Delta 204 User Manual

To remove lid on enclosures H,K & M rotate lid

locking mechanism and where lid is tight use a

flat bar (see below) or edge of ring spanner to

Recommended size of bar suitable for opening

instrument. Material needs to be hard chrome

ADJUSTER KNOB

All dimensions mm. (inc

hes)

* Add 10mm.(0.39”) for enclosure N

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.

HEALTH AND SAFETY AT WORK ACT 1974
WARNINGS

1. 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.

2. 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
MIS-APPLICATION IS AVOIDED.

3. TYPE W AND A ENCLOSURES HAVE A SAFETY
BLOW-OUT DISC FITTED IN THE REAR OF THE
ENCLOSURE TO PREVENT DANGEROUS
PRESSURISATION OCCURRING IN THE EVENT OF
A DIAPHRAGM FAILURE. THIS MUST NOT BE
OBSTRUCTED DURING INSTALLATION. LEAVE AT
LEAST 6MM CLEARANCE BETWEEN THE BACK
FACE OF THE ENCLOSURE AND THE MOUNTING
SURFACE. DO NOT REMOVE OR REPLACE WITH
ANY OTHER DEVICE NOT APPROVED BY DELTA
CONTROLS. DO NOT REMOVE AND REFIT
BACKPLATE SO AS TO OBSTRUCT THE BLOW­OUT DISC.

OPERATING PRINCIPLES

A diaphragm is used to sense the process pressure.
The diaphragm transmits a force proportional to the
applied pressure to an operating beam. The beam is
restrained by an adjustable spring. When the force on
the beam overcomes the spring tension the beam
moves and operates a switch or switches. On
reduction of the applied pressure the force applied to
the beam also falls, the beam is restored to its original
position by the spring, and the switch resets.

REPLACEMENT PARTS

Use only factory authorised parts and procedures.
The only parts recommended for site replacement
are the microswitches.

WARRANTIES - SEE CONDITIONS OF SALE

SPDT

NC = NORMALLY CLOSED
COM = COMMON
NO = NORMALLY OPEN

REAR FRONT
SWITCH SWITCH
2 x SPDT

Fig. 1

Fig. 2

INSTALLATION, OPERATING AND

MAINTENANCE INSTRUCTIONS FOR

DIAPHRAGM OPERATED SERIES 200

PRESSURE SWITCHES

(MODELS 204, 208, 209)

ISSUE G 05/09

PRODUCT CODE

ENCLOSURE

MODEL

ELECTRICAL ENTRY

MATERIAL OF WETTED PARTS

RANGE

SWITCHING OPTIONS

PROCESS CONNECTION

OPTIONS AND TREATMENTS
SPECIAL ENGINEERING

On enclosures H, K and M remove the lid using an
appropriate tool if tight, eg edge of spanner or a metal rod
(fig 3).

open

steel spanner grade.

LOCKING SCREW

LOCKING PLATE

SCALE PLATE
INDICATOR

In the interest of development and improvement Delta Controls Ltd, reserve the right to amend without notice,

details contained in this publication. No legal liability will be accepted by Delta Controls Ltd, for any errors,

DELTA CONTROLS LIMITED, ISLAND FARM AVENUE, WEST MOLESEY, SURREY KT8 2UZ

T [phone] F [phone] E [e-mail] W www.delta-controls.com

INSTALLATION

The instruments are designed to be mounted vertically with
the process connection underneath. They can be mounted
either direct to process or to a wall or panel using the
backplate provided. Select the mounting point so as to
avoid excessive shock, vibration or temperature
fluctuation. Instruments should be mounted to avoid
excessive heat transfer from the process lines or adjacent
plant.

If sudden changes of pressure (pulsations) are likely then
we recommend that snubbers are fitted between the
process line and the switch.

Model 204
Use a spanner to support the process connection when
fitting the instrument. When fitting the instrument lid make
sure gaskets or 'O' rings are in good condition and fitted
correctly.

WARNING: CHECK THE CONNECTION THREAD SIZE
AND SPECIFICATION ON THE UNIT TO AVOID MIS­MATCHING WITH THE PROCESS CONNECTION
ADAPTOR. SEE DIGIT 11 OF PRODUCT CODE.

WIRING (Fig 1)

Wire in accordance with local and National codes. Use
cables no larger than 2.5 mm sq. (14AWG). Deliver
electrical connection through a suitable cable gland which
will maintain the IP rating of the instrument. Insert bare
wires fully into the terminal block and tighten securely.
Keep wiring tails to a minimum and check that wires do not
interfere with the operating mechanism. Use the earthing
points provided.

