Side Mounting Liquid Level Controls Installation and Operating Manual Liquid Level Control Read this Manual Before Installing This manual provides information on Side Mounting Liquid Level Controls. 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. Low Voltage Directive For use in Installation Category II, Pollution Degree 2. If equipment is used in a manner not specified by the manufacturer, protection provided by the equipment may be impaired. Notice of Trademark, Copyright, and Limitations Magnetrol & Magnetrol logotype are registered trademarks of Magnetrol International. Copyright © 2010 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. Repair parts are warranted free of defects in materials and workmanship for one year from the date of shipment. Materials, specifications, and contents are subject to change without prior written notice. 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. Side Mounting Liquid Level Controls Table of Contents 1.0 Introduction 1.1 Principle of Operation .............................................4 1.2 Operating Cycle.......................................................4 2.0 Installation .....................................................................4 2.1 Unpacking ...............................................................4 2.2 Mounting.................................................................5 2.3 Wiring .....................................................................6 2.4 Differential Adjustment ...........................................8 2.4.1 Level Differential vs. Mounting Nozzle Length.........................................................10 3.0 Reference Information 3.1 Preventive Maintenance .........................................11 3.1.1 What To Do................................................11 3.1.2 What To Avoid............................................12 3.2 Troubleshooting .....................................................13 3.2.1 Check Switch Mechanism ...........................13 3.2.2 Check Sensing Unit ....................................14 3.2.3 Check Complete Unit.................................14 3.3 Agency Approvals...................................................15 3.4 Specifications .........................................................16 3.4.1 Dimensional Specifications .........................16 3.4.2 Actuation Levels..........................................18 3.5 Replacement Parts..................................................19 3.5.1 Replacement Assemblies Parts Identification...............................................19 3.5.2 Models T52 and T63 ..................................20 3.5.3 Models T62 Threaded, T62 Flanged, T67 Threaded and T67 Flanged .................21 3.6 Model Numbers.....................................................22 3.6.1 T52, T62, T63, T64 and T67 Models ........22 1.0 Side mounting controls mount horizontally to any tank or vessel through a threaded or flanged pipe connection. Standard models are equipped with a single switch mechanism for high or low level alarm or control applications. Tandem models, with two switch mechanisms, are available for two level stage applications—providing the operating functions of two separate instruments, such as high and low level alarm. Pivot Return Spring 3 Introduction 2 1 Pivot Float 1.1 Principle of Operation Side mounting units employ permanent magnetic force as the only link between the float and the switching element. As the pivoted float follows liquid level changes, it moves a magnetic sleeve (1) into or out of the field of a switch actuating magnet (2) causing switch operation. A nonmagnetic barrier tube (3) effectively isolates the switch mechanism from the controlled liquid. Figure 1 Pivot Return spring 1.2 Swing out position Operating Cycle As the liquid level falls in the vessel, refer to Figure 1, the float moves the magnetic attraction sleeve up within the enclosing tube and into the field of the switch mechanism magnet. As a result, the magnet is drawn in tightly to the enclosing tube causing the switch to trip, making or breaking an electrical circuit. As the liquid level rises, the float moves the attraction sleeve out of the magnetic field, releasing the switch at a predetermined level. Refer to Figure 2. The tension spring ensures the return of the switch in a snap action. Figure 2 2.0 Installation 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, making sure all components have been removed from the packing material. Inspect all components for damage, and report any concealed damage to the carrier within 24 hours. 