44-604.18 Top Mount IO

Top Mounting
T20 and T21
Installation and Operating Manual
Liquid
Level
Switches
Read this Manual Before Installing
This manual provides information on the Top Mounting
Liquid Level Switch. It is important that all instructions
are read carefully and followed in sequence. Detailed
instructions are included in the Installation section of
this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey
specific types of information. General technical material,
support data, and safety information are presented in
narrative form. The following styles are used for notes,
cautions, and warnings.
NOTES
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that
could injure personnel, damage equipment, or reduce
a component’s mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific
materials. In this manual, a caution box indicates a
potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
WARNINGS
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, if not avoided,
could result in serious injury or death.
Safety Messages
Follow all standard industry procedures for servicing electrical equipment when working with or around high
voltage. Always shut off the power supply before touching
any components.
WARNING! Explosion hazard. Do not connect or dis-
connect equipment unless power has been switched off or
the area is known to be non-hazardous.
2
Low Voltage Directive
For use in Category II installations. If equipment is used
in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
Notice of Trademark, Copyright, and Limitations
Magnetrol® & MAGNETROL logotype are registered
trademarks of MAGNETROL International.
Copyright © 2016 MAGNETROL International,
Incorporated. All rights reserved.
Performance specifications are effective with date of
issue and are subject to change without notice.
MAGNETROL reserves the right to make changes to
the product described in this manual at any time without notice. MAGNETROL makes no warranty with
respect to the accuracy of the information in this
manual.
Warranty
All MAGNETROL mechanical level and flow controls
are warranted free of defects in materials or workmanship
for five full years from the date of original factory shipment.
If returned within the warranty period; and, upon factory
inspection of the control, the cause of the claim is
determined to be covered under the warranty; then,
MAGNETROL will repair or replace the control at no
cost to the purchaser (or owner) other than transportation.
MAGNETROL shall not be liable for misapplication,
labor claims, direct or consequential damage or expense
arising from the installation or use of equipment. There
are no other warranties expressed or implied, except special written warranties covering some MAGNETROL
products.
Quality Assurance
The quality assurance system in place at MAGNETROL
guarantees the highest level of quality throughout the
company. MAGNETROL is committed to providing full
customer satisfaction both in quality products and quality
service.
MAGNETROL’s quality assurance system is registered to ISO 9001 affirming
its commitment to known international
quality standards providing the strongest
assurance of product/service quality
available.
44-604 Top Mounting Liquid Level Switches
Top Mounting
Liquid Level Switches
Table of Contents
1.0 Introduction
1.1 Principle of Operation...........................................4
2.0 Installation
2.1 Unpacking.............................................................4
2.2 Critical alarm function ..........................................5
2.3 Mounting ..............................................................5
2.4 Wiring...................................................................6
3.0 Switch Differential Adjustment ...................................8
4.0 Preventive Maintenance
4.1 What to do..........................................................10
4.1.1 Keep control clean ....................................10
4.1.2 Inspect switch mechanisms, terminals,
and connections monthly .........................10
4.1.3 Inspect entire unit periodically..................11
4.2 What to avoid .....................................................11
44-604 Top Mounting Liquid Level Switches
5.0 Reference Information
5.1 Troubleshooting...................................................12
5.1.1 Check switch mechanism..........................12
5.1.2 Check complete unit ................................13
5.2 Agency Approvals ................................................14
5.3 Specifications.......................................................15
5.3.1 Physical.....................................................15
5.4 Replacement Parts ...............................................16
5.4.1 Model T20 Parts Identification.................16
5.4.1.1 Model T20......................................17
5.4.1.2 Mounting flanges ............................17
5.4.1.3 Switch and housing reference ..........17
5.4.2 Model T21 Parts Identification.................18
5.4.2.1 Model T21......................................19
5.4.2.2 Mounting flanges and
guide cage gaskets............................19
5.4.2.3 Switch and housing reference ..........19
5.5 Model Numbers ..................................................20
5.5.1 Model T20 ...............................................20
5.5.2 Model T21 ...............................................22
3
1.0
T20 and T21 level switches are float operated units
designed for top mounting to a tank or vessel by means of
threaded or flanged pipe connections. T20 standard units
are equipped with a single switch mechanism for high or
low level alarm or control applications. T21 tandem units
are equipped with two switch mechanisms, each operated
by a separate float, for applications requiring widely spaced
separate high and low level switch actuation.
2
5
Introduction
Pivot
6
4
Return
Spring
1
1.1
Principle of Operation
The simple and foolproof operation of the top mounted
float switches is illustrated in figures 1 and 2.
3
A permanent magnet ➀ is attached to a pivoted switch
actuator and adjustment screw ➁. As the float ➂ rises
following the liquid level, it raises the attraction sleeve ➃
into the field of the magnet, which then snaps against the
non-magnetic enclosing tube ➄, actuating the switch ≈.
The enclosing tube provides a static pressure boundary
between the switch mechanism and the process. On a
falling level, an inconel spring retracts the magnet,
deactivating the switch.
Process Liquid
Rising Level
Figure 1
2.0
Installation
This section provides detailed procedures for properly
installing top mounted level switches.
Process Liquid
Falling Level
Figure 2
Caution: If equipment is used in a manner not specified by the
manufacturer, protection provided by the equipment may
be impaired.
2.1
Unpacking
Unpack the instrument carefully. Inspect all units for
damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip against
purchase order. Check and record the model number
against serial number for future reference when ordering
parts.
