Installation, Operation & Maintenance Instructions IOM-GR-A : AUGUST 2016 Installation, Operation & Maintenance Instructions GR Series Models GR2, GR4 (Pressure Switches) Models GR3,

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IOM-GR-A : AUGUST 2016

Installation, Operation &

Maintenance Instructions

GR Series Models GR2, GR4 (Pressure Switches) Models GR3, GR6 (Differential Pressure Switches) Model GR7 (Temperature Switches)

General The unit is manufactured, checked and supplied in accordance with our published specification, and when installed and used in normal or prescribed applications, with the lid in place and within the parameters set for mechanical and electrical performance, will not cause danger or hazard to life or limb.

THE USERS ATTENTION IS DRAWN TO THE FACT THAT, WHEN THE UNIT IS ‘LIVE’ WITH RESPECT TO ELECTRICAL OR PRESSURE SUPPLIES, A HAZARD MAY EXIST IF THE UNIT IS OPENED OR DISMANTLED. UNITS MUST BE SELECTED AND INSTALLED BY SUITABLY TRAINED AND QUALIFIED PERSONNEL IN ACCORDANCE WITH APPROPRIATE CODES OF PRACTICE SO THAT THE POSSIBILITY OF FAILURE RESULTING IN INJURY OR DAMAGE CAUSED BY MISUSE OR MISAPPLICATION IS AVOIDED. THE MICROSWITCH ASSEMBLY WITH FACTORY SEALED LEADS HAS BEEN CAREFULLY POSITIONED AT THE FACTORY. ANY DISTURBANCE MAY RENDER THIS UNIT INOPERATIVE.

Operating principles Pressure Switch models GR2, GR4 and Differential Pressure Switch models GR3, GR6 are diaphragm operated switches. These diaphragms generate a force proportional to the applied pressure and are balanced by a user adjustable control spring. When the force exceeds that created by the control spring, the diaphragm moves causing a push rod to actuate a snap-acting micros-witch. Temperature model GR7 works in the same way as the Pressure models with the exception that the applied pressure comes from the expansion of a vapour enclosed in either a rigid stem or semi-rigid thermal system.

CERTIFICATIONS

Intrinsically Safe Models Intrinsically safe models carry the following label markings: This equipment may be used in zones 0, 1 & 2 with flammable gases and vapours with apparatus groups IIA, IIB & IIC and with temperature classes T1, T2, T3, T4, T5 & T6. This equipment is only certified for use in ambient temperatures in the range –40°C to +60°C for T6 and –40°C to +85°C for T4 and should not be used outside this range. The certificate number has an ‘X’ suffix which indicates that special conditions of installation and use apply. Those installing or inspecting this equipment must have access to the contents of the certificate or these instructions. The conditions listed in the certificate are reproduced below:

THE APPARATUS MUST BE INSTALLED SUCH THAT THE RISK OF IMPACT OR ABRASION IS NEGLIGIBLE. THE PERMANENTLY ATTACHED LEADS MUST BE SUITABLY PROTECTED AGAINTS MECHANICAL DAMAGE AND TERMINATED IN A SUITABLE JUNCTION OR TERMINAL FACILITY WITH A MINIMUM DEGREE OF PROTECTION OF AT LEAST IP6X. THE INSTALLATION OF EXTERNAL CONNECTIONS TO MODELS OF THE APPARATUS WITH TERMINAL ENCLOSURES MUST BE CARRIED OUT USING APPROPRIATE CONDUIT OR CABLE GLAND WITH A DEGREE OF PROTECTION OF AT LEAST IP6X, COMPONENT CERTIFIED BY AN EU APPROVED CERTIFICATION BODY.