4 44-602 Side Mounting Liquid Level Controls Check the contents of the carton, making sure it agrees with the packing slip and the purchase order. Verify that the model number imprinted on the nameplate matches the number on the packing slip and the purchase order. Report any discrepancies to the factory. Check and record the serial number for future reference when ordering parts. 2.2 Mounting Caution: This instrument is intended for use in Installation Category II, Pollution Degree 2. Before assembling control to tank or vessel, check threaded or flanged mounting nozzle for the following: • Nozzle length and inside diameter must be sized correctly to allow for switch actuation at design levels within the maximum differential available. Refer to the chart on page 10. • Nozzle should be checked for horizontal alignment. Finished mounting must allow control switch housing to be within 3° of vertical for proper operation. A three degree slant is noticeable by eye, but installation should be checked with a spirit level on top and/or sides of float body. 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 Lock Nut practice for reducing the likelihood of damage to the conFloat Stem trol is to equalize pressure across the device very slowly. • Before installation, assemble float and stem to sensing unit. See Figure 3. Fulcrum Pin 1. Remove screw from end of fulcrum bar and replace with float stem. Fulcrum Bar Figure 3 Float Stem Assembly 2. Make sure end of float stem sets completely in groove of fulcrum pin as shown in Figure 3. 3 Tighten lock nut with wrench. If float stem is properly located, fulcrum pin can not be pushed out. 44-602 Side Mounting Liquid Level Controls 5 2.3 Wiring Caution: Level controls are shipped from the factory with the enclosing tube tightened and the middle set screw, on the housing base, locked to the enclosing tube. Failure to loosen the set screw prior to repositioning the conduit connection may cause the enclosing tube to loosen, resulting in the possible leakage of the process liquid or vapor. Screw Set Screw Screw Figure 4 NEMA 4X, NEMA 4X/7/9 NEMA 4X/7/9 Group B Side mounting controls are shipped with the conduit entry of the switch housing placed 180° opposite to the tank connections to simplify installation in most cases. If this configuration 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. 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. 1. Loosen set screw(s) at base of switch housing. Refer to Figure 4. 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. 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 in your switch bulletin for this information. Switch instruction manual numbers are as indicated in chart on page 7. 6 44-602 Side Mounting Liquid Level Controls Switch Series Letter Description Bulletin No. B, C, D Dry Contact Switch 42-683 G, H, I Vibration Resistant Dry Contact Switch, Dual Magnets 42-684 HS Hermetically Sealed Snap Switch 42-694 J Bleed Type Pneumatic Switch 42-685 K Non-Bleed Type Pneumatic Switch 42-686 F, R, 8, 9 High Temperature Dry Contact Switch 42-799 NOTE: For supply connections, use wire with a minimum rating of +167° F (+75° C) as required by the process conditions. Use a minimum of 14 AWG wire for power and ground field wires. NOTE: Housing must be grounded via protective ground screw in base of housing. Internal Circuit (Left) Switch Close on low level 4 1 5 2 6 3 Internal Circuit (Right) Switch Load Load Common Common Close on high level Line Close on low level Close on high level Load Load Figure 5 Wiring diagram for side-mounted float switch (except HS) Line 6. Dress wiring to ensure no interference or contact with the switch, or replacement of switch housing cover. 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 is screwed down securely. 7. Replace housing cover. 8. If control has been furnished with an explosion proof or moisture proof (gasketed) 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 float chamber. 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 housings. 