Model Number
Serial Number
4
44-604 Top Mounting Liquid Level Switches
2.2
Critical alarm function
It is recommended that for critical alarm functions, an
additional level switch be installed as a high–high or low–
low level alarm for maximum protection.
2.3
Mounting
Caution: Operation of all buoyancy type level devices should be done
in such a way as to minimize the action of dynamic forces
on the float or displacer sensing element. Good practice for
reducing the likelihood of damage to the control is to equalize pressure across the device very slowly.
Ensure that no tubes, rods, or other obstacles in the tank
or vessel which could interfere with the operation of
float(s).
Caution: This instrument is intended for use in Installation Category II,
Pollution Degree 2.
Adjust the process connection as required to bring control
to a vertical position. MAGNETROL controls must be
mounted within three degrees of vertical in all directions.
A three degree slant is noticeable by eye, but installation
should be checked with a spirit level on top and/or sides of
float stem or enclosing tube.
NOTE: Do not insulate switch mechanism housing.
On controls equipped with pneumatic switch assemblies,
consult bulletin on mechanism furnished for air (or gas)
piping instructions.
Switch Series
Letter
44-604 Top Mounting Liquid Level Switches
Description
B, C, D
Dry Contact Switch
F
Hermetically Sealed Snap Switch
HS
Hermetically Sealed Snap Switch
Bulletin
No.
42-683
42-694
J
Bleed Type Pneumatic Switch
42-685
K
Non-Bleed Type Pneumatic Switch
42-686
R, 8, 9
High Temperature Switch
42-799
5
2.4
Wiring
Caution: All Top Mounting units are shipped from the factory with
the enclosing tube tightened and the switch housing set
screw locked to the enclosing tube. Failure to loosen the
set screw prior to repositioning the supply and output
connections may cause the enclosing tube to loosen,
resulting in possible leakage of the process liquid or vapor.
Screw
Top mounting controls are shipped with the conduit entry
of the switch housing placed 180° opposite the tank connections to simplify installation in most cases. If the location of the conduit entry on the level switch is appropriate
to the installation, proceed to Step 4 to begin wiring the
unit. If another configuration is desired, the switch housing
can be easily rotated by first following Steps 1, 2, and 3.
Set Screw
Screw
Figure 3
Housing Set Screws
NOTE: A switch or circuit breaker shall be installed in close proximity
to equipment and within easy reach of operator. It shall be
marked as the disconnecting device for the equipment.
Internal Circuit
(Left) Switch
5
4
1
6
Close on high level Load
Common
Internal Circuit
(Right) Switch
2
3
Load Close on high level
1. Loosen set screw(s) at base of switch housing. Refer to
Figure 3.
2. Switch housing may be rotated 360° to allow correct positioning of conduit outlet.
3. Tighten set screw(s) at base of switch housing.
4. Unscrew and remove switch housing cover. The threads
have been lubricated to facilitate removal.
Common
Close on
low level Load
Close on
Load low level
Line
Line
Figure 4
Terminal Connections
DPDT Switch Mechanism
Series B, C, and D
NOTE: For supply connections use wire with a minimum rating of
75 °C, as required by process conditions. Use a minimum
of 14 AWG wire for power and ground field wires. On high
temperature applications (above 250 °F [121 °C] at mounting
flange or bushing), high temperature wire should be used
between control and first junction box located in a cooler area.
On non-hazardous applications, flexible conduit may be used
between the control and the first junction box.
5. The switch terminals are located next to the conduit outlet
to facilitate wiring. Bring supply wires through conduit
outlet. Route extra wire around enclosing tube under the
baffle plate, and connect them to the proper terminals.
Refer to the wiring diagram, Figure 4, or your switch
bulletin for this information.
6
44-604 Top Mounting Liquid Level Switches
6. Dress wiring to ensure no interference or contact with
the switch actuation arm, or replacement of switch
housing cover.
NOTE: Observe all applicable electrical codes and proper wiring
procedures.
Prevent moisture seepage into the enclosure by installing
approved seal-drain fittings in the conduit run leading into
the unit.
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and the enclosure cover is screwed
down securely.
7. Replace housing cover.
8. If control has been furnished with an explosion proof or
moisture proof switch housing, it must be sealed at the
conduit outlet with a suitable compound or non-hardening sealant to prevent entrance of air.
9. Test switch action by varying liquid level in the tank or
vessel. The upper switch on Model T21 units is actuated
by movement of the lower float, while the lower switch is
actuated by the upper float.
NOTE: If switch mechanism fails to function properly, check vertical
alignment of control housing and consult installation bulletin
on switch mechanism furnished.
10. Check cover to base fit to be certain gasketed joint is tight.
A positive seal is necessary to prevent infiltration of moisture laden air or corrosive gasses into switch housing.
44-604 Top Mounting Liquid Level Switches
7
3.0
Switch Differential Adjustment
The standard differential of the single float Model T20
may be field adjusted. Adjustment may be necessary if
a wider differential needs to be set to overcome switch
chatter caused by the process.
The differential, or the amount of level travel between
switch-on and switch-off, may be adjusted by repositioning the lower jam nuts on the float stem. The standard factory setting is for a minimum amount of play (gap)
between the top jam nuts and the attraction sleeve as
shown in Figure 6.
NOTE: For assistance in computing level differential change for a
specific control, consult the factory giving the model and
serial numbers of the control.
Caution: Maximum differential adjustment is 0.50 inch.
