Instruction Manual - Magnetrol International

Side Mounting
®
Liquid float level switches
INSTRUCTION MANUAL AND REPLACEMENT PARTS
DESCRIPTION
Magnetrol side mounting controls mount horizontally to any
tank or vessel through a treaded or flanged pipe connection. Standard models are normally 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.
OPERATING PRINCIPLE
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 ➀ into or out the field of a switch actuating magnet ➁ causing switch operation. A non-magnetic
barrier tube ➂ effectively isolates the switch mechanism
from the controlled liquid.
Mercury
switch
4
Pivot
5
6
4
3
5
6
Return
spring
2
AGENCY APPROVALS
1
Pivot
Float
Falling level
Rising level
Agency
Approval
ATEX
II 2G EEx d II C T6, explosion proof
II 1G EEx ia II C T6, intrinsically safe
CCE ➀
Explosion proof & intrinsically safe
FM
Class I, Div. 1, Groups C & D
Class II, Div. 1, Groups E, F & G, Type NEMA 7/9
Non-Hazardous area
FM/CSA ➁
Figure 1
UNPACKING
Unpack the instrument carefully. Inspect all units for damage. Report any concealed damage to carrier within 24
hours. Check the contents of the packing slip and purchase
order. Check and record the serial number for future reference when ordering parts.
Explosion proof area –
Groups B, C, D, E, F & G Type NEMA 4X/7/9
SAA ➁
LRS
Explosion proof area
Lloyds Register of Shipment (marine applications)
GOST/
GOSGORTECHNADZOR ➁
Russian Authorisation Standards
Other approvals are available, consult factory for more details
➀ For CCE approved units, use the ATEX model numbers.
➁ Consult factory for proper model numbers.
MODEL IDENTIFICATION
A complete measuring system consists of:
1. Code for side mounted models (each unit can be factory calibrated when specific level differentials are specified separately).
2. Code for modified models or adders: put an "X" in front of the closest matching order code and specify the modifications/
adders separately
eg. XT62-AG3A-AAP
X = with material certification EN 10204 / DIN 50049-3.1.B
3. OPTION: External cage: consult factory for model description.
1. Code for T62/T67 side mounted float level switch
BASIC MODEL NUMBER1
– Single switch model
T 6 2
down to S.G. 0,50
up to 34,5 bar (500 psi)
– Dual switch model
T 6 7
down to S.G. 0,50
up to 34,5 bar (500 psi)
MATERIALS OF CONSTRUCTION
Code
Cage & process
connection material
A
Float and trim
400 series SST
Carbon steel
B
Magnetic sleeve
316 SST (1.4401)
316 SST (1.4401)
316/316L (1.4401/1.4404)
D
PROCESS CONNECTION
– threaded
F 2
3" NPT
– ANSI flanges
G 3
3" 150 lbs
G 4
3" 300 lbs
H 3
4" 150 lbs
H 4
4" 300 lbs
ANSI
ANSI
ANSI
ANSI
.– DIN flanges
7 F
DN 80, PN 16 DIN 2527 form C
7 G
DN 80, PN 25/40 DIN 2527 form C
8 F
DN 100, PN 16 DIN 2527 form C
8 G
DN 100, PN 25/40 DIN 2527 form C
RF
RF
RF
RF
FLOAT AND STEM LENGTH
Stem length versus min S.G.
Float size
203 mm
305 mm
457 mm
660 mm
mm (inches) ➀
(8")
(12")
(18")
(26")
A
0,80
B
0,80 C 0,90 D 0,90
ø 64 (2.50)
E
0,52
F
0,55 G 0,60 H 0,66 ø 64 x 102 (2.50 x 4.00)
J
0,55
K
0,55
L
0,60 M 0,60
ø 76 (3.00)
N 0,50
P
0,50 Q 0,55 R 0,55
ø 89 (3.50)
S
0,65
T
0,65
V
0,70 W 0,70 ø 76 x 127 (3.00 x 5.00)
Max pressure bar (psi)
@ 40 °C @ 400 °C
(100 °F)
(750 °F)
24,1 (350) 13,8 (200)
6,9 (100)
4,1 (60)
17,2 (250) 10,3 (150)
27,6 (400) 15,5 (225)
34,5 (500) 20,7 (300)
➀ All floats can be screwed to float stem from inside of vessel in case the float cannot pass through the nozzle.