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Flameproof Models Flameproof models carry the following label markings: This equipment may be used in zones 1 & 2 with flammable gases and vapours with apparatus groups IIA, IIB & IIC for temperatures classes T1, T2, T3, T4, T5 & T6. This equipment is only certified for use in ambient temperatures in the range –40°C to +60°C for T6 and –40°C to +85°C for T4 and should not be used outside this range. The certificate number has an ‘X’ suffix which indicates that special conditions of installation and use apply. Those installing or inspecting this equipment must have access to the contents of the certificate or these instructions. The conditions listed in the certificate are reproduced below:

THE PERMANENTLY ATTACHED LEADS MUST BE SUITABLY PROTECTED AGAINTS MECHANICAL DAMAGE AND TERMINATED IN A SUITABLE JUNCTION OR TERMINAL FACILITY.

Models with Junction Boxes Junction boxes with Exe approval carry the following label markings: This equipment is only certified for use in ambient temperatures in the range –20°C to +40°C for T6 and should not be used outside this range.

Option include:

Code ‘C’: see Fig 1

Code ‘D’: same dimensions as code ‘C’ but Exe approved for use in Zone 1.

Code ‘V’ and ‘W’ same dimensions as code ‘C’ but Exia approved for use in Zone 0.

Code ‘J’ :see Fig 2. Exe approved for use in Zone 1.

Note: When weatherproof junction box code ‘C’ is fitted the unit must not be used in hazardous areas unless the circuit or system to which it is connected is Intrinsically Safe.

INSTALLATION

Mounting (All models) The instruments are designed to be mounted vertically with the process connection underneath. However, mounting up to 45° from the vertical in any plane is acceptable, although a small calibration shift may occur. They can be mounted either direct to process, or to a wall or panel using the back plate provided. Select the mounting point so as to avoid stresses, excessive shock, vibration or temperature fluctuation being imparted to the switch during operation. Instruments should be mounted to avoid excessive heat transfer from the process lines or adjacent plant. To avoid undue stresses being imparted to the instrument when wall/panel mounted, it is recommended that a short length of flexible line be installed between the instrument and process line. If sudden changes of pressure (pulsations) are likely then we recommend that snubbers are fitted between the process line and instrument.

ALWAYS HOLD A WRENCH ON THE PRESSURE ENTRY HEX WHEN MAKING PRESSURE CONNECTION TO THE SWITCH. DO NO TIGHTEN BY TURNING THE ENCLOSURE.

CHECK THE CONNECTION THREAD SIZE AND SPECIFICATION ON THE UNIT TO AVOID MIS-MATCHING WITH THE PROCESS CONNECTION ADAPTOR. SEE DIGIT 11 OF PRODUCT CODE.

Mounting (Model GR7- Rigid Stem) Assemble the unit via a thermowell, using the spanner facility provided and ensuring that: a) the sensing bulb is fully immersed in the process temperature b) the sensing bulb does not bottom out in the thermowell which could cause damage

Mounting (Model GR7 - Capillary system) Mount the sensing bulb so that the capillary end is above the bulb and the bulb is level with, or no more than 250mm below the base of the instrument. The stem is fitted with a sliding compression gland to accommodate different thermowells.

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Junction Boxes Various optional junction boxes can be provided and are defined by the 5th character of the model code.

Installation of electrical adaptors and ca-ble glands to the electrical entry - when Junction Box is fitted The standard entry is a single 1/2” NPT - M thread. Other non-ISO and tapered threads will have their size and type stamped on the enclosure next to the entry.

TAKE CARE TO SELECT AND INSTALL ADAPTORS THAT DO NOT REDUCE THE ENCLOSURE’S DEGREE OF PROTEC-TION WHEN IN USE IN ZONE 1 HAZARD-OUS AREAS.

IT IS A SAFETY REQUIREMENT THAT AT LEAST 5 FULL THREADS ARE ENGAGED BETWEEN THE ADAPTER, CABLE GLAND OR STOPPING PLUG, AND THE ELECTRICAL ENTRY WHEN THE UNIT IS IN OPERATION. NEVER OPERATE THE UNIT UNLESS THIS CONDITION IS MET.

