F10 Vane type flow switches ® INSTRUCTION MANUAL AND PARTS LIST DESCRIPTION The F10 is a vane type flow switch designed to be installed in 2" through 30" horizontal pipeline by means of a threaded or flanged connection. PART NUMBER CONSTRUCTION F10 – Example: – Part number code 1 Materials of construction 2 Pipeline connection 3 Switch mechanism & enclosure 1 Code Mounting connection material 1 2 3 Materials of construction Trim Carbon steel Sleeve 304 SS Sheathed 3 304 stainless & magnetic 4 316 stainless 316 SS sleeve Switch description Max. process temp. °C (°F) ④ 2" 4" 6" 8" 10" D22 D24 D26 D28 D20 2 1/2" 150 lb. ANSI R.F. flange ② – E54 E56 E58 E50 2 1/2" 300 lb. ANSI R.F. flange – E64 E66 E68 E60 2 1/2" 600 lb. ANSI R.F. flange – E74 E76 E78 E70 ① For flow lines above 10" consult factory. ② For larger flanges consult factory. Select pneumatic switch mechanism & housing Switch description Series J Bleed Max. supply pressure Max. process temperature Bleed orifice diameter Code (NEMA 1 enclosure) 6.9 bar (100 PSIG) 200°C (400°F) 1.60 mm (0.063") JGF 2.39 mm (0.094") JHF 4.1 bar (60 PSIG) Series K Non-bleed Switch enclosure ③ NEMA 4X cast aluminium 4.1 bar (60 PSIG) 230°C (450°F) 1.40 mm (0.055") JJF 6.9 bar (100 PSIG) 200°C (400°F) – KOF (2.8 bar) (40 PSIG) KOH ③ Housing heater and drain available in option. Consult factory for proper model numbers. ④ Process temperatures are based upon +38°C (100°F) ambient. NEMA 7/9 cast iron PG 16 SPDT AAB A2B A3B AKM AK5 AU5 Mercury switch (450°F) DPDT ADB A8B A9B ANM AD5 AW5 Series A – 230°C 1" NPT CENELEC cast iron M 20 x 1.5 : Code vane sized flow line ① 2" NPT Cont. one per encl. 1" NPT Select pipeline connection Connection 3 Select electric switch mechanism & enclosure M20 x 1.5 3/4" NPT Series B – 120°C SPDT BAB B2B B3B BKM BK5 BU5 Snap switch (250°F) DPDT BDB B8B B9B BNM BD5 BW5 Series C – 230°C SPDT CAB C2B C3B CKM CK5 CU5 Snap switch (450°F) DPDT CDB C8B C9B CNM CD5 CW5 Series D – 120°C SPDT Snap switch (250°F) for DC current DPDT DAB D2B D3B DKM DK5 DU5 DDB D8B D9B DNM DD5 DW5 EAB E2B E3B EKM EK5 EU5 Series E – 230°C SPDT Vibr. resistant (450°F) mercury switch DPDT Series HS – 288°C SPDT Hermetically (550°F) sealed with DPDT terminal block EDB E8B E9B ENM ED5 EW5 HM2 H7A H6A HS3 HB3 HB4 HM6 H7C H6C HS7 HB7 HB8 Series U – 120°C SPDT UAB U2B U3B UKM UK5 UU5 Snap switch (250°F) DPDT UDB U8B U9B UNM UD5 UW5 Series W – Snap switch hermetically sealed 120°C (250°F) SPDT WAB W2B W3B WKM WK5 WU5 DPDT WDB W8B W9B WNM WD5 WW5 Series X – Snap switch hermetically sealed 230°C (450°F) SPDT XAB X2B X3B XKM XK5 XU5 DPDT XDB X8B X9B XNM XD5 XW5 OPERATING PRINCIPLE Switch mechanism The actuating vane is magnetically linked to a pivoted electric (or pneumatic) switch, which is isolated from the process by a non-magnetic barrier tube. As the actuating vane moves with an increase in flow, it drives a magnetic sleeve ① into the field of a permanent magnet ② located outside the barrier tube ③ which trips the switch. As flow decreases, the actuating vane returns to a vertical position, allowing the magnet and switch assembly to return to the “No Flow” position. Adjusting screw Magnetic sleeve Magnet Actuating vane NO FLOW POSITION POSITION WITH ACTUATING FLOW PRESENT Figure 1 INSTALLATION UNPACKING MOUNTING — THREADED CONNECTION Unpack the intrument carefully. Inspect all units for damage. Report any concealed damage to the carrier within 24 hours. Check the content of the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. A. Installation of F10 in line (cont.) PIPING The F10 flow switch should be located in a horizontal run pipe with the arrow on the body bushing or mounting flange pointing in the direction of flow. MOUNTING — THREADED CONNECTION A. Installation of F10 IN LINE 1. Insert a length of pipe in 2" 3,000 Ib. Threadolet fitting. 