Tuffy® T3 Liquid Level Controls with Electric Switches Installation and Operating Manual Side Mounted Float Level Switch ® UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number (Model number/approvals as per inserted separate sheet) to be sure it agrees with the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. Nameplate: - partnumber - switch - serial n° - tag n° For flanged units Cut and remove the plastic shipping straps on flanged units. 0038 0344 These units are in conformity with the provisions of: 1. Directive 94/9/EC for Equipment or protective system for use in potentially explosive atmospheres. Ex d models: EC-type examination certificate number ISSeP10ATEX032. Notified Body: ISSeP, notified body N° 0492, Zoning A. Schweitzer, B7340 Colfontaine, Belgium. The following harmonized standards have been applied: EN 60079-0:2009 / EN 60079-1:2007 / EN 60079-26:2007 Ex ia models: EC-type examination certificate number ISSeP00ATEX010X. Notified Body: ISSeP, notified body N° 0492, Zoning A. Schweitzer, B7340 Colfontaine, Belgium. The following standards have been applied: EN 50014: 1997 +A1 + A2 / EN 50020: 1994 / EN 50284: 1999 2. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. Notified body: Lloyd's Register of Shipping, 71, Fenchurch Street, London EC 3M-4BS, UK, notified body N° 0038. The following standard has been applied: ANSI/ASME B31.3 MOUNTING Cage mounted Air Threaded max nozzle length: 84 mm (3.29") Oil Flanged max nozzle length: 85 mm (3.35") Field adjustable differential max nozzle length: 110 mm (4.35") Interface max nozzle length: 147 mm (5.80") Water Note: min nozzle size is 3" SCH 80 (max nozzle lengths are specified as per this size) 2" NPT Tuffy Flanged Tuffy Locking screw, loosen before removing cover (refasten after replacing) Locking screw, loosen before removing cover (refasten after replacing) External cage mounted Tuffy 4. Fasten bolts and studs in a star pattern Shut-off valve Safety check valve Pressure vessel CL M20 x 1.5 or 3/4" NPT cable entry; should always be pointing down 2 Apply Teflon tape or Petrolatum Use wrench size 65 mm 3/4"NPT cable entry 3. M20 x 1.5 or 3/4" NPT cable entry; should always be pointing down 1. Install a proper gasket. 2. Cut and remove the shipping straps, slide the control in the nozzle and align the bold holes. Drain valve CL Shut-off valve Switch actuation level CL WIRING CAUTION: power must be switched OFF before wiring the unit. Terminal connections DPDT dry contact switch with silver contacts Terminal connections SPDT dry contact switch with silver or gold contacts Internal ground wire External ground wire use min. 14 AWG wire Terminal connections DPDT dry contact switch with gold contacts Allowable operating range Cast iron housing with silver switch contacts with silver/gold contacts HS Allowable operating range Aluminium housing with silver switch contacts with silver/gold contacts HS 60 Ambient Temperature (°C) Ambient Temperature (°C) 40 20 0 -20 60 40 20 0 -20 -40 -40 0 50 100 150 200 250 Process Temperature (°C) 300 350 -40 Allowable operating range Cast iron housing with gold switch contacts 0 50 100 150 200 250 Process Temperature (°C) 300 350 60 Ambient Temperature (°C) 40 20 0 -20 -40 -40 Allowable operating range Aluminium housing with gold switch contacts 60 Ambient Temperature (°C) Terminal connections SPDT HS switch with silver or gold contacts 40 20 0 -20 -40 0 50 100 150 200 250 Process Temperature (°C) 300 350 -40 -40 0 50 100 150 200 250 Process Temperature (°C) 300 350 3 CALIBRATION For T31-T35 / T3B / T3D and T3E units Properly selected TUFFY units do not need any field calibration. For T3C: field adjustable differential units The Adjustable Differential Tuffy II, model T3C, may be set in the field for one of a variety of level differentials. By specific placement of the stops in the holes of the adjustment plate, the level differential may be changed. D C L B K A H E J G Partnumber T3C-4XXX-XXX Level Rising Falling Rising Falling Rising Falling T3C-8XXX-XXX T3C-CXXX-XXX B +47 +80 +63 +115 +85 +160 F To determine the differential Example: T3C-C unit with stop holes B