Tuffy® Liquid Level Controls with Electric Switches

Tuffy®
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 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.
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.
Notice of Trademark, Copyright, and Limitations
Magnetrol & Magnetrol logotype, and Tuffy are registered
trademarks of Magnetrol International, Incorporated.
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.
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.
MODEL IDENTIFICATION
DESCRIPTION
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 single switch
mechanism for high or low level alarm or control applications.
This instruction manual covers Tuffy level controls which have
electric switches. For Tuffy controls with pneumatic switches,
please consult Bulletin 44-606.
APPLICATIONS
Tuffy is recommended as a Hi/Lo Alarm switch for clean
liquid applications only.
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 nonmagnetic, pressure tight barrier.
39-500 0 -
Approval
0 = FM, CSA
Switch
1 = 5 Amp Resistive SPDT, 120 vAC
2 = 15 Amp Resistive SPDT, 120 vAC
3 = 15 Amp Resistive Form Z, 120 vAC
5 = 1 Amp Resistive SPDT Hermetic, 120 vAC
6 = 10 Amp Resistive DPDT, 120 vAC
Housing
0 = Carbon steel, 3⁄4" NPT
1 = Stainless steel, 3⁄4" NPT
Specific Gravity
0 = 0.6 Minimum
4 = 0.4 Minimum
OPERATING CYCLE
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 switch to trip, making or breaking an
electrical circuit. As liquid level rises, the float pulls the magnet downward until the switch magnet tilts the switch in an
opposite direction, thus reversing the switch action. Refer to
Figure 2.
When liquid level recedes, the float once again moves the
magnet upward causing the switch to assume its original position.
INSTALLATION
Barrier (Non-Magnetic)
Figure 1
Low level
MOUNTING
Switch
Mechanism
Pivot
Magnet
Pivot
Magnet
Float
1. 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 on page 4.
b. Nozzle must be checked for horizontal alignment.
Switch
Actuating Arm
Barrier (Non-Magnetic)
Figure 2
High level
Switch
Mechanism
2. Thread a one foot pipe into the 3⁄4" NPT conduit as a handle
or use a pipe wrench. Engage 2" NPT threads by hand. Then
pull the threads tight in the tank by rotating the unit clockwise.
Pivot
Magnet
Magnet
Float
Switch
Actuating Arm
CAUTION: During installation of Tuffy, the counter balance
area must be free of metallic particles that might attract to
the magnets in this section.
Pivot
UNPACKING
Unpack the instrument carefully. Inspect all units for damage.
Report any concealed damage to the carrier within 24 hours.
Check the contents of the packing slip and purchase order
and report any discrepancies to the factory. Check and record
the serial number for future reference when ordering parts.
NOTE: To prevent galling of Tuffy mounting (2" NPT) and cover
threads (25⁄8" x 16"), apply either Teflon tape or Petrolatum (petrocene jelly) to the threads.
CAUTION: The Tuffy must be installed with the 3/4" NPT
connection pointing down to allow for correct switching action.
NOTE: The correct positioning of the 3⁄4" NPT connection will
also prevent the entrance of moisture into the switch enclosure via the conduit. Refer to Figure 3 on page 4.
3
INSTALLATION cont.
MOUNTING cont.
Switch Cover
FORM “Z” SWITCH WIRING cont.
Float must
clear inner
tank wall
Tank Wall
For example: A user is filling a tank and wants to turn off the
pump and get a “full” signal when the tank is full. When the
level is below the trip point, the pump runs. As soon as the
level is above the trip point, the pump turns off and the “full”
signal is given.
5 Amp SPDT, 15 Amp SPDT, 1 Amp SPDT Hermetic Switches
Load
3/4" NPT
Conduit Connection
Common
2" NPT Nozzle
C
NO
Load
NC
Figure 3
Line
Close On Rise, Wire C & NC
Close on Fall, Wire C & NO
WIRING
On high temperature applications (above 250° F or 120° C),
a suitable covered wire should be used between Tuffy and
the first junction box located in a cooler area. On non-hazardous applications, flexible conduit may be used between
Tuffy and the first junction box. Conduit should have sufficient slack to permit removal of the switch assembly.
10 Amp SPDT Micro Switch
Common
Load
Load
NC NO
1. To gain access to the switch mechanism, unscrew the
switch cover (21⁄4" spanner wrench required).
2. Pull in supply wires (conductors) and connect to the
Pproper terminals. Be certain that excess wire does not interfere with replacement of the switch cover, or the moveable switch mechanism. Refer to Figure 4 for Wiring
Diagrams.
NOTE: The green headed ground screw is to the right of the
switch. In hazardous locations a conduit seal is required within 18" (457 mm) of the conduit connection
and conduit must be screwed into the housing a minimum of 5 turns.
C
Line
Close on Rise, Wire C & NC
Close on Fall, Wire C & NO
Form “Z” Micro Switch Wired for SPDT Function
Load
NO1 NO2
Load
Common
NC1 NC2
Line
Close on Rise, Wire NC1 & NC2
Close on Fall, Wire NO1 & NO2
3. Replace the switch cover.
NOTE: Cover requires approximately 61⁄2 turns to tighten.
