Dungs CPI 400 User manual

Closed position indicator that visually and electrically displays when the valve is either in the closed or open position. Mounts
directly to the DMV, SV, MVD and HSAV series valves. When the valve is closed (NO position) a orange light is visible, when
the valve is open (NC position) a green light is visible.
Gases
Natural gas, Propane, Noncorrosive gases, and Air
Switch Type
SPDT
Switch Action
valve open: switch in NC position, Green light
valve closed: switch in NO ,position, Orange light
Contact Rating
10 A res, 8 FLA, 48 LRA @120 Vac
Enclosure
NEMA 4 when 1/2” NPT to PG11 adapter is sealed
with RTV.
CPI 400
Installation Manual
SPECIFICATIONS
Mounting
• The valve must be de-energized and the gas supply shut
off before mounting the CPI 400.
• Disconnect all power to the switch before beginning to
prevent electrical shock and equipment damage.
Mounting Procedure (reference Fig. 1 on page 2)
• IMPORTANT!! Before mounting the bass adapter to the
valve or to the CPI 400, use your fingers to verify that
the pin slides freely inside the brass adapter. If this
pin is does not slide freely, apply a large enough force
to the appropriate side to free the pin.
• Using a 5 mm hex wrench, remove the plug and its oring
located at the bottom of the valve.
• Verify that the brass adaptor has a clean oring, and its
threads and the groove, into which the brass adapter
mounts, are clean and in good condition.
• Mount the brass adapter into the valve.
• Use a 9/16” (14 mm) open end wrench and turn 1/4
to 1/2 additional turn (after finger tight). DO NOT over
INSTALLATION
• Read these instructions carefully.
• Failure to follow them and/or improper installation may
cause explosion, property damage and injuries.
• Installation must be done with the supervision of a
licensed burner technician.
• The system must meet all applicable national and local
code requirements.
• Check the ratings above and on the switch
to make sure that it is suitable for your application.
• Never perform work if gas pressure or power is applied,
or in the presence of an open flame.
• Protect surfaces. Make sure that seals and O - rings are
clean and in good condition.
• Once installed, perform a complete checkout including
a gas leak test.
• Label all wires prior to disconnecting when servicing
switches. Wiring errors can cause improper and danger-
ous operation.
• Verify proper operation after servicing.
CPI 400 Installation Manual - 80114 - 01/2006
tighten.
• Mount the CPI switch onto the brass adaptor. Push the
CPI housing towards the valve until it stops.
• Turn/Position the CPI so that the wiring and condiut con-
nection apply the least amount of torque as possible.
• Tighten the set screw so that the CPI housing is secured
to the brass adaptor.
• Do not turn the CPI 400 after tightening the set screw; this
may strip the brass adatper. The brass adaptor could
loosen and the asembly may leak.
• Perform a leak test to verify that no leakage occurs around
the oring.
Karl Dungs Inc.
•524 Apollo Drive Suite 10 Lino Lakes, MN 55014, U.S.A. • Phone [phone] • Fax [phone]

Required Wiring:
• Do not exceed the electrical ratings given in the switch
specifications.
• Use 14 or 16 guage wire for at least 75˚C (167˚F).
• For NEMA 4 applications, NEMA 4 conduit or wiring
methods must be used.
• Run one wire (the COMMON) to the L1 terminal, one
to the GROUND terminal, one from the NO terminal to
the Proof of Closure terminal of the Flame Safeguard,
and one (the NEUTRAL) to L2 on the CPI 400.
NOTE: If N is not wired to L2, the lights will not prop-
erly indicate the valve position. The ORANGE light
shall be on when the valve is closed, The GREEN light
shall be on when the valve is open (FM and NPFA 86
requirement).
The CPI 400 must be calibrated to the specific valve it is used
on. Failing to properly calibrate this switch may need lead to
nuisance problems or to an unsafe startup condition.
Calibrating the CPI: (Reference Fig. 2)
• The CPI must be properly mounted to the valve, and the
valve must be closed.
• Disconnect all power to the CPI 400 before adjusting
to prevent electrical shock and equipment damage.
• Remove clear cover.
• Turn the adjustment dial counterclockwise until it stops.
• Then turn the adjustment dial clockwise until the
switch makes. If by chance there is too much noise to hear
the switch trip, proceed to Calibrating the CPI in noisy
environments.
• Note the position of the set point in reference to the
white lines on the scale.
• Turn the adjustment dial two additional increments clock
wise to the same relative position.
• Replace clear cover, the CPI is now adjusted.
Calibrating the CPI in noisy environments:
• Verify that there are no stray wires that are potentially a
shock hazard while the dial is being manually adjusted.
Calibration and Testing
Fig. 3 NO contact is open when valve is OPENED.
NO contact is closed when valve is CLOSED.
Fig. 2
• Apply 120Vac to terminals L1 and L2 of the CPI.
• Turn the adjustment dial counterclockwise until it
stops. The GREEN Light should be illuminated.
• Then turn the adjustment dial clockwise until the
RED light illuminates.
• Note the position of the set point in reference to the
white lines on the scale.
• Turn the adjustment dial two additional increments clock-
wise to the same relative position.
• Replace clear cover, the CPI is now adjusted.
Annual Testing
• Perform a switch continuity test at least annually to verify
that there is continuity between the switch contacts 3
(COM) and 2 (NO), and verify that there is no continuity
between the switch contacts 3 (COM) and 1 (NC).
• Then, energize the valve that the CPI is mounted to, and
verify that there is continuity between the switch contacts
3 (COM) and 1 (NC). Then verify that there is no continuity
between the switch contacts 3 (COM) and 2 (NO).
• If any above check fails, do not use the CPI and contact
DUNGS as soon as possible.
Fig. 1
O-Ring
Pin
Set Screw
Brass Adapter