CERTIFIED ENCLOSURES
All Series 200 Pressure Switches can be supplied with
BASEEFA certified enclosures to the following standards:

Zone 1 (Div. 1) IEC 79-1

BS 5501: Parts 1 and 5: EN50 014 and EN50 018
CENELEC. Codes "H" for aluminium and "K" for cast iron.
EExd IIC T6.
Code "M" Cast Iron Exd I T6 for mining.
Zone 2 (UK Only)
BS 4683: Part 3, Enclosure Code "N". ExN II T6

All the above mentioned enclosures are suitable for
outdoor use rated IP 66. Only operation, maintenance or
repair procedures either contained herein or approved by
Delta Controls may be used, to avoid rendering the
equipment unsafe in operation and/or nullifying the
Certification. NO MODIFICATIONS ARE PERMITTED.

Electrical Adaptors
Zone 1. Use only certified adaptors for Zone 1.

WARNING: IT IS A REQUIREMENT OF SAFETY THAT
AT LEAST 5 FULL THREADS ARE ENGAGED
BETWEEN THE ADAPTOR AND CONDUIT ENTRY.
TAKE CARE TO SELECT AND INSTALL ADAPTORS
THAT DO NOT REDUCE THE ENCLOSURE IP RATING.

Zone 2. Adaptors used must have equivalent IP rating to

the enclosure and be impact resistant to 7 N.m
References for Selection and Installation
BS 5345 Part 3 for Enclosure Codes H and K
BS 5345 Part 4 for all Enclosure Codes
(Intrinsic Safety)
BS 5345 Part 7 for Enclosure Code N
BS EN 60529 IP RATING (Ingress Protection)

MODEL 204

Fig. 3

Fig. 4

YOUR TRUSTED PARTNER IN PROCESS INSTRUMENTATION

MODEL 208

MODEL 209

Registered Office Registered in England No 5369683

omissions or amendments.

Fig. 5

Fig. 6

MAINTENANCE

Inspections should be carried out at quarterly to yearly
intervals depending upon operating conditions.
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.

CAUTION
Moving parts have been treated with a water repelling
lubricant before leaving the factory. Occasional
inspection and the application of a water repelling
lubricant is recommended to ensure moving parts
remain free under all conditions.

WARNING: DOES NOT APPLY TO OXYGEN SERVICE.
Zone 1 enclosures

Thread seal and contact surfaces must be lightly lubricated
using a non-setting non-corrosive grease compatible with
the Nitrile lid seal. Do not use copper bearing grease on
aluminium. Screw on lid hand tight making sure that
mating surfaces of the lid and enclosure are in contact. Re­tighten the lid lock screw.

WARNING: IT IS A SAFETY REQUIREMENT THAT AT
LEAST 5 FULL THREADS ARE ENGAGED WHEN THE
UNIT IS IN OPERATION. NEVER OPERATE THE UNIT
UNLESS THIS CONDITION IS MET. DO NOT USE
GREASES OR LUBRICANTS NOT COMPATIBLE WITH
THE ENVIRONMENT OR PROCESS.

Weatherproof enclosure (W and N)

If lid gasket is dried out or damaged, replace with new
greased gasket.

Stainless Steel Weatherproof Enclosure (A)

Check gasket. If damaged, replace.

OPERATION

Pressure switches are supplied calibrated against falling
pressure unless otherwise specified. Set Point adjustment
refers to falling pressure. Switching differential is the
difference between the set point and the operating value
on rising pressure.

Set Point Adjustment: Models 204, 208, 209 (Fig 2)

1. Isolate the instrument from process and power.

2. Remove the instrument lid.

3. Loosen the M3 hexagon head locking screw.

4. Rotate the 20 mm A/F hexagon head adjuster knob to
move the indicator along the calibrated scale. Rotate
clockwise to increase the set point and counter clockwise
to decrease the set point.

5. Retighten the locking screw taking care not to
overtighten.

6. Replace the instrument lid (See maintenance).
Note: For accurate setting, a suitable pressure gauge

must be used in conjunction with the above procedure. Do
not attempt to set the switch outside the scale limits.
Though the unit may be set anywhere within its operation
range, for optimum performance, it is good practice to
have a set point value between 25% and 75% of span.

MODELS H, K, M 204

Fig. 7

Fig. 7

Stock No: 002522/204

REDUCER

‘W’ CABLE GLAND ASSY

Switch products with enclosure codes

marked must be installed and used in accordance with the

ain instructions and this addendum supplied with each product. Products rated

lower than 50V ac and 75 V dc are outside the scope of the LVD, and therefore, do

marking under this directive. The LVD does not apply to products

with enclosure c

odes ‘H’, ‘K’, ‘R’, ‘M’, ‘N’ for use in hazardous areas. Switch products

with enclosure codes ‘H’, ‘K’, ‘R’, ‘M’, ‘N’, are covered by the Explosive Atmospheres

marked will indicate compliance with this

The following directives do not apply to switch products

nylon M20 cable gland with thread length of 10 mm and locknut. Fit the nylon reducer provided

