAGE RATINGS. Current Output

PERMANENT DAMAGE NOT COVERED BY WARRANTY WILL Supply Voltage 10-36 VDC
RESULT. SIMULTANEOUS OUTPUTS ARE NOT DESIGNED FOR AC VOLTAGE Loop Resistance 0-1250 Ω
OPERATION.
Voltage Output

VOUT
Supply Voltage 17-36 VDC

COM
VDC
VAC
21.6-33 VAC isolated
Minimum Output Load Resistance 1000 Ω

DIP SWITCH SETTINGS

DIP switch settings are marked directly on the PCBA as shown in Figure 5. Switches
are factory-set, based on the order configuration. You can also use a small screwdriver
+ CURRENT - or pen to change the position of the switches.
RECEIVER
NOTICE Figure 5 is a depiction of a 5 in w.c. pressure board. Other
pressure boards, while similar, will vary from the below.

WARNING There are no hazardous voltages if supplied power is within the

DC POWER VOLTAGE specified range. However, it is a good idea to shut control systems
+ SUPPLY - - +
RECEIVER down while changing DIP switches to prevent erratic control system behavior.
10-36 VDC

Figure 4: Simultaneous current and voltage output wiring

The terminal block is removable and each of the terminals is labeled underneath the
terminal block on the circuit board. Positive polarity is indicated by VOUT. The VDC
terminal and a DC power supply must be used for Simultaneous Current and Voltage
Output. The voltage output and the power supply must have separate wire leads
that are only joined at terminal 2 of the transmitter. Additional error may occur for the
voltage output if a single wire is used or if the wires are joined at the power supply or
receiver.

For the current output, the maximum allowable loop resistance (wiring + receiver
resistance) is dependent on the power supply. The maximum loop voltage drop must
not reduce the transmitter voltage below 17 V. The maximum loop resistance (RMAX)
for a given power supply voltage (VPS) can be calculated using the following equation:
Figure 5: 5 in w.c. pressure board
(VPS – 17.0)
RMAX =
20 mA DC
Key To DIP Switch Settings
The equation uses 17.0 instead of 10.0 as seen in the equation earlier with Figure DIP Switch 4 - Voltage Output Range
1. This represents the minimum voltage supply which is higher on the simultaneous Voltage output range can be either 0-10 V or 0-5 V depending on the position of DIP
output configuration due to the requirements of the voltage outputs. Switch 4.
• When the switch is in the OFF or down position, the output will be 0-10 V
Shielded 4-wire cable is recommended for control loop wiring. Ground the shield • When the switch is in the ON or up position, the output will be 0-5 V.
at the power supply end only. Should the polarity of the transmitter or receiver be
inadvertently reversed, the unit will not function properly, but no damage will be done DIP Switch 6 - Response Time Selection
to the transmitter. DIP Switch 6 toggles to select the desired response time.
• When the switch is in the OFF or down direction, the transmitter response time will
For voltage outputs, the minimum receiver load is 1 kΩ. The resistance due to the be instantaneous.
wire should be low compared to the receiver load resistance. While the voltage at the • When the switch is in the ON or up direction, the response time will be 3 seconds.
terminal block remains unchanged with a 10 mA current flow, resistive losses in the
NOTICE The remaining DIP switches are disabled.
wiring do cause errors in the voltage delivered to the receiver. For a 1% accurate gage,
the resistance of the wires should be less than 0.1% of the value of the receiver load
resistance. This will keep the error caused by the current flow below 0.1%.
CALIBRATION
There is a 3 second delay from the time the zero or span calibration buttons are
The output across VOUT and COM will be either 0-5 V or 0-10 V depending on the DIP
released until the time that the change in calibration takes place. This delay is used to
switch setting. See DIP Switch Settings Section for more information.
prevent stress related offsets on the lower ranges.

Zero Calibration
The zero calibration can be set by applying zero pressure to both of the pressure ports
and pressing the zero button for 3 seconds. If the LCD display is present, the display
will read ZERO and then sequence back to the home display.

Span Calibration

NOTICE For a positive span, apply pressure to the positive “+” port.

The span calibration function allows the pressure value to be adjusted so that the
currently applied pressure is the maximum configured pressure. This will in turn set
the maximum analog output at the set pressure. It is recommended that the ZERO
function be applied before performing a span. Apply the maximum desired pressure
to the device, press and hold span for 3 seconds. If the LCD display is present, SPAN
is displayed. The span function will be processed 3 seconds after the span button is
released.
LCD DISPLAY
The LCD comes with a housing cover, which contains a window. The display plugs
into the pins on top of the circuit board. The LCD is 180° rotatable so that it will read
properly if the device must be mounted with the connections facing up.

The following error messages will appear if an LCD is present and the device is an
error state.

LCD ERROR MESSAGES

Error Code Message
OVER The applied pressure is 3% greater than the selected output high
value causing an Over Range Error.
UNDR The applied pressure is 1% less than the selected output low value
causing an Under Range Error.
FAIL When the span button is pressed, the pressure value is out of the
range to allow a correct setting.
ER 1 The pressure applied to the sensor is beyond its ability to read.
ER 2 The pressure sensor is communicating but reporting an internal error.
ER 3 The pressure sensor is not communicating.
ER 4 The stored user settings are invalid.
ER 5 The stored factory settings are invalid.
ER 6 Non-volatile user memory has failed.
ER 7 Non-volatile factory memory has failed.

MAINTENANCE/REPAIR
Upon final installation of the Series 616W Differential Pressure Transmitter, no routine
maintenance is required. The Series 616W is not field serviceable and is not possible
to repair the unit. Field repair should not be attempted and may void warranty.

This symbol indicates waste electrical products should not be disposed

of with household waste. Please recycle where facilities exist. Check with
your Local Authority or retailer for recycling advice.

WARRANTY/RETURN
Refer to “Terms and Conditions of Sale” in our catalog and on our website. Contact
customer service to receive a Return Goods Authorization number before shipping the
product back for repair. Be sure to include a brief description of the problem plus any
additional application notes.

©Copyright 2022 Dwyer Instruments, Inc. Printed in U.S.A. 8/22 FR# 444343-50

DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/872-9057 e-mail: info@dwyermail.com