2. Plumb the vertical center line of the fitting and trace around the fitting to locate center line of required 67 mm (2.62") ø hole (Figure 2). 2" pipe, ±305 mm (12") long Figure 2 Air bubble in level position (3000 lb.) 2" threadolet fitting 1.5 mm (0.06") ø spacer wire to provide root cap Marker (note A2) Vertical centerline must be plumb 3. Clean-up inside edges of hole and remove any slag on the bottom of line that could interfere with vane. 4. With fitting concentrically positioned over the 67 mm (2.62") ø. hole and the vertical center line held plumb (as shown in Figure 3), tack weld the fitting at 4 equally space points. After tacking, remove 1.5 mm (0.06") ø spacer wire (Figure 2). Air bubble in level position NOTE: A hole in the pipeline less than 67 mm (2.62") in diameter will limit travel of the pivoted vane. If this condition cannot be avoided, the width of the vane should be reduced to 38 mm (1.50") maximum. IMPORTANT: For installation in 2.00" pipe lines, disregard 67 mm (2.62") dimension and use inside of Threadolet as template. 5. Proper operation of the model F10 depends upon the vertical center line of the 2" NPT coupling being plumb within 3°; keep fitting plumb while welding the continuous passes according to threadolet manufacturers installation procedure. B. Positioning vane perpendicular to flow 6. With large and small vanes unassembled, tighten thread the F10 body bushing into the coupling on the pipeline until one of the 3 decal flow arrows is pointing parallel with flow. 7. Mark the bushing thread even with the top of the threadolet as a reference point for trimming vane to correct length. Remove 2 arrows not parallel with pipe. 8. Remove F10 from pipeline. 9. Check position of arrow stamped on vane support bracket. This arrow should be pointing parallel with the flow arrow on the body bushing (as shown in Figure 4). If arrows are not parallel, remove the three vane support bracket mounting screws and rotate bracket until the stamped arrow is pointing parallel with the flow arrow; replace mounting screws. Figure 4 1/4"NPT plug Adjusting screw safety retainer Adjusting screw Cover Switch (SPDT dry contact shown) Flow arrow must be pointing parallel with the line flow Electrical outlet Body bushing Air bubble in level position Figure 3 Stamped arrow located on vane support bracket Reference mark (note B8) Vane support bracket with 3 mounting screws Top of 2" threadolet fitting * Pivot pin Tack weld 4 places Small vane Large vane 67 ø (2.62") Top of pipeline * 40 ± 0.06 (1.56 ± 2) Flow Dimension C Inside bottom of pipeline (see note at right) Vertical centerline must be plumb 5 (0.19) 2 INSTALLATION (cont.) MOUNTING — THREADED CONNECTION C. Trimming vane to fit line size 10. The Model F10 is furnished as standard with vanes suitable for use on 2" through 30" pipelines. Assemble vane (or vanes) to F10 and trim according to applicable line size as follows: 2.00" line (SCH.40) – Use small vane only (no cutting should be necessary). 2.50" line – Use small vane with large vane trimmed to 38 mm (1.50") wide (same as small vane) and length trimmed to dimension C less 5 mm (0.19"), as shown in Figure 5. 3.00" line and larger – Use small vane with large vane length trimmed to dimension C less 5 mm (0.19"), as shown in Figure 5. Upon final assembly of trimmed vanes, firmly tighten 2 screws (item 27, page 7). It is recommended that the lower retaining screw be peened over on the threaded end. MOUNTING — FLANGED CONNECTIONS Figure 6 shows 1 method which may be used to mount the Model F10 flow switch to 2 1/2" through 30" run pipes. Before final welding, alignment of mounting flange should be checked to be certain it is plumb. Finished mounting must allow control switch housing to be within 3° degrees of vertical for proper operation. A 3° slant is noticeable by eye, but installation should be checked with a spirit level. Vertical centerline must be plumb 2 1/2" ANSI mounting flange ① Reference mark (note B8 & D11) 13 (0.50) 6 (0.25) Dimension C * * 19 (0.75) 2 1/2" PS ANSI flange ② 133 (2.25) ④ 2 1/2" PS pipe nipple (Sched. 