SWITCH MECHANISM & ENCLOSURE
- for T62 units (see page 3)
- for T67 units (see page 4)
- for pneumatic switch mechanisms (see table below)
complete code for T62/T67 side mounted float level switch
T 6
Select pneumatic switch mechanism & enclosure - for T62/T64 models
Pneumatic switch type
Series J
(open air)
Series K
(closed circuit)
2
NEMA 3R (IP 53)
Max supply pressure
bar (psi)
Max liquid temperature
°C (°F)
Bleed orifice Ø
mm (inches)
material code A
material codes B & D
6,9 (100)
200 (400)
1,60 (0.063)
JDE
JDE
4,1 (60)
200 (400)
2,39 (0.094)
JEE
JEE
4,1 (60)
370 (700)
1,40 (0.055)
JFE
JFE
6,9 (100)
200 (400)
–
–
KOE
2,8 (40)
200 (400)
–
KOG
–
1. Code for T64 side mounted float level switch
BASIC MODEL NUMBER1
– Single switch model
T 6 4
down to S.G. 0,40
up to 82,7 bar (1200 psi)
MATERIALS OF CONSTRUCTION
Code
Cage & process
connection material
Carbon steel
A
Float and trim
Magnetic sleeve
304 SST (1.4301) / 316 SST (1.4401)
400 series SST
PROCESS CONNECTION
– ANSI flanges
H 3
4" 150 lbs ANSI RF
H 4
4" 300 lbs ANSI RF
H 5
4" 600 lbs ANSI RF
.– DIN flanges
8 F
DN 100,
8 G
DN 100,
8 H
DN 100,
8 J
DN 100,
PN
PN
PN
PN
16 DIN 2527 form C
25/40 DIN 2527 form C
64 DIN 2527 form E
100 DIN 2527 form E
FLOAT AND STEM LENGTH
N
Fixed stem length: 203 mm (8")
Min. S.G: 0,40
Float size: ø 89 mm (3.50")
Float rating: 82,7 bar (1200 psi) @ 40 °C (100 °F)
400 °C (750 °F) @ 51,7 bar (750 psi)
SWITCH MECHANISM & ENCLOSURE
T 6 4
A
- for electric switch mechanisms (see table below)
- for pneumatic switch mechanisms (see page 2)
complete code for T64 side mounted float level switch
N
Select electric switch mechanism & enclosure for T62 and T64 models (see page 3 for switch ratings)
All models with material code A
qty and
switch
type
A
3
B
C
D
F
HS
U
V
W
X
Weather proof
(IP 66)
cast Aluminium
All models with material codes B and D
ATEX (IP 66)
FM (IP 66)
II 2G EEx d IIC T6 II 1G EEx ia II C T6 II 2G EEx d IIC T6
NEMA 7/9
Weather proof
(IP 66)
cast Iron
cast Alu.
cast Aluminium
M20 x 1,5 3/4" NPT
cast Aluminium
cast Aluminium
ATEX (IP 66)
FM (IP 66)
II 2G EEx d IIC T6 II 1G EEx ia II C T6 II 2G EEx d IIC T6
cast Aluminium
cast Aluminium
NEMA 7/9
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
1 x SPDT
A2P
AAP
AHC
AAC
-
-
AK7
AU7
AKP
A2Q
AAQ
AH9
AA9
-
-
AK5
AU5
AKQ
1 x DPDT
A8P
ADP
AJC
ABC
-
-
AD7
AW7
ANP
A8Q
ADQ
AJ9
AB9
-
-
AD5
AW5
ANQ
1 x SPDT
32P
3AP
3HC
3AC
-
-
3K7
3U7
3KP
32Q
3AQ
3H9
3A9
-
-
3K5
3U5
3KQ
1 x DPDT
38P
3DP
3JC
3BC
-
-
3D7
3W7
3NP
38Q
3DQ
3J9
3B9
-
-
3D5
3W5
3NQ
1 x SPDT
B2P
BAP
BHC
BAC
-
-
BK7
BU7
BKP
B2Q
BAQ
BH9
BA9
-
-
BK5
BU5
BKQ
1 x DPDT
B8P
BDP
BJC
BBC
-
-
