TUFFY® Liquid Level Controls with Pneumatic Switches ® (For Tuffy controls with electric switches, consult bulletin BE 44-605) INSTRUCTION MANUAL AND PARTS LIST DESCRIPTION OPERATING CYCLE Tuffy liquid level switches are designed for horizontal mounting in a tank or vessel through threaded or flanged pipe connections. Standard models are equipped with a threeport/two-position valve, actuated by a magnetically actuated pivoted cam mechanism. This instruction manual covers Tuffy level controls which have pneumatic switches. For Tuffy controls with electric switches, please consult Bulletin BE 44-605. At a “low operating level” of liquid in a tank or vessel (refer to Figure 1), the float moves the magnet upward and into the field of the switch mechanism magnet. As a result, the magnets repel causing the pivot arm and valve plunger to move so that air is allowed to pass from air inlet A to air outlet C. As liquid level rises, for “High Operating Level” indication (refer to Figure 2), the float moves the magnet downward until the switch mechanism magnet reverses position, allowing the valve plunger to move so that air is allowed to pass from air inlet B to air outlet C. OPERATING PRINCIPLE Figures 1 and 2 illustrate the simple Magnetrol operating principle. Switching action is obtained through the use of a magnet attached to a float and a switching mechanism. These two basic component assemblies are separated by a non-magnetic, pressure tight barrier. APPLICATIONS Tuffy is recommended as a high or low alarm switch for clean liquid applications only. Air inlet B (no air flow) Tuffy body (non-magnetic) Magnet pivot Magnets Pivot Float Air inlet A Spring For direct acting low level operation, air inlet A is closed off when liquid level increases. Conversely, for direct acting high level operation, air inlet B is closed off when liquid level recedes. For reverse acting operation, air inlet A is used for high level and air inlet B is used for low level. The air inlet that is not in use should be plugged to prevent foreign materials from entering. 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 and purchase order. Check and record the serial number for future reference when ordering parts. Valve plunger Falling level Valve body Air outlet C MODEL IDENTIFICATION Pivot arm Figure 1: Low level operation – direct acting PNEUMATIC SWITCH Air inlet B Tuffy body (non-magnetic) Magnet pivot SPECIFIC GRAVITY 0 4 Rising level Air inlet A (no air flow) Magnets Spring Valve plunger Valve body Pivot Air outlet C Pivot arm Figure 2: High level operation – direct acting Float 0 3 9 6 0 0 0 1 0 0,6 minimum 0,4 minimum INSTALLATION MOUNTING 1. 2. Before assembling Tuffy in a tank or vessel, check threaded or flanged mounting nozzle for the following: a. Nozzle length and inside diameter must be sized correctly to allow for switch actuation at design levels. Refer to Figure 3. b. Nozzle must be checked for horizontal alignment. Tuffy mounting does not differ for high level or low level operation. For proper operation, the serial number tag must be on top. Depending on whether direct or indirect action is required, air inlet A or air inlet B are used for supply air input. Air outlet C is always used for output. Table 1 summarizes the pneumatic valve action that takes place based on the inlets used. Serial No. Tag 1/4" NPT inlet (B) 3. Inlet air should be filtered with a 5 micron or finer filter. This will extend the life of the valve mechanism. Connect the inlet air line to the 1⁄4" NPT connection for either air inlet A or air inlet B, depending on the valve action desired (refer to Table 1). Inlet air pressure should be between 0–13.8 bar (0–200 PSIG). Refer to Figure 3 for location of air inlets. Connect outlet air line to the 1⁄4" NPT connection on the bottom of the valve. This air outlet is designated with a “C”. Refer to Figure 3 for location. If 3-way function is used, attach the exhaust air line to the appropriate 1⁄4" NPT connection based on valve action described in Table 1. 4. 5. 6. Float must clear inner tank wall Port 2-Way N.O. (direct) 2-Way N.C. (reverse) 3-Way N.O. (direct) Down (Low) A Inlet Plug Inlet Exhaust Outlet Outlet Up (High) B Plug Inlet Exhaust Inlet Outlet Inlet — C Outlet Outlet Outlet Outlet Inlet Outlet Float Position 1/4" NPT inlet (A) 1/4" NPT outlet (C) 3-Way N.C. Diverter (reverse) Selector N.O.—Direct Acting: Air supply on switch condition. N.C.