NOTE: To widen the differential 0.50 inch, the lower jam nuts must
be set proportionately lower on the stem (i.e., in this example
0.50 inch).
Switch housing
cover
Enclosing tube
Refer to Figures 6 and 7
Conduit
connection
Housing base
Enclosing tube nut
Caution: Before attempting any work on the control, pull disconnect switch, or otherwise assure that electrical circuit(s)
through the control is deactivated. Close operating medium supply valve on controls equipped with pneumatic
switch mechanisms.
1.
2.
3.
4.
Float
Figure 5
Determine what change in differential is necessary.
Make sure power source is turned off.
Unscrew and remove switch housing cover.
Disconnect power supply wires from switch mechanism.
Pull wires out of conduit connection opening in housing
base. Refer to Figure 5.
5. Perform system shut-down procedures as required to
relieve pressure from tank or vessel and drain off liquid
head, if required. Allow unit to cool.
NOTE: The amount of level travel between switch-on and switch-off
actuation (differential) may be field adjusted by repositioning
the lower jam nuts on the float stem. The standard factory
setting is for a minimum amount of play (gap) between the
top jam nuts and the attraction sleeve, as shown in Figure 6.
This setting may be increased to a maximum of 0.50"
(13 mm), as shown in Figure 7.
6. Remove switch housing assembly by loosening the enclosing tube nut, which is located immediately below housing
base. Refer to Figure 5.
8
44-604 Top Mounting Liquid Level Switches
7. With switch housing and enclosing tube removed, jam
nuts and attraction sleeve are accessible. Measure position
of upper jam nuts from stem end; then loosen and remove
upper jam nuts, guide washer, and attraction sleeve.
8. Loosen and adjust lower jam nuts to desired position.
Make certain jam nuts are retightened securely.
NOTE: Use new enclosing tube gasket in assembly of switch housing
to the mounting bushing or flange. Refer to Sections 5.4.1.1
and 5.4.2.1 for enclosing tube gasket part numbers.
9. Test switch actuation by varying liquid level in tank or
vessel.
Caution: Instructions given are for standard base model units which
use a single magnet switch mechanism only. No differential adjustment should be attempted on tandem float models in the field. Switch actuation levels have been set at
the factory to meet specific customer specifications.
Variations in actual conditions from design conditions
usually requires special control modifications. Consult
with the factory or local representative for assistance.
For access to bottom
jam nuts, mark position,
remove top jam nuts,
Replace in
washer, and attracting same position
sleeve.
Slight play (gap)
must be allowed
(.03" [.8 mm] typical)
Position of bottom
jam nuts (normal
factory setting)
Maximum gap setting
(Applies to models having
0.50"
a single switch mechanism
(13 mm)
with a single magnet
actuator only)
Drop bottom jam nuts to
increase gap setting
(see instructions below)
CAUTION: After increasing gap setting, be certain to
check for proper operation of switch mechanism by raising and lowering float assembly. Magnet must snap
cleanly, with additional float movement available after
magnet snaps.
Float
Figure 6
Normal Factory Setting
(minimum differential)
44-604 Top Mounting Liquid Level Switches
Figure 7
Differential
adjustment
9
4.0
Preventive Maintenance
Periodic inspections are a necessary means to keep your
level control in good working order. This control is a safety device to protect the valuable equipment it serves.
Therefore, a systematic program of “preventive maintenance” must be implemented when the control is placed
into service. If the following sections on “what to do” and
“what to avoid” are observed, your control will provide
reliable protection of your equipment for many years.
4.1
What to do
4.1.1 Keep control clean
Be sure the switch housing cover is always in place on the
control. This cover is designed to keep dust and dirt from
interfering with 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 or any seals become
damaged or misplaced, obtain a replacement immediately.
4.1.2 Inspect switch mechanisms, terminals, and
connections monthly
1. Switches should be inspected for excessive wear on actuating
lever or misalignment of adjustment screw at point of
contact between screw and lever. Such wear can cause false
switch actuating levels. See switch mechanism bulletin
supplied with control should switch adjustment or
replacement be necessary.
2. DO NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch
mechanisms furnished for service instructions.)
3. Level controls may sometimes be exposed to excessive heat
or moisture. Under such conditions, insulation on electrical wiring may become brittle, eventually breaking or
pealing away. The resulting “bare” wires can cause short
circuits.
NOTE: Check wiring carefully and replace at the first sign of brittle
insulation.
4. Vibration may sometimes cause terminal screws to work
loose. Check all terminal connections to be certain that
screws are tight.
10
44-604 Top Mounting Liquid Level Switches
5. On units with pneumatic switches, air (or gas) lines subjected to vibration, may eventually crack or become loose
at connections causing leakage. Check lines and connections carefully and repair or replace, if necessary.
NOTE: As a matter of good practice, spare switches should be kept
on hand at all times.
4.1.3 Inspect entire unit periodically
Isolate control from vessel. Raise and lower liquid level to
check for switch contact and reset.
4.2
What to avoid
1. Never leave switch housing cover off the control longer
than 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, be
certain it is removed before placing control into service.
3. Never attempt to make adjustments or replace switches
without reading instructions carefully. Certain adjustments
provided for in level controls should not be attempted in
the field. When in doubt, consult the factory or your local
representative.
4. Never use lubricants on pivots of switch mechanisms.
A sufficient amount of lubricant has been applied at the
factory to ensure a lifetime of service. Further oiling is
unnecessary and will only tend to attract dust and dirt
which can interfere with mechanism operation.
