44-607.13 Tuffy II IO

Tuffy® II
Liquid Level Controls
with Electric Switches
Installation and Operating Manual
Side
Mounted
Float Level
Switch
Read this Manual Before Installing
This manual provides information on the Tuffy® II Float
Level Switch. It is important that all instructions are read
carefully and followed in sequence. Detailed installation
and wiring instructions are included in 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 disconnect equipment unless power has been switched off or
the area is known to be non-hazardous.
Notice of Trademark, Copyright, and Limitations
Magnetrol® & Magnetrol® logotype, and Tuffy® are registered
trademarks of Magnetrol® International, Incorporated.
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.
The MAGNETROL 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.
Low Voltage Directive
For use in Installations Category II, Pollution Degree 2.
If equipment is used in a manner not specified by the
manufacturer, protection provided by equipment may be
impaired.
44-607 Tuffy® II Liquid Level Switch
Tuffy® II Liquid Level Controls
with Electric Switches
Table of Contents
1.0 Installation
1.1 Unpacking.............................................................4
1.2 Before You Begin ...................................................4
1.2.1 Site Preparation ..........................................4
1.2.2 Equipment and Tools..................................4
1.3 Mounting ..............................................................5
1.3.1 Mounting an NPT Tuffy® II.......................5
1.3.2 Mounting a Flanged Tuffy® II.....................5
1.3.3 Mounting External Cage Tuffy® II ..............5
1.4 Wiring...................................................................7
1.5 Adjustable Differential...........................................8
1.6 Interface ................................................................9
2.0 Reference Information
2.1 Description ...........................................................9
2.2 Theory of Operation...............................................10
2.3 Troubleshooting...................................................10
2.3.1 External Causes ........................................10
2.3.2 Tuffy® II Causes........................................10
44-607 Tuffy® II Liquid Level Switch
2.4 Preventive Maintenance.......................................12
2.4.1 What to Do ..............................................12
2.4.2 What to Avoid ..........................................13
2.4.3 Switch Mechanism Replacement...............13
2.5 Agency Approvals ................................................14
2.6 Parts ....................................................................14
2.6.1 Replacement Parts ....................................14
2.6.2 Recommended Spare Parts........................14
2.7 Specifications.......................................................15
2.7.1 Functional ................................................15
2.7.2 Performance..............................................15
2.7.3 Switch Temperature Ratings .....................16
2.7.4 Physical.....................................................19
2.8 Model Numbers ..................................................21
2.8.1 Standard Narrow Differential Models .......22
2.8.2 Chamber Model Number .........................23
2.8.3 Interface Models .......................................24
2.8.4 Adjustable Wide Differential Models ........26
1.0
Installation
This section provides detailed procedures for properly
installing the Tuffy® II Liquid Level Switch.
Caution: If equipment is used in a manner not specified by
manufacturer, protection provided by equipment may be
impaired.
1.1
Unpacking
Unpack the instrument carefully. Inspect all units for damage.
Report any concealed damage to the carrier within 24 hours.
Ensure all components have been removed from the packing
material. Check all the contents against the packing slip and
report any discrepancies to the factory. Check the nameplate
model number to ensure that it agrees with the packing slip
and purchase order. Record the serial and model numbers
for future reference when ordering parts.
Model Number
Serial Number
1.2
Tuffy® II Maximum Nozzle Lengths
(distance from face of mounting flange
to end of 3" sch 80 nozzle or the tip of
the mounting threads to the end of 2"
nozzle with ID same as 2" NPT)
T31 or T35
with NPT connection
3.29"
T31, T32, T33, T34 or T35
with flanged connection
3.35"
T3B
5.80"
T3C
4.35"
Figure 1
Maximum nozzle length
Before You Begin
1.2.1 Site Preparation
1. Ensure that the length and inside diameter of the mounting
nozzle are sized correctly for the TUFFY II model and the
required actuation levels. Maximum nozzle lengths for each
model are specified in Figure 1.
2. Ensure that the mounting nozzle or coupling is within 3°
of horizontal. If mounting the TUFFY in an external cage,
ensure that the cage is mounted within 3° of horizontal
and that the top/bottom piping is within 3° of vertical in
all directions.
3. Ensure that the area is free of metallic particles which might
be attracted to the magnet holder/counterbalance and interfere with the function of the TUFFY II.
1.2.2 Equipment and Tools
•
•
•
•
4
No special equipment or tools are required to install
the TUFFY Liquid Level Switch. The following items are
recommended:
Wrenches, flange gaskets and flange bolting appropriate for
process connection(s).
Pipe wrench
Level
Flat head screwdriver
44-607 Tuffy® II Liquid Level Switch
1.3
Mounting
The TUFFY II Liquid Level Switch is available with a 2"
NPT mounting bushing, a variety of flange mountings and
external cages for mounting outside of the vessel.
Caution: This instrument is intended for use in Installation Category II,
Pollution Degree 2.
1.3.1 Mounting an NPT Tuffy® II
Conduit Entry
(down)
1. Apply either Teflon® tape or appropriate lubricant to the
mounting threads to prevent galling.
