Dixon A540 Series Operating and maintenance manual

30710PA
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Maintenance & Operating Instructions
For
DIXON-ADS
Industrial Fluid Controls
A540 SERIES GROUND CLAMP

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Contents
Overview......................................................................................................................................... 2
Features ........................................................................................................................................... 2
Technical Specifications ................................................................................................................. 3
Installation....................................................................................................................................... 6
Maintenance.................................................................................................................................... 8
Replacement parts....................................................................................................................... 8
Operation......................................................................................................................................... 9
Warranty ......................................................................................................................................... 9
Sales and Service Contacts ........................................................................................................... 10
Overview
The A540 Series ground clamps are key to creating a quality temporary connection for antistatic
grounding applications. The clamp features three teeth to penetrate dirt, corrosion, and road grime
when in use. The teeth are constructed of stainless steel to ensure lasting operation, and isolated from
the clamp handle to allow operators to establish ground and a ground-verification signal in a single
clamp action. The A540 also includes a high durability cable and junction box for convenient wiring
access during installation and maintenance.
Common applications for the A540 series ground clamp include:
•Tank truck and Rail car loading facilities
•Drum and barrel filling sites
•Loading of stationary tanks
Features
•Clamp tethered to cable by stainless steel strap to protects connection from strain and wear.
•Pull-out resistant cord grip on junction box holds cable tighter the harder it is pulled.
•Junction box creates convenient service point for hazardous location installations.
•Coiled cable for compact storage.
•Strong clamping force to penetrate grime and remain connected during loading process.
•Can provide ground and a ground-verification signal in a single clamp

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Technical Specifications
MIN
MAX
NOMINAL
AMBIENT TEMPERATURE
-40°C
90°C
-
JUNCTION BOX
HEIGHT
10.75 in. [27.3cm] INCLUDES STRAIN RELIEF
WIDTH
3.0 in. [7.62cm]
DEPTH
3.0 in. [7.62cm]
WEIGHT
5 lbs. (2.27 kg)
INGRESS PROTECTION
Weatherproof, raintight, and dust tight
CONDUIT ENTRIES
ONE ¾” TRADE SIZE HOLE + FACTORY INSTALLED CABLE ON
BOTTOM
SUITABLE FOR INSTALL IN
HAZARDOUS LOCATIONS:
Class I, Division 1 & 2, Groups B, C, and D hazardous
locations
Class II, Division 1 & 2, Groups E, F, and G hazardous
locations
Class III hazardous locations
SUITABLE FOR CONNECTION TO
HAZARDOUS LOCATIONS:
Class I, Division 1 & 2, Groups A, B, C, and D hazardous
locations
Class I, Zone 0, 1 & 2, Groups IIC, IIB, and IIA hazardous
locations
CABLE
LENGTH
25 ft. stretched [7.6m] (Standard; other lengths available)
DIAMETER
0.4 in. [1.0cm]
WEIGHT
2.5 lbs. [1.13kg]; 0.1 lbs. PER FOOT [0.15g per meter]
JACKET MATERIAL
Thermoplastic Elastomer, resistant to harsh environments.
RESISTANCE
0.14Ω (6mΩ/foot)
RECOMMENDED WIRE
BETWEEN CONTROLLER AND
A540
18 GA Stranded copper wire (THHN)

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Accessories
Ground Verification Monitor:
The A240 series ground verification monitors are designed to mitigate the danger of static buildup by
verifying the presence of a high quality and reliable earth-ground bond. With the presence of a ground
path for static to dissipate, loading and unloading of flammable or combustible liquids can be done
safely. The A240 monitor verifies the bond is of sufficient quality to prevent static buildup. Internal
indicators inform the operator whether the process connection is safely grounded and internal relay
contacts may be used to interlock operations until a safe earth bonding has been established.
Sealing Fitting:
Sealing fittings are required within 18 inches of each enclosure entry used. These seal conduits from
passing hazardous vapors or propagating flame. Sealing fittings are installed in-line with conduit, then
filled with sealing compound once wiring has been installed and verified. Downstream junction boxes
containing Intrinsically Safe circuits may be serviced without danger.
¾” NPT Vertical Seal fitting with nipple; P/N: 30192AL
Note: Actual color may differ

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Wiring Diagram

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Installation
INSTALLATION MUST BE COMPLETED BY QUALIFIED PROFESSIONAL
A540 Series ground clamps are suitable for installation and use in ordinary and specific hazardous
locations (listed in technical specifications section) as defined by NEC NFPA70 and IECEx standard 60079.
Installation to be performed by a qualified professional.
Mechanical
It is recommended to wall mount the unit using stainless steel or galvanized steel hardware suitable for
the monitor’s weight and wall material.
1. Using the bolt pattern provided below, locate a sturdy area, large enough to install the junction
box.
For greatest environmental resistance it is recommended to mount the junction box in the
orientation shown. Keep in mind the coiled cable will hang below the box, and the clamp must
be stored in an ungrounded position. The enclosure can withstand rain and sun exposure but
will last longer when protected from the elements.
2. Level the bolt pattern and drill two holes marked on the pattern.
3. Have another person lift the junction box into position in front of the drilled holes.
4. Insert the two anchors or bolts into the two mounting holes shown below.
5. Tighten all the screws and ensure that the junction box is secure.