Wiring

DISCONNECT ALL SUPPLY CIRCUITS BEFORE WIRING DO NOT EXCEED ELECTRICAL RATINGS STATED IN LITERATURE AND ON NAME-PLATES. THE LEADS ARE FACTORY SEALED SO IT IS UNNECESSARY TO SEAL THE CON-DUIT TO THE CONDUIT NIPPLE. HOWEV-ER, THE LEADS MUST BE SUITABLY PROTECTED AGAINST MECHANICAL DAMAGE AND TERMINATED IN A SUITA-BLE JUNCTION BOX OR TERMINAL FA-CILITY IN ACCORDANCE WITH LOCAL AND NATIONAL CODES. EACH CON-DUCTOR IS PROVIDED WITH AN IDENTI-TY TAG. IF THESE BECOME DETACHED REFER TO THE COLOUR CODE IN THE WIRING DIAGRAM (FIG 3). IF THE EQUIPMENT IS LIKELY TO COME INTO CONTACT WITH AGGRESSIVE SUBSTANCES, E.G. ACIDIC LIQUIDS OR GASES THAT MAY ATTACK METALS OR SOLVENTS THAT MAY AFFECT POLY-MER MATERIALS, THEN IT IS THE RE-SPONSIBILITY OF THE USER TO TAKE SUITABLE PRECAUTIONS THAT PRE-VENT IT FROM BEING ADVERSELY AF-FECTED THUS ENSURING THAT THE TYPE OF PROTECTION IS NOT COM-PROMISED.

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Fig 3

Fig 2

Fig 1

JUNCTION BOX

CODES ‘C’ & ‘D’

4 MOUNTING HOLES 4.5 mm DIA SUITABLE FOR M4 SCREWS MAX HEAD DIA 7.5 mm

CONDUIT ENTRY M20 x 1.5

20

0.7

9

15.0

0.5

9

45.0

1.7

7

17

1.0

6.7

3



Wiring - when Junction Box is fitted (See Fig. 4) Some models may be provided with an integral weatherproof or Ex junction box.

WIRE IN ACCORDANCE WITH LOCAL AND NATIONAL CODES. USE CABLES NO LARGER THAN 2.5 MM² (14 AWG)

Insert bare wires fully into the terminal block and tighten securely. Keep wiring tails to a minimum.

End of line resistors Some products may be supplied to order fitted with end of line resistors. Resistors in use may generate a heat source. The type, quantity, configuration, fitment method and allowable electrical loads are limited by the scope of the certification.

NEVER FIT END OF LINE RESISTORS OR MODIFY WITHOUT REFERENCE TO DELTA CONTROLS

Replacing cover on Flameproof enclosures Before connecting to electrical power, screw on cover hand tight making sure that mating surfaces of the lid and enclosure are in contact. Use the locking screws provided to prevent casual and unauthorised removal of the cover.

DO NOT USE GREASES OR

LUBRICANTS NOT COMPATIBLE WITH

THE ENVIROMENT, PROCESS OR

ALUMINIUM.

IT IS A SAFETY REQUIREMENT THAT AT

LEAST 5 FULL THREADS ARE ENGAGED

BETWEEN THE COVER / LID AND THE

ENCLOSURE WHEN THE UNIT IS IN

OPERATION. NEVER OPERATE THE

UNIT UNLESS THIS CONDITION IS MET.

OPERATION

Adjustments Pressure and Temperature Switches are supplied calibrated at the midpoint of their range and to a falling pressure or temperature unless otherwise specified.

Set point adjustments (All Models): (See Fig. 5) 1. Isolate the instrument from process and power

(Adjustment may be carried out with the unit live) 2. Loosen both cover screws 3. Rotate cover anti-clockwise to allow access. 4. Using a screwdriver, rotate the range adjuster to

obtain the desire setting. Turn right to left to increase the setting. An appropriate setting is shown by pointer against reference scale.

5. Rotate cover clockwise to close and tighten screws.

As a guide, one complete revolution of the adjuster will alter the set point by approximately 15% of the range.

Note: For accurate setting of Pressure and Differential Pressure models, a suitable pressure gauge must be used in conjunction with the above procedure. Do not attempt to set the switch outside the scale limits. For Temperature models a suitable calibrated temperature source should be used. Though the unit may be set anywhere within its range, for optimum performance, it is good practice to have a set point value between 25% and 75% of span.