BD7
BW7
BNP
B8Q
BDQ
BJ9
BB9
-
-
BD5
BW5
BNQ
1 x SPDT
C2P
CAP
CHC
CAC
C2L
CAL
CK7
CU7
CKP
C2Q
CAQ
CH9
CA9
C2S
CAS
CK5
CU5
CKQ
1 x DPDT
C8P
CDP
CJC
CBC
C8L
CDL
CD7
CW7
CNP
C8Q
CDQ
CJ9
CB9
C8S
CDS
CD5
CW5
CNQ
1 x SPDT
-
-
-
-
-
-
-
-
-
D2Q
DAQ
DH9
DA9
-
-
DK5
DU5
DKQ
1 x DPDT
-
-
-
-
-
-
-
-
-
D8Q
DDQ
DJ9
DB9
-
-
DD5
DW5
DNQ
1 x SPDT
F2P
FAP
FHC
FAC
-
-
FK7
FU7
FKP
F2Q
FAQ
FH9
FA9
-
-
FK5
FU5
FKQ
1 x DPDT
F8P
FDP
FJC
FBC
-
-
FD7
FW7
FNP
F8Q
FDQ
FJ9
FB9
-
-
FD5
FW5
FNQ
1 x SPDT
-
-
-
-
-
-
-
-
-
H7A
HM2
HFC
HA9
-
-
HB3
HB4
HM3
1 x DPDT
-
-
-
-
-
-
-
-
-
H7C
HM6
HGC
HB9
-
-
HB7
HB8
HM7
1 x SPDT
U2P
UAP
UHC
UAC
U2L
UAL
UK7
UU7
UKP
U2Q
UAQ
UH9
UA9
U2S
UAS
UK5
UU5
UKQ
1 x DPDT
U8P
UDP
UJC
UBC
U8L
UDL
UD7
UW7
UNP
U8Q
UDQ
UJ9
UB9
U8S
UDS
UD5
UW5
UNQ
-
-
-
-
-
VFS
VHS
-
-
-
-
-
-
-
V5S
VBS
-
-
-
1 x SPDT
W2P
WAP
WHC
WAC
W2L
WAL
WK7
WU7
WKP
W2Q
WAQ
WH9
WA9
W2S
WAS
WK5
WU5
WKQ
WNQ
1 x DPDT
-
-
-
-
-
-
-
-
-
W8Q
WDQ
WJ9
WB9
W8S
WDS
WD5
WW5
1 x SPDT
X2P
XAP
XHC
XAC
X2L
XAL
XK7
XU7
XKP
X2Q
XAQ
XH9
XA9
X2S
XAS
XK5
XU5
XKQ
1 x DPDT
-
-
-
-
-
-
-
-
-
X8Q
XDQ
XJ9
XB9
X8S
XDS
XD5
XW5
XNQ
3
Select electric switch mechanism & enclosure for T67 models (see page 3 for switch ratings)
All models with material code A
qty and
switch
type
A
3
B
C
D
F
U
W
X
4
Weather proof
(IP 66)
cast Aluminium
All models with material codes B and D
ATEX (IP 66)
FM (IP 66)
II 2G EEx d II C T6 II 1G EEx ia II C T6 II 2G EEx d II C T6 NEMA 7/9
cast Aluminium
cast Aluminium
Weather proof
(IP 66)
FM (IP 66)
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
AV7
ALA
A4B
ABB
AL9
AD9
-
-
AL5
AV5
ALB
AO7
AY7
AOA
A1B
AEB
AP9
AG9
-
-
AO5
AY5
AOB
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
2 x SPDT
A4A
ABA
ALC
ADC
-
-
AL7
2 x DPDT
A1A
AEA
APC
AGC
-
-
cast Aluminium
ATEX (IP 66)
II 2G EEx d II C T6 II 1G EEx ia II C T6 II 2G EEx d II C T6 NEMA 7/9
cast Aluminium
cast Aluminium
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
1" NPT
2 x SPDT
34E
3BE
39E
3DE
-
-
3L7
3V7
3LE
34B
3BB
3L9
3D9
-
-
3L5
3V5
3LB
2 x DPDT
31A
3EA
3PC
3GC
-
-
3O7
3Y7
3OA
31B
3EB
3P9
3G9
-
-
3O5
3Y5
3OB
2 x SPDT
B4A
BBA
BLC
BDC
-
-
BL7
BV7
BLA
B4B
BBB
BL9
BD9
-
-
BL5
BV5
BLB
2 x DPDT
B1A
BEA
BPC
BGC
-
-
BO7
BY7
BOA
B1B
BEB
BP9
BG9
-
-
BO5
BY5
BOB
2 x SPDT
C4A
CBA
CLC
CDC
C4X
CBX
CL7
CV7
CLA
C4B
CBB
CL9
CD9
C4T
CBT
CL5
CV5
CLB
2 x DPDT
C1A
CEA
CPC
CGC
C1X
CEX
CO7
CY7
COA
C1B
CEB
CP9
CG9
C1T
CET
CO5
CY5
COB
2 x SPDT
D4B
DBB
DL9
DD9
-
-
DL5
DV5
DLB
D4B
DBB
DL9
DD9
-
-
DL5
DV5
DLB
2 x DPDT
D1B
DEB
DP9
DG9
-
-
DO5
DY5
DOB
D1B
DEB
DP9
DG9
-
-
DO5
DY5
DOB
2 x SPDT
FFA
FBA
FLC
FDC
-
-
FL7
FV7
FLA
FFB
FBB
FL9
FD9
-
-
FL5
FV5
FLB
2 x DPDT
FHA