2. Engage the 2" NPT by hand to avoid damaging threads.
3. Using a pipe wrench, rotate the unit clockwise until threads
are tight in mounting. Ensure that the conduit entry points
down. See Figure 2.
Figure 2
NPT Mounting Orientation
Caution: The TUFFY II must be installed with the conduit connection
pointing downward to ensure correct switching action.
1.3.2 Mounting a Flanged Tuffy® II
1. Have proper flange bolting and gasket on hand.
2. Cut and remove plastic shipping straps.
3. Carefully align TUFFY flange raised face (cladding) with
the face of the vessel mounting flange. Slide the flange on
the control to the vessel mounting flange and align bolt
holes. Ensure that the conduit entry is pointing down.
Conduit Entry
(down)
Figure 3
See Figure 3.
Flanged Mounting Orientation
4. Ensure that the flange gasket is seated properly. Install
flange bolts and nuts.
5. Tighten alternating flange bolts in a star pattern.
Caution: The TUFFY II must be installed with the conduit connection
pointing downward to ensure correct switching action.
Shut–off
Valve
Safety
Check
Valve
CL
Pressure
Vessel
CL
CL
Shut–off
Valve
NPT
Conduit
Connection
Drain Valve
CL
Switch
Actuation
Level
1.3.3 Mounting External Cage Tuffy® II
A typical TUFFY external cage installation is shown in
Figure 4.
1. Install cage so that trappings are within 3° of vertical in all
directions. Check installation with a level.
2. Mount cage as close to vessel as possible to provide more
accurate level in cage. Long pipe runs may result in cooler,
denser liquid than that in the vessel and cause inaccurate
level in the TUFFY cage.
Figure 4
External Cage Mounting
44-607 Tuffy® II Liquid Level Switch
5
6
Figure 5
Figure 6
Terminal Connections
DPDT Dry Contact switch
with silver contacts
Terminal Connections
DPDT Dry Contact switch
with gold contacts
Figure 7
Figure 8
Terminal Connections
SPDT Dry Contact switch
with silver or gold contacts
Terminal Connections SPDT HS switch
with silver or gold contacts
44-607 Tuffy® II Liquid Level Switch
3. Use pipe of sufficient size and strength to support the
control. Provide a hanger or stand to help support the
weight of the cage if necessary.
4. All piping should be straight and free of low spots or pockets.
Lower liquid line should drain toward vessel and upper line
toward control.
5. Shut-off valves are recommended for installation between
the vessel and the cage assembly.
6. Once external cage is mounted, install TUFFY II into cage
per Section 1.3.1 or Section 1.3.2 on page 5.
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.
1.4
Wiring
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.
NOTE: For supply connections in installations with ambient temperature up to +158° F (+70° C), use wire with a minimum rating of
+167° F (+75° C), as required by process conditions.
Installations with ambient temperatures up to +176° F (+80° C)
require wire with a minimum rating of +185° F (+85° C) as
required by the process conditions. Use a minimum of 14 AWG
wire for power and ground field wires.
On high temperature applications above +250° F (+120° C)
process temperature, a suitable heat resistant covered wire
should be used between the TUFFY II and the first junction
box located in a cooler area. On non-hazardous applications,
flexible conduit may be used between TUFFY II and the first
junction box. Conduit should have sufficient slack to permit
removal of the switch assembly.
1. Unscrew and remove switch cover.
2. Pull in supply wires and connect to the proper terminals,
Figure 5, 6, 7 & 8. Please note that some switches are
reverse acting. Be sure to connect to proper terminals
according to wiring diagrams.
NOTE: Ensure that excess wire does not interfere with replacement of
the switch cover or movement of the switch mechanism.
NOTE: The ground screw (green head) is located to the right of the
switch. Housing must be grounded via protective ground screw
in base of housing. Hazardous locations require a conduit seal
within 18" (457 mm) of the conduit connection, and the conduit
must be screwed into the housing a minimum of 5 times.
44-607 Tuffy® II Liquid Level Switch
7
NOTE: For ATEX Flameproof Installations, the cable entry device
must be certified in type protection flameproof enclosure “d”,
suitable for the conditions of use and currently installed.
For ambient temperatures above +55° C, suitable heat resistant
cables must be used.
3. Replace the switch cover.
NOTE: Hand-tighten cover. Then using a persuader, tighten 1⁄4 turn
more. This entire process should take approximately 61⁄2 turns.
4. To prevent the entrance of air, seal housing at the conduit
outlet with a suitable pipe compound.
5. Connect power supply to TUFFY and test switch action by
varying level in vessel.
NOTE: If the switch mechanism fails to function properly, ensure that
the conduit connection is vertically aligned and pointing down.
1.5
Adjustable Differential
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
F
G
Figure 9
Adjustment Plate Stop Position
To determine the best placement of the stops for your application, refer to Figures 9 and 10. By subtracting the actuating level of the lower hole on the adjusting plate on falling
level from the actuating level of the upper hole on the
adjusting plate on rising level, the total level differential
between the switch actuating and resetting can be calculated.