80 max. wall thickness) 2 1/2" 3000 lb. sockolet fitting 5 (0.19) (5) min. Top of run pipe ③ 76 (3) ø hole in run pipe Flow ⑤ 5 (0.19) min. Actuating vane Inside bottom of run pipe Top of threadolet Figure 6 40 (1.56) Dimension C Bottom of pipeline Figure 5 D. Final Mounting of F10 11. Apply sealing compound to body bushing threads. 12. Thread F10 into threadolet fitting and tighten body bushing to the same seal tight position as in note B6, so that the flow arrow is pointing parallel with the line flow. 13. Connect power lines. ① Electrical outlet may be rotated 360° for wiring convenience. ② Flange to match flange of F10 flow switch and positioned with bolt holes straddling center lines. ③ For proper attachment procedure, refer to fitting manufacturer’s recommendation. ④ Dimension shown is for use with 1.5 mm (0.06") thick flange gasket. If thicker gasket is used, reduce dimension amount equal to additional thickness. ⑤ For run pipe sizes over 2 1/2" P.S. only. For installation on 2 1/2" run pipes, disregard 3" dimension and use inside of adaptor fitting as template. ⑥ Follow sections B and C of MOUNTING — THREADED CONNECTION to position the vane perpendicular to the flow and trim the vane to size. 3 INSTALLATION (cont.) WIRING SWITCH ACTUATION ADJUSTMENT NOTE: All Model F10 switch housings are designed to allow 360° positioning of the electrical outlet(s) for wiring convenience by loosening the set screw(s) located under the housing base. The Model F10 flow switch is factory set to actuate at the minimum flow rate. Actuation flow rate can be increased while the unit is in service (under pressure) by removing the 1/4” NPT plug to gain access to the “O” ring sealed adjusting screw. Each clockwise turn of the adjusting screw increases the actuating flow rate approximately 10% of the range of the specific flow vane being used. 1. On high temperature applications (above 120°C (250°F) in pipeline), high temperature wire should be used between Magnetrol control and first junction box located in a cooler area. 2. To gain access to switch mechanism, remove switch housing cover. 3. Pull in supply wires (conductors), wrap them around enclosing tube beneath the baffle plate and connect to proper terminals. Check to be certain that excess wire does not interfere with “tilt” of switch and that adequate clearance exists for replacement of switch housing cover. 4. Connect power supply to control and test switch actuation by varying flow rate within pipeline. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and refer to installation bulletin on mechanism furnished, as listed below. 5. Replace switch housing cover. NOTE: NEMA 7/9 housings, the housings must be “sealed” at the electrical outlet with suitable compound 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. 6. Place flow switch into service. Switch mechanism Mercury switches Dry contact switches Anti-vibration mercury switches Bleed type pneumatic valve Non-bleed type pneumatic valve 4 Bulletin n° Series ref. A B, C, D, U, W,X E J K 42-783 42-685 42-686 CAUTION: The safety retainer above the adjusting screw is there to help prevent the accidental removal of the adjusting screw. Do not defeat its purpose by forcefully backing out the adjustment screw. Be sure to replace 1/4” NPT plug and tighten firmly. SPECIFICATIONS Model F10 flow switch with flanged connection B Line size Dim. X max. Equivalent max. wall schedule 2" 46 (1.81) 180 2 1/2" 49 (1.94) 160 3" 48 (1.88) 180 3 1/2" 48 (1.88) 180 4" 51 (2.00) 120 5" 52 (2.06) 120 6" 54 (2.12) 120 8" 56 (2.19) 100 over 8" 59 (1.31) 1— Rotation clearance A E C 2 1/2" ANSI mounting flange D 2 1/2" ANSI flange (to match