Alternately, the enclosure may be s

Alternatives:

An earthi

Enclosure ‘A’ is supplied with an M20 x 1.5 tapped hole. Use a

when both parts are screwed together. An earthing poi

Pollution degree

all products are suitable for use in pollution degree 3. For extreme

conditions where condensation may readily form, then sealed contacts should be used. See

ducts are not suitable for electrical isolation. Always isolate

C O D E

V A C

M4 S CR EW

STRA P

M4 S TUD

COIL W ASH ER

LID

As the manufacturers of the apparatus listed, declare under our sole responsibility that t

he products listed

An

Low Voltage Directive (LVD) – 2006/95/AC.
‘W’ and ‘A’ supplied CE­m

not require CE-

Directive ATEX – 94/9/EC and when CE­directive alone.
manufactured by Delta Controls:
Electromagnetic Compatibility EMC – 2004/108/EC
Machinery Safety Directive MSD – 2006/42/EC

WIRING
ENCLOSURE ‘W’
Cable Glands and adaptors – If enclosure ‘W’ is supplied with a through hole of 22 mm

blanked with a blind grommet. Discard the grommet and fit a suitable proprietary brass or
to the inside and a fibre washer to the outside. See diagram 1.
accept the customer’s gland or conduit system.
i) a metal or nylon adaptor may be used to accommodate other sizes of gland eg NPT, or

conduit system. See diagram 2.
ii) an elbow kit may be supplied to enable the entry to be rotated axially through 90° and
radially through 360°. See diagram 3.

Earthing / grounding – The user must make suitable local earthing arrangements, if required,
to ensure that metal glands are earthed.

reassembled correctly to be an effective earth and prevent ingress. See diagram 4. When
removing the lid slacken the M4 nut first and ensure it is re tightened whenever the lid is
replaced. See diagram 4.1.

ENCLOSURE ‘A’
Cable Glands and adaptors –

suitable stainless steel cable gland and sealing washer. Alternately the enclosure may be
supplied with a threaded adaptor fitted at the factory ready to accept the customer’s gland or
conduit system. See diagram 5.

Earthing / grounding – Bonding between the enclosure and gland / adaptor will be achieved
this is disturbed in any way it must be reassembled correctly to be an effective earth and

prevent ingress. See diagram 4.
EARTHING / GROUNDING OF PROCESS CONNECTION AND BACK PLATES – All the

internal dead metal work is bonded to the enclosure earthing point. Due to requirements of
sealing, the process connection and back plates may be isolated from the earthing point. Do
not, therefore, rely on either for earthing, instead always use the earthing point provided. If
required, the process connection and back plates may be bonded locally. Never use the
process connection or inlet pipe for locally grounding welding equipment unless it is separately
earth bonded.

Declaration of Conformity

We: Delta Controls Ltd
Island Farm Avenue
West Molesey
Surrey, UK
KT8 2UZ

below:
Pressure, Pressure Difference, Temperature & Flow switches series “W” or “A”:

201, 202, 203, 281, 204, 207, 208, 209, 231, 232, 233, 234, S21, S22, S24, GR2, GR4, VM2, VM4.
301, 303, 304, 381, 384, 306, 386, 310, 316, S31, S34, GR3, GR6.
721, 731, 771, 722, 732, 772, 723, 733, 773, 781, 734, 774, 741, 742, 743, 744, S71, GR7.

131.
To which this declaration relates are in conformity with the following relevant standards or parts thereof:
EN 60947-1 :1992 Low voltage switch gear and control-gear-general rules.

EN 60947-5-1:1992 Low voltage switch gear and control-gear-control circuit devices and switching
elements.
EN 60529: 1991 Specification for classification of degrees of protection provided by enclosures.
EN 60950:1992 Safety of information technology equipment including electrical business equipment:
section 2.5.
BS 6134:1991 Specification for pressure and vacuum switches.

d thereby conforms to the requirements of the Low Voltage Directive 73/23/EC amended by 93/68/EEC.

………………….

R. Harrison
Managing Director

Original dated 22nd June 2000
Rev. B dated 12

ng point is provided inside the enclosure. If this is disturbed in any way it must be

th

August 2009

upplied from the factory with a threaded adaptor ready to

nt is provided inside the enclosure. If

Signed:

Table A codes 08/09, 0G/0H, H2/H3/H6.
Electrical isolation – These pro

circuit separately to carry out any electrical work.