44-604 Top Mounting Liquid Level Switches
11
5.0
Reference Information
5.1
Troubleshooting
Usually the first indication of improper operation is failure
of the controlled equipment to function, (i.e.: pump will
not start (or stop), signal lamps fail to light, etc.) When
these symptoms occur, whether at time of installation or
during routine service thereafter, check the following
potential external causes first.
a. Fuses may be blown.
b. Reset button(s) may need resetting.
c. Power switch may be open.
d. Controlled equipment may be faulty.
e. Wiring leading to control may be defective.
If a thorough inspection of these possible conditions fails
to locate the trouble, proceed next to a check of the
control's switch mechanism.
5.1.1 Check switch mechanism
1. Pull disconnect switch or otherwise disconnect power to
the control.
2. Remove switch housing cover.
3. Disconnect power wiring from switch assembly.
4. Swing magnet assembly in and out by hand to check carefully for any sign of binding. Assembly should require
minimal force to move it through its full swing.
5. If binding exists, magnet may be rubbing enclosing tube.
If magnet is rubbing, loosen magnet clamp screw and shift
magnet position. Retighten magnet clamp screw.
6. If switch magnet assembly swings freely and mechanism
still fails to actuate, check installation of control to be
certain it is within the specified three degrees of vertical.
(Use spirit level on side of enclosing tube in two places,
90° apart.
7. Check the continuity of the microswitch with ohmmeter.
Replace immediately if found defective.
8. If switch mechanism is operating satisfactorily, proceed to
check sensing unit.
12
44-604 Top Mounting Liquid Level Switches
5.1.2 Check complete unit
1. Reconnect power supply and carefully actuate switch
mechanism manually (using a non-conductive tool) to
determine whether controlled equipment will operate.
Caution: With electrical power on, care should be taken to avoid
contact with switch leads and connections at terminal
block.
2. If controlled equipment responds to manual actuation test,
trouble may be located in the level sensing portion of the
control–float(s), stem(s), and magnetic attraction sleeve(s).
NOTE: Ensure that liquid is entering the storage tank or vessel.
A valve may be closed or a pipe line plugged.
Caution: Be certain to pull disconnect switch or otherwise ensure
that electrical circuit(s) through control is deactivated.
Close operating medium supply valve on controls
equipped with pneumatic switch mechanisms.
3. With liquid in tank or vessel, raise the liquid level above
the set points. Magnets should “pull-in” on rising level. On
Model T21 the lower float actuates the upper switch, and
the upper float actuates the lower switch. If magnets fail to
“pull-in”, lower the level and purge pressure.
a. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit or operating
medium line connections to switch housing.
b. Remove switch housing assembly by loosening hex nut,
which is located immediately below housing base.
4. With switch housing assembly removed, inspect attraction
sleeve(s) and inside of enclosing tube for excessive corrosion or solids buildup, which could restrict movement,
preventing sleeve(s) from reaching field of switch
magnet(s).
5. If differential has been changed in the field by repositioning the lower jam nuts on the float stem, check tightness
and position of the jam nuts. Refer to Figure 6.
NOTE: Differential adjustment affects a change in the amount of level
travel between switch-on and switch-off actuation. Do not
attempt adjustment without first consulting factory for assistance in computing level differential change for your control.
44-604 Top Mounting Liquid Level Switches
13
6. Check float to be certain it is buoyant in the liquid (tank
or vessel must have adequate liquid level). If float is determined to be filled with liquid, or it is collapsed, it must be
replaced immediately. Do not attempt to repair a float.
If all components in the control are in operating condition,
the trouble must be (and should be) located external to the
control. Repeat inspection of external conditions previously
described.
When communicating about your control, be certain to
always specify the complete Model and Serial numbers.
5.2
Agency Approvals
AGENCY
MODEL APPROVED
APPROVAL CLASSES
FM
All with an electric switch mechanism and a housing
listed as TYPE 4X/7/9
Class I, Div 1, Groups C & D
Class II, Div 1, Groups E, F & G
All with an electric switch mechanism and a housing
listed as TYPE 4X/7/9 Class I, Div 1, Group B
Class I, Div 1, Groups B, C & D
Class II, Div 1, Groups E, F & G
All with a Series HS, F, 8 or 9 electric switch
mechanism and a housing listed as CSA TYPE 4X
Class I, Div 2, Groups A, B, C & D
All with an electric switch mechanism and a housing
listed as TYPE 4X/7/9
Class I, Div 1, Groups C & D
Class II, Div 1, Groups E, F & G
All with an electric switch mechanism and a housing
listed as TYPE 4X/7/9 Class I, Div 1, Group B
Class I, Div 1, Groups B, C & D
Class II, Div 1, Groups E, F & G
All with an electric switch mechanism and an
ATEX housing ➀
ATEX II 2 G EEx d IIC T6
94/9/EC
IEC Ex Ex d IIC T6
IP 66
Low Voltage Directives 2006/95/EC
Per Harmonized Standard:
EN 61010-1/1993 & Amendment No. 1
Installation Category II
Pollution Degree 2
CSA
ATEX / IEC Ex ➁
CE
➀ Dual stage units with ‘HS’ switches are not ATEX approved.
➁ IEC Installation Instructions:
The cable entry and closing devices shall be Ex d certified suitable for the conditions of use
and correctly installed.
For ambient temperatures above +55 °C or for process temperatures above +150 °C, suitable
heat resistant cables shall be used.
