OPERATION AND MAINTENANCE INSTRUCTIONS FOR GM/GA/GK 200/300/020

PRESSURE / DIFFERENTIAL PRESSURE SWITCHES

SWITZER Pressure or Differential Pressure Switch is a 8. For outdoor installation, provide protection against
simple electro mechanical device operating on basic aggressiveness of very high or low temperature, air,
principles of Levers and opposing forces.Three essential dust, solar radiation, water penetration etc.
elements, various combinations of which form the basics 9. If process temperature is higher than the following
for presenting hundreds of variants to suit a variety of permissible maximum temperature it can be
industrial applications. They are : brought down by using longer pressure piping. Ask
1. Sensing element either of bellows or diaphragm factory for piping nomogram.
(metallic or elastomeric)
2. Stable spring to determine the range setpoint and Bellows operated Pressure Switch
110°C for PB , 170°C for SS
3. Snap-acting microswitch available in a wide variety.
Elastomer Diaphragm operated Pressure Switch
General 95°C for Neoprene , 110°C for Nitrile
The instrument is manufactured, checked and supplied 130°C for EPDM , 200°C for Silicone
in accordance with our published specification,and when
installed and used in normal or prescribed applications Elastomer Diaphragm operated DP Switch
with the lid in place and within the parameters set for 70°C for Nitrile
mechanical and electrical performance, will not cause Metallic Diaphragm operated Pressure & DP Switch
danger or hazard to life or limb. 70°C for SS
Health and safety warnings 10. For steam application use condenser coil or a syphon
a) Opening or dismantling when unit is live with respect 11. For air and gas application, use proper filters (dust
to ELECTRICAL OR PRESSURE will result in a hazard. collectors) to ensure that the process line is not
b) Units must be selected and installed by suitably trained clogged with accumulation of dust / foreign particles.
and qualified persons in accordance with appropriate 12. Ensure that suitable dampener / snubber is used
codes of practice to avoid failure resulting in injury or in rapidly fluctuating pressure to avoid chattering.
damage due to misuse or misapplications
13. Use a 3 or 5 way manifold for Differential pressure
Note: The instrument is calibrated within the claimed switch. Keep the equaliser valve open at startup.
accuracy with precision and skill. Therefore tampering
of adjustments of striker screw or any other component OPERATION
where there is red paint seal will lead to malfunctioning Pressure Switch : Models 201, 203, 281, 204, 208,
Storage 209 and 021 & 023
– Storage temperature –10°C to +60°C. Process pressure when applied to the sensing element
creates a force which overcomes that of a pre-tensioned
– In damp areas drying agents or heating is required
spring, and in turn moves a balancing arm to effect a
against formation of water condensation.
minimal movement that is required to actuate the
Transport microswitch (es).
– Transport temperature –10°C to +60°C Refer table below for sensing element type and material.
– Protect from external effects such as shock, vibration
and impact. Instru ment On-off
Sensor & Material
Handling prior to fitting Model D ifferential
– Remove the plastic cover / protective cap only just B ellow s
before the installation. 201 P hosphor B ronze / Fixed
– Protect against effects of weather 316L SS / Monel
– Check the connection thread size to avoid mismatch B ellow s
of pressure adaptor & pressure port. 203 P hosphor B ronze / A djustable
Mounting / Connections / Precautions 316L SS / Monel
1. Position gaskets / O ring correctly while the covers 281 B ellow s
are fixed. Cover mounting screws must be tight. (D ual P hosphor B ronze / Fixed
2. Properly seal the electrical entries and cables with S etpoint) 316L SS / Monel
correct cable gland, weatherproof or flameproof as 204
required. If in doubt, consult factory. Metallic D iap hragm
(High Static Fixed
316L SS / Monel / Hast'l C
3. Do not exceed stated maximum working pressure & P ressure)
maximum temperature. The sensing element will be Metallic D iap hragm
permanently damaged if exceeded EVEN ONCE. 208 Fixed
316L SS / Monel / Hast'l C
4. Connected electrical load should not exceed stated
209
maximum electrical capacity in BOTH Amps and volts. (Food Grade / Metallic D iap hragm
Fixed
5. Do not establish pressure connections by rotating Hygenic 316L S S
the housing. Hold hexagon of the sensor pressure Service)
connector with suitable spanner and tighten. 021
E lastomer D iaphragm
6. Flush the pipe system before fitting. Ensure that no (D raft &
Nitrile / EP D M / Neoprene Fixed
stress is produced and are sealed without leak. C ompound
/ Silicone
Ranges)
7. Mount the instrument firmly and rigidly either directly
on the pressure piping or on a vibration free wall, 023
E lastomer D iaphragm
panel or pipe stanchion. The instruments are for (D raft &
Nitrile / EP D M / Neoprene A djustable
vertical mounting. Any tilt may lead to set point shift. C ompound
/ Silicone
Ranges)