Example 1: To determine the level differential of a unit with
a 7.50" stem and stops positioned in holes L & B, subtract
the actuating level of stop position B with a 7.50" stem
from the actuating level of stop position L.
6.01" - 4.51" = 1.50" level differential
Example 2: The level differential of a unit with a 12.25"
stem and stops positioned in holes C & G is as follows:
7.20"- (-8.06") = 15.26"
Stem
Length
3.75
Rising
7.50
12.25
3.75
Falling 7.50
12.25
A
+0.16
-0.12
-0.43
+1.51
+1.98
+2.61
Pin Position
B
C
D
E
F
G
+1.84 +3.54 +4.87 -1.47 n/a
n/a
+2.49 +5.14 +7.20 -2.65 n/a
n/a
+3.36 +7.20 +10.20 -4.12 n/a
n/a
+3.14 n/a
n/a -0.39 -1.87 -3.21
+4.51 n/a
n/a -0.99 -3.29 -5.37
+6.28 n/a
n/a -1.69 -5.04 -8.06
H
J
K
L
-1.65 n/a +1.52 +4.10
-2.94 n/a +1.99 +6.01
-4.54 n/a +2.62 +8.46
0.16 -2.44 +3.32 n/a
-0.12 -4.16 +4.80 n/a
-0.44 -6.31 +6.71 n/a
Figure 10
Stop Position Actuation Levels
(Inches (± 0.25) at minimum S.G.)
8
44-607 Tuffy® II Liquid Level Switch
Once the desired stop positions are determined, remove the
cotter pins holding the stops in the adjusting plate holes.
Move each stop to the desired location on the adjusting
plate and replace the cotter pins. Ensure that the float stem
is positioned between the two stops.
When determining stop positions, please note that some
stop position combinations are impossible due to the diameter of the float stem. The following combinations are not
possible: Stop positions A & B, A & E, A & H, A & K,
B & C, B & K, C & D, C & K, C & L, D & L, E & F,
E & H, F & H, F & J, F & G and G & J.
1.6
Interface
Each interface unit is calibrated at the factory by precise
positioning of the calibration weight on the float stem.
Do not attempt to adjust calibration in the field. Calibration
weight should not be moved. If unit does not function
properly in interface service, consult factory.
2.0
Reference Information
This section presents an overview of the operation of the
TUFFY II Liquid Level Switches, including information on
troubleshooting common problems, maintenance procedures, listings of agency approvals, lists of replacement and
recommended spare parts, and detailed physical, functional,
and performance specifications.
2.1
Description
The TUFFY II Liquid Level Switches are float actuated
devices designed for horizontal mounting in a tank or vessel
through threaded or flanged pipe connections. The compact
size allows for installation in small vessels while its many features provide a variety of application uses. The single switch
mechanism is available in SPDT or DPDT forms on units
designed for fixed or adjustable, narrow or wide differential,
interface service and offset levels. This manual covers
TUFFY II level switches that have electric switches. For
TUFFY with a pneumatic switch, see bulletin 44-606.
44-607 Tuffy® II Liquid Level Switch
9
2.2
Theory of Operation
The TUFFY II achieves switching action through the use of a
magnetic switch mechanism and a magnet attached to the
float assembly. Separating the two magnets is a non-magnetic
pressure barrier.
The float along with the float magnet moves as the liquid
level changes. The float and switch magnets repel each other
causing movement of the switch magnet assembly, tripping
the switch and making or breaking an electrical circuit.
See Figure 11.
Float Magnet
Non-magnetic
Float holder
(pressure boundary)
2.3
Troubleshooting
The TUFFY II Liquid Level Switch is designed and
engineered for trouble-free operation. Common problems
are discussed in terms of their symptoms and corrective
actions as recommended.
Switch Magnet
Assembly
Figure 11
2.3.1 External Causes
Magnet/Switch Action
Actuating Arm
•
•
•
•
•
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 the time of installation or
during routine service thereafter, check for the following
potential external causes first:
Blown fuses
Tripped reset button(s)
Open power switch
Faulty equipment controlled by level switch
Defective wiring to level switch
2.3.2 Tuffy® II Causes
Magnet
Figure 12
Switch Actuating Arm
and Magnet Assembly
10
1.
2.
3.
4.
If a thorough inspection of these possible conditions fails to
locate the cause of the problem, proceed to a check of the
TUFFY II switch mechanism.
Disconnect power to the level switch.
Remove switch housing cover.
Disconnect power wiring from switch mechanism.
Examine the switch actuating arm and magnet assembly for
evidence of binding or wiring interference. See Figure 12.
The switch and magnet assembly must move throughout its
entire range of motion without interference. If there is any
binding, the ENTIRE switch mechanism (switch and
magnet assembly) must be replaced.
44-607 Tuffy® II Liquid Level Switch
5. If the switch mechanism does move freely, use an electrical
continuity checker to determine if the switch is electrically
functional. Refer to Figures 5, 6, 7 & 8 on page 6 for the
appropriate wiring diagram. If the switch operates properly
when moved mechanically but not when electrically activated, the switch must be replaced.