44-602 Side Mounting Liquid Level Controls 7 2.4 Guide washer The level differential of single switch models may be adjusted by repositioning the jam nuts on the magnetic sleeve stem as shown in Figure 6. Upper jam nuts A B Lower jam nuts Magnetic sleeve Pivot Magnetic sleeve stem High level CL of control Figure 6 Refer to the chart below for the minimum and maximum levels obtainable. Inches (millimeters) Differential Pivot Float stem length minus approx. 3/4" Differential Adjustment Low level Float Differentials Obtainable Approx. Jam Float Stem Length Nut Setting Model 8.00 12.00 18.00 26.00 A B (230) (305) (457) (660) Min. T52 Max. Min. T63 Max. T62 (Threaded) T62 (Flanged) Min. Max. Min. Max. 1.25 (32) 4.75 (121) 1.75 (44) 7.00 (178) 2.50 (64) 10.25 (260) 3.50 (89) 14.50 (368) 0.81 (21) 1.31 (33) 0.03 (0.8) 1.06 (27) 1.00 (25) 2.62 (67) 1.75 (44) 5.00 (127) 2.50 (64) 7.38 (187) 3.50 (89) 10.50 (267) 0.81 (21) 1.31 (33) 0.03 (0.8) 1.06 (27) 1.25 (32) 5.81 (148) 2.00 (51) 8.12 (206) 2.88 (73) 11.56 (294) 4.00 (102) 16.12 (409) 0.81 (21) 1.31 (33) 0.03 (0.8) 1.06 (27) 1.25 (32) 3.50 (89) 1.62 (41) 5.12 (130) 2.62 (67) 7.50 (191) 3.75 (95) 10.75 (273) 0.62 (16) 1.12 (28) 0.03 (0.8) 0.69 (18) NOTES: All models are factory set at minimum differential unless otherwise specified. To maintain maximum differential, nozzle length "L" (Fig. 3) must not exceed: 2.38" (60 mm) model T52; 1.19" (30 mm) model T63; 2.50" (64 mm) model T62 threaded; or 3.50" (89 mm) model T62 flanged. Dimensions given are approximate and will vary slightly with each unit. Consult factory for differentials of models not shown. Tandem models (T67, T68) are not field adjustable. Caution: Before attempting any work on the control, be certain to pull disconnect switch or otherwise assure that electrical circuit(s) through control is deactivated. Close operating medium supply valve on controls equipped with pneumatic switch mechanisms. 8 44-602 Side Mounting Liquid Level Controls 1. Disconnect wiring from supply side of switch mechanism and electrical conduit or operating medium line connections to switch housing. 2. Perform system shutdown as required to relieve pressure from tank or vessel and drain off liquid head above control mounting position. Allow unit to cool. 3. Remove switch housing assembly by loosening hex nut located immediately below the housing base. With switch housing removed, jam nuts and magnetic sleeve are now accessible. Refer to Figure 6. Raising the lower jam nuts will reduce the differential. Jam nut adjustments in opposite directions will increase the differential. As the first step in any adjustment procedure, the position of the lower jam nuts (Dimension A) should be established. 4. Loosen and remove upper jam nuts, guide washer and magnetic sleeve. Dimension A, as measured from the top of the stem to the top of the lower jam nuts, may now be increased or decreased as required. Tandem model controls should not be adjusted in the field. If differential adjustment is required, consult factory. NOTE: Be certain to tighten jam nuts securely after adjustment. 5. Replace magnetic sleeve on stem and position upper jam nuts to desired B dimension by measuring from top of sleeve to bottom of upper jam nuts to guide washer. 6. Reassemble control. 7. Test switch actuation by varying liquid level in tank or vessel. Caution: After increasing differential adjustment, be certain to check carefully for proper operation of switch mechanism. Magnet must “snap” cleanly, with additional float movement available after magnet snaps. 44-602 Side Mounting Liquid Level Controls 9 2.4 Differential Adjustment (cont.) 2.4.1 Level Differential vs. Mounting Nozzle Length Minimum nozzle opening Switch mechanism actuates on rising level CL of control Level differential The table below may be used to determine the maximum level travel (differential) available between “Switch on” and “Switch off ” actuations with mounting nozzles of different lengths. The differentials given occur with the minimum tank opening diameter listed for each model and are applicable to standard controls. Switch mechanism actuates on falling level L Figure 7 Inches (millimeters) Maximum Level Differential Available with Several Nozzle Lengths Nozzle Length In. (mm) Model T52 with 3.12" (79 mm) Diameter Minimum Tank Nozzle Opening Model T63 with 2.31" (59 mm) Diameter Minimum Tank Nozzle Opening Model T62 Threaded with 3.06" (78 mm) Diameter Minimum Tank Nozzle Opening Model T62 