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Differential Pressure Switch : Models 301, 303, 381,
304, 384, 306, 386, 310, 313
When pressures from two different sources in a process
are connected across the sensing diaphragm, metallic
or elastomeric, the pressure difference creates force
which when overcomes that of a pre-tensioned spring,
moves a balancing arm to effect the minimal movement
required to actuate a microswitch(es).
High and low pressures are applied on either side of
the specially contoured diaphragm and this design feature
straight away eliminates the errors due to the difference
in area, a common problem present in twin element
pressure differential switches. In models 301/ 304, 303,
381/ 4, 306, 386 , a unique motion transfer assembly is
used, which is sensitive to minute movements of the
diaphragm but immune to the application of very high
static pressure. In models 310 & 313, the task of
transferring the resultant movement of the diaphragm is
achieved by employing an additional sealing diaphragm
above the low pressure chamber.
Refer table below for sensing element type and material.
In s tru m e n t
S e n s o r & M a te ria l
M odel D iffe re n tia l
Fixed ON-OFF Differential Models
a) Rotate the range adjustment screw clockwise to
increase the switching point. Rotating anti-clockwise
will decrease the switching point.
b) After setting, re-fix the locking device back in position
to prevent unauthorised adjustment of the setpoint.
c) The center screw and the striker screw are precisely
adjusted and factory-set using thread lock sealant.
Alteration of centre screw height will disturb the
contact established between the sensor and the
balance beam. Disturbance of stricker screw will
result in microswitch not acting or set-point shift.
Ref. Fig 1.
Range
Adjuster
O n -o ff

M e ta llic D ia p h ra g m
301 F i xe d Micro switch
316L SS

M e ta llic D ia p h ra g m
303 A d ju s ta b le
316L SS
Striker Screw
304
D ia p h ra g m
(H ig h S ta ti c F i xe d
316L SS
P re s s ure )

381 D ia p h ra g m Center Screw

F i xe d
(D ua l S e tp o i nt) 316L SS
Fig.1 : Fixed On-Off Differential Model
384
(D u a l S e tp o in t, D ia p h ra g m Adjustable ON-OFF Differential Models
F i xe d
H ig h S ta ti c 316L SS
On-Off differential value can be adjusted for a wider
P re s s ure )
value from about 10 to 15% of the FSR to a maximum
306
D ia p h ra g m of 60% as specified against each range. The minimum
(E c o no m y F i xe d value will vary with different switch combinations. This
N i trile
V e rs i o n )
adjustment is achieved by an auxiliary spring brought
386 into action when the switch actuating plate moves up
(D u a l S e tp o in t, D ia p h ra g m before it operates the microswitch. Adjustment of the
F i xe d
E c o no m y N i trile load of the spring decides the pressure difference
V e rs i o n )
between the on point and off point. Ref Fig.2
D ia p h ra g m
310
N e o p re n e / E P D M / F i xe d Range Adjuster
(L o w R a ng e s )
S i lic o ne
Terminal Block
D ia p h ra g m
313 N e o p re n e / E P D M / A d ju s ta b le
S i lic o ne
Nyloc Nut
SETTING OF SWITCHING POINTS
Differential
A pressure source and a master gauge of accuracy Adjuster
better than 0.5% is required to set the actuating point.
In the case of Differential Pressure switches connect Aux. Spring
the pressure source to the high pressure port and leave Microswitch
the low pressure port vented to atmosphere.
Aux. Spring Seat
Switching point should preferably lie in the mid 50% of
Striker Screw
the adjustable range span.
Markings provided on the range scale are just for guidance Center Screw
& generally marked for falling pressure. To set switching
points precisely use a master Pressure Gauge.
Fig.2 : Wideband Adj. Differential Mechanism
Factory Setting: Even factory adjusted set points get
shifted in rare cases when consignments are badly
handled during transit. When the user needs precise a) In adjustable differential model set the lower switching
point first. Release the aux. spring to be free by
set point actuation, it is advised to cross-check and re- lifting up the nyloc nut and the Diffl. Adjuster. Using
adjust the set point with a master gauge. the range adjuster set the lower switching point. Then
Now proceed with the setting of the switching points as load the aux. spring by turning in the Diffl. Adjuster
below. The switching point can be set, either for fall or clockwise to set the upper switching point.
rise in pressure.

