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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: info@karldungsusa.com

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.

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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

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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