Heat extensions (between process connection and housing) shall never be insulated.
Special conditions for safe use:
When the equipment is installed in process temperatures higher than +85 °C the temperature
classification must be reduced according to the following table as per IEC60079-0.
14
Maximum Process
Temperature
Temperature
Classification
< 85 °C
T6
< 100 °C
T5
< 135 °C
T4
< 200 °C
T3
< 300 °C
T2
< 450 °C
T1
These units are in conformity with IECEx KEM 05.0020X
Classification Ex d IIC T6
Tambient -40 °C to +70 °C
44-604 Top Mounting Liquid Level Switches
5.3
Specifications
5.3.1 Physical inches (mm)
B
B
A
A
6.25*
(158)
6.25*
(158)
7.94*
(201)
7.94*
(201)
2.44
(61)
1.81 (45) Ref.
1" NPT
Distance to
actuating level
(4" min.
Distance to
actuating level
(4" min)
Actuating
level
Actuating
level
Model T20 with flange
Model T20 with 1" NPT
* These dimensions increase by 2.19 (55) when unit is
supplied with an HS switch with terminal block.
B
A
8.46
(214)
Housing ➀
A
B
Conduit Connections
TYPE 4X/7/9,
Group B
5.93
(151)
3.87
(98)
1" NPT dual entry
4.70
(119)
5.00
(127)
NEMA 1 ➁
Pneumatics
10.12
(257)
1
⁄4" NPT single entry
➀ All housings rotatable 360°.
➁ Pneumatic switches available with Series T20 units only.
1.81 (45) Ref.
Distance to
upper actuating
level (4" min.)
Actuating
level
8" min.
Actuating
level
Distance
to lower
actuating
level
Distance To
Maximum
Minimum
Upper level
40" (1016)
4" (102)
Lower level
48" (1219)
12" (305)
NOTE: On Model T21 the lower float actuates
upper switch mechanism. The upper float
actuates the lower switch mechanism.
Model T21 with flange
44-604 Top Mounting Liquid Level Switches
15
5.4
Replacement Parts
1
5
3
6
4
2
11
10
9
12
7
8
5.4.1 Model T20 Parts Identification
Item
1
2
3
4
5
6
7
8
9
10
11
12
16
Description
Housing cover
Housing base
Switch mechanism
Attraction sleeve
Jam nuts
Guide washer(s)
Float stem
Float
Adaptor bushing/guide tube assembly
Enclosing tube gasket
Enclosing tube
Mounting flange
44-604 Top Mounting Liquid Level Switches
5.4.1.1 Model T20
T20-1
Housing cover
Housing base
Switch mechanism
Stem kit: includes items 4, 5, 6, & 7
Float: 3.00" ¥ 5.00"
T20-4
See below
See below
See below
Consult factory
Z07-1202-003
3.50" ¥ 6.00"
Z07-1202-009
4.00"
4.50"
Adaptor bushing/guide tube assembly
Float stem
Enclosing tube gasket
Enclosing tube
Mounting flange
Z07-1102-008
Z07-1102-009
Consult factory
Consult factory
012-1301-002
Z32-6325-001
Z32-6325-002
See below
5.4.1.2 Mounting flanges
4"
5"
6"
8"
flange
flange
flange
flange
125 lb cast iron
Z04-5840-001
Z04-5840-002
Z04-5840-003
Z04-5840-004
150 lb forged steel 300 lb forged steel 150 lb forged 304
Z04-5840-011
Z04-5840-016
004-5840-021
Z04-5840-012
Z04-5840-017
004-5840-022
Z04-5840-013
Z04-5840-018
004-5840-023
Z04-5840-014
Z04-5840-019
004-5840-024
150 lb forged 316
004-5840-026
004-5840-027
004-5840-028
004-5840-029
5.4.1.3 Switch and housing reference
Dry contact
Hermetically sealed
Hermetically sealed
Bleed type pneumatic
Non-bleed type pneumatic
High Temperature
Series Type
B, C, D
F
HS
J
K
R, 8, 9
Bulletin#
42-683
42-683
42-694
42-685
42-486
42-799
Important: When ordering spare parts, please specify:
A. Model and serial numbers.
B. Name and part number of replacement part or assembly.
All replacement parts are for standard models only. Consult your local representative for ordering assistance on all
specially modified models (model numbers preceded by an X).