6. If the switch functions properly both mechanically and electrically but does not activate when the float changes position, remove level switch from service. Check the float
assembly for obstructions or accumulation of particles
which may cause binding. If binding is present in the float
assembly and cannot be cleared by normal cleaning procedures, the entire control must be replaced.
7. If the complete TUFFY II level switch operates properly
when removed from service, check to ensure that liquid is
entering the tank or vessel. A closed valve or clogged
pipeline may prevent movement of the liquid in the vessel.
8. Check the float to make sure it is buoyant in the liquid
(tank or vessel must have adequate level).
9. If the float is determined to be filled with liquid or is
collapsed, the entire level switch must be replaced. Do not
attempt to repair the float.
If all the components of the level switch are in operating
condition, the trouble is located external to the level switch.
Repeat inspection of external conditions as described in
Section 2.3.1, External Causes.
NOTE: When in doubt about the condition or performance of a
TUFFY II control, consult the factory for further instructions.
44-607 Tuffy® II Liquid Level Switch
11
2.4
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.
2.4.1 What to Do
1. Keep control clean.
Be sure the switch housing cover is always in place. This
cover is designed to keep dust and dirt from interfering with
the switch mechanism operation. It also 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 II level switches may at times 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 the 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 II unit periodically.
A periodic cleaning of the float and counterweight assembly
will ensure continued free movement of the mechanism.
12
44-607 Tuffy® II Liquid Level Switch
2.4.2 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.
2.4.3 Switch Mechanism Replacement
1. Have the proper replacement switch mechanism on hand.
See Section 2.6.1 on page 14 for replacement parts.
2. Remove housing cover.
3. Remove the four screws in the corners of the switch
mounting bracket and remove switch mechanism and
magnet assembly.
4. Place new mechanism into the housing.
NOTE: Looking into the switch housing with the conduit connection
pointing downward, the correct orientation of the switch mechanism is with the green head ground screw on the right hand
side of the enclosure.
5. Once it is properly placed, secure the mechanism into the
housing by replacing the four screws in the corners of the
mounting bracket.
6. By moving the level in the vessel or by moving the float by
hand, ensure that the switch actuates properly.
7. Replace housing cover.
44-607 Tuffy® II Liquid Level Switch
13
2.5 Agency Approvals
AGENCY
APPROVED MODEL
PROTECTION METHOD
AREA CLASSIFICATION
FM
T3X-XXXX-XXA
T3X-XXXX-XXB
Explosion Proof
Class I, Div 1; Groups B, C, D
Class II, Div 1; Groups E, F, G
Class III, Type 4X IP66
CSA
T3X-XXXX-XXC
T3X-XXXX-XXD
Explosion Proof
Class I, Div 1; Groups B, C, D
Class II, Div 1; Groups E, F, G
Class III, Div 1; Type 4X
ATEX
T3X-XXXX-XX1
T3X-XXXX-XX2
T3X-XXXX-XX3
T3X-XXXX-XX4
Flame Proof
Certificate ISSeP10ATEX032,
applied standards EN60079-0:2009,
EN60079-1:2007 and
EN60079-26:2007
II 1/2 G Ex d II C T6 Ga/Gb
IP66
T3X-XXXX-XXM
T3X-XXXX-XXN
T3X-XXXX-XXP
T3X-XXXX-XXR
Certificate ISSeP00ATEX010X
applied standards EN50014:1999,
EN50020:1994 and EN50284:1999
T3X-XXXX-XX1
T3X-XXXX-XX2
T3X-XXXX-XX3
T3X-XXXX-XX4
Certificate BKI13.0006 applied
standards IEC60079-0:2011,
IEC60079-1:2007, IEC60079-26:2006
IEC
CE
T3X-XXXX-XXX
Intrinsically Safe ➀
Flame Proof
Low Voltage Directives
2006/95/EC
Per Horizontal Standard:
EN 61010-1/1993 & Amendment No.
II 1G EEx ia II C T6/T4
IP66
Exd IIC T6 Ga/Gb
IP66
Installation Category II
Pollution Degree 2
Special conditions for safe use:
➀ When the material is equipped with an aluminum enclosure, all
precautions shall be taken to avoid all impacts or frictions which
can result in the ignition of the potentially explosive atmosphere.
2.6 Parts
2.6.1 Replacement Parts
Switch
Mechanisms
SPDT silver contacts
DPDT silver contacts
SPDT gold contacts
DPDT gold contacts
HS SPDT silver contacts
HS SPDT gold contacts
31-5144-001
31-5146-001
31-5144-002
31-5146-002
31-5145-001
31-5145-002
Housing
Cover
FM/CSA XP Cast Aluminum
FM/CSA XP Cast Iron
ATEX XP Cast Aluminum
ATEX XP Cast Iron
ATEX IS Cast Aluminum
ATEX IS Cast Iron
089-6609-001
089-6609-002
089-6609-003
089-6609-004
089-6609-005
089-6609-006
Cover O-ring
2.6.2
Item
1
14
12-2201-240
Recommended Spare Parts
Description
Part Number
Switch Mechanism
See replacement parts chart.
