SERIES 75 ® Liquid Level Switches INSTRUCTION MANUAL AND REPLACEMENT PARTS DESCRIPTION Magnetrol’s Series 75 level switches are float operated units suitable for use on clean liquid applications for level alarm, pump control and safety shutdown functions. OPERATING PRINCIPLE A permanent magnet ① is attached to a pivoted switch actuator ②. As the float/ displacer ③ rises following the liquid level, it raises the attraction sleeve ④ into the field of the magnet, which then snaps against the non-magnetic enclosing tube ⑤, actuating the switch. The enclosing tube provides a static pressure boundary between the switch mechanism and the process. On a falling level, an inconel spring retracts the magnet, deactivating the switch. pivot ② ⑤ return spring ① ④ ③ AGENCY APPROVALS Rising level Falling level Agency Approval ➀ CENELEC EEx d IIC T6, explosion proof EEx ia IIC T6, intrinsically safe➁ BASEEFA Ex d IIC T6 CSA ➀ Non-Hazardous CSA Type 4X Class I, Div. 2, Groups 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 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. FM ➀ Non-Hazardous NEMA 4X 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 SAA ➀ Ex d IIC T6 (IP65) ➀ Not available with all switches; Consult factory for proper model numbers. ➁ Consult factory for proper model numbers. MODEL IDENTIFICATION A complete series 75 liquid level switch, consists of 1 code: Code MODEL NUMBER – SPECIFIC GRAVITY & PRESSURE RATINGS — CARBON STEEL CHAMBERS ① Min. specific gravity Models with material construction code 1 2 A B C G J 0.60 0.75 0.60 0.55 0.50 40° C bar @ °C 230° C 42,7 69,0 34,5 51,7 27,6 29,0 58,6 25,5 38,6 20,3 0.65 0.75 0.60 0.57 0.53 Pressure rating ③ PSIG @ °F 400° C 100° F 450° F 25,2 51,7 20,7 32,7 17,2 620 1000 500 750 400 750° F 420 850 370 560 295 365 750 300 475 250 Code MODEL NUMBER – SPECIFIC GRAVITY & PRESSURE RATINGS — STAINLESS STEEL CHAMBERS ② Min. specific gravity Models with material construction code 4 A B C G P O 0.65 0.75 0.60 0.57 0.75 0.85 Pressure rating ③ 40° C bar @ °C 230° C 400° C 100° F PSIG @ °F 450° F 750° F 42,7 69,0 34,5 51,7 27,6 27,6 29,0 58,6 22,4 38,6 17,9 22,4 25,2 51,7 19,6 32,7 15,5 19,6 620 1000 500 750 400 400 420 850 325 560 260 325 365 750 285 475 225 285 ① Carbon steel chamber models are used with MATERIALS OF CONSTRUCTION Chamber Float 1 2 4 Carbon steel ① Carbon steel ① 316 SS ② material of construction codes 1 and 2 only. Sleeve 316 SS 316 SS 316 SS ② Stainless steel chamber models are used with material of construction code 4 only. 400 SS 316 SS 316 SS ③ Models are limited to max. temperature rating of selected switch mechanism. See Switch mechanism charts on page 3. ④ Contact factory for high pressure and high temperature applications. SIZE AND TYPE OF TANK CONNECTIONS (see configurations on pages 6 & 8) Threaded Socket weld 1" size CONNECTION SIZE 1 1/2" size 2" size B20 B30 C20 C30 D20 D30 Flange 150 300 STYLE & CONNECTION SIZE – ANSI 1 1/2" size Cage mounting flange ratings – ANSI 600 150 300 600 150 N30 S30 N40 S40 N50 S50 1" size upper side/bottom side/side Flange NW 25 (DIN) ND16 ND25 ND40 P30 T30 P40 T40 P50 T50 Q30 V30 STYLE & CONNECTION SIZE – DIN NW 40 (DIN) Cage mounting flange ratings – DIN ND64 ND16 ND25 ND40 ND64 ND16 2" size 300 600 Q40 V40 Q50 V50 NW 50 (DIN) ND25 ND40 ND64 (DIN 2633) (DIN 2634) (DIN 2635) (DIN 2636) (DIN 2633) (DIN 2634) (DIN 2635) (DIN 2636) (DIN 2633) (DIN 2634) (DIN 2635) (DIN 2636) Form C Form C Form C Form E Form C Form C Form C Form E Form C Form C Form C Form E (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) (DIN 2526) upper side/bottom side/side 1FA 1FB 1GA 1GB 1HA 1HB 1JA 1JB 2FA 2FB 2GA 2GB 2HA 2HB 2JA 2JB SWITCH MECHANISM AND ENCLOSURE Refer to right page for pneumatic and electric switch mechanisms. 7 5 2 code for sealed external cage float level switch 3FA 3FB 3GA 3GB 3HA 3HB 3JA 3JB SELECT PNEUMATIC SWITCH MECHANISM & ENCLOSURE Pneumatic switch Max. supply pressure Max. liquid temperature Bleed orifice Ø bar (PSIG) °C (°F) mm (inches) mat'l. code 1 mat'l. code 2 & 4 description Series J bleed type Series K non bleed type Code (NEMA 3R encl.) 6.9 bar (100 PSIG) 200°C (400°F) 1.60 mm (0.063") JDG JDE 4.1 bar (160 PSIG) 200°C (400°F) 2.39 mm (0.094") JEG JEE 4.1 bar (160 PSIG) 370°C (700°F) 1.40 mm (0.055") JFG JFE 6.9 bar (100 PSIG) 200°C (400°F) — KOE KOE 2.8 bar (140 PSIG) 200°C (400°F) — KOG — ① ② All models with material of construction code 1 Cont. per enclosure Switch Description Max. liquid temp. °C (°F) Contacts SELECT ELECTRIC SWITCH MECHANISM & ENCLOSURE NEMA 4X cast aluminium NEMA 7/9 cast iron 1" PG 16 NPT M 20 x 1.5 1 2 3 AAA ABA ACA A2A A4A A6A A3A A5A A7A 1 2 ADA AEA A8A A1A 1 2 3 3AA 3BA 3CA 1 2 AAB ABB ACB A2B A4B A6B A3B A5B A7B AKM ALM