FEA
FPC
FGC
-
-
FO7
FY7
FOA
FHB
FEB
FP9
FG9
-
-
FO5
FY5
FOB
2 x SPDT
U4A
UBA
ULC
UDC
U4X
UBX
UL7
UV7
ULA
U4B
UBB
UL9
UD9
U4T
UBT
UL5
UV5
ULB
2 x DPDT
U1A
UEA
UPC
UGC
U1X
UEX
UO7
UY7
UOA
U1B
UEB
UP9
UG9
U1T
UET
UO5
UY5
UOB
2 x SPDT
W4A
WBA
WLC
WDC
W4X
WBX
WL7
WV7
WLA
W4B
WBB
WL9
WD9
W4T
WBT
WL5
WV5
WLB
2 x DPDT
W1B
WEB
WP9
WG9
W1T
WET
WO5
WY5
WOB
W1B
WEB
WP9
WG9
W1T
WET
WO5
WY5
WOB
2 x SPDT
X4A
XBA
XLC
XDC
X4X
XBX
XL7
XV7
XLA
X4B
XBB
XL9
XD9
X4T
XBT
XL5
XV5
XLB
2 x DPDT
X1B
XEB
XP9
XG9
X1T
XET
XO5
XY5
XOB
X1B
XEB
XP9
XG9
X1T
XET
XO5
XY5
XOB
INSTALLATION
MOUNTING
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 (see table on page 4).
– Nozzle should be checked for horizontal alignment.
Finished mounting must allow control switch housing to
be within 3° degrees of vertical for proper operation. A
three degree slant is noticeable by eye, but installation
should be checked with a spirit level.
OBSERVE ALL APPLICABLE ELECTRICAL CODES AND
PROPER WIRING PROCEDURES
NEMA 4x
WIRING
Most mechanical control switch housings are designed to
allow 360° positioning of the cable entries by loosening the
set screw(s). See figure 2. On high temperature applications (above 120° C [250° F]), high temperature wire should
be used between control and first junction box located in a
cooler area.
1. To gain access to switch mechanism(s) remove switch
housing cover.
2. Pull in supply wires (conductors), wrap them around
enclosing tube under the baffle plate and connect to
proper terminals. Be certain that excess wire does not
interfere with "tilt" of switch and that adequate clearance
exists for replacement of switch housing cover.
Set screw
NEMA 7/9
NOTE: See bulletin on switch mechanism furnished with
your control (as listed below) for proper connections.
3. Connect power supply to control and test switch action
by varying liquid level in tank or vessel.
Set screw
NOTE: If switch mechanism fails to function properly, check
vertical alignment of control housing and consult installation
instructions in switch mechanism bulletin.
Set screw
Position
screw
4. Replace switch housing cover and place control into service.
ATEX
NOTE: If control has been furnished with an explosion proof
(cast) or moisture proof (gasketed) switch housing, check
the following:
– After wiring connections have been completed, housings
must be sealed via the correct cable gland to prevent
entrance of air.
– 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 gases into switch housing.
CAUTION:
In hazardous area, do not power the unit until
the cable gland is sealed and the enclosure
cover is screwed down securely.