Flanged with 2.88" (73 mm) Diameter Minimum Tank Nozzle Opening Float Stem Length Float Stem Length Float Stem Length Float Stem Length 8.00 (203) 12.00 (305) 18.00 (457) 26.00 (660) 8.00 (203) 12.00 (305) 18.00 (457) 26.00 (660) 8.00 (203) 12.00 (305) 18.00 (457) 26.00 (660) 8.00 (203) 12.00 (305) 18.00 (457) 26.00 (660) 2.00 (51) 4.75 (121) 7.00 (178) 10.25 (260) 14.50 (368) 2.62 (67) 5.00 (127) 7.38 (187) 10.50 (267) 5.81 (148) 8.12 (206) 11.56 (294) 16.12 (409) 3.50 (89) 5.12 (130) 7.50 (191) 10.75 (273) 4.00 (102) 4.00 (102) 5.62 (143) 8.12 (206) 11.62 (295) 1.88 (48) 3.50 (89) 5.25 (133) 7.50 (191) 4.38 (111) 6.12 (155) 8.69 (221) 12.19 (310) 3.25 (83) 4.75 (121) 7.00 (178) 10.00 (254) 6.00 (152) — 4.25 (108) 6.25 (159) 8.88 (226) — 2.75 (70) 4.12 (105) 5.88 (149) 1.50 (38) 4.69 (119) 6.69 (170) 9.31 (236) — 3.75 (95) 5.38 (137) 7.75 (197) 8.00 (203) — 3.50 (89) 5.12 (130) 7.25 (184) — 2.38 (60) 3.38 (86) 4.88 (124) — 3.81 (97) 5.44 (138) 7.56 (192) — 3.00 (76) 4.50 (114) 6.25 (159) 10.00 (254) — 2.88 (73) 4.25 (108) 6.00 (152) — 2.00 (51) 2.88 (73) 4.12 (105) — 3.19 (81) 4.56 (116) 6.38 (162) — 2.50 (64) 3.75 (95) 5.38 (137) 12.00 (305) — — 3.62 (92) 5.12 (130) — — 2.50 (64) 3.50 (89) — — 3.94 (100) 5.44 (138) — — 3.25 (83) 4.62 (117) NOTES: Nozzle length is dimension L from end of standard control body to opening in tank having minimum diameter listed for each model. Minimum diameter given is I.D. of float switch body. Minimum diameter given is I.D. of 3" schedule 40 pipe. Minimum diameter given is I.D. of 3" schedule 80 pipe. Consult factory for maximum differential available for models T64 and T67. 10 44-602 Side Mounting Liquid Level Controls 3.0 Reference Information 3.1 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. A systematic program of preventive maintenance must be implemented when the control is placed into service. If the following is observed, your control will provide reliable protection of your capital equipment for many years. 3.1.1 What To Do 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. 2. Inspect switch mechanisms, terminals, and connections monthly. a. Dry contact 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. Adjust switch mechanism to compensate (if possible) or replace switch. b. DO NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms furnished for service instructions.) c. Side mounting 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. Check wiring carefully and replace at the first sign of brittle insulation. d. Vibration may sometimes cause terminal screws to work loose. Check all terminal connections to be certain that screws are tight. 44-602 Side Mounting Liquid Level Controls 11 e. On units with pneumatic switches, air (or gas) operating medium 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. 3. Inspect entire unit periodically. Isolate control from vessel. Raise and lower liquid level to check for switch contact and reset. 3.1.2 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 side mounting 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. 12 44-602 Side Mounting Liquid Level Controls 3.2 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. —Fuses may be blown. —Reset button(s) may need resetting. —Power switch may be open. —Controlled equipment may be faulty. —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. 3.2.1 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 3° of vertical. Use spirit level on side of enclosing tube in two places, 90° apart. 7. Examine the switch closely as previously described in Preventive Maintenance section. Check continuity of switch with ohmmeter. If switch does not function properly, replace it immediately. 8. If switch mechanism is operating satisfactorily, proceed to check sensing unit. 44-602 Side Mounting Liquid Level Controls 13 3.2.2 Check Sensing Unit 1. Check to be certain liquid is entering float chamber. A valve may be closed or piping plugged. 2. Proceed to check level sensing action by removing switch housing assembly, as described in Steps 4 through 7 of the Switch Differential Adjustment section on pages 8 and 9. Caution: Unit must be normalized to atmospheric pressure before removing switch housing assembly. 3. Inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids build-up which could restrict movement, preventing sleeve(s) from reaching field of magnet(s). 