44-607 Tuffy® II Liquid Level Switch
2.7
Specifications
2.7.1 Functional
Output
Type
Switch closure, SPDT or DPDT
Ratings
Up to 10 amps @ 120 or 240 VAC, 50–60 Hz
Up to 6 amps @ 24 VDC
Up to 0.6 amps @ 120 VDC
Contacts
Silver, gold plated, hermetically sealed silver,
hermetically sealed gold plated
Housing
Material
Polymer coated cast aluminum or cast iron
Cable entry
3
4
⁄ " NPT
Process Connections
Materials
Carbon Steel
316/316L stainless steel
Hastelloy C
316/316L stainless steel clad carbon steel
Hastelloy C clad carbon steel
Configurations
Tank
2" NPT,
3", 4", 5" & 6" ANSI Flange
Chambered: 1" top-bottom NPT
Wetted parts
Float & Trim
316/316L stainless steel or Hastelloy C
Process Conditions
Process temperature
range
-40° to +750° F (-40° to +400° C) with
ambient temperature within range
specified below
Maximum process
pressure
2630 psig @ +100° F (181 bar @ +38° C)
Liquid specific gravity
0.40 or greater
Environmental
Ambient temperature
range
0° to +100° F (-18° to +38° C)
For ambient temperature outside this range,
derate maximum process temperature per
charts on pages 16–18.
2.7.2 Performance
Repeatability
44-607 Tuffy® II Liquid Level Switch
± 0.25" (± 6mm)
15
2.7.3 Switch Temperature Ratings
Process Temp Range:
Cast Iron Housing
Cast Aluminum Housing
HS with silver contacts
-65° to +750° F (-54° to +399° C)
-65° to +650° F (-54° to +343° C)
HS with gold contacts
-65° to +750° F (-54° to +399° C)
-65° to +650° F (-54° to +343° C)
Snap with silver contacts
-40° to +750° F (-40° to +399° C)
-40° to +650° F (-40° to +343° C)
Snap with gold contacts
-40° to +375° F (-40° to +190° C)
-40° to +325° F (-40° to +162° C)
150
16
44-607 Tuffy® II Liquid Level Switch
2.7.3 Switch Temperature Ratings (continued)
350
44-607 Tuffy® II Liquid Level Switch
17
2.7.3 Switch Temperature Ratings (continued)
18
44-607 Tuffy® II Liquid Level Switch
2.7.4 Physical
Dimensional Specifications – inches (mm)
8.29*
(211)
C
3.29
(84)
4.39
(112)
D
F
G
2" NPT
¾" NPT
2" NPT Narrow Differential Unit (T31, T35)
8.23*
(209)
E
3.35
(85)
4.39
(112)
D
F
G
¾" NPT
Flanged Narrow Differential Unit (T31, T32, T33, T34, T35)
8.23*
(209)
E
3.35
(85)
4.39
(112)
D
F
¾" NPT
G
Interface Unit (T3B)
* This dimension is specific for cast iron housing.
Subtract 0.31" for aluminum housing.
Inches (mm)
Dimension
B
C
D
E
F
G
Maximum
Nozzle Length
T31
—
8.66
(220)
3.59
(91)
8.72
(221)
2.00
(51)
5.25
(133)
3.29
(84)
44-607 Tuffy® II Liquid Level Switch
T32
T33
T34
—
—
—
—
—
—
3.36
(85)
8.02
(204)
2.00
(51)
4.55
(116)
3.35
(85)
3.58
(91)
7.50
(190)
2.38
(60)
4.00
(102)
3.35
(85)
3.59
(91)
7.97
(202)
2.00
(51)
4.50
(114)
3.35
(85)
T35
—
7.86
(199)
3.33
(85)
7.92
(201)
2.00
(51)
4.45
(113)
3.29
(84)
T3B
—
3.75
(95)
T3C
7.5
(190)
12.25
(311)
—
—
—
—
6.78
(172)
17.62
(448)
2.66
(68)
6.00
(152)
5.80
(147)
13.62
(346)
12.86
(327
18.54
(471)
16.61
(422)
2.66
(68)
6.00
(152)
4.35
(110)
24.76
(629)
21.36
(543)
19
2.7.4 Physical (continued)
Dimensional Specifications – inches (mm)
8.23*
(209)
E
3.35
(85)
4.39
(112)
D
F
B
G
¾" NPT
Adjustable Differential Unit (T3C)
(See model number on page 26 for dimension B)
1.31
(33)
(2) 1" NPT
4.50
(114)
Dia.
2" NPT
1.31
(33)
6.40
(163)
11.25 .12
(286 3)
Tuffy® Chamber
* This dimension is specific for cast iron housing.
Subtract 0.31" for aluminum housing.
20
44-607 Tuffy® II Liquid Level Switch
2.8 Model Numbers
Narrow Differential:
Interface Service:
Single Liquid:
Adjustable Differential:
Switch differential of approximately 0.5" (1.7" on interface unit), for actuation of an alarm
or system shutdown.