Switch mechanism
Bulletin
Mercury switches
42-783
A
Dry contact switches
42-683
B, C, D, U, W, X
Anti-vibration dry contact switches
42-684
G, H, I
Bleed type pneumatic valve
42-685
J
Non-bleed type pneumatic valve
42-686
K
Anti-vibration mercury switches
Reference series
E
Locking screw
Figure 2
CAUTION:
- DO NOT attempt to reposition NEMA 4 /
NEMA 7/9 housings without loosening the
set screws; ATEX housings MAY NOT BE
REPOSITIONNED. ALWAYS retighten set
screw(s) after repositionning.
- DO NOT attempt to unscrew cover of ATEX
housings before loosening locking screw in
base of housing. ALWAYS retighten locking
screw after replacing cover.
5
LEVEL DIFFERENTIAL ADJUSTMENT
The level differential setting of the side mounting controls
can be field adjusted within limits specified in the table at
right by repositioning the jam nuts on the magnetic sleeve
stem.
NOTE: The control need not be removed from tank or vessel to make differential adjustment.
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.
guide washer
upper jam nuts
A
B
lower
jam nuts
magnetic
sleeve
magnetic
sleeve stem
4. Loosen and remove upper jam nuts, guide washer and
magnetic sleeve. Dimension “A”, as measured from top
of stem to top of lower jam nuts, may now be increased
or decreased as desired.
Tandem model units have two switch mechanisms actuated by two independent magnetic sleeves. For adjustment
purposes, each sleeve and jam nut set is considered as an
individual unit in conjunction with the switch mechanism it
operates.
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. Lock upper
jam nuts to guide washer.
6. Reassemble control in reverse of steps 1 through 3, previously described.
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.
6
CL of control
– differential –
low level
float stem length
minus approx. 3/4"
float
Figure 3
2. Perform system shut-down as required to relieve pressure from tank or vessel and drain off liquid “head”
above control mounting position. Allow unit to cool.
With switch housing removed, jam nuts and magnetic
sleeve are now accessible, as in Figure 3. Raising the
lower jam nuts or lowering the upper jam nuts will reduce
the differential. Jam nut adjustments in opposite directions
will, of course, increase the differential. As the first step in
any adjustement procedure, the position of the lower jam
nuts (dimension A) should be established.
high level
pivot
1. Disconnect wiring from supply side of switch mechanism
and electrical conduit or operating medium line connections to switch housing.
3. Remove switch housing assembly by loosening hex nut
located immediately below housing base.
pivot
Millimeters
Differentials Obtainable ➁ ➃
Float Stem Length
Model ➀
203
305
457
Min.
32
51
73
T62
(Threaded) Max. 148
206
294
Min.
32
41
67
T62
(Flanged) Max.
89
130
191
Approx. Jam
Nut Setting ➂
660
102
409
95
273
A
21
33
16
28
B
0.8
27
0.8
18
Inches
Differentials Obtainable ➁ ➃
Approx. Jam
Nut Setting ➂
Float Stem Length
➀
Model
8.00 12.00 18.00 26.00
A
B
Min.
1.25
2.00
2.88
4.00
0.81
0.03
T62
(Threaded) Max. 5.81
8.12 11.56 16.12 1.31
1.06
Min.
1.25
1.62
2.62
3.75
0.62
0.03
T62
(Flanged) Max. 3.50
5.12
7.50 10.75 1.12
0.69
Notes:
➀ All models are factory set at minimum differential unless otherwise specified.
➁ To maintain maximum differential, nozzle length "L" (Fig. 2) must
not exceed: 64 mm (2.50") model T62 threaded; or 89 mm (3.50")
model T62 flanged.
➂ Dimensions given are approximate and will vary slightly with each
unit.
➃ Consult factory for differentials of models not shown.
LEVEL DIFFERENTIAL ADJUSTMENT (cont.)
LEVEL DIFFERENTIAL VS. MOUNTING NOZZLE LENGTH
The tables 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.