and G 1. Select the rising level of the upper stop: example: upper stop = hole B: +85 mm 2. Select the falling level of the lower stop: example: lower stop = hole G: -205 mm 3. Substract levels: rising level / upper stop - falling level / lower stop: example: +85 mm - (-205 mm) = +290 mm Example 2:T3C-8 unit: with stop holes D and B: +183 mm - (+115 mm) = 68 mm Stop holes in mm (divide by 25,4 to obtain inches) Upper stops middle Lower stops C D K L A E F G H J +90 +124 +39 +104 +4 -37 n/a n/a -42 n/a n/a n/a +84 n/a +38 -10 -47 -82 +4 -62 +131 +183 +51 +153 -3 -67 n/a n/a -75 n/a n/a n/a +122 n/a +50 -25 -84 -136 -3 -106 +183 +259 +67 +215 -11 -105 n/a n/a -115 n/a n/a n/a +170 n/a 66 -43 -128 -205 -11 -106 Impossible stop hole combinations due to the diameter of the stem (of the float): A and B A and E A and H A and K B and C B and K C and D C and K C and L TROUBLESHOOTING Symptom Failure of the controlled equipment eg. pump does not start, signal lamps fail to operate etc... D and L E and F E and H F and H F and J F and G J and G Cause of malfunction / Action Check external causes first: - blown fuses - tripped reset button - open power switch. - controlled equipment fails. - defective wiring to level switch. Check wiring as per wiring diagrams on page 3 Check actuating arm and magnet assembly 1. Remove switch mechanism 2. Check for wiring interference or binding of actuating arm. The switch and magnet must move throughout its entire range of motion without interference. 3. Replace the switch mechanism in case of binding. Float magnet Non-magnetic float holder (pressure boundary) Switch magnet 4 Check float assembly 1. Remove the unit from service 2. Clean the mechanism if required 3. Tilt the float, when the unit is limited by its motion: check differential setting (for T3C units only) – see above 4. Replace the unit in case cleaning and/or resetting did not solve the problem. Magnet/Switch action PREVENTIVE MAINTENANCE Periodic inspections are a necessary means to keep your level control in good working order. This control is a safety device that protects the valuable equipment it serves. A systematic program of preventive maintenance should be implemented when the control is placed into service. If the following instructions are observed, your control will provide reliable protection of your equipment for many years. What to do 1. Keep control clean. Be sure the switch housing is always in place. This cover is designed to keep dust and dirt from interfering with the switch mechanism operation. In addition it protects against damaging moisture and acts as a safety feature by keeping bare wires and terminals from being exposed. Should the housing cover become damaged or misplaced, obtain a replacement immediately. 2. Inspect switch mechanisms, terminals and connections monthly. Tuffy T3 level switches may sometimes be exposed to excessive heat or moisture. Under such conditions insulation on electrical wires may become brittle, eventually breaking or peeling away. The resulting bare wires can cause short circuits. Check wiring carefully and replace at first sign of brittle insulation. Vibration may sometimes cause terminal screws to loosen. Check all terminal connections to ensure that screws are tight. Check wiring carefully and repair or replace if necessary. Note: It is recommended that spare switches, housing covers and o-rings be kept on hand at all times. 3. Inspect entire Tuffy T3 unit periodically. A periodic cleaning of the float and counterweight assembly will ensure continued free movement of the mechanism. What to avoid 1. NEVER leave the switch housing cover off of the control longer than is necessary to make routine inspections. 2. NEVER place a jumper wire across terminals to “cut-out” the control. If a jumper is necessary for test purposes, ensure that it is removed before placing the control into service. 3. NEVER attempt to make adjustments to or replace switches without reading instructions carefully. When in doubt, consult the factory or your local representative. 4. NEVER use in systems containing iron particles. The magnet in the float assembly can attract the particles and become jammed. 