4. If the differential has been changed in the field, check tightness and position of the jam nuts. NOTE: Differential adjustment causes a change in the amount of level travel between switch-on and switch-off actuations. Refer to pages 8 and 9. 5. Vary liquid level in vessel. Check float to be certain it is buoyant in the liquid (vessel must have adequate liquid level). If float is determined to be filled with liquid or collapsed, float must be replaced. Do not attempt to repair a float. 3.2.3 Check Complete Unit Caution: With electrical power on, care should be taken to avoid contact with switch leads and connections at terminal block. Reassemble unit. Reconnect power supply and carefully actuate switch mechanism manually (using a non-conductive tool) to determine whether controlled equipment will operate. 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. NOTE: If difficulties are encountered which cannot be identified, consult the factory or your local representative for assistance. A complete description of the trouble should be provided along with information concerning your piping and mounting arrangement, plus a description of your operating sequence. Sketches or photographs showing the installation are also beneficial. When communicating about your control, be certain always to specify the complete Model and Serial numbers. 14 44-602 Side Mounting Liquid Level Controls 3.3 Agency Approvals AGENCY APPROVED MODEL 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, H1, F, 8 or 9 electric switch mechanism and a housing listed as CSA Type 4X Class I, Div 2, Groups 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 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 CE Dual stage units with ‘HS’ switches are not ATEX approved. 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. 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 44-602 Side Mounting Liquid Level Controls 15 3.4 Specifications 3.4.1 Dimensional Specifications Inches (mm) 3.12 (79) Dia. Hole Single switch models B A This dimension equals stem length plus float length minus 2.50 (64). 4.50 (114) 45° 45° C plugged D Four 1/2" studs extending 1.25 (32) from tank on 4.62 (117) bolt circle. Min. nozzle opening 3.12 (79) dia. Switch actuates rising level 2.25 (57) W 2 W CL of control Switch actuates falling level L 4.50 (114) Square flange This dimension equals stem length plus float length minus 2.25 (67). 2.50 (64) dia. float (std) B Model T52 with flanged body A Figure 8 4.50 (114) plugged C D Min. nozzle opening 3.06 (78) diameter Switch actuates rising level W 2 This dimension equals float stem length minus 3.38 (86). Rotation clearance 5.25 (133) A B 1.75 (44) 3.00 (76) Male pipe thread L W Switch actuates falling level Model T62 with threaded body .93 (23) Min. nozzle opening 2.31 (59) C D Figure 9 Thread Plugged Switch actuates rising level W 2 CLof control W 1.94 (49) 2 1/2" NPT L Switch actuates falling level Model T63 with threaded body Figure 10 16 44-602 Side Mounting Liquid Level Controls 3.4 Specifications 3.4.1 Dimensional Specifications (cont.) Inches (mm) Tandem switch models This dimension equals stem length plus float length minus 2.54 (65). B 4.50 (114) A Min. Nozzle Opening 2.31 (59) C D "A" mechanism actuates on rising level plugged Y W "A" on falling level "B" on rising level X Z "B" mechanism actuates on falling level 3.00 Male pipe threads 2.25 Maximum nozzle (57) length (L) to inside of tank This dimension equals stem length plus float length minus 2.92 (74). B Model T67 with threaded body A Figure 11 4.75(121) C plugged "A" mechanism actuates on rising level D Y W "A" on falling level "B" on rising level X Z "B" mechanism actuates on falling level Flange bolt holes straddle vertical C L 3.50 (89) Maximum nozzle length (L) to inside of tank Model T67 with flanged body Figure 12 Outline Dimensions T52/T62 Housing NEMA 4X NEMA 4X/7/9 GROUP B NEMA 1 PNEUMATIC T63 T67 A B C 3.87 (98) 5.93 (151) 10.69 (272) 10.69 (272) 12.88 (327) Electrical Switches NEMA 4X/7/9: 1" NPT Group B: 1" NPT 5.00 (127) 4.69 (119) 9.00 (229) 9.12 (323 — Pneumatic Switches 1/4" NPT NEMA 1: 44-602 Side Mounting Liquid Level Controls Conduit Connections D NOTE: Allow 8.00 (203) overhead clearance for cover removal. 