HS Hermetically Sealed Switch ® INSTALLATION / INSTRUCTION MANUAL AND PARTS LIST Housing Cover HT & electrical entry size mm (inches) Contacts HS switch with terminal block SPDT – NEMA 4X (1" NPT entry) HS switch code wiring leads 5A HMB One cont. NEMA 4X (M20 x 1.5 entry) H4B per encl. NEMA 4X (PG 16) H5B NEMA 7/9 std (1" NPT entry) ① DPDT – NEMA 4X (1" NPT entry) 102 HMC (4") HME One cont. NEMA 4X (M20 x 1.5 entry) H4E per encl. NEMA 4X (PG 16) H5E SPDT – Not available HWS Not available NEMA 7/9 std (1" NPT entry) ① HMF HWW NEMA 4X (1" NPT entry) HMH HM2 One cont. NEMA 4X (M20 x 1.5 entry) H4H H42 per encl. NEMA 4X (PG 16) H5H H52 NEMA 7/9 std (1" NPT entry) ① HMJ HS3 NEMA 7/9 Group B (1" NPT entry) HMK HM4 BASEEFA (M20 x 1.5 entry) ① HB1 BASEEFA (3/4" NPT entry) ① Not CENELEC (M20 x 1.5 entry) ① available CENELEC (3/4" NPT entry) ① HS switch with wiring leads SPDT – H4M H5M NEMA 7/9 std (1" NPT entry) ① HB3 HMM 152 per encl. NEMA 4X (PG 16) DESCRIPTION HB2 HB4 NEMA 4X (1" NPT entry) Two cont. NEMA 4X (M20 x 1.5 entry) The HS switch contains a snap action micro switch which is hermetically sealed in a positively pressurised capsule for extended switch mechanism and contact life. terminal block 5A (6") NEMA 7/9 Group B (1" NPT entry) Not available HMN HMP DPDT – NEMA 4X (1" NPT entry) HMR HM6 One cont. NEMA 4X (M20 x 1.5 entry) H4R H46 per encl. NEMA 4X (PG 16) H5R H56 AGENCY APPROVALS NEMA 7/9 std (1" NPT entry) ① HM5 HS7 CENELEC, BASEEFA, CSA, FM: approved for hazardous/ non-hazardous locations. NEMA 7/9 Group B (1" NPT entry) HMT HM8 BASEEFA (M20 x 1.5 entry) ① MODEL NUMBER DESCRIPTION Magnetrol controls are identified by an alphanumeric numbering system. The last 3 digits of the number describe the type of switch mechanism furnished. Example: B 7 5 1 B 2 0 H M H Basic model number 240/120 V AC 24 V DC 120 V DC 240 V DC Max. process temp. Max. ambient temp. CENELEC (M20 x 1.5 entry) ① available DPDT – NEMA 4X Series H2/H3/H8 and HK H4X per encl. NEMA 4X (PG 16) H5X 5.0 A 5.0 A 0.5 A .– 290°C (550°F) 070°C (160°F) 1.0 A 1.0 A 0.4 A 0.25 A 400°C (750°F) – SPDT HB7 HMX NEMA 7/9 std (1" NPT entry) ① HMY NEMA 7/9 Group B (1" NPT entry) HMZ Housing Cover HT mm (inches) Series HM/H4/H5/ HW/HS and HB HB6 HB8 Two cont. NEMA 4X (M20 x 1.5 entry) Contacts BASIC ELECTRICAL RATINGS Voltage Not CENELEC (3/4" NPT entry) ① Switch mechanism & enclosure Tank connection & cage material HB5 BASEEFA (3/4" NPT entry) ① NEMA 4X (1" NPT entry) NEMA 4X (M20 x 1.5 entry) HS switch code wiring leads 1 A - one cont. H2B H3B (4") NEMA 7/9 Group B (1" NPT entry) HKH 152 NEMA 4X (PG 16) NEMA 7/9 std (1" NPT entry) ① NEMA 7/9 Group B (1" NPT entry) Not available H8C – NEMA 4X (1" NPT entry) NEMA 4X (M20 x 1.5 entry) terminal block 1 A - two cont. HKB 102 NEMA 4X (PG 16) NEMA 7/9 std (1" NPT entry) ① Not available (6") HKZ H2H H2Z H3H H3Z H8J H8N HKK HKP All housings are cast aluminium, except for those with a ①: cast iron. WIRING OF SWITCH MECHANISM WITH TERMINAL BLOCK 11. Remove switch housing cover. a. NEMA 4X & 7/9 – Unscrew cover and set aside. b. BASEEFA & CENELEC – Loosen cover and set screw. Unscrew cover and set aside. Internal circuit (right switch) 1 12. Make sure power to control wires is disconnected. Bring in control wires through electrical entry. 2 3 13. Wire the switch as shown in Fig. 1& 2: a. SPDT switch – see Fig.1. b. DPDT switch – see Fig. 2. Load Close on low level Common Note: Double pole action is obtained by simultaneous operation of the right and left side SPDT switches. Load Close on high level Line 14. Dress wiring to ensure no interference or contact with switch housing cover during replacement. Figure 1 – SPDT terminals 15. OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES. 16. Prevent moisture seepage into the enclosure by installing approved seal drain fittings onto the unit. Caution: In hazardous areas, do not power the unit until the enclosure cover is screwed down securely and properly sealed. Internal circuit (left switch) 4 1 5 2 6 3 Internal circuit (right switch) 17. Replace housing cover. 18. Turn on power to the unit. 19. Test switch action by varying liquid level in float chamber. 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 gases into switch housing. Load Close on low level Load Common Close on high level Close on low level Common Load Load Close on high level Line Line Figure 2 – DPDT terminals Note: If switch mechanism fails to function properly, check vertical alignment of control housing. WIRING OF SWITCH MECHANISM WITH WIRING LEADS Load 11. Wiring leads will extend through electrical entry of the switch housing base. Each wiring lead is marked with a number; from 1 to 3 for SPDT switches; or, 1 to 6 for DPDT switches. See Figure 3. These numbers correspond to the numbers marked on the terminal block models. close on low level 3 Load close on high level 1 12. Make sure power to control wires is disconnected. Wire the switch as shown in Figure 3. 