Process configurations (Models GR3, GR6 - other than range BC) For normal pressure difference operation, the connections are made to the High Pressure (HP) and Low Pressure (LP) ports as appropriate. For single-ended positive pressure operation, the HP only is used and the LP is left open to atmosphere. The single-ended negative pressure operation, the LP only is used and the HP is left open to atmosphere. Use a breather / filter in the vacant port of single-ended operation.

SCREW DRIVER LOCATION SLOTS LOWEST SET POINT HIGHEST SET POINT ADJUST RIGHT TO LEFT TO INCREASE SET POINT

Fig 3

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Fig 5

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NC

COM

NO

NC

COM

NO

EARTH SCREW TERMINAL BLOCK

NORMAL R H

ELECTRICAL ENTRY

Fig 2 Fig 4



Compound range eg –12.5 to +12.5 mbar (Models GR3, GR6 - range BC) For normal operation, negative pressure may be applied to the LP port, whereby the HP port is left open to atmosphere and the set point is between 0 and +12.5 mbar. For reverse operation, negative pressure may be applied to the HP port, whereby the LP port is left open to atmosphere and the set point is between 0 and –12.5 mbar. For positive pressures, the opposite applies. It is recommended that the minimum setting is to be not less than 5% of FS either side approaching zero.

MAINTENANCE Inspections should be carried out at quarterly to yearly intervals depending upon operating conditions. Where a terminal enclosure is fitted, isolate the unit from process and power and remove the lid. Check all terminals for tightness. Check that cable tails are not fouled or chafed. Check for internal condensation. Rectify as necessary. It is recommended that instruments used to provide an alarm are operated periodically to ensure they are functioning correctly. If further maintenance is required, seek advice from DELTA CONTROLS before attempting repair or replacement of parts. Should the diaphragm fail the process will vent to atmosphere via a control orifice without pressurising the switch enclosure. Periodically ensure the vent area does not become blocked and vent plug has not degraded. Ensure that the vent area is not obstructed.

THE EQUIPMENT CONTAINS NO

USERREPLACEABLE PARTS AND IS NOT

INTENDED TO BE REPAIRED BY THE

USER. REPAIR OF THE EQUIPMENT IS

TO BE CARRIED OUT BY THE

MANUFACTURER, OR THEIR APPROVED

AGENTS, IN ACCORDANCE WITH THE

APPLICABLE CODE OF PRACTICE.

ELECTRICAL ISOLATION—THESE

PRODUCTS ARE NOT SUITABLE FOR

ELECTRICAL ISOLATION. ALWAYS

ISOLATE CIRCUIT TO CARRY OUT ANY

ELECTRICAL WORK.

REPLACEMENT PARTS: Use only factory authorised parts and the fitting instructions that are supplied.



DIMENSIONS

Enclosures Styles

Sensors

4.3

7

111.0

'A' A

PP

RO

X

FLYING LEADS CODE ‘A’

½” NPT

GROUND SCREW ‘H’

OR ‘R’

MOUNTING HOLES FOR M5 SCREWS

VENTING DEVICE (WHEN FITTED) ‘H’

OR ‘R’

PROCESS CONNECTOR

UNITS DIM ‘A’

½”NPT MALE INCHES 1.85

MM 47

OTHERS INCHES 1.46

MM 37

JUNCTION BOX

CODES ‘C’ & ‘D’

4 MOUNTING HOLES 4.5 mm DIA SUITABLE FOR M4 SCREWS MAX HEAD DIA 7.5 mm

CONDUIT ENTRY M20 x 1.5

20

0.7

9

15.0

0.5

9

45.0

1.7

7

17

1.0

6.7

3

Installation, Operation & Maintenance Instructions IOM-GR-A : AUGUST 2016 Installation, Operation & Maintenance Instructions GR Series Models GR2, GR4 (Pressure Switches) Models GR3,

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