17 3.4 Specifications 3.4.2 Actuation Levels Inches (mm) Model T52 Length of Float Stem 8.00 12.00 18.00 26.00 (203) (305) (457) (660) Differential Levels Obtainable W Minimum Maximum 1.25 (32) 4.75 (121) 1.75 (44) 7.00 (178) 2.50 (64) 10.25 (260) 3.50 (89) 14.50 (368) Maximum Differential (W) with Nozzle Lengths (L) of 2.00 (51) 4.00 7.00 10.25 14.50 (102) (178) (260) (368) 4.00 (102) 6.00 (152) 8.00 (203) 10.00 (254) – 5.62 (143) 8.12 (206) 11.62 (295) – 4.25 (108) 6.25 (159) 8.88 (226) – 3.50 (89) 5.12 (130) 7.25 (184) – 2.88 (73) 4.25 (108) 6.00 (152) Maximum Nozzle Length (L) to Maintain Maximum 12.00 (305) Differential – – 3.62 (92) 5.12 (130) 2.38 (60) Model T62 with threaded body Length of Float Stem 8.00 12.00 18.00 26.00 (203) (305) (457) (660) Differential Levels Obtainable W Minimum Maximum 1.25 (32) 5.81 (148) 2.00 (51) 8.12 (206) 2.88 (73) 11.56 (294) 4.00 (102) 16.16 (410) Maximum Differential (W) with Nozzle Lengths (L) of 2.00 (51) 5.81 8.12 11.56 16.16 (148) (206) (294) (410) 4.00 (102) 6.00 (152) 8.00 (203) 10.00 (254) 4.38 6.12 8.69 12.19 1.50 4.69 6.69 9.31 – 3.81 (97) 5.44 (138) 7.56 (192) – 3.19 (81) 4.56 (116) 6.38 (162) (111) (155) (221) (310) (38) (119) (170) (236) Maximum Nozzle Length (L) to Maintain Maximum 12.00 (305) Differential – – 3.94 (100) 5.44 (138) 2.50 (64) Model T63 Length of Float Stem 8.00 (203) 12.00 (305) 18.00 (457) 26.00 (660) Differential Levels Obtainable W Minimum Maximum 1.00 (25) 2.62 (67) 1.75 (44) 5.00 (127) 2.50 (64) 7.38 (187) 3.50 (89) 10.50 (267) Maximum Differential (W) with Nozzle Lengths (L) of 2.00 (51) 2.62 5.00 7.38 10.50 (67) (127) (187) (267) 4.00 (102) 6.00 (152) 1.88 3.50 5.25 7.50 – – – – 2.75 (70) 4.12 (105) 5.88 (149) 2.38 (61) 3.38 (86) 4.88 (124) 2.00 (51) 2.88 (73) 4.12 (105) – 2.50 (64) 3.50 (89) (48) (89) (133) (190) 8.00 (203) 10.00 (254) Maximum Nozzle Length (L) to Maintain Maximum 12.00 (305) Differential 1.19 (30) Model T67 Length of Float Stem 8.00 12.00 18.00 26.00 (203) (305) (457) (660) Switch Actuation Levels Obtainable With Standard Length Float Stems W&X Y&Z Minimum Maximum Minimum Maximum 2.50 (64) 2.50 (64) 1.00 (25) 2.50 (64) 3.75 (95) 3.75 (95) 1.50 (38) 3.75 (95) 5.50 (140) 5.50 (140) 2.12 (54) 5.50 (140) 7.75 (197) 7.75 (197) 3.00 (76) 7.75 (197) Differential adjustment on tandem units must be done at the factory. Advise required differentials at time of order placement. Dimensions W and X set for maximum unless otherwise specified. Dimensions Y and Z set for maximum unless otherwise specified. 18 44-602 Side Mounting Liquid Level Controls 3.5 Replacement Parts 3.5.1 Replacements Assemblies Parts Identification Spacer Bracket for Tandem Switch Mechanisms 1 20 7 4 5 8 3 6 2 Serial No. Tag (Ref.) 14 9 21 19 16 10 18 (T63) 18 (T52 and T57) 12 11 13 15 16 17 Figure 13 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Description Switch housing cover Switch housing base Switch mechanism Spacer bracket Rd head screws Attraction sleeve(s) Jam nuts Guide washer Sleeve stem Connecting pin Fulcrum Fulcrum pin Pivot bracket Rd head screws Float stem Stem lock nuts Float Body E-tube gasket Enclosing tube Flange gasket 20 1 3 7 8 2 Serial No. Tag (Ref.) 18 (T62 and T67) Flanged 6 16 19 9 10 18 (T62 and T67) Threaded 11 12 21 15 17 Figure 14 44-602 Side Mounting Liquid Level Controls 19 3.5 Replacement Parts 3.5.2 Models T52 and T63 Switch hsg cover Switch hsg base Switch mechanism Spacer bracket Rd head screws Standard sleeve assy (includes items 6 through 16) Sheathed sleeve assy (includes items 6 through 16) Float 2.50 2.50 x 4.00 3.00 Body E-tube gasket Enclosing tube Flange gasket T52 T63 Refer to Bulletin 42-680/42-780 for switch housing cover and base assembly Refer to Bulletin 42-680/42-780 for switch housing cover and base assembly Refer to bulletin on switch mechanism furnished (refer to chart on page 7) Not required Not required 089-5508-001 089-5516-001 089-5517-001 Z07-1102-001 Z07-1202-001 Z07-1202-004 Z07-1102-004 Consult Factory 012-1301-002 Z32-6325-001 012-1301-003 Not Required NOTES: All replacement assemblies listed are for standard base models which use Series B, C, D, F, 8, 9 and J switch mechanisms only. Consult your local representative for ordering assistance on all special model replacement parts not listed above. Sleeve kits contain 8.00 inch (203 mm) stem lengths. Consult factory for longer stem lengths. Standard sleeve is type 400 series stainless steel. Sheathed attraction sleeves are used on models specified for corrosive service. Sheathed sleeve kits are used on models with material of construction codes 2 through 9. This e-tube is for models with material of construction code 1 only. Consult factory for e-tubes used with other material of construction codes. 