44-604 Top Mounting Liquid Level Switches
17
5.4
Replacement Parts
1
3
5
6
4
10
9
2
14
13
12
15
17
11
16
7
8
18
5.4.2 Model T21 Parts Identification
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Housing cover
Housing base
Switch mechanism
Upper attraction sleeve
Jam nuts
Guide washer(s)
Upper stem assembly
Lower float
Lower attraction sleeve, stop tube, and washers
Retaining rings
Upper float and tube assembly
Adaptor bushing
Enclosing tube gasket
Enclosing tube
Mounting flange
Float guide cage (optional)
Float guide cage gasket (optional)
44-604 Top Mounting Liquid Level Switches
5.4.2.1 Model T21
T21-1
Housing cover
Housing base
T21-4
See below
See below
Switch mechanism
Float stem kit: includes items 4, 5, 6, & 7
Lower float: 3" ¥ 5"
See below
Consult factory
Z07-1201-003
Z07-1202-003
4.00"
4.50"
Upper float and tube assembly kit: includes items 9, 10, & 11
Adaptor bushing
Enclosing tube gasket
Enclosing tube
Mounting flange
Guide cage kits: includes items 16 & 17
Z07-1101-015
Z07-1102-008
Z07-1102-009
Consult factory
Z04-5734-110
004-5734-123
012-1301-002
Z32-6325-004
Z32-6325-005
See below
Consult factory
5.4.2.2 Mounting flanges
4"
5"
6"
8"
flange
flange
flange
flange
125 lb cast iron
Z04-5840-001
Z04-5840-002
Z04-5840-003
Z04-5840-004
150 lb forged steel 300 lb forged steel 150 lb forged 304
Z04-5840-011
Z04-5840-016
004-5840-021
Z04-5840-012
Z04-5840-017
004-5840-022
Z04-5840-013
Z04-5840-018
004-5840-023
Z04-5840-014
Z04-5840-019
004-5840-024
150 lb forged 316
004-5840-026
004-5840-027
004-5840-028
004-5840-029
5.4.2.3 Switch and housing reference
Dry contact
Hermetically sealed
Hermetically sealed
Bleed type pneumatic
Non-bleed type pneumatic
High Temperature Snap
Series Type
B, C, D
F
HS
J
K
R, 8, 9
Bulletin#
42-683
42-683
42-694
42-685
42-486
42-799
Important: When ordering spare parts, please specify:
A. Model and serial numbers.
B. Name and part number of replacement part or assembly.
All replacement parts are for standard models only. Consult your local representative for ordering assistance on all
specially modified models (model numbers preceded by an X).
44-604 Top Mounting Liquid Level Switches
19
5.5
Model Numbers
5.5.1 Model T20
IMPORTANT: Actuating level(s), in either the rising or falling state, and specific gravity
must be provided upon placement of order.
MODEL NUMBER CODE AND MATERIALS OF CONSTRUCTION
Model No.
T20-1
T20-4
Set Points
Tank Connection
Carbon steel
316 SS
1—Single float
Float and Trim
300 Series SS
316 SS
Sleeve
400 Series SS
316 SS
IMPORTANT: The maximum available insertion depth is governed by the liquid specific gravity and selected
float size as given in the table below. The minimum insertion depth is four inches.
MAXIMUM INSERTION LENGTH inches (mm)
Liquid
Specific
Gravity
1.00
0.90
0.80
0.70
0.60
3.00 x 5.00
(76 x 127)
39 (991)
20 (508)
—
—
—
Float Size
4.00
(102)
48 (1219)
33 (838)
11 (279)
—
—
FLOAT PRESSURE RATINGS
Float Size
4.50
(114)
48 (1219)
48 (1219)
48 (1219)
38 (965)
6 (152)
Inches
(mm)
3.00 x 5.00
(76 x 127)
4.00
(102)
3.50 x 6.00
(89 x 152)
4.50
(114)
Pressure Rating PSIG (bar)
100° F
(38° C)
500
(34)
600
(41)
500
(34)
500
(34)
750° F
(399° C)
377
(26)
483
(33)
403
(27)
403
(28)
900° F
(482° C)
353
(24)
465
(32)
388
(26)
388
(27)
1000° F
(538° C)
335
(23)
459
(32)
383
(26)
383
(26)
TANK CONNECTION AND FLOAT SIZE
Tank Connection ➀
Float Diameter
3.50 x 6.00 (89 x 152)»
3.00 x 5.00 (76 x 127)
4.00 (102)
4.50 (114)
4" 125 lb. C.I. flange ➁ ➂
B2A
B2B
B2C
B2D
H2A
—
—
H2D
4" 150 lb. F.S. flange
H3A
—
—
H3D
4" 300 lb. F.S. flange
H4A
—
—
H4D
1" NPT
5" 125 lb. C.I. flange ➁ ➂
J2A
J2B
J2C
J2D
5" 150 lb. F.S. flange
J3A
J3B
J3C
J3D
5" 300 lb. F.S. flange
6" 125 lb. C.I. flange ➁ ➂
J4A
J4B
J4C
J4D
K2A
K2B
K2C
K2D
6" 150 lb. F.S. flange
K3A
K3B
K3C
K3D
6" 300 lb. F.S. flange
K4A
K4B
K4C
K4D
➀ Flanges are ANSI standard threaded onto 1" NPT bushing. Forged steel
flanges have standard raised face.
➁ Not available with Model T20-4.
➂ Available only in cast iron.
➃ Process temperature based on +100 °F (+38 °C) ambient.
➄ Uncontrolled housing heater or drain available in TYPE 4X/7/9 enclosure.
≈ Consult factory for TYPE 4X/7/9 cast iron housings.
➆ On steam applications, temperature down-rated to +400 °F (+204 °C) process
at +100 °F (+38 °C) ambient.
➇ CSA approval does not apply to Series HE switches.
» Not available when 4" nozzle is sch 160 or greater.