TABLE A – MICROSWITCH RATINGS

0 0

&

0 1

0 2

&

0 3

0 4

&

0 5

0 8

&

0 9

0 G

&

0 H

0 C

0 D

H 2

&

H 3

&

H 6

S W I T C H

M I C R O S W I T C H

( R E S I S T I V E )

* S E E N O T E

5 A @ 1 1 0 / 2 5 0

5 A @ 1 1 0 / 2 5 0

2 A @ 3 0 V D C

1 A @ 1 2 5 V A C

* 1 0 0 m A @ 3 0

1 1 0 / 2 5 0 V A C
5 A @ 3 0 V D C

* 1 A @ 3 0 V A C

5 A @ 1 1 0 / 2 5 0

5 A @ 1 1 0 / 2 5 0

2 A @ 3 0 V D C

5 A @ 1 1 0 / 2 5 0

2 A @ 3 0 V D C

–

U L / C S A

R A T I N G

V A C

0 . 8 k V

V A C

V D C

* 5 A @

0 . 5 k V

0 . 5 k V

& 3 0 V D C

V A C

V A C

V A C

IEC 947-5-1 / EN 60947-5-1 RATING

0 . 8 k V

0 . 8 k V

0 . 8 k V

0 . 5 k V

R A T I N G

( I e I U e )

Uimp

Ui

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0 V A C

2 5 0

V

0 . 2 2 / 0 . 1 A @

1 2 5 / 2 5 0 V D C

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0 V A C

2 5 0 V

0 . 2 2 / 0 . 1 A @

1 2 5 / 2 5 0 V D C

1 A @ 1 2 5 V A C R E S I S T I V E ( I E C 1 0 5 8 - 1 / E N 6 1 0 5 8 - 1 )

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0 V A C

2 5 0 V

0 . 2 2 / 0 . 1 A @

1 2 5 / 2 5 0 V D C

1 2 5 V

2 5 0 V

2 5 0 V

2 5 0 V

0 . 3 A @ 1 2 0

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0

V A C

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0 V A C

0 . 2 2 / 0 . 1 A @

1 2 5 / 2 5 0 V D C

0 . 6 / 0 . 3 A @

1 2 0 / 2 4 0 V A C

0 . 2 2 / 0 . 1 A @

1 2 5 / 2 5 0 V D C

A C 1 4 /

D e s i g n a t i o n

&

U t i l i s a t i o n

C a t e g o r y

A C 1 4 /

D 3 0 0

D C 1 3 /

R 3 0 0

A C 1 4 /

D 3 0 0

D C 1 3 /

R 3 0 0

A C 1 4 /

D 3 0 0

D C 1 3 /

R 3 0 0

E 1 5 0

A C 1 4 /

D 3 0 0

A C 1 4 /

D 3 0 0

D C 1 3 /

R 3 0 0

A C 1 4 /

D 3 0 0

D C 1 3 /

R 3 0 0

AC 4 3 2

D C

A C

D C

A C

D C

A C

A C

A C

D C

A C

D C

Th e electrica l rating is d ependent on t h e microswitc h fitted to
the instrument. The electric a l r a ting is defined by each
approval th a t the microswitch complies wi t h and is shown on
the pr o duct na meplate, ie UL / CSA, or IE C . It should be
noted that the switch must be use d w i t h i n t he electrical rating
specified from the approval you requi r e . Table A lists the
actual IEC r a t i ngs a g a i nst th e De s i g nation & U t i l isation
Category ma rk e d o n the nameplate. In the a b s ence o f an y
verification by UL / CSA the mi croswitch *m a n u fac turer’s
rating is s p ecified in b o l d italics . If in dou b t , seek guida n c e
from factory.

DIAG 1

LOCKNUT

NYLON 22/20

ENCLOSURE WALL

FIBRE WASHER

PROPRIETARY

GLAND

DIAG 2

CABLE GLAND /
CONDUIT ADAPTOR

‘W’ ADAPTOR ASSY

DIAG 3

GLAND

FIBRE

SCREW

WASHER

DIAG 4.1

M4 NUT

M4 S ING LE

EARTH STRAP

ENCLOSURE

WALL

O RING
SEAL

ELBOW ASSY

GAS KE T

½" NPT Pg 13.5
M20 X 1.5 ¾ ET

M4 PLA IN
WA SHE R

EAR TH

BAS E

EAR TH LABEL

SING LE
CO IL
WASHE R

NUT

PLAIN
WASHER S

D IAG 5

NU T

STAR W AS HER

EN C L O S U R EM 2 0 x 1.5

DIAG 4

ENC LOSURE W A LL
(EXTE R IO R )

BO N D ED S EAL

EARTH ING ASSY

F IB R E W A S H ER

‘A ’ A D AP T O R

VA

Make

2 8 2 8

4 3 2 7 2

2 8 2 8

4 3 2 7 2

2 8 2 8

2 1 6 3 6

4 3 2 7 2

4 3 2 7 2

2 8 2 8

4 3 2 7 2

2 8 2 8

SC R EW

AD A P TO R

Break

7 2