20 44-602 Side Mounting Liquid Level Controls 3.5 Replacement Parts 3.5.3 Models T62 Threaded, T62 Flanged, T67 Threaded and T67 Flanged Switch hsg cover Switch hsg base Switch mechanism Spacer bracket Rd head screws Standard sleeve assy (includes items 6 through 16) Sheathed sleeve assy (includes items 6 through 16) Float 2.50 2.50 x 4.00 3.00 3.50 3.00 x 5.00 3.00 x 6.00 Body Consult Factory E-tube gasket Enclosing tube Flange gasket T62 Threaded T62 Flanged T67 Threaded T67 Flanged Refer to Bulletin 42-680/42-780 for switch housing cover and base assembly Refer to Bulletin 42-680/42-780 for switch housing cover and base assembly Refer to bulletin on switch mechanism furnished (refer to chart on page 7) Not required 005-7542-121 Not required 010-1409-006 089-5510-001 089-5511-001 089-5514-001 N/A N/A 089-5546-001 089-5553-001 089-5551-001 089-5552-001 089-5554-001 089-5555-001 012-1301-002 Z32-6325-001 Not Required Not Available Z32-6325-007 Not Required Not Available NOTES: All replacement assemblies listed are for standard base models which use Series B, C, D, F, 8, 9 and J switch mechanisms only. Consult your local representative for ordering assistance on all special model replacement parts not listed above. Sleeve kits contain 8.00 inch (203 mm) stem lengths. Consult factory for longer stem lengths. Standard sleeve is type 400 series stainless steel. Sheathed attraction sleeves are used on models specified for corrosive service. Sheathed sleeve kits are used on models with material of construction codes 2 through 9. This e-tube is for models with material of construction code 1 only. Consult factory for e-tubes used with other material of construction codes. Flange gaskets used on models T62 and T67 are standard ANSI type, readily available at local supply houses. 44-602 Side Mounting Liquid Level Controls 21 3.6 Model Numbers 3.6.1 T52, T62, T63, T64 and T67 Models MODEL NUMBER, MATERIAL OF CONSTRUCTION AND TANK CONNECTION Model T52 T62 Set Points Code Cast Iron body, 300 Series SS trim, 400 Series SS sleeve 2 Cast Iron body, 316 SS trim and sleeve 1 Carbon Steel body, 300 series SS trim, 400 Series SS sleeve T64 T67 1 1 2 Code Description E3 4" Cast Iron Square Flange F2 3" NPT 4 316 SS body, trim and sleeve 1 Cast Iron body, 300 Series SS trim, 400 Series SS sleeve E2 4 316 SS body, trim and sleeve 1 Carbon Steel body, 300 Series SS trim, 400 Series SS sleeve 1 Carbon Steel body, 300 Series SS trim, 400 Series SS sleeve 2 Carbon Steel body, 316 SS trim and sleeve 304 SS body, 300 Series SS trim and sleeve Pressure Rating psig @ °F bar @ °C 100 450 750 900 1000 38 232 399 482 538 Tank Connection G3 G4 G5 H3 H4 H5 3 T63 Description 1 1 1 Material of Construction H3 H4 H5 F2 G3 G4 G5 H3 3" 3" 3" 4" 4" 4" 150 300 600 150 300 600 lb. lb. lb. lb. lb. lb. RF RF RF RF RF RF 250 150 n/a 500 — n/a 17 10 n/a n/a n/a 377 353 144 34 — 26 24 23 n/a n/a n/a 26 24 23 Flange Flange Flange Flange Flange Flange 21⁄2" NPT n/a ANSI RF Flange Ratings 250 150 n/a 4" 150 lb. RF Flange 4" 300 lb. RF Flange 4" 600 lb. RF Flange 3" NPT 500 3" 150 lb. RF Flange 3" 300 lb. RF Flange 3" 600 lb. RF Flange 4" 150 lb. RF Flange n/a n/a 17 10 ANSI RF Flange Ratings — 377 353 144 34 — ANSI RF Flange Ratings FLOAT AND FLOAT STEM LENGTH Float Stem Length and Inches mm Inches mm 8.00 203 12.00 305 Inches mm S.G. Code S.G. Code 2.50 64 0.80 0.80 A B 2.50 × 4.00 64 × 102 0.52 0.55 E F 0.55 0.55 3.00 76 J K 0.50 0.50 3.50 89 N P 0.65 3.00 × 5.00 76 × 127 0.65 S T Model T64 Only 3.50 89 0.40 — — N Float Size All Models Excluding T64 Specific Gravity Rating Inches mm Inches mm 18.00 457 26.00 660 S.G. Code S.G. Code 0.90 0.90 C D 0.60 0.66 G H 0.60 0.60 L M 0.55 0.55 Q R 0.70 0.70 V W — — — — Pressure/Temperature Ratings 100 350 100 250 400 500 PSIG 750 282 81 201 322 377 @°F 900 1000 271 268 78 77 194 191 310 306 353 335 Bar @ ° C 38 399 482 24 19 19 7 6 5 17 14 13 28 22 21 34 26 24 1200 936 876 794 83 65 60 538 18 5 13 21 23 58 Compare with float rating and use lower value for selection. Float cannot pass through 3" NPT opening. To pass float, tank nozzle internal bore diameter must not be less than 3.06 (78). 