4. Seal housing at the conduit outlet with a suitable pipe compound to prevent entrance of air.
Form “Z” Switch Wired for DPDT Function
Load
Close on Rise
Line 2
5. Connect power supply to Tuffy and test switch action by
varying liquid level in tank or vessel.
NC1 NC2
Load
NOTE: If the switch mechanism fails to function properly,
make sure the conduit connection is vertically aligned
and pointing down. Also, check cover to housing fit to
be certain gasketed joint is tight. A positive seal is
necessary to prevent infiltration of moisture laden air
or corrosive gases into switch housing.
NO1 NO2
Line 1
Open on Rise
10 Amp DPDT Snap Action Switch
FORM “Z” SWITCH WIRING
Both sets of contacts carry the identical ratings and the resistive rating is independent of voltage. Also, the switch action is break before make. This means both circuits will not be
energized simultaneously.
Switch #2
T1
C
Float Position
Down
Up
Relay Terminal
T1 to C
T2 to C
Closed
Open
Open
Closed
Figure 4
4
White
Red
Orange
Light Blue
T2
Black
The switch has four terminals. Two marked NC (normally
closed) and two marked NO (normally open). These terminals
can be wired to allow the switch to function as an SPDT or
DPDT unit. Refer to Figure 4 for exact wiring details.
Switch #1
Violet
The primary advantage of the Form “Z” is that it has two independent switches in the same housing. Also, the special
contact configuration allows for a high electrical rating.
EXTERNAL CAGE INSTALLATION
Figure 5 shows a typical piping installation of a Tuffy External
Cage Assembly. Switch actuates within 0.75 inch (19mm)
above the Tuffy cage centerline for rising level and within 0.75
inch (19 mm) below the centerline on falling level.
The external cage must be installed so that the trappings are
vertical. Installation should be checked with a spirit level on
top and/or sides of 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 line will drain toward the vessel and upper
vapor line will drain toward the control. Shut-off valves are
recommended for installation between vessel and the cage
assembly. If the 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 indications.
In this case, DO NOT insulate the switch mechanism housing.
Typical Piping Arrangement
Figure 5
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 should be implemented, when control is placed into service. If the following instructions are observed, your control will provide reliable protection of your capital
equipment for many years.
WHAT TO DO
WHAT TO DO cont.
1. KEEP CONTROL CLEAN.
3. INSPECT ENTIRE TUFFY UNIT PERIODICALLY.
• 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 become
damaged or misplaced, obtain a replacement immediately.
2. INSPECT SWITCH MECHANISMS, TERMINALS AND
CONNECTIONS MONTHLY.
• Tuffy controls may sometimes be exposed to excessive
heat or moisture. Under such conditions, insulation on
electrical wires may become brittle, eventually breaking
or peeling away. The resulting “bare” wires can cause
short circuits.
Check wiring carefully and replace at the first sign of
brittle insulation.
• A periodic cleaning of the float and counterweight assembly will assure continued free movement of the mechanism.
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. When in doubt, consult
the factory or your local representative.
4. 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.
• Vibration may sometimes cause terminal screws to work
loose. Check all terminal connections to be certain that
screws are tight. Check wiring carefully and repair or replace if necessary.
NOTE: As a matter of good practice, spare switches and covers
should be kept on hand at all times.
5
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.
1. Pull disconnect switch or otherwise disconnect power to
the control.
2. Remove switch cover.
3. Disconnect power wiring from switch assembly.
4. Failure of the switch to operate is most likely caused by:
a. Mechanical binding of the switch mechanism. Carefully
inspect
the
switch
actuating
arm
and
magnet assembly for evidence of binding or wiring interference (refer to Figure 1). The switch and magnet assembly must move throughout its entire range
without interference. If there is any binding, the ENTIRE
switch and magnet assembly must be replaced.
operation, but does not activate when the float changes
position, remove Tuffy from service. Check the float assembly for obstructions or an 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.
6. 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 pipeline clogged.
7. Check the float to be certain that it is buoyant in the liquid (tank or vessel must have adequate level).
8. 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 are in operating condition, the trouble
must be (and should be) located external to the level switch.
Repeat inspection of external conditions previously described.
NOTE: When in doubt about the condition or performance
of a Tuffy control, consult the factory for further instructions.
b. Failure of the switch’s electrical circuits. If the assembly
can move freely, use an electrical continuity checker to determine if the switch is operating electrically. Refer to
Figure 4 for the appropriate wiring diagram. If the
switch operates properly when moved mechanically,
but not when electrically activated, the entire switch
and magnet assembly must be replaced.
5. If the switch responds to both mechanical and electrical
REPLACEMENT PARTS
Switch and Magnet Assemblies are factory calibrated after
being installed in the control to ensure proper operation.
This cannot be done in the field. Your replacement assembly has been calibrated to a typical standard. If, because
of the field application or the specific gravity of the media,
the new assembly does not function properly, the entire unit
must be returned for factory calibration.