AMM AK6 AL6 A66 AU6 AV6 A76 AK5 AL5 A65 AU5 AV5 A75 AX8 AY8 AD7 AO7 AW7 AY7 ADB AEB A8B A1B A9B AZB ANM AOM AN6 AO6 AX6 AY6 AD5 AO5 AW5 AY5 3K8 3L8 368 3U8 3V8 378 3K7 3L7 367 3U7 3V7 377 3AB 3BB 3CB 32B 34B 36B 33B 35B 37B 3KM 3LM 3MM 3K6 3L6 366 3U6 3V6 376 3K5 3L5 365 3U5 3V5 375 3ND 3OD 3N8 3O8 3X8 3Y8 3D7 3O7 3W7 3Y7 3DB 3EB 38B 31B 39B 3ZB 3NM 3OM 3N6 3O6 3X6 3Y6 3D5 3O5 3W5 3Y5 B3A B5A B7A BKD BLD BMD BK8 BL8 B68 BU8 BV8 B78 BK7 BL7 B67 BU7 BV7 B77 BAB BBB BCB B2B B4B B6B B3B B5B B7B BKM BLM BMM BK6 BL6 B66 BU6 BV6 B76 BK5 BL5 B65 BU5 BV5 B75 B8A B1A B9A BZA BND BOD BN8 BO8 BX8 BY8 BD7 BO7 BW7 BY7 BDB BEB B8B B1B B9B BZB BNM BOM BN6 BO6 BX6 BY6 BD5 BO5 BW5 BY5 CAA CBA CCA C2A C4A C6A C3A C5A C7A CKD CLD CMD CK8 CL8 C68 CU8 CV8 C78 CK7 CL7 C67 CU7 CV7 C77 CAB CBB CCB C2B C4B C6B C3B C5B C7B CKM CLM CMM CK6 CL6 C66 CU6 CV6 C76 CK5 CL5 C65 CU5 CV5 C75 1 2 CDA CEA C8A C1A C9A CZA CND COD CN8 CO8 CX8 CY8 CD7 CO7 CW7 CY7 CDB CEB C8B C1B C9B CZB CNM COM CN6 CO6 CX6 CY6 CD5 CO5 CW5 CY5 Series D – 120°C Snap switch (250°F) SPDT for DC current applications DPDT 1 2 3 DAB DBB – D2B D4B – D3B D5B – DKM DLM – DK6 DL6 – DU6 DV6 – DK5 DL5 – DU5 DV5 – DAB DBB DCB D2B D4B D6B D3B D5B D7B DKM DLM DMM DK6 DL6 D66 DU6 DV6 D76 DK5 DL5 D65 DU5 DV5 D75 1 2 DDB DEB D8B D1B D9B DZB DNM DOM DN6 DO6 DX6 DY6 DD5 DO5 DW5 DY5 DDB DEB D8B D1B D9B DZB DNM DOM DN6 DO6 DX6 DY6 DD5 DO5 DW5 DY5 Series E – 290°C Vibration (550°F) SPDT resistant mercury switch DPDT 1 2 3 EAA EBA ECA E2A E4A E6A E3A E5A E7A EKD ELD EMD EK8 EL8 E68 EU8 EV8 E78 EK7 EL7 E67 EU7 EV7 E77 EAB EBB ECB E2B E4B E6B E3B E5B E7B EKM ELM EMM EK6 EL6 E66 EU6 EV6 E76 EK5 EL5 E65 EU5 EV5 E75 1 2 EDA EEA E8A E1A E9A EZ8 END EOD EN8 EO8 EX8 EY8 ED7 EO7 EW7 EY7 EDB EEB E8B E1B E9B EZ7 ENM EOM EN6 EO6 EX6 EY6 ED5 EO5 EW5 EY5 Series 2 – 400°C Vibr. resistant (750°F) SPDT mercury switch with DPDT beaded leads 1 2 3 2AA 2BA 2CA 22A 24A 26A 23A 25A 27A 2KD 2LD 2MD 2K8 2L8 268 2U8 2V8 278 2K7 2L7 267 2U7 2V7 277 2AB 2BB 2CB 22B 24B 26B 23B 25B 27B 2KM 2LM 2MM 2K6 2L6 266 2U6 2V6 276 2K5 2L5 265 2U5 2V5 275 1 2 2DA 2EA 28A 21A 29A 2ZA 2ND 2OD 2N8 2O8 2X8 2Y8 2D7 2O7 2W7 2Y7 2DB 2EB 28B 21B 29B 2ZB 2NM 2OM 2N6 2O6 2X6 2Y6 2D5 2O5 2W5 2Y5 400°C SPDT (750°F) 1 2 FAA FBA FCA FFA FPA FRA FKD FLD FK8 FL8 FU8 FV8 FK7 FL7 FU7 FV7 FAB FBB FCB FFB FPB FRB FKM FLM FK6 FL6 FU6 FV6 FK5 FL5 FU5 FV5 DPDT 1 2 FDA FEA FGA