3.50 (89) diameter and 3.00 x 5.00 (76 x 127) floats not available in models T52 and T63. Process temperature based on +100° F (+38° C) ambient. Dual switches available only with tandem model T67. CSA approval does not apply to Series HE switches. On condensing applications, temperature down-rated to +400° F. Pneumatic switches not available on models T64 or T67. (Select from Next Page) 22 44-602 Side Mounting Liquid Level Controls 3.6 Model Numbers 3.6.1 T52, T62, T63, T64 and T67 Models (cont.) ELECTRIC SWITCH MECHANISM AND ENCLOSURE Switch Description All models with Material of All models with Material of Construction Code 1, Construction Codes 2, 3 & Model T64 only Process except model T64 4, except model T64 Temperature Set Contacts TYPE 4X/7/9 Aluminum Enclosure Range Points Class I, Div Class I, Div ATEX Class I, Div Class I, Div ATEX Class I, Div Class I, Div ATEX °F (°C) Series B Snap Switch -40 to +250 (-40 to +121) Series C Snap Switch -40 to +450 (-40 to +232) DPDT SPDT DPDT Series D DC Current -40 to +250 Snap Switch (-40 to +121) SPDT DPDT Series F -50 to +750 Hermetically Sealed (-46 to +399) Snap Switch SPDT Series HS Hermetically Sealed 5-amp Snap Switch with Wiring Leads Series HS Hermetically Sealed 5-amp Snap Switch with Terminal Block Series H1 Hermetically Sealed 1-amp Snap Switch with Wiring Leads Series R High Temperature Snap Switch 1 2 1 2 1 2 1 2 1 1 1 2 1 2 SPDT DPDT SPDT -50 to +550 (-46 to +288) 1 Groups C&D 1 Group B BKP BLA BNP BOA CKP CLA CNP COA BKT BLJ BNT BOJ CKT CLJ CNT COJ Ex II 2 G EEx 1 d IIC T6 Groups C&D BAC BDC BBC BGC CAC CDC CBC CGC N/A FKP FLA FNP FOA FKT FLJ FNT FOJ FAC FDC FBC FGC 1 BKQ BNQ CKQ CNQ DKQ DNB FKQ FNQ HMC 1 Group B Ex II 2 G EEx 1 d IIC T6 Groups C&D BKS N/A BNS N/A CKS N/A CNS N/A DKS DNK FKS N/A FNS N/A -50 to +550 (-46 to +288) 1 SPDT 1 BKA BB9 BNA CA9 CKA CB9 CNA DA9 DF9 FA9 DKB DNB FKA FB9 FNA HEK N/A DPDT BA9 1 Group B Ex II 2 G EEx d IIC T6 BKJ N/A BNJ N/A CKJ N/A CNJ N/A DKK DNK FKJ N/A FNJ N/A BCC HMJ HMK HMS HMT N/A BFC CCC CFC DC9 DF9 FCC FFC N/A HMF HET HM3 HM4 HA9 HM3 HM4 HA9 HM7 HM8 HB9 HM7 HM8 HB9 HKJ HKK N/A RC9 N/A -50 to +750 (-46 to +399) -40 to +750 (-40 to +399) DPDT 1 SPDT 1 SPDT 1 N/A HKC N/A RKB RKK RC9 RKB RKK RNB RNK RF9 RNB RNK RF9 8KQ 8KS N/A 8NS N/A 9KS N/A 9NS N/A 8A9 8KA 8CC 8B9 8NA 8KJ N/A 8NJ N/A 9KJ N/A 9NJ N/A N/A DPDT 1 1 2 1 2 1 2 1 2 SPDT Series 8 -50 to +750 Hermetically Sealed (-46 to +399) Snap Switch DPDT 8KP 8LA 8NP 8OA 9KP 9LA 9NP 9OA 8KT 8LJ 8NT 8OJ 9KT 9LJ 9NT 9OJ 8AC 8DC 8BC 8GC 9AC 9DC 9BC 9GC 8NQ 8FC 9KQ 9A9 9KA 9CC Series 9 SPDT High Temperature -50 to +750 Hermetically Sealed (-46 to +399) 9NQ 9B9 9NA 9FC DPDT Snap Switch CS/ CS/ CS/ Process Cast Iron Cast Iron Cast Iron Aluminum Aluminum Switch Temperature Contacts Set Aluminum Range Description Points NEMA 4X Class I, Div 1 Class I, Div 1 NEMA 4X Class I, Div 1 Class I, Div 1 NEMA 4X Class I, Div 1 Class I, Div 1 °F (°C) Groups C&D Group B Groups C&D Group B Groups C&D Group B 1 R1M RKM RKW R1M RKM RKW SPDT Series R 2 N/A N/A -40 to +1000 High Temperature N/A (-40 to +538) 1 RDM RNM RNW RDM RNM RNW Snap Switch DPDT 2 N/A N/A 1 9AR 9KR 9KV 9AY 9KY 9KW 9AD 9KD 9KV Series 9 SPDT 2 9BD 9LD 9LV N/A N/A High Temperature -50 to +1000 Hermetically Sealed (-46 to +538) 1 9DR 9NR 9NV 9DY 9NY 9NW 9DD 9ND 9NV DPDT Snap Switch 2 9ED 9OD 9OV N/A N/A PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Switch Description Series J Bleed Type Series K Non-Bleed Type Maximum Supply Pressure Maximum Process Temperature Bleed Orifice Diameter All Models with Material of Construction Code 1 All Models w/Material of Construction Codes 2, 3 or 4 PSIG Bar °F °C Inches mm NEMA 1 NEMA 1 100 60 100 40 7 4 7 3 400 400 400 400 204 204 204 204 0.63 0.94 — — 1.6 2.3 — — JDE JEE — KOG JDE JEE KOE — 44-602 Side Mounting Liquid Level Controls 23 ASSURED QUALITY & SERVICE COST LESS Service Policy Return Material Procedure Owners of Magnetrol controls 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. 2. 3. 4. 5. 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. 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. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 Copyright © 2010 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 are registered trademarks of Magnetrol International. BULLETIN: 44-602.20 EFFECTIVE: May 2010 SUPERSEDES: June 2009