—Reverse Acting: Air cut-off on switch condition. Wrench flats Figure 3 Table 1 EXTERNAL CAGE INSTALLATION Figure 4 shows a typical piping installation of a Tuffy External Cage Assembly. Switch actuates within 19 mm (0.75") above the cage-Tuffy centerline for rising level and within 19 mm (0.75") below the centerline on falling level. Shutt-off Valve Safety Check Valve Pressure Vessel 1/4" NPT inlet (B) CL Shutt-off Valve 1/4" NPT outlet (C) 1/4" NPT inlet (A) Drain Valve Figure 4 2 Switch Actuation Level The external cage must be installed so that the tappings are vertical. Installation should be checked with a spirit level on top and/or sides of the cage. Controls should be mounted as close to the vessel as possible. This will result in a more responsive and accurate level change in the cage. Liquid in a long pipeline may be cooler and more dense than liquid in a vessel causing lower level indication in the control than actual level in the vessel. Use pipe of sufficient strength to support the control. If necessary, provide a stand or hanger to help support its weight. All piping should be straight and free of “low spots” or “pockets” so that lower liquid will drain towards the vessel and upper vapor line will drain toward the control. Shutoff valves are recommended for installation between the vessel and the cage assembly. If a control is to be used with a low temperature liquid (one which will “boil” in the float chamber if outside heat is absorbed), the chamber and piping should be insulated. Such boiling in the chamber will cause false level indicators. In this case, DO NOT insulate the switch mechanism housing. PREVENTIVE MAINTENANCE Periodic inspections are a necessary means to keep your Magnetrol 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 should be implemented when the control is placed into service. Based on utilizing a preventative maintenance program and observing the following section on “what to avoid”, your Tuffy will provide reliable protection of your capital equipment for many years. WHAT TO AVOID 1. Use only the 2" wrench flats to install or remove the unit. Refer to Figure 3. Use of any other surface could change the calibration. The valve body is calibrated at the factory and locked in place. 2. 3. NEVER attempt to make adjustments without reading the instructions carefully. When in doubt, consult the factory or your local representative. NEVER use in systems which have excess iron particles in the solution. The magnet at the counterweight end of the float can attract the particles which could cause the float rod to jam. TROUBLESHOOTING FAILURE TO SHUT OFF OR TURN ON INLET AIR 1. Check float for full range of travel; clicking of mechanism should be heard. 2. If the complete Tuffy mechanism operates properly when removed from service, check to be certain that liquid is entering the storage tank or vessel. A valve may be closed or a pipe line clogged. 3. 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. 4. The factory calibration setting should not require any adjustment in the field. Check to see that the unit is installed properly with the serial number tag positioned on the top of the unit. If the unit is still not operating correctly, please contact the factory. NOTE: When in doubt about the condition or performance of a control, please contact the factory for assistance. SPECIFICATIONS MECHANICAL SPECIFICATIONS Description Specification Max. design pressure 0,6 SG: 103 bar @ 040°C (1500 PSIG @ 100°F) 0,4 SG: 34 bar @ 040°C (1500 PSIG @ 100°F) -40°C to 200°C (-40°F to 400°F) Vacuum - max 13.8 bar (200 PSIG) 14.16 l/h (0.5 SCFH) 2.55 m3/h (1.5 SCFM) 0.6 minimum or 0.4 minimum 316/316 SS wetted components including ANSI B 31.3/NACE 316/316 L SST Carbon steel or 316 / 316L stainless steel 103 bar @ 260°C (1500 PSIG @ 500°F) 017 bar @ 204°C (0250 PSIG @ 400°F) Max. process temperature Pneumatic switch supply pressure Max. leakage rate Max. air flow Specific gravity Materials of construction Housing Cage (optional) Cage rating Square flange (optional) rating DIMENSIONAL SPECIFICATIONS in mm (inches) 329 (12.94) 226 (8.91) [Sp. Gr. 0.4 Min.] Float Size = 51 (2) Ø x 130 (5.12) Long 202 (7.96) [Sp. Gr. 0.6 Min.] Float Size = 51 (2) Ø x 116 (4.57) Long 1/4" NPT inlet (B) 1/4" NPT inlet (A) 76 (3) max. nozzle length 19 (0.75) C L Falling Level Switch Actuates 64 (2.5) Ø 1/4" NPT outlet (C) Switch Actuates Rising Level 95 (3.75) float minimum clearance 2" NPT 3 REPLACEMENT PARTS Optional accessories For selection of cages and flanges please refer to bulletin BE 44-118. The pneumatic Tuffy is designed for years of trouble free use. Due to the nature of the valve design and the factory calibration required for proper operation, no specific replacement parts are offered. IMPORTANT SERVICE POLICY Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour and the parts required to rebuild or replace the equipment. In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of our warranty. No claims for misapplication, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. Purchaser Name 2. Description of Material 3. Serial Number 4. Desired Action 5. Reason for Return 6. Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: BE 44-606.3 EFFECTIVE: JANUARY 1998 SUPERSEDES: March 1991 UNDER RESERVE OF MODIFICATIONS BELGIUM ® DEUTSCHLAND FRANCE ITALIA UNITED KINGDOM INDIA Heikensstraat 6, 9240 Zele Tel. (052) 45.11.11 Fax (052) 45.09.93 Schloßstraße 76, D-51429 Bergisch Gladbach-Bensberg Tel. (02204) 9536-0 Fax (02204) 9536-53 11, Rue A. Einstein, Espace Descartes, 77420 Champs-sur-Marne adresse postale: 77436 Marne-la-Vallée Cédex 2 Tel. (0) 164.68.58.28 Fax (0) 164.68.58.27 Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) Fax (02) 668.66.52 Unit 1 Regent Business Centre Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 Fax (01444) 871317 B4/115 Safdurjung Enclave, New Delhi 110 029 Tel. 91 (11) 6186211 Fax 91 (11) 6186418