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Electrical
•To be installed per NEC NFPA70 requirements for U.S. installations.
•Installation in other regions must conform to local electrical codes. Instructions provided below
are general guidelines and may not cover local requirements.
1. Remove the lid from the A540 junction box.
2. Run conduit to junction box. Ensure conduit has sealing fitting at feeder end if installation is in
hazardous location.
Conduit connection should be sealed from water intrusion through either rubber washers,
caulking, or other sealing means.
3. Pull cable from process controller into A540 junction box.
4. Refer to wiring diagram above, as well as documentation for process controller to properly wire
the process controller to the A540 ground cable.
5. Reinstall lid onto junction box.
6. Designate an ungrounded location to store the ground clamp while not in use. It is critical that
the ground clamp be ungrounded while not in use. Storing in a grounded state can lead to
unsafe loading conditions.
7. Verify proper functionality of system by testing before putting into service.

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Maintenance
SERVICE SHOULD BE COMPLETED ONLY BY A QUALIFIED HAZARDOUS LOCATION TECHNICIAN.
REPLACE PARTS WITH GENUINE DIXON OR APPROVED EQUIVALENT PARTS; SUBSTITUTION MAY
IMPAIR INTRINSIC SAFETY.
The A540 has few parts that will require regular maintenance and is designed for long service periods.
Unsheltered units should be serviced in dry weather to prevent rainwater from entering the enclosure
and minimize moisture exposure.
1. If the ground connection is becoming intermittent, it is advised to inspect the clamp and cable.
2. Dulling of the clamp teeth may be a sign that the clamp has reached the end of its usable life
and should be replaced. Contact Dixon for replacement parts.
3. Checking the cable for a failing conductor can be done by clamping to a known grounded piece
of metal, then flexing the cable. If the ground controller’s indicator changes while flexing the
cable, the cable has reached the end of its usable life and should be replaced. Do not attempt to
repair the cable. Contact Dixon for replacement parts.
a. In the event that the cable does need to be replaced, it can be removed while energized.
b. Open the A540 junction box and note the wire positions for each conductor in the A540
cable on the terminal block.
c. Remove the wires from the terminal block.
d. Compress the mesh cordgrip by pushing it toward the bottom of the junction box.
e. With the cordgrip compressed, the old cable may be pulled out, and new cable installed.
f. Once the new cable has been installed into the mesh cordgrip, re-wire the cable into the
A540 junction box terminal strip.
g. Close the A540 junction box.
h. Verify proper functionality of system by testing before putting into service.
Replacement parts
Description
Part Number
Rack Cable with clamp
30585
Cord Grip
30708
Sealing Fitting; ¾” Vertical
30129AL
Sealing Compound
30339 for 5 lbs. or 30339-002 for 1 lb.

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Operation
WARNING - USING THE A540 IN A MANNER NOT DEFINED IN THIS MANUAL MAY IMPAIR SAFETY.
1. Verify process controller is powered on and idle.
2. Test the controller’s operation by clamping to a known grounded piece of metal. Verify the
controller’s indicator changes from RED to GREEN. Remove the clamp from the test point.
3. Before any other electrical connections are made, secure the A540 clamp to the process
connection that is to be loaded.
4. Verify the process controller’s indicator changes from RED to GREEN.
5. Complete any other process connections.
6. Once all other safety measures are active, begin the loading process.
7. Once loading is complete, remove all other process connections, then the A540 last.
8. Return the A540 clamp to the isolated storage facility, verifying the indicator remains red.
Warranty
For warranty claims and information regarding coverage, please contact Dixon Support at
[phone]

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Sales and Service Contacts
Europe:
Dixon Group Europe Ltd.
Preston, England
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Canada:
Dixon Group Canada Limited
Innisfil (Barrie), Ontario
Phone: [phone]
Fax: [phone]
Toll Free: 877-963-4966
E-mail: [e-mail]
USA:
Dixon Bayco USA
Chestertown, Maryland
Phone: [phone]
Fax: [phone]
Toll Free: 800-355-1991
E-mail: [e-mail]
Mexico:
Dixva, S. de R.L. de C.V.
Monterrey, N.L
Phone: [phone]-DIXON (34966)
Fax: [phone]
E-mail: [e-mail]
Asia Pacific:
Dixon (Asia Pacific) Pty Ltd Wingfield, South
Australia
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]