20
44-604 Top Mounting Liquid Level Switches
ELECTRIC SWITCH MECHANISM AND ENCLOSURE
Switch
Description
Series B
Snap Switch
Series C
Snap Switch
Series D DC Current
Snap Switch
T20-1 Models
T20-4 Models
Process ➃
TYPE
4X/7/9
Aluminum
Enclosure
ƒ≈
Temperature
Set
Contacts
Range
ATEX
ATEX
Points Class I, Div 1 Class I, Div 1
Class I, Div 1 Class I, Div 1
Ex II 2 G EEx
Ex II 2 G EEx
°F (°C)
Groups C&D
Group B
Groups C&D
Group B
d IIC T6
d IIC T6
BKP
BKT
BAC
BKQ
BKS
BA9
SPDT
1
-40 to +250
(-40 to +121)
DPDT
1
BNP
BNT
BBC
BNQ
BNS
BB9
SPDT
1
CKP
CKT
CAC
CKQ
CKS
CA9
-40 to +450
(-40 to +232)
DPDT
1
CNP
CNT
CBC
CNQ
CNS
CB9
SPDT
1
DKQ
DKS
DA9
DKQ
DKS
DA9
-40 to +250
(-40 to +121)
DPDT
1
DNQ
DNS
DB9
DNQ
DNS
DB9
Series F
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Series HS
Hermetically Sealed
5-amp Snap Switch
with Wiring Leads
-50 to +550 ∆
(-46 to +288)
Series HS
Hermetically Sealed
5-amp Snap Switch
with Terminal Block
-50 to +550 ∆
(-46 to +288)
Series R
High Temperature
Snap Switch
-40 to +750
(-40 to +399)
Series 8
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Series 9
High Temperature
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Switch
Description
SPDT
1
FKP
FKT
FAC
FKQ
FSS
FA9
DPDT
1
FNP
FNT
FBC
FNQ
FNS
FB9
SPDT
1
HMC
HEK «
HMC
HEK «
HET «
—
HMF
DPDT
1
HMF
HET «
—
SPDT
1
HM3
HM4
HA9
HM3
HM4
HA9
DPDT
1
HM7
HM8
HB9
HM7
HM8
HB9
SPDT
1
RKQ
RKS
RA9
RKQ
RKS
RA9
DPDT
1
RNQ
RNS
RB9
RNQ
RNS
RB9
SPDT
1
8KP
8KT
8AC
8KQ
8KS
8A9
DPDT
1
8NP
8NT
8BC
8NQ
8NS
8B9
SPDT
1
9KP
9KT
9AC
9KQ
9KS
9A9
DPDT
1
9NP
9NT
9BC
9NQ
9NS
9B9
Process ➃
CS/Aluminum
CS/Aluminum
Cast Iron
Cast Iron
Set
Temp. Range Contacts
Class
I,
Div
1
Class
I,
Div
1
Class
I,
Div
1 Class I, Div 1
Points NEMA 4X
NEMA 4X
°F (°C)
Groups C&D
Group B
Groups C&D
Group B
Series R
High Temperature
Snap Switch
-40 to +1000
(-40 to +538)
Series 9
High Temperature
Hermetically Sealed
Snap Switch
-50 to +1000
(-46 to +538)
SPDT
1
R1Y
RKY
RKW
R1Y
RKY
RKW
DPDT
1
RDY
RNY
RNW
RDY
RNY
RNW
SPDT
1
9AR
9KR
9KV
9AY
9KY
9KW
DPDT
1
9DR
9NR
9NV
9DY
9NY
9NW
PNEUMATIC SWITCH MECHANISM AND ENCLOSURE
Switch
Description
Series J
Bleed Type
Series K
Non-Bleed
Maximum
Maximum
Supply
Process
Pressure Temperature
100 psig
(7 bar)
400° F
(204° C)
60 psig
(4 bar)
60 psig
700° F
(4 bar)
(371° C)
100 psig
(7 bar)
400° F
(204° C)
40 psig
(3 bar)
Bleed Orifice NEMA 1
Diameter
44-604 Top Mounting Liquid Level Switches
.063
(1.6 mm)
.094
(2.4 mm)
.055
(1.4 mm)
JDE
JEE
JFE
—
KOE
—
KOG
21
5.5
Model Numbers
5.5.2 Model T21
IMPORTANT: Actuating level(s), in either the rising or falling state, and specific gravity
must be provided upon placement of order.
MODEL NUMBER CODE AND MATERIALS OF CONSTRUCTION
Model No.
T21-1
T21-4
Set Points
Tank Connection
Carbon steel
316 SS
2—Tandem float
Float and Trim
300 Series SS
316 SS
Sleeve
400 Series SS
316 SS
IMPORTANT: The maximum available insertion depth is governed by the liquid specific gravity and selected
float size as given in the table below. The minimum insertion depth is four inches. The minimum
distance between the top and bottom insertion depths is eight inches.
MAXIMUM INSERTION LENGTH inches (mm)
Float Size
Liquid
3.00 x 5.00
4.00
(76 x 127)
(102)
Specific
Gravity Upper Lower Upper Lower
21
48
32
48
1.00
(533) (1219) (813) (1219)
9
30
18
44
0.90
(229) (762) (457) (1118)
4
21
0.80
—
—
(102) (533)
0.70
—
—
—
—
4.50
(114)
Upper Lower
40
48
(1016) (1219)
40
48
(1016) (1219)
40
48
(1016) (1219)
21
48
(533) (1219)
FLOAT PRESSURE RATINGS
Float Size
Inches (mm)
3.00 x 5.00
(76 x 127)
4.00
(102)
4.50
(114)
100 °F
(38 °C)
500
(34)
600
(41)
500
(34)
Pressure Rating PSIG (bar)
750 °F
900 °F
1000 °F
(399 °C)
(482 °C)
(538 °C)
377
(26)
483
(33)
403
(28)
353
(24)
465
(32)
388
(27)
335
(23)
459
(32)
383
(26)
TANK CONNECTION AND FLOAT SIZE
Tank Connection ➀
4" 125 lb. C.I. flange ➁ ➂
4" 150 lb. F.S. flange
5" 125 lb. C.I. flange ➁ ➂
5" 150 lb. F.S. flange
6" 125 lb. C.I. flange ➁ ➂
6" 150 lb. F.S. flange
6" 300 lb. F.S. flange
3.00 x 5.00 (76 x 127)
H2A
H3A
J2A
J3A
K2A
K3A
—
Float Diameter
4.00 (102)
—
—
J2B
J3B
K2B
K3B
—
4.50 (114)
—
—
J2C
J3C
K2C
K3C
K4C ➁
➀ Flanges are ANSI standard. Forged steel flanges have standard raised face.