Level differential in mm (inches)
Models
T62
threaded
dim. "D"
77,9 mm (3.07")
3" – Sch 40
dim. "L"
203 mm (8")
305 mm (12")
457 mm (18")
660 mm (26")
min
Not applicable
32 (1.26)
51 (2.01)
73 (2.87)
102 (4.02)
50 mm (2")
148 (5.83)
206 (8.11)
294 (11.58)
409 (16.10)
100 mm (4")
111 (4.37)
155 (6.10)
221 (8.70)
310 (12.20)
150 mm (6")
38 (1.50)
119 (4.69)
170 (6.69)
236 (9.29)
200 mm (8")
-
97 (3.82)
138 (5.43)
192 (7.56)
250 mm (10")
-
81 (3.19)
116 (4.57)
162 (6.38)
max
min
T62
flanged
73,7 mm (2.90")
3" – Sch 80
Float stem length versus level differential
Differential
305 mm (12")
-
-
100 (3.94)
138 (5.43)
Not applicable
32 (1.26)
41 (1.61)
67 (2.64)
95 (3.74)
50 mm (2")
89 (3.50)
130 (5.12)
191 (7.52)
273 (10.75)
100 mm (4")
83 (3.27)
121 (4.76)
178 (7.01)
254 (10.00)
150 mm (6")
-
95 (3.74)
137 (5.39)
197 (7.76)
200 mm (8")
-
76 (2.99)
114 (4.49)
159 (6.26)
250 mm (10")
-
64 (2.52)
95 (3.74)
137 (5.39)
305 mm (12")
-
-
83 (3.27)
117 (4.61)
fixed
max 178 mm (7")
32 (1.26)
Not applicable
Not applicable
Not applicable
min
max 57 mm
(2.25")
25 (1.00)
38 (1.50)
54 (2.12)
76 (3.00)
64 (2.50)
95 (3.75)
140 (5.50)
197 (7.75)
max 89 mm
(3.50")
25 (1.00)
38 (1.50)
54 (2.12)
76 (3.00)
48 (1.88)
68 (2.69)
99 (3.88)
140 (5.50)
max
T64 flanged
102,3 mm (4.03")
4" – Sch 40
T67
threaded
77,9 mm (3.07")
3" – Sch 40
max
T67
flanged
73,7 mm (2.90")
3" – Sch 80
max
min
All units are factory set at minimum differential unless otherwise specified.
Consult factory for differentials not shown.
ø D min. nozzle opening
ø D min. nozzle opening
switch actuates
rising level
CL
of control
level diff.
switch 1 level
level diff. differential
switch 2
switch actuates
falling level
T67
L
float
switch actuates
rising level
CL
of control
level diff.
switch 1 level
level diff. differential
switch 2
switch actuates
falling level
T67
T62
L
T62/T64
float
7
PREVENTIVE MAINTENANCE
Periodic inspections are a necessary means to keep your Magnetrol level control in good working order. This control
is, in reality, a safety device to protect the valuable equipment it serves. Therefore, a systematic program of "preventive maintenance" should be implemented when control is placed into service. If the following sections on "what to
do" and "what to avoid" are observed, your control will provide reliable protection of your capital equipment for many
years.
WHAT TO DO
WHAT TO AVOID
1. Keep control clean
1. NEVER leave switch housing cover off the control longer
than necessary to make routine inspections.
NEVER leave switch housing cover off 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, order a replacement immediately.
2. NEVER use lubricants on pivots of switch mechanisms.
A sufficient amount of lubricant has been applied at the
factory to insure a lifetime of service. Further oiling is
unnecessary and will only tend to attract dust and dirt
which can interfere with mechanism operation.
2. Inspect switch mechanisms, terminals and connections monthly.
3. NEVER place a jumper wire across terminals to "cutout" the control. If a "jumper" is necessary for test purposes, be certain it is removed before placing control
into service.
– Mercury switches may be visually inspected for short
circuit damage. Check for small cracks in the glass
tube containing the mercury. Such cracks can allow
entrance of air into the tube causing the mercury to
"oxidize". This is noticeable as the mercury will
appear dirty and have a tendency to "string out" like
water, instead of breaking into round pools. If these
conditions exist, replace the mercury switch immediately.
4. NEVER attempt to make adjustments or replace switches without reading instructions carefully. Certain adjustments provided for in Magnetrol controls should not be
attempted in the field. When in doubt, consult the factory or your local Magnetrol representative.
– Dry contact switches should be inspected for excessive wear on actuating lever or misalignment of
adjusting 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.
Do NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch
mechanism furnished for service instructions).