Switch to detect the interface between two liquids with SGUs that differ by at least 0.1.
Switch to detect the top of layer of a single liquid with no other liquid above it.
Wide switch differential from approximately 1.36" to 18.26" which may be adjusted in the
field by repositioning pins on the adjustment plate.
Basic Model Flow Chart
T3B
Interface
Hastelloy C
Wetted Parts
Narrow
Differential
T33
0.4 min SG
720 psi
T31
0.6 min. SG
1500 psi
T35
300# ANSI
0.4 min. SG
T31
1800 psi
0.6 min. SG
T35
900# ANSI
0.6 min. SG
T32
0.7 min. SG
Up to 2625 psi
T34
NPT Conn
Single Liquid
Carbon Steel
and/or 316 SS
Wetted Parts
Flange Conn
Wide
Differential
T3C
See following pages for complete model selection
44-607 Tuffy® II Liquid Level Switch
21
2.8 Model Numbers
2.8.1 Standard Narrow Differential Models
BASIC MODEL NUMBER
TUFFY II Electric Liquid Level Switch
T3
FUNCTION/FLOAT
Compatible Model Codes
Code
Level
Differential
SGU
Min
Max. ➀
Pressure
psig (bar)
Process
Connection
Size Codes
Process
Connection
Type Codes
Process Connection
Material/Design
Codes
1
0.40
750 (52)
All
N, A, B
A,B,E,F,J,K,N,P,1,2
2
0.60
2220 (153)
3, 4, 5, 6
A, B, C, D
A,B,E,F,J,K,N,P,1,2
3
Narrow
(0.5")
0.65
750 (52)
3, 4, 5, 6
A, B
C,D,G,H,L,M,R,T
4
0.70
2630 (181)
4
E
A,B,E,F,J,K,N,P,1,2
5
0.60
1800 (124)
All
N, A, B, C
A,B,E,F,J,K,N,P,1,2
PROCESS CONNECTION SIZE
Code
Function/Float
Codes
Size
2
2"
3
ANSI 3"
4
ANSI 4"
Compatible Model Codes
Process
Process Connection
Connection
Material/Design
Type Codes
Codes
1, 5
N
B, F, K, P
1, 2, 3, 5
A, B, C, D
All
1, 2, 3, 4, 5
A, B, C, D, E
All
5
ANSI 5"
1, 2, 3, 5
A, B
All
6
ANSI 6"
1, 2, 3, 5
A, B
All
PROCESS CONNECTION TYPE ➀
Code
Type
N
NPT
A
ANSI RF Flange, 150#
B
ANSI RF Flange, 300#
C
ANSI RF Flange, 600#
D
E
ANSI RF Flange, 900#
ANSI RF Flange, 1500#
Compatible Model Codes
Function/ Process
Process Connection
Float
Connection
Material/Design
Codes Size Codes
Codes
1, 5
2
B, F, K, P
1, 2, 3, 5
3, 4, 5, 6
All
1, 2, 3, 5
3, 4, 5, 6
All
2, 5
3, 4
A, B, E, F, J, K, N, P, 1, 2
2, 5
4
3, 4
4
A, B, E, F, J, K, N, P, 1, 2
A, B, E, F, J, K, N, P, 1, 2
PROCESS CONNECTION MATERIAL/DESIGN CODE
SWITCH TYPE
HOUSING MATERIAL/APPROVAL
See opposite page
➀ Rated pressure limited by maximum Float or
Flange pressure, whichever is less.
T
22
3
0
0
complete order code for
TUFFY II Float Level Switch
44-607 Tuffy® II Liquid Level Switch
2.8 Model Numbers
2.8.1 Standard Narrow Differential Models (continued)
PROCESS CONNECTION MATERIAL/DESIGN CODE
ASME B31.1
&
Standard ASME B31.3
NACE
ASME B31.1,
ASME B31.3
& NACE
Process Connection Material
Compatible Model Codes
Process
Process
Function/ Connection Connection
Float Codes Size Codes Type Codes
1
2
N/A
N/A
Carbon Steel Flange and cladding
with 316/316L SS float holder & trim
A
E
J
N
Carbon Steel Flange with
316/316L SS process wetted face
1, 2, 4, 5
3, 4, 5, 6
A, B, C, D, E
B
F
K
P
All 316/316L Stainless Steel
1, 2, 4, 5
All
All
3
3, 4, 5, 6
A, B
3
3, 4, 5, 6
A, B
C
G
L
R
Carbon Steel Flange with
Hastelloy C process wetted face
D
H
M
T
All Hastelloy C
1, 2, 4, 5
3, 4, 5, 6
A, B, C, D, E
SWITCH TYPE
Electric Switch Rating
VAC
VDC
Maximum Process
Temperature ➀➁
Code
Contact Type and Material
120
240
24
120
0
1
2
3
SPDT w/silver contacts
DPDT (dual SPDT) w/silver contacts
SPDT w/gold plated contacts
DPDT (dual SPDT) w/gold plated contacts
10.0
10.0
0.1
0.1
10.0
10.0
—
—
6.0
6.0
0.1
0.1
0.6
0.6
—
—
Cast Iron
Housing
+750° F (+399°
+750° F (+399°
+375° F (+190°
+375° F (+190°
C)
C)
C)
C)
Cast Alum.