➁ Not available with -4 Materials of Construction.
➂ Available only in cast iron.
➃ Process temperature based on +100 °F (+38 °C) ambient.
➄ Uncontrolled housing heater or drain available in TYPE 4X/7/9 enclosure.
≈ Consult factory for TYPE 4X/7/9 cast iron housings.
➆ On steam applications, temperature down-rated to +400 °F (+204 °C) process
at +100 °F (+38 °C) ambient.
22
44-604 Top Mounting Liquid Level Switches
ELECTRIC SWITCH MECHANISM AND ENCLOSURE
Switch
Description
Series B
Snap Switch
Series C
Snap Switch
Series D DC Current
Snap Switch
T21-1 Models
T21-4 Models
Process ➃
TYPE
4X/7/9
Aluminum
Enclosure
➄≈
Temperature
Set
Contacts
Range
ATEX
ATEX
Points
Class I, Div 1 Class I, Div 1
Class I, Div 1 Class I, Div 1
Ex II 2 G EEx
Ex II 2 G EEx
°F (°C)
Groups C&D
Group B
Groups C&D
Group B
d IIC T6
d IIC T6
SPDT
2
BLA
BLJ
BDC
BLB
BLK
BD9
-40 to +250
(-40 to +121)
DPDT
2
BOA
BOJ
BGC
BOB
BOK
BG9
SPDT
2
CLA
CLJ
CDC
CLB
CLK
CD9
-40 to +450
(-40 to +232)
DPDT
2
COA
COJ
CGC
COB
COK
CG9
SPDT
2
DLB
DLK
DD9
DLB
DLK
DD9
-40 to +250
(-40 to +121)
DPDT
2
DOB
DOK
DG9
DOB
DOK
DG9
Series F
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Series HS
Hermetically Sealed
5-amp Snap Switch
with Wiring Leads
-50 to +550 ➆
(-46 to +288)
Series R
High Temperature
Snap Switch
-40 to +750
(-40 to +399)
Series 8
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Series 9
High Temperature
Hermetically Sealed
Snap Switch
-50 to +750
(-46 to +399)
Switch
Description
SPDT
2
FLA
FLJ
FDC
FLB
FLK
FD9
DPDT
2
FOA
FOJ
FGC
FOB
FOK
FG9
SPDT
2
HMN
HMP
HMN
HMP
HMY
HMZ
—
—
DPDT
2
HMY
HMZ
SPDT
2
RLB
RLK
RD9
RLB
RLK
RD9
DPDT
2
ROB
ROK
RG9
ROB
ROK
RG9
SPDT
2
8LA
8LJ
8DC
8LB
8LK
8D9
DPDT
2
8OA
8OJ
8GC
8OB
8OK
8G9
SPDT
2
9LA
9LJ
9DC
9LB
9LK
9D9
DPDT
2
9OA
9OJ
9GC
9OB
9OK
9G9
Process ➃
Cast Iron
Cast Iron
CS/Aluminum
CS/Aluminum
Set
Temp. Range Contacts
Class
I,
Div
1
Class
I,
Div
1
Class
I,
Div
1 Class I, Div 1
Points NEMA 4X
NEMA 4X
°F (°C)
Groups C&D
Group B
Groups C&D
Group B
Series R
High Temperature
Snap Switch
-40 to +1000
(-40 to +538)
Series 9
High Temperature
Hermetically Sealed
Snap Switch
-50 to +1000
(-46 to +538)
SPDT
2
R3M
RLM
RLW
R3M
RLM
RLW
DPDT
2
REM
ROM
ROW
REM
ROM
ROW
SPDT
2
9BD
9LD
9LV
9BM
9LM
9LW
DPDT
2
9ED
9OD
9OV
9EM
9OM
9OW
44-604 Top Mounting Liquid Level Switches
23
ASSURED QUALITY & SERVICE COST LESS
Service Policy
Return Material Procedure
Owners of MAGNETROL 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.
Controls returned under our service policy must be returned
by Prepaid transportation. MAGNETROL will repair or
replace the control at no cost to the purchaser (or owner)
other than transportation if:
So that we may efficiently process any materials that are
returned, it is essential that a “Return Material
Authorization” (RMA) number be obtained from the factory,
prior to the material's return. This is available through
MAGNETROL’s local representative or by contacting the
factory. Please supply the following information:
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim to
be covered under the warranty.
If the trouble is the result of conditions beyond our control;
or, is NOT covered by the warranty, there will be charges
for labor 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.
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
No claims for misapplication, labor, direct or consequential
damage will be allowed.
705 Enterprise Street • Aurora, Illinois 60504-8149 • 630-969-4000 • Fax 630-969-9489
[email protected] • www.magnetrol.com
Copyright © 2016 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International.
CSA logotype is a registered trademark of Canadian Standards Association
BULLETIN: 44-604.18
EFFECTIVE: March 2016
SUPERSEDES: January 2015