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Karl Dungs, Inc3890 Pheasant Ridge Dr. NE, Suite 150, Blaine, MN 55449 U.S.A.
Phone: (763) 582-1700 Fax: (763) 582-1799 E-mail: [email protected]
Enclosure Rating NEMA Type 4Maximum Operating Pressure 7 PSI (500 mbar) Ambient / Fluid Temperature Versions -2, -3, -5, & -6; -40°F to +140°F; (-40°C to +60°C) Version -8; -20°F to +140°F; (-30°C to +60°C) Materials in contact with Gas Housing: aluminum & steel; Diaphragm: NBR-based rubberApprovals UL Listed: File #. MH 16628 CSA Certified: File # 201527 FM Approved: Report J.I. 1Y9A9.AF CommonwealthofMassachusettsApprovedProductApprovalcodeG3-0106-191
GAO-A2,GMH-A2,andGML-A2GasPressureSwitchInstallationInstructions
SPECIFICATIONSHigh/low ventless gas pressure switch (SPDT) with automatic or manual reset. Includes visual indication of switch position. Mounts directly to various ports on the SV, DMV and MB series valves and FRI series regulators.
Gxx
_A2
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Gases Dry, natural gas, propane, butane; other noncorrosive gases. Suitableforupto0.1%byvolume,dryH2S. A “dry” gas has a dew point lower than +15 °F and its relative humidity is less than 60 %.Switch action GAO: high/low limit, NC breaks on rise, automatic reset GMH: high limit, NC breaks on rise, manual reset GML: low limit, NO breaks on fall, manual resetSwitch Type and Contact Rating SPDT; 10 A res., 8 FLA, 48 LRA @120 Vac; 1A @ 12-48Vdc.Vent Limiter IncorporatesaventlimiterasperUL353andlimitstheescapeofgaslessthan1.0CFHofnaturalgasat7PSIifinternalswitchdiaphragmrupture.Electrical Connection 1/2” NPT conduit connection via screw terminals
ATTENTION•Readtheseinstructionscarefully.•Failuretofollowthemand/orimproperinstallationmaycauseexplosion,propertydamageandinjuries.•Installationmustbedonewiththesupervisionofalicensedburnertechnician.•Checktheratingsinthespecificationstomakesurethattheyaresuitableforyourapplication.•Neverperformworkifgaspressureorpowerisapplied,orinthepresenceofanopenflame.•Ensurethattheswitchisnotsubjectedtovibrationduringoperation.
•Onceinstalled,performacompletecheckoutincluding leak testing.•Labelallwirespriortodisconnectionwhenservicing.Wiringerrorscancauseimproperanddangerousoperation•Verifyproperoperationafterservicing.•Thesystemmustbeinstalled,used,andmaintanedtomeetallapplicablenationalandlocalcoderequirementssuchasbutnotlimitedtoNFPA85,NFPA86,UL795,CSD-1,ANSIZ83.4,ANSIZ83.18,ANSIZ21.13,andCSAB149.3.
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MOUNTING
WiringProcedureRemovetheclearcoverfromtheswitch.•Use14or16AWGwireratedforatleast75°C•Routethewiresthroughtheconduitconnector.•Installaconduitplugatsomepointintheconduitrun•betweentheswitchandclosestpanelthatcontainsswitchingcontactsorothersparkingdevices(seeNFPA86requirementsaboutpotentialrisksofgasleakingdownconduit).Connectthewiringtotheappropriatescrewterminals.•
CAUTION:Allwiringmustcomplywithlocalelec-trical codes, ordinances and regulations.
WIRING
CAUTION:Donotexceedtheswitchratingsgiveninthespecificationsandontheswitch.
RecommendedMountingProcedureRemovetheclearcoveroftheswitchinordertore-•movethethreadformingsocketheadscrews.VerifythattheO-ringandthegroove,inwhichtheO-•oringisplaced,arecleanandfreeofnotchesorburrs.PlacetheO-ringintothegrooveonthebackofthe•pressureswitch.Thisislocatedontheflatesideofthealuminum housing.Usinga3mmhexwrench,removetheG1/8plugfrom•theportonwhichtheswitchistobemounted.Thiswillbeeitheraflange,thesideoftheFRIregulator,oraG1/8portofDungssafetyshutoffvalve.Mounttheswitchontotheportusingthethread-form-•ingsocketheadscrews.TheO-ringcanslideduringthemountingprocess,so•itisrecommendedthatastheswitchispressedontotheport,visuallyverifythattheO-ringremainsinthegroove.Tightenthescrewsbutdonotexceed22lb-in.Perform•aleaktesttoverifythatnoleakageoccursaroundtheo-ring.