Housing
650° F (+343° C)
650° F (+343° C)
325° F (+162° C)
325° F (+162° C)
4
HS SPDT w/silver contacts
1.0
1.0
3.0
0.5
+750° F (+399° C)
650° F (+343° C)
6
HS SPDT w/gold plated contacts
0.5
0.5
0.5
0.5
+750° F (+399° C)
650° F (+343° C)
➀ Maximum process temperature is based on an ambient temperature between 0° and +100° F (-18° and +30° C).
For ambients outside this range, see switch temperature charts on pages 16–18.
➁ See Switch Temperature Ranges on page 16 for minimum process temperatures.
HOUSING MATERIAL/APPROVAL
FM
CSA ATEX Ex d ATEX IS IEC Ex d
A
C
1
M
1
Cast Aluminum, 3⁄4" NPT Conduit Entry
B
D
2
N
2
Cast Iron, 3⁄4" NPT Conduit Entry
3
P
3
Cast Aluminum, M20 ¥ 1.5 Conduit Entry
4
R
4
Cast Iron, M20 ¥ 1.5 Conduit Entry
N/A
2.8.2 Chamber Model Number
MATERIALS OF CONSTRUCTION/PRESSURE RATING
0-001
Carbon Steel
2200 psig @ +400° F (152 bar @ +204° C), 1400 psig @ +750° F (97 bar @ +399° C)
0-002
316 Stainless Steel
2500 psig @ +400° F (172 bar @ +204° C), 2013 psig @ +750° F (139 bar @ +399° C)
1-001
Carbon Steel
1200 psig @ +400° F (83 bar @ +204° C), 780 psig @ +750° F (54 bar @ +399° C)
1-002
316 Stainless Steel
1400 psig @ +400° F (97 bar @ +204° C), 1127 psig @ +750° F (78 bar @ +399° C)
Note: Flanged chambers
and process flanges
available. Consult factory.
Z
3
44-607 Tuffy® II Liquid Level Switch
3
4
7
4
23
2.8 Model Numbers
2.8.3 Interface Models
Process Connection:
Wetted Materials:
Max. Float Pressure:
Min. SG of Lower Liquid:
Min SG difference:
Level Differential:
ANSI Flanges
Carbon steel and/or 316/316L SS
750 psi (52 bar) ➀
0.81
0.1
1.72" (HL=0.82" LL=1.06")
BASIC MODEL NUMBER
TUFFY II Electric Liquid Level Switch
T3
FUNCTION/FLOAT
B
Interface Level
LOWER FLUID SPECIFIC GRAVITY
0.81 0.82 0.83 0.84 0.85 0.86 0.87 0.88 0.89 0.90
A
B
C
D
E
F
G
H
J
K
0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.00
L
M
N
P
R
S
T
U
V
W
Specific Gravity
Code
Specific Gravity
Code
PROCESS CONNECTION SIZE
3
4
5
6
ANSI
ANSI
ANSI
ANSI
3"
4"
5"
6"
PROCESS CONNECTION TYPE ➀
A
B
ANSI RF Flange, 150#
ANSI RF Flange, 300#
➀ Rated pressure limited by maximum Float or Flange pressure, whichever is less.
PROCESS CONNECTION MATERIAL/DESIGN CODE
SWITCH TYPE
HOUSING MATERIAL/APPROVAL
See opposite page
T
24
3
B
0
complete order code for
TUFFY II Float Level Switch
44-607 Tuffy® II Liquid Level Switch
2.8 Model Numbers
2.8.3 Interface Models (continued)
PROCESS CONNECTION MATERIAL/DESIGN CODE
Standard
ASME B31.1
&
ASME B31.3
NACE
ASME B31.1,
ASME B31.3
& NACE
1
2
N/A
N/A
A
E
J
N
Carbon Steel Flange with
316/316L SS process wetted face
B
F
K
P
All 316/316L Stainless Steel
Process Connection Material
Carbon Steel Flange and cladding with
316/316L SS float holder & trim
SWITCH TYPE
Electric Switch Rating
VAC
VDC
Maximum Process
Temperature ➀➁
Code
Contact Type and Material
120
240
24
120
0
1
2
3
SPDT w/silver contacts
DPDT (dual SPDT) w/silver contacts
SPDT w/gold plated contacts
DPDT (dual SPDT) w/gold plated contacts
10.0
10.0
0.1
0.1
10.0
10.0
—
—
6.0
6.0
0.1
0.1
0.6
0.6
—
—
Cast Iron
Housing
+750° F (+399°
+750° F (+399°
+375° F (+190°
+375° F (+190°
C)
C)
C)
C)
Cast Alum.