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b) Adjusting the differential adjuster will shift only the
upper switching point i.e. the switching pressure
difference (on-off differential) alone changes. A
clockwise rotation will increase upper switching point
and anti-clockwise rotation will decrease it.
c) The upper switching point should not exceed the
maximum range value.
d) After setting the differential, tighten the Nyloc nut to
lock the differential adjuster to prevent loosening
during operation.
e) Precaution: The switch actuating screw on the
balancing arm is critically adjusted. Disturbance
of this would result in malfunctioning while ON-
OFF differential adjustments are made. If accidentally
disturbed, to reset microswitch adjust the striker
screw height such that the balancing arm is not in
contact with auxillary spring seat during switch de-
actuation thereby ensuring that the auxillary spring
remains unloaded during de-actuation. Refer Fig.3
. Low Pr.
Microswitch
Fig.3 : Aux. Spring
Switch at Aux. Spring seat
‘OFF’ Position 0.5/0.8 mm
Aux Spring load Gap
not acting
For actuation of the microswitch, the balance beam
has to lift the aux. spring seat which is pre-loaded
with the desired value of wide band On-Point.
Ref Fig.4
Microswitch
Aux. Spring
Aux.Spring Seat
Fig.4 : Switch at ‘ON’
Position-
Aux Spring load
acting
Notes
1) In the instruments with 2 SPDT switches for DPDT
action, the synchronization of actuation is achieved
within practical limits.The switches are synchronized
as per customer preference either on falling or on
rising pressure. If no preference is indicated,
synchronization is done on fall in pressure at factory.
2) ON & OFF set point should not exceed the upper or
lower range of scale reading
3) Ensure that impulse pipework applies no stress on
sensing element housing and use spanners to hold
pressure port/ housing when connections are made.
4) Thermal expansion of the pipe work must be taken
up by compensators.
5) Use the device only for the medium specified.
6) Bleed the system before putting into operation.
7) Avoid pressure shocks and excess deflections on
the measurement systems.
8) In DP Switch ensure that low pressure side does
not exceed high pressure side.
General remarks on the operating instructions
All the above guidelines on installation explained herein
show how the instrument can be installed and operated
safely.If difficulties arise, which cannot be solved with
this instruction sheet and product information, further
data should be ascertained from factory. Switzer reserves
all rights for making technical changes / improvements
on a continual basis.
Models 281 & 381/384 provide an independently
adjustable high and low setpoint facility. A single sensing
element actuates two different balance arms through a
floating arm. See Fig.5. Two sets of range springs, range
scales, balance arms and micro switches are
independently operated.
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Fig.5 : Operating Principle of Dual Setpoint
Version
High
Low Setpoint
Setpoint Spring
Spring
Force from Process
Both the range springs are clearly marked for high and
low functions. First set the low range spring and adjust
the desired value for the actuation of the microswitch.
The high range spring should then be adjusted similarly
to the desired high setpoint. Ensure that the correct
microswitch is monitored while settings are done. Refer
Fig.6.
Range Spring Range Spring
High Pr.
Micro switch
Stricker Screw
Bal. Beam Lo Bal. Beam Hi
Floating
Cross Beam
Force from Process
Fig.6 : Side-view of Mechanical Frame sub assy
Models 281 & 381/384 :FIXATION OF SETPOINT
(HI-LO or hi-vhi or lo-vlo)
The two setpoints are independently adjustable. Select
and set one of the two setpoints - the rear range screw
adjuster for high set point and the front range screw
adjuster for low setpoint.
After adjusting one setpoint (either Hi or Lo), the second
setpoint has to be adjusted. However, in case you need
to change any one of the setpoints, it is essential that
the second setpoint is also re-adjusted to the desired
value.
This is due to the fact that whenever one setpoint is
readjusted for a different value, the second setpoint
will also undergo a minor shift in its value. Therefore
cross-checking the second setpoint vis-[-vis the first
setpoint is a necessity.
MAINTENANCE
Inspections should be carried out at quarterly to yearly
intervals depending upon operating conditions.
Isolate unit from process and power and remove lid.
Check terminals for tightness.Check that cable tails are
not fouled or chafed. Check for internal condensation
and rectify.
It is recommended that the instruments are checked for
calibration/operation once a year. However, in critical
applications, microswitch is to be operated and checked
more frequently to ensure correct functioning.
Instruments are so designed with rugged components
that they seldom require maintenance. Occasional
cleaning of moving parts, checking of the microswitch(s)
and ensuring firm electrical contacts at the terminals
will provide a long trouble-free performance.
Process lines are to be periodically checked for
accumulation of dust / foreign particles to avoid clogging.
Clogging would render the instrument non-functioning
as the sensing element shall not have free movement
during pressure fluctuations.
In the case of diaphragm operated instruments, do not
attempt dismantling the sensing diaphragm as it would
permanently disturb the factory settings. Special jigs
are needed for reassembly and hence replacement is
not recommended at the user end. However, cleaning
of the diaphragm chamber can be performed by flushing
with a cleaning fluid, which is compatible with the
diaphragm and its housing material.
Vent or Drain periodically.
 Switzer Pr
witzer
witz ocess Instr
Process uments Pvt. Ltd.
Instruments
IM–PS & DPS –Rev.7D (1114)

web–site
www.switzerprocess.co.in
REGD. OFFICE : 128, Sidco North Phase, Ambattur Estates, Chennai 600 098.
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17 , South Boag Road, Chennai 600 017 128, Sidco North Phase, Ambattur Estates, Chennai 600 050
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E-mail : sales@switzerprocess.co.in E-mail : works@switzerprocess.co.in
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