To replace the switch mechanism, remove 2 slot head
screws holding the switch mounting bracket. Remove the
switch and bracket from the housing. Replace the switch
bracket and magnet assembly.
The switch mechanism and cover are the only replaceable
parts on a Tuffy level switch. If any other part on a unit fails,
the entire unit must be replaced.
6
Model No.
39-5000-100
39-5000-200
39-5000-300
39-5000-400
39-5000-500
39-5000-600
39-5001-100
39-5001-200
39-5001-300
39-5001-400
39-5001-500
39-5001-600
Switch Assembly No.
Cover No.
89-7301-001
89-7303-001
89-7301-002
89-7303-001
89-7301-003
89-7303-001
Consult Factory
89-7301-005
89-7303-001
89-7301-006
89-7303-001
89-7301-001
89-7301-002
89-7301-003
Consult
Factory
Consult Factory
89-7301-005
89-7306-001
SPECIFICATIONS
AGENCY APPROVALS
MECHANICAL SPECIFICATIONS
Pressure
Process
Temperature
Ambient
Temperature
Switch Process
Temperature
Rating
Specific
Gravity
Materials of
Construction
Housing
Cage (optional)
Cage Rating
Schedule 80
Schedule 40
Flange Rating
(optional)
0.6 SG 1500 psig (103 bar)
0.4 SG 500 psig (34 bar)
Agency
-40° F to +400° F (-40° C to +204° C)
CSA
Maximum 100° F (38° C) with
maximum process temperature
5 Amp
400° F (204° C)
15 Amp
220° F (104° C)
15 Amp Form Z
400° F (204° C)
1 Amp Hermetic 220° F (104° C)
10 Amp DPDT
400° F (204° C)
FM
CENELEC
Approval
Models
Class I, Groups C & D
Class II, Groups E, F & G
Class I, Div. 1, Groups C & D
Class II, Div. 1, Groups E, F & G
39-5000-1XX
39-5000-2XX
39-5000-3XX
39-5000-5XX
39-5000-6XX
39-5001-1XX
39-5001-2XX
39-5001-3XX
39-5001-5XX
39-5001-6XX
EEx d IIC T6
0.6 minimum, or 0.4 optional
316 SST wetted components,
(316L SST optional) (NACE and ASME B31.3)
NEMA 7/9 carbon steel (316 SST optional)
Carbon steel (316 SST optional)
1500 psig @ 400° F (103 bar @ 204° C)
1000 psig @ 400° F (69 bar @ 204° C)
250 psig @ 400° F (17 bar @ 204° C)
DIMENSIONAL SPECIFICATIONS INCHES (mm)
Level switch
15.38 (391) or 16.31 (414)
8.91 (226) [Sp. Gr. 0.4 min.]
Float size = 2.00 (51) Dia. x 5.12 (130) Long
7.96 (202) [Sp. Gr. 0.6 min.]
Float size = 2.00 (51) Dia. x 4.57 (116) Long
3.00 (76) Max.
Nozzle Length
2.88
(73)
Dia.
Switch Actuates
Rising Level
3.75 (95)
.75
Float
(19)
Minimum
Clearance
Falling Level
Switch Actuates
C
L
2" NPT
Switch Housing
3/4" NPT
Conduit Connection
Cage
Flanges
0.56 (14) Dia. Holes [4]
on 3.62 (92) B.C.
(2) 1" NPT
1.31
(33)
3.50
(89)
4.50
(114)
Dia.
3.50
(89)
2" NPT
6.40
(163)
2" NPT
1.31
(33)
Flange Part Number: 04-6804-001
Flange Rating: 250 psig @ 400° F (17 bar @ 204° C)
11.25 ± .12
(286 ± 3)
2" NPT
Cage
Part Number
33-4740-001
33-4740-002
33-4741-001
33-4741-002
Chamber
Construction
4" Sch. 80 carbon steel
4" Sch. 80 316 SST
4" Sch. 40 carbon steel
4" Sch. 40 316 SST
Pressure
1500 psig
(103 bar)
1000 psig
(69 bar)
Temperature
400° F
(204° C)
ASME Flange
(Consult factory when ordering)
7
ASSURED QUALITY & SERVICE COST LESS
Service Policy
Return Material Procedure
Owners of Magnetrol may request the return of a control
or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned
by Prepaid transportation. Magnetrol will repair or replace
the control at no cost to the purchaser (or owner) other
than transportation if:
So that we may efficiently process any materials that are
returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior
to the material's return. This is available through Magnetrol’s local representative or by contacting the factory.
Please supply the following information:
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim to
be covered under the warranty.
If the trouble is the result of conditions beyond our control;
or, is NOT covered by the warranty, there will be charges
for labor and the parts required to rebuild or replace the
equipment.
In some cases it may be expedient to ship replacement
parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is
desired, notify the factory of both the model and serial
numbers of the control to be replaced. In such cases, credit
for the materials returned will be determined on the basis
of the applicability of our warranty.
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
No claims for misapplication, labor, direct or consequential
damage will be allowed.
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.
BULLETIN: 44-605.9
EFFECTIVE: May 2006
SUPERSEDES: June 1998