Housing
650° F (+343° C)
650° F (+343° C)
325° F (+162° C)
325° F (+162° C)
4
HS SPDT w/silver contacts
1.0
1.0
3.0
0.5
+750° F (+399° C)
650° F (+343° C)
6
HS SPDT w/gold plated contacts
0.5
0.5
0.5
0.5
+750° F (+399° C)
650° F (+343° C)
➀ Maximum process temperature is based on an ambient temperature between
0° and +100° F (-18° and +30° C). For ambients outside this range, see switch
temperature charts on pages 16–18.
➁ See Switch Temperature Ranges on page 16 for minimum process temperatures.
HOUSING MATERIAL/APPROVAL
FM
CSA ATEX Ex d ATEX IS IEC Ex d
A
C
1
M
1
Cast Aluminum, 3⁄4" NPT Conduit Entry
B
D
2
N
2
Cast Iron, 3⁄4" NPT Conduit Entry
3
P
3
Cast Aluminum, M20 ¥ 1.5 Conduit Entry
4
R
4
Cast Iron, M20 ¥ 1.5 Conduit Entry
N/A
44-607 Tuffy® II Liquid Level Switch
25
2.8 Model Numbers
2.8.4 Adjustable Wide Differential Models
Process Connection:
Wetted Materials:
Max. Float Pressure:
Min SG:
Level Differential:
ANSI Flanges
Carbon steel and/or 316/316L SS
750 psi (51 bar) ➀
0.78
Adjustable from 1.36" to 18.26"
BASIC MODEL NUMBER
TUFFY II Electric Liquid Level Switch
T3
FUNCTION/FLOAT
C
Adjustable Differential Level
STEM EXTENSION LENGTH “B” DIMENSION (See page 20)
4
8
C
3.75 inch (95 mm) stem extension
7.50 inch (190 mm) stem extension
12.25 inch (311 mm) stem extension
PROCESS CONNECTION SIZE
3
4
5
6
ANSI
ANSI
ANSI
ANSI
3"
4"
5"
6"
PROCESS CONNECTION TYPE ➀
A
B
ANSI RF Flange, 150#
ANSI RF Flange, 300#
➀ Rated pressure limited by maximum Float or Flange pressure, whichever is less.
PROCESS CONNECTION MATERIAL/DESIGN CODE
SWITCH TYPE
HOUSING MATERIAL/APPROVAL
See opposite page
T
26
3
C
0
complete order code for
TUFFY II Float Level Switch
44-607 Tuffy® II Liquid Level Switch
2.8 Model Numbers
2.8.4 Adjustable Wide Differential Models (continued)
PROCESS CONNECTION MATERIAL/DESIGN CODE
Standard
ASME B31.1
&
ASME B31.3
NACE
ASME B31.1,
ASME B31.3
& NACE
1
2
N/A
N/A
A
E
J
N
Carbon Steel Flange with
316/316L SS process wetted face
B
F
K
P
All 316/316L Stainless Steel
Process Connection Material
Carbon Steel Flange and cladding with
316/316L SS float holder & trim
SWITCH TYPE
Electric Switch Rating
VAC
VDC
Maximum Process
Temperature ➀➁
Code
Contact Type and Material
120
240
24
120
0
1
2
3
SPDT w/silver contacts
DPDT (dual SPDT) w/silver contacts
SPDT w/gold plated contacts
DPDT (dual SPDT) w/gold plated contacts
10.0
10.0
0.1
0.1
10.0
10.0
—
—
6.0
6.0
0.1
0.1
0.6
0.6
—
—
Cast Iron
Housing
+750° F (+399°
+750° F (+399°
+375° F (+190°
+375° F (+190°
C)
C)
C)
C)
Cast Alum.
Housing
650° F (+343° C)
650° F (+343° C)
325° F (+162° C)
325° F (+162° C)
4
HS SPDT w/silver contacts
1.0
1.0
3.0
0.5
+750° F (+399° C)
650° F (+343° C)
6
HS SPDT w/gold plated contacts
0.5
0.5
0.5
0.5
+750° F (+399° C)
650° F (+343° C)
➀ Maximum process temperature is based on an ambient temperature between
0° and +100° F (-18° and +30° C). For ambients outside this range, see switch
temperature charts on pages 16–18.
➁ See Switch Temperature Ranges on page 16 for minimum process temperatures.
HOUSING MATERIAL/APPROVAL
FM
CSA ATEX Ex d ATEX IS IEC Ex d
A
C
1
M
1
Cast Aluminum, 3⁄4" NPT Conduit Entry
B
D
2
N
2
Cast Iron, 3⁄4" NPT Conduit Entry
3
P
3
Cast Aluminum, M20 ¥ 1.5 Conduit Entry
4
R
4
Cast Iron, M20 ¥ 1.5 Conduit Entry
N/A
44-607 Tuffy® II Liquid Level Switch
27
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 a MAGNETROL 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.
No claims for misapplication, labor, direct or consequential damage will be allowed.
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.
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.
Performance specifications are effective with date of issue and are subject to change without notice.
Magnetrol & Magnetrol logotype and Tuffy are registered trademarks of Magnetrol International, Incorporated.
Teflon is a registered trademark of DuPont.
BULLETIN: 44-607.13
EFFECTIVE: January 2016
SUPERSEDES: January 2014