5. NEVER put insulation over the switch housing. REPLACEMENT PARTS (includes ) N° 1 Switch only 2 Switch mechanisms 3 Housing cover 4 Cover o-ring Discription SPDT silver contacts DPDT silver contacts SPDT gold contacts DPDT gold contacts HS SPDT silver contacts HS SPDT gold contacts SPDT silver contacts DPDT silver contacts SPDT gold contacts DPDT gold contacts HS SPDT silver contacts HS SPDT gold contacts Aluminium Cast Iron Part number Right hand* Left hand* 37-4814-001 not applicable 37-4814-001 37-4814-002 37-4814-003 not applicable 37-4814-003 37-4814-004 37-9101-001 37-9101-001 37-9102-001 37-9102-001 Consult factory 04-9197-005 04-9197-002 12-2201-240 * Position of the switch is determined by looking at the terminal block with the cable entry pointing downward. 5 SPECIFICATIONS PHYSICAL SPECIFICATIONS Description Measured variable Physical range Ambient temperature Process temperature Process pressure Wetted parts Flange materials Housing materials ELECTRICAL SPECIFICATIONS Description Switch ratings Signal output Switch types Approvals Cable entries 6 Specification Liquid level Narrow differential: 13 mm (0.5") Adjustable differential: up to 464 mm (18.26") Interface Service Differential: 44 mm (1.72") Interface: min S.G. difference between both liquids: 0,1 -40 °C to + 70 °C (-40 °F to +160 °F) From -55 °C (-65 °F) up to 400 °C (750 °F) depending switch/housing selection Standard models: up to 50 bar abs. (720 psi) High pressure models: up to 150 bar abs. (2160 psi) 316/316L (1.4401/1.4404) or Hastelloy C (2.4819) Carbon steel 316/316L (1.4401/1.4404) or Carbon steel with 316/316L (1.4401/1.4404) cladding Hastelloy C (2.4819) or Carbon steel with Hastelloy C (2.4819) cladding Cast aluminium or cast iron Specification Up to 10 A @ 240 V AC Up to 6.0 A @ 24 V DC Single SPDT or single DPDT contacts Dry contact with silver or gold plated contacts Hermetically sealed for corrosive environment ATEX II 1/2 G / IECEx Ex d IIC T6 Ga/Gb, explosion proof ATEX II 1G EEx ia II C T6, intrinsically safe NEMA 4X/7/9, Class 1, Div 1, Groups B, C & D 3/4" NPT or M20 x 1,5 DIMENSIONS in mm (inches) T31 and T35: threaded narrow differential 211 (8.29) 84 (3.29) T31: 220 (8.66) T35: 200 (7.86) T31: 91 (3.59) T35: 85 (3.33) 112 (4.39) 2" NPT Cable entries: M20 x 1.5 or 3/4" NPT T31, T33 and T35: flanged narrow differential 211 (8.29) 85 (3.35) T31: 221 (8.72) T33: 190 (7.50) T35: 201 (7.92) 112 (4.39) T31/T33: 91 (3.59) T35: 85 (3.33) Cable entries: M20 x 1.5 or 3/4" NPT T32: flanged high pressure narrow differential 211 (8.29) 85 (3.35) 204 (8.02) 112 (4.39) 85 (3.35) Cable entries: M20 x 1.5 or 3/4" NPT T3C: adjustable wide differential 209 (8.23) 85 (3.35) Stem length (code 4): 327 (12.86) Stem length (code 8): 422 (16.61) Stem length (code C): 543 (21.36) 112 (4.39) Stem length (code 4): 346 (13.62) Stem length (code 8): 471 (18.54) Stem length (code C): 629 (24.76) Cable entries: M20 x 1.5 or 3/4" NPT Stem le Stem le ngth (code 4 Stem le ngth (code 8):): 95 (3.75) ngth (c ode C): 190 (7.50) 311 (12 .25) 7 DIMENSIONS in mm (inches) T3B: interface 209 (8.23) 112 (4.39) Cable entries: M20 x 1.5 or 3/4" NPT 8 85 (3.35) 448 (17.62) 172 (6.78) MODEL IDENTIFICATION T T T T T T 3 3 3 3 3 3 1 2 3 5 B C Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,4 / max 50 bar abs (720 psi) Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 150 bar abs (2160 psi) Tuffy with Hastelloy C (2.4819) float - min S.G. 0,65 / max 50 bar abs. (720 psi) Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 103 bar abs (1500 psi) Interface Tuffy with 316/316L (1.4401/1.4404) float - max 50 bar abs (720 psi) Adjustable diff. Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,78 / max 50 bar abs (720 psi) NARROW DIFFERENTIAL UNITS - T31, T32, T33 AND T35 O Standard level differential of 13 mm (0,5") SPECIFIC GRAVITY OF LOWER LIQUID FOR T3B 0,81 0,82 A B 0,91 0,92 L M 0,83 C 0,93 N 0,84 D 0,94 P 0,85 E 0,95 R 0,86 F 0,96 S 0,87 G 0,97 T 0,88 H 0,98 U 0,89 J 0,99 V 0,90 K 1 W STEM EXTENSION LENGTH FOR T3C - DIMENSION "A" 4 95 mm (3.75") stem extension / 346 mm (13.62") differential 8 190 mm (7.50") stem extension / 471 mm (18.54") differential C 311 mm (12.25") stem extension / 629 mm (24.76") differential PROCESS CONNECTION – ANSI Flanges 3 A 3" 150 lbs RF ANSI Flange 3 B 3" 300 lbs RF ANSI Flange 3 C 3" 600 lbs RF ANSI Flange 3 D 3" 900 lbs RF ANSI Flange 4 A 4" 150 lbs RF ANSI Flange 4 B 4" 300 lbs RF ANSI Flange 4 C 4" 600 lbs RF ANSI Flange 4 D 4" 900 lbs RF ANSI Flange 5 A 5" 150 lbs RF ANSI Flange 5 B 5" 300 lbs RF ANSI Flange 6 A 6" 150 lbs RF ANSI Flange 6 B 6" 300 lbs RF ANSI Flange PROCESS CONNECTION – THREADED 2 N 2" NPT connection Specific Gravity Code Specific Gravity Code PROCESS CONNECTION – EN/DIN Flanges A 1 DN 80, PN 16 EN 1092-1 Type B1 A 2 DN 80, PN 25/40 EN 1092-1 Type B1 A 3 DN 80, PN 63 EN 1092-1 Type B2 A 4 DN 80, PN 100 EN 1092-1 Type B2 A 5 DN 80, PN 160 DIN 2527 Form E flange B 1 DN 100, PN 16 EN 1092-1 Type B1 B 2 DN 100, PN 25/40 EN 1092-1 Type B1 B 3 DN 100, PN 63 EN 1092-1 Type B2 B 4 DN 100, PN 100 EN 1092-1 Type B2 B 5 DN 100, PN 160 DIN 2527 Form E flange C 1 DN 125, PN 16 EN 1092-1 Type B1 C 2 DN 125, PN 25/40 EN 1092-1 Type B1 D 1 DN 150, PN 16 EN 1092-1 Type B1 D 2 DN 150, PN 25/40 EN 1092-1 Type B1 SEE PAGE 10 T 3 0 complete code for TUFFY® T3 9 MODEL IDENTIFICATION SEE PAGE 9 DESIGN CODE AND FLANGE MATERIAL Standard 1 A B C D Design codes ANSI/ NACE ASME B31.3 2 3 E J F K G L H M Not for all models ANSI/ASME B31.3 & NACE 4 N P R T Flange material Carbon steel Carbon steel w. 316/316L cladding 316/316L (1.4401/1.4404) stainless steel Carbon steel w. Hastelloy C cladding Hastelloy C (2.4819) SWITCH TYPE (see table below - "SWITCH MECHANISMS") 0 SPDT with silver contacts 1 DPDT with silver contacts 2 SPDT with gold plated contacts 3 DPDT with gold plated contacts 4 Hermetically sealed, SPDT with silver contacts 6 Hermetically sealed, SPDT with gold plated contacts HOUSING MATERIALS AND CABLE ENTRY Consult factory for proper partnumbers for FM/CSA approved units 1 2 3 4 M N P R T 3 Cast Cast Cast Cast Cast Cast Cast Cast aluminium, single 3/4" NPT cable entry, iron, single 3/4" NPT cable entry, aluminium, single M20 x 1,5 cable entry, iron, single M20 x 1,5 cable entry, aluminium, single 3/4" NPT cable entry, iron, single 3/4" NPT cable entry, aluminium, single M20 x 1,5 cable entry, iron, single M20 x 1,5 cable entry, ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb ATEX II 1G EEx ia II C T6 ATEX II 1G EEx ia II C T6 ATEX II 1G EEx ia II C T6 ATEX II 1G EEx ia II C T6 complete code for TUFFY® T3 SWITCH MECHANISMS All TUFFY® are available with a selection of switch modules that vary in switch rating (Amp) and max process temperature allowance. The max temperature is dependent upon the housing material selected. Consult table below, before selecting the proper module in the order number structure on pages 9 or 10. 10 Code 0 1 2 3 4 6 Electric switch rating V AC V DC Contacts and type 120 240 24 120 SPDT with silver contacts 10.0 10.0 6.0 0.6 DPDT with silver contacts 10.0 10.0 6.0 0.6 SPDT with gold plated contacts 0.1 0.1 DPDT with gold plated contacts 0.1 0.1 HS SPDT with silver contacts 1.0 1.0 3.0 0.5 HS SPDT with gold plated contacts 0.5 0.5 0.5 0.5 Process temperature range @ 40 °C (100 °F) ambient temp. Cast Iron Cast Aluminium -40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F) -40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F) -40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F) -40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F) -55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F) -55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F) 11 IMPORTANT SERVICE POLICY Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour and the parts required to rebuild or replace the equipment. In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of our warranty. No claims for misapplication, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. 6. Purchaser Name Description of Material Serial Number and Ref Number Desired Action Reason for Return Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. 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