2 common Line 13. OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES. Figure 3a – SPDT switch Caution: In hazardous areas, do not power the unit until the enclosure cover is screwed down securely and properly sealed. 14. Turn on power to the unit. 15. Test switch action, by varying liquid level in the float chamber of the control. 16. 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. Note: If switch mechanism fails to function properly, check vertical alignment of control housing. 2 Load Load close on low level 6 3 4 1 5 2 Load Load close on high level common Line close on low level Figure 3b – DPDT switch close on high level Line common REPLACEMENT PARTS Replacement parts for the HS hermetically Sealed switch mechanism are available as a kit only. When ordering a kit, please be sure to specify: Contacts SPDT 5A 1. The model number of the level control in which the switch was installed, e.g. B75. 2. The serial number of the level control in which the switch was installed. See the plate attached to the control. SPDT 1A 3. The model code of the switch being replaced, e.g. HS3. DPDT 5A 4. The part number of the replacement switch kit. Description HS switch Order qty. Switch model code Replacement part number with terminal block max. 290°C (550°F) 1 HM2, H42, H52, HWS, HS3, HB1, HB2, HB3, HB4, HM4 089-8301-002 with wiring leads max. 290°C (550°F) 1 HMB, H4B, H5B, HMH, H4H, H5H, HMC, HMJ, HMK 089-8301-004 with wiring leads max. 540°C (1000°F) with terminal block max. 290°C (550°F) with wiring leads max. 290°C (550°F) 5. The quantity of the replacement switch kits. 2 HMM, H4M, H5M, HMN, HMP, 1 HKB, H2B, H3B, HKH, H2H, H3H, H8C, H8J, HKK 2 HKZ, H2Z, H3Z, H8N, HKP 1 HM6, H46, H56, HWW, HS7, HB5, HB6, HB7, HB8, HM8 089-8301-001 1 HME, H4E, H5E, HMR, H4R, H5R, HMF, HM5, HMT 089-8301-003 2 HMX, H4X, H5X, HMY, HMZ 089-8301-015 REPLACEMENT OF THE SWITCH MECHANISM Should the switch need to be replaced, it may be done by following the steps below: 1. Disconnect all power to the control. 2. Remove switch housing cover. 3. Remove all control wiring from the switch terminal block or wiring leads. 4. Loosen the clamp screw at the top of the switch by turning it counterclockwise. See Figure 5. 5. a. If replacing an existing single HS switch: lift the switch assembly and the switch spacer or washer off the enclosing tube. Discard these parts. b. If replacing a single switch which used a baffle plate: lift the entire switch assembly and the baffle plate off the enclosing tube. Discard these parts. See Figure 4. Caution: When replacing an HS switch with wiring leads, be sure the side of the switch with the clamp screw is on top. The HS switch will not actuate if it is installed upside down. 18. Tighten the clamp screw at the top of the switch by turning it clockwise until the switch is secure on the enclosing tube. 19. Replace the control wires on the appropriate terminals or wiring leads of the new HS switch. See Figures 1, 2 or 3 as necessary. 10. Replace the switch housing cover. 11. Turn on power to the unit. 12. Test switch action by varying liquid level in the float cage. Original switch Note: If replacing two switches, which were nested; the top switch will actuate when the level is 25 mm (1") higher than the original actuation level. Baffle plate c. If replacing two switches with wiring leads: lift both switch assemblies and the switch spacer or washer off the enclosing tube. Discard these parts. d. If replacing two stacked switches which used a baffle plate: lift both switch assemblies and the baffle plate off the enclosing tube. Discard these parts. Enclosing tube Housing base 6. Slide the new switch spacer over the enclosing tube. Discard the switch washer included in the replacement switch parts kit. Figure 4 – Original switch configuration Caution: The switch washer must be used when replacing switches which used baffle plates to ensure that the actuation levels for the control remain the same. 7. a. Single switches: Slide the new HS switch over the enclosing tube until it rests on top of the switch washer. See Figure 5. b. Two switches with wiring leads: Slide one new HS switch over the enclosing tube until it rests on top of the switch washer. Slide the second HS switch over the enclosing tube until it rests on top of the first HS switch. Discard the second switch washer included in the second switch's part kit. Replacement switch Enclosing tube Switch washer Housing base Figure 5 – Replacement switch 3 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. 2. 3. 4. 5. 6. Purchaser Name Description of Material Serial Number Desired Action Reason for Return 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 BELGIUM ® DEUTSCHLAND FRANCE ITALIA UNITED KINGDOM INDIA BE 42-794.0 JANUARY 1994 New 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