– Magnetrol 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 first sign of brittle
insulation.
– Vibration may sometimes cause terminal screws to
work loose. Check all terminal connections to be certain that screws are tight. 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.
– On units with pneumatic switches, air (or gas) operating medium lines subjected to vibration, may eventually crack or become loose at 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.
8
TROUBLE SHOOTING
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.
CHECK SWITCH MECHANISM
1. Pull disconnect switch or otherwise disconnect power to
the control.
2. Remove switch housing cover.
3. Disconnect power wiring from switch assembly.
4. Swing magnet assembly in and out by hand to check
carefully for any sign of binding. Assembly should
require minimal force to move it through its full swing.
5. If binding exists, magnet may be rubbing enclosing
tube. If magnet is rubbing, loosen magnet clamp screw
and shift magnet position. Retighten magnet clamp
screw.
6. If switch magnet assembly swings freely and mechanism
still fails to actuate, check installation of control to be certain it is within the specified three (3°) degrees of vertical
(Use spirit level on side of enclosing tube in two place, 90°
apart).
7. If mechanism is equipped with a mercury switch,
examine glass mercury tube closely as previously
described in “Preventive Maintenance” section. If
switch is damaged, replace it immediately.
8. If switch mechanism is operating satisfactorily, proceed
to check sensing unit.
2. If controlled equipment responds to manual actuation
test, trouble may be located in the level sensing portion
of the control (float, stem and magnetic attraction
sleeve[s]).
NOTE: Check first to be certain liquid is entering storage
tank or vessel. A valve may be closed or pipe line plugged.
3. With liquid in tank or vessel, proceed to check level
sensing action by removing switch housing assembly.
4. Inspect magnetic attraction sleeve(s) and inside of
enclosing tube for excessive corrosion or solids buildup which could restrict movement, preventing sleeve(s)
from reaching field of magnet(s).
5. If differential has been changed in the field, check tightness and position of the jam nuts.
NOTE: Differential adjustment affects a change in the
amount of level travel between “switch on” and “switch off”
actuations. Do NOT attempt adjustment without first consulting factory for assistance in computing level differential
change for your control.
6. Check float to be certain it is buoyant in the liquid (tank
or vessel must have adequate liquid level). If float is
determined to be filled with liquid or collapsed, it must
be replaced immediately. Do NOT attempt to repair a
float.
If all the 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: When in doubt about the condition or performance
of a Magnetrol control, return it to the factory. See “Our
Service Policy” on back page.
CHECK SENSING UNIT
1. Re-connect power supply and carefully actuate switch
mechanism manually (using a non-conductive tool) to
determine whether controlled equipment will operate.
CAUTION:
With electrical power “on”, care should be taken
to avoid contact with switch leads and connections at terminal block.
9
DIMENSIONAL SPECIFICATIONS in mm (inches)
X
X
Y
Y
V
Z
V
Z
W
W
78*
(3.07)
X
78*
(3.07)
Y
124 (4.88)
114 (4.50)
219 (8.62)
Z
this dimension
equals float,
+ stem length,
minus 66
(2.60)
model T62/T67 threaded
V
this dimension
equals float,
+ stem length,
minus 76
(3.00)
229 (9.00)
W
model T62/T67 flanged
90*
(3.54)
min level
differential
32 (1.25)
137 (5.39)
267 (10.50)
267 (10.50)
* Dimensions for all housings, except for cast iron
housing, add for these 76 mm (3")
Housing type
Models
WeatherproofFM (NEMA 7/9) ATEX (Cast Alu)
ATEX (Cast Iron)
Pneumatics
Switch Module J
Pneumatics
Switch Module K
model T64 flanged
V
W
mm
inches
T62/T64 with HS-switch
and T67
257
10.12
T62/T64 excl. HS-switch
202
7.94
All
249
T62/T64
165
øX
Y
Z
mm
inches
mm
inches
mm
inches
42
1.66
151
5.93
109
4.29
M20 x 1,5 (*) or 1" NPT
(2 entries - 1 plugged)
(*) not for FM (NEMA 7/9)
9.80
45
1.77
143
5.63
110
4.33
M20 x 1,5 or 3/4" NPT
(single entry - 2 entries at request)
110
4.33
6.50
39
1.54
118
4.65
130
5.12
1/4" NPT
Allow 200 mm (7.87") overhead clearance / All housings are 360 ° rotatable
REPLACEMENT PARTS
Spacer bracket for tandem
switch mechanisms
Serial no. tag (ref.)