GAOLoworHighGasSwitch(Operatingstateshownasahighlimit). Aspressurerisesabovesetpoint,1NCopens,2NOcloses,NeonlightON (fault). As pressure falls below set point, switch resets: 1 NC closesand2NOopens.
GMH High Gas Switch (Operating state shown) As pressure rises abovesetpoint,2NOcloses,1NCopens,andNeonlightON(fault),switchtripsandlocksout.
GMLLowGasSwitch(Operatingstateshown)Aspressurefallsabovesetpoint,2NOopens,1NCcloses,NeonlightON(fault),switchtripsandlocksout.
Wiringterminalillustration
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AnnuallychecktheswitchforproperoperationSetPointCalibrationThesetpointdialoftheGAOandGMHisfactorycalibrat-edwithincreasingpressure(GML:decreasingpressure).Duetohysteresis,theGAOswitchwillactuateataslightlylowerpointasthepressuredecreases.AdjustingtheSetPoint•Removetheclearcoverfromtheswitch.•Turnthedialuntilthedesiredtrippressureisoppositethewhitearrow(mark)ontheyellowdialface.•Afteradjustingthesetpointfornormaloperationchecktoseethatthegaspressureswitchoperatesasintended.•Useanaccuratepressuregaugeconnectedupstreamfromtheswitchtomeasuretheactualpressure.•Replacetheclearcover.
OPERATIONANDADJUSTMENTAutomaticResetTheNCcontactoftheGAObreakswhenpressurerisesabovethesetpoint.Itmakesautomaticallywhenpressurereturnstothenormaloperatinglevel.ManualResetTheNCcontactoftheGMHbreakswhenpressurerisesabovethesetpoint.TheNOcontactoftheGMLbreakswhenpressurefallsbelowthesetpoint.Neitheroftheswitcheswillreturntotheirformerpositionautomatically.Toreset,waituntilthepressurereturnstothenormaloperat-inglevel.Thenpressandreleasetheclearcoverovertheredresetbuttoninthecenteroftheyellowdialface;itisnotnecessarytoremovethecover.TheneonlightindicatesafaultconditionfortheGMLandGMHseriesandfortheGAOserieswhenusedasahighgaslimit.Theleadforthelightwiredtoterminal#2ontheGAOseriesshouldbewiredtoterminal#1whenusedasalowgaslimit.
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MAINTENANCEANDTESTINGAnnuallychecktheswitchforproperoperation
LowGasPressureSwitch:First,connectametercapableofreading+/-0ohmsto•theNOandCOMcontacts,andverifythattheNOandCOMcontactsaremade.Measuretheresistance,andiftheresistanceismorethan1ohm,removeswitchfromservice.ismorethan1ohm.(Seeterminalillustrationbelowforguidance).Then,verifythatthelowgaspressureswitchwillchange•statewhenalowgasconditionissensedbyconnect-ingametercapableorreading+/-0ohmstotheNCandCOMcontactsandthenbycausingtheswitchtogointoafaultcondition.Oncethefaultoccurs,Measurethe resistance, and if the resistance is more than 1 ohm, removeswitchfromservice.ismorethan1ohm.Tocausethefault,performoneofthetwoprocedures:•
Turnthepressureswitchsetpointcounterclockwise1. untiltheswitchtrips.Depressurizethevolumeofgasthelowgaspressure2. switchissensing.ForFRI/6regulators,thiscanbedonebyopeningthesidetapontheoppositivesideoftheFRI/6regulator.ForDMVandMBCsafetyshutoffvalves,thiscanbedoneopeningtheport1pressuretap.ForSVvalves,openport1oftheupstreamvalve.
Allowtheburnertogothroughastartupsequence,and•thenverifythattheburnerfaultsandisnotallowedtolightoff.Closealltesttaps(ports)andopenupstreamballvalve.•Whenfinished,closeallpressuretestpointsused,and•thenopentheupstreamballvalveSLOWLYtoallowgaspressuretograduallybleedintothesystem.