F10) Electrical connections E 187 (7.38) Electrical switches: NEMA 4X: 1" NPT – M20 x 1,5 – PG 16 (2 entries – 1 plugged) NEMA 7/9: 1" NPT-F entry CENELEC: M 20 x 1,5 or 3/4"NPT-F entry 133 (5.25) 76 ø (3.00) Pneumatic switches: K series: 1/4" NPT-F (2 entries) J series: 1/4" NPT-F (1 entry) 5 (0.19) min. Flow vane Model F10 flow switch with threaded connection OUTLINE DIMENSIONS Housing Threaded mounting A 108 (4.29) B 151 (5.93) C 314 (12.38) D 48 (1.88) NEMA 7/9 100 (3.94) 143 (5.63) 336 (13.23) 42 (1.65) CENELEC 110 (4.33) 143 (5.63) 339 (13.35) 45 (1.77) Pneum. sw. J 110 (4.33) 118 (4.64) 306 (12.05) 39 (1.53) Pneum. sw. K 130 (5.12) 118 (4.64) 306 (12.05) 39 (1.53) NEMA 4X Housing B 151 (5.93) C 257 (10.12) D 48 (1.88) NEMA 7/9 100 (3.94) 143 (5.63) 246 (9.68) 42 (1.65) CENELEC 110 (4.33) 143 (5.63) 249 (9.80) 45 (1.77) Pneum. sw. J 110 (4.33) 118 (4.64) 216 (8.50) 39 (1.53) Pneum. sw. K 130 (5.12) 118 (4.64) 216 (8.50) 39 (1.53) A C E Flanged mounting A 108 (4.29) NEMA 4X B Rotation clearance 2" NPT D 2" NPT 3000# bonney threadolet or equal (supplied by customer) FLOW "X" 40 ± 2 (1.56 ± 0.06) 191 (7.50) – length furnished unless otherwise specified 44 (1.75) 3" pipe and up Vane width Pipe line size (horizontal lines only) 62 ø ± 2 (2.56 ø ± 0.06) 38 (1.50) 2" and 2 1/2" pipe 5 REPLACEMENT PARTS Item no. Description Qty. Carbon steel mounting T316 SS mounting Forged steel flange T304 SS flange T316 SS flange 1 Switch housing cover 1 See bulletin 42-780 for switch housings, items 2 & 3 only applicable on steel NEMA 4 housing, 4 Switch housing base 1 see bulletin 42-680. 5 1/4-20 set screw 1 (item 2: head screw — item 3: retaining washer) 6 Switch mechanism 1 See appropriate bulletin on switch mechanism (listed on page 4) 7 Baffle plate assembly 1 8 6-32 round head screw 1 9 1/4-20 NPT plug 1 E-tube kit E-tube kit E-tube kit E-tube kit E-tube kit E-tube kit 10 Safety retainer 1 89-5912-001 89-5913-001 189-5914-001 189-5928-001 89-5929-001 189-5930-001 11 Washer 1 12 “O” ring 1 13 Adjustment screw 1 14 Enclosing tube 1 15 Enclosing tube gasket 1 16a Body bushing 1 089-5704-001 089-5705-001 189-5706-001 16b Stem. cam 150 lb. follower, and 300 lb. flange assembly 600 lb. 36-5303-001 10-1409-005 12-1204-001 1 — 1 — 32-7203-001 32-7204-001 32-7205-001 32-7203-002 32-7204-002 32-7205-002 32-7203-003 32-7204-003 32-7205-003 17 Flow arrow 05-9822-001 18 Upper spring guide 1 Stem Stem Attraction sleeve Attraction 19 Range spring 1 kit kit and sleeve and 20 10-32 hex nut 3 89-5541-001 189-5542-001 21 Lower spring guide 1 22 Attraction sleeve 1 23 Drain washer 1 24 Stem assembly 1 25 No. 8 lockwasher 3 — 26 8-32 fil. hd. screw 3 27 8-32 rd. hd. screw 2 Vane kit 89-6703-001 28 Small vane 1 Vanes for pipe runs over 8" are special order items. See important order note below. 29 Large vane 30 Instruction tag (not shown) spring kit spring kit 189-5544-001 189-5545-001 — 1 IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Name and Number of replacement assembly. NOTE: Consult factory for CENELEC housing. 6 T304 SS mounting 05-9816-001 REPLACEMENT PARTS (cont.) Serial number tage (ref.) Threaded mounting Flanged mounting 7 AGENCY APPROVALS Agency Approval CENELEC EEx d II C T6 (IP 66) explosion proof EEx ia II C T6 intrinsically safe ① CSA ➀ Non-hazardous NEMA 4X (IP 65) Class I, Div. 2, Groups A, B, C & D Class I, Div. 1, Groups C & D Class II, Div. 1, Groups E, F & G Class I, Div. 1, Groups B, C & D Class II, Div. 1, Groups E, F & G FM ➀ Non-Hazardous NEMA 4X (IP 65) Class I, Div. 1, Groups C & D Class II, Div. 1, Groups E, F & G Class I, Div. 1, Groups A, B, C & D Class II, Div. 1, Groups E, F & G SAA ➀ Ex d II C T6 (IP 65) ① Consult factory for proper model numbers. 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 47-602.14 EFFECTIVE: AUGUST 1995 SUPERSEDES: July 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