Serial no. tag (ref.)
(T62 & T67)
flanged
(T63 & T68)
(T52 & T57)
(T62 & T67)
threaded
10
REPLACEMENT PARTS
Replacement assemblies ➀
Item
Model
Description
T62
threaded
T62
flanged
T64
T67
threaded
T67
flanged
1
Switch housing cover
2
Switch housing base
Housing
kits
See bulletin BE 42-680/BE 42-780 ref. A, B, C, D & E switch housings replacement assemblies. Consult factory on series G, H, I, J & K.
3
Switch mechanism(s)
—
See bulletin on switch mechanism(s) furnished, as listed below.
4
Spacer bracket
—
05-7542-121
N/R
5
Round head screws (2)
6
Attraction sleeve(s)
7
Jam nuts
8
Guide washer
9
Sleeve stem
—
Stem
kits
➁
10
Connecting pin
11
Fulcrum
12
Fulcrum pin
13
Pivot bracket
14
Round head mach. screws
15
Float stem
16
Stem lock nuts
17
10-1409-006
Float ⑥
89-5510-001
Standard sleeve
Kits shown
contain
203 mm (8.08")
stem lengths.
Consult factory
for
longer
stem lengths.
89-5514-001
Sheathed sleeve
④
—
ø 64 (2,5")
89-5546-001
89-5546-001
89-5553-001
89-5553-001
ø 76 (3")
89-5551-001
89-5551-001
ø 89 (3,5")
89-5552-001
18
Body
—
19
E-tube gasket
—
Materiel
code
1,2
NEMA 4
NEMA 7/9
Pneumatic
housing
Materiel
code
4
NEMA 4
NEMA 7/9
Pneumatic
housing
07-1101-012
89-5554-001
—
89-5555-001
33-6120-001
33-6124-001
Flange gasket
—
89-5555-001
33-6120-001
33-6124-001
12-1301-002 ➄
32-6302-031
32-6302-033
32-6344-002
32-6302-036
ATEX
21
89-5552-001
89-5554-001
ATEX
Enclosing tube
89-5511-001
Standard
sleeve
ø 64 x 102
(2,5" x4")
ø 76 x 127
(3" x 5")
ø 76 x 152
(3" x 6")
20
89-5512-001
Standard
sleeve
32-6302-037
32-6344-001
N/R
N/A ③
N/R
N/A ③
N/R = not required – N/A = not available
① All replacement assemblies listed are for standard base models which use Ref. series A, B, C, D, E and J switch mechanisms only. Consult local representative for ordering assistance on all special model replacement parts not included in the
above listing.
② Sheathed attraction sleeves are used on models specified for corrosive service. Standard sleeve is type 400 series stainless steel.
③ Flange gasket used on T62, T64 and T67 units is standard ANSI type, readily available at local supply houses.
④ Sheathed sleeve stem kits are used on models with Material of Construction Codes 2 through 9.
⑤ Above 300 Lb. rating, use 12-1204-001.
⑥ Dimensions in millimeters (inches).
IMPORTANT:
When ordering, please specify:
A. Model and serial number of control.
B. Name and number of replacement assembly.
11
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°:
EFFECTIVE:
SUPERSEDES:
UNDER RESERVE OF MODIFICATIONS
www.magnetrol.com
®
BE 44-602.12
JANUARY 2005
December 1996
BENELUX
Heikensstraat 6, 9240 Zele, België
Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected]
DEUTSCHLAND
Alte Ziegelei 2-4, D-51491 Overath
Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected]
FRANCE
40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard
Tél. 01.34.44.26.10 • Fax. 01.34.44.26.06 • E-Mail: [email protected]
ITALIA
Via Arese 12, I-20159 Milano
Tel. (02) 607.22.98 (R.A.) • Fax. (02) 668.66.52 • E-Mail: [email protected]
UNITED
KINGDOM
Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
Tel. (01444) 871313 • Fax (01444) 871317 • E-Mail: [email protected]
INDIA
E-22, Anand Niketan, New Delhi - 110 021
Tel. 91 (11) 6186211 • Fax 91 (11) 6186418 • E-Mail: [email protected]