CAUTION:Openingtheupstreamballvalvetoofastcanpermanentlydamagetheregulator.
HighGasPressureSwitch:First,connectametercapableofreading+/-0ohmsto•theNCandCOMcontacts,andverifythattheNCandMeasure the resistance, and if the resistance is more than1ohm,removeswitchfromservice.ismorethan1ohm. Then,verifythatthehighgaspressureswitchwill•changestatewhenahighgasconditionissensedbyconnectingametercapableorreading+/-0ohmstotheNOandCOMcontactsandthenbycausingtheswitchtogointoafaultcondition.Tocausethefault,performoneofthetwoprocedures:•
Turnthepressureswitchsetpointclockwiseuntilthe1. switchtrips.Pressurizethevolumeofgasthehighgaspres-2. sureswitchissensing.Thiscanbedonebyclosingthedownstreamballvalve,openingport3taponaDMVandMBCsafetyshutoffvalves,orport2or3ofthedownstreamSVvalve,andthenusingapumptopressurizethetestchamber.
MeasuretheresistanceacrosstheNOandCOM•contacts.Iftheresistanceismorethan1ohm,removeswitchfromservice.Allowtheburnertogothroughastartupsequence,and•thenverifythattheburnerfaultsandisnotallowedtolightoff.Whenfinished,closealltesttaps(ports)andopenthe•dowmstreamballvalve.
NOTE:Aresistanceofmorethan1ohmindicatesthattheswitchcontactsarestartingtoeithercorrodeorcarbonize.
TerminalIllustration
Donotsimilatefaultconditionswhiletheburnerisfiring.
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LocationModelseriesGAO-A2-4,GMH-A2-4,andGML-A2-4canbemounteddirectlytovariousportsonaDUNGSvalve.Thepressureswitchshouldbemountedinlocationsmeetingtherequirementsoftheapplicablecode.Ordermountingkit214-975forDMVport3mountandMBCport3mounting,andkit225-047formountingswitchverticallyonavalveflange.
MOUNTINGTOSAFTYVALVES
2016 12 8
4
pBr
2
3
1 1
4 455
3
3
2
2
1
1
54
2016 12 8
4
pBr
A2mountingoptionsDMV701-703Dualmodularvalve
A2mountingoptionsSV1010,SV1012,SV1015,andSV1020seriessafetyvalve
Pressuretap
1 2 3 4 5
Mountingpossible? yesyesyesnoyes
A2mountingoptionsSV 1005 and SV 1007 series safetyvalve
Pressuretap 1 2 3 4 5
Mountingpossible? yesyesyes,with#214-975yes,horizontalyes,verticalwith#225-047yes,horizontalyes,verticalwith#225-047
Pressuretap
1 2 3 4
Mountingpossible? noyesnono
A2mountingoptionsMBCseriesmultifunctionalcontrol
Pressuretap
1 2 3 4 5
Mountingpossible?yesyesyes,with#214-975yes,horizontalyes,verticalwith#225-047yes,horizontalyes,verticalwith#225-047
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REPLACEMENTPARTS
Replacementcover(screwsnotincluded) Screwforreplacementcover
PG11-1/2”NPTconduitadapter
120VACneonlight
24VAC/VDClight(orange)
DINconnector(femaleplug)
MaleplugforDINconnector
Mountingscrewkit
M20-1/2”NPTAdapter
Port3adapter
Adapterwith1/4”NPTthreadedcon-nectionandpressuretapforverticallymountingpressureswitchonaSV,DMV,orMBCflange.
228-732(forGAOswitches)and233-113(forGMHandGMLswitches)
237-675
220-566
244-156 for orange 248-240 for green
244-157
210-318
219-659 (forGAOswitches)and227-644 (forGMHandGMLswitches)
226-188(includeso-ringandtwoM4threadformingscrews)
240-671
214-975(forMBC1000-4000seriesandDMV701-703series)
225-047
A2mountingoptionsFRIgaspressureregulator
Pressuretap
1 2 3
M o u n t i n gpossible?yesyesyes
MOUNTINGTOSAFTYVALVESorFRIREGULATORA2mountingoptionsDMV525,5040-5125/11dualmodularvalve
Pressuretap
1 2 3 4 5 6
Mountingpossible?yesyesyesyesnono