FHA F9A FZA FND FOD FN8 FO8 FX8 FY8 FD7 FO7 FW7 FY7 FDB FEB FGB FHB F9B FZB FNM FOM FN6 FO6 FX6 FY6 FD5 FO5 FW5 FY5 1 HM2 H7A H6A HS3 HB1 HB2 HB3 HB4 HM2 H7A H6A HS3 HB1 HB2 HB3 HB4 1 HM6 H7C H6C HS7 HB5 HB6 HB7 HB8 HM6 H7C H6C HS7 HB5 HB6 HB7 HB8 1 2 3 UAA UBA UCA U2A U4A U6A U3A U5A U7A UKD ULD UMD UK8 UL8 U68 UU8 UV8 U78 UK7 UL7 U67 UU7 UV7 U77 UAB UBB UCB U2B U4B U6B U3B U5B U7B UKM ULM UMM UK6 UL6 U66 UU6 UV6 U76 UK5 UL5 U65 UU5 UV5 U75 1 2 UDA UEA U8A U1A U9A UZA UND UOD UN8 UO8 UX8 UY8 UD7 UO7 UW7 UY7 UDB UEB U8B U1B U9B UZB UNM UOM UN6 UO6 UX6 UY6 UD5 UO5 UW5 UY5 1 2 3 WAA WBA WCA W2A W4A W6A W3A W5A W7A WKD WLD WMD WK8 WL8 W68 WU8 WV8 W78 WK7 WL7 W67 WU7 WV7 W77 WAB WBB WCB W2B W4B W6B W3B W5B W7B WKM WLM WMM WK6 WL6 W66 WU6 WV6 W76 WK5 WL5 W65 WU5 WV5 W75 1 2 WDB WEB W8B W1B W9B WZB WNM WOM WN6 WO6 WX6 WY6 WD5 WO5 WW5 WY5 WDB WEB W8B W1B W9B WZB WNM WOM WN6 WO6 WX6 WY6 WD5 WO5 WW5 WY5 1 2 3 XAA XBA XCA X2A X4A X6A X3A X5A X7A XKD XLD XMD XK8 XL8 X68 XU8 XV8 X78 XK7 XL7 X67 XU7 XV7 X77 XAB XBB XCB X2B X4B X6B X3B X5B X7B XKM XLM XMM XK6 XL6 X66 XU6 XV6 X76 XK5 XL5 X65 XU5 XV5 X75 1 2 XDB XEB X8B X1B X9B XZB XNM XOM XN6 XO6 XX6 XY6 XD5 XO5 XW5 XY5 XDB XEB X8B X1B X9B XZB XNM XOM XN6 XO6 XX6 XY6 XD5 XO5 XW5 XY5 DPDT Series C – Snap switch 230°C (450°F) SPDT DPDT Series F – Snap switch hermetically sealed Series HS – 290°C Snap switch (550°F) SPDT hermetically sealed with DPDT terminal block Series U – Snap switch 120°C (250°F) SPDT DPDT ① ② Series W – Snap switch hermetically sealed 230°C (450°F) SPDT Series X – Snap switch hermetically sealed 230°C (450°F) SPDT DPDT DPDT AU8 AV8 A78 A9A AZA AND AOD AN8 AO8 32A 34A 36A 33A 35A 37A 3KD 3LD 3MD 3DA 3EA 38A 31A 39A 3ZA 1 2 3 BAA BBA BCA B2A B4A B6A 1 2 BDA BEA 1 2 3 1" 1" PG 16 NPT M20 x 1.5 3/4" CENELEC cast iron AU7 AV7 A77 120°C (250°F) SPDT AK8 AL8 A68 3/4" BASEEFA cast iron AK7 AL7 A67 Series B – Snap switch AKD ALD AMD M20 x 1.5 NEMA 7/9 cast iron NPT Series 3 – 400°C Mercury switch (750°F) SPDT with beaded leads DPDT NPT NPT 3/4" NEMA 4X cast aluminium NPT DPDT M20 x 1.5 All models with material of construction codes 2 and 4 CENELEC cast iron M 20 x 1.5 Series A – 290°C Mercury switch (550°F) SPDT 1" BASEEFA cast iron NPT M20 x 1.5 3/4" NPT Housing heater available in NEMA 4X and 7/9 enclosures. Drain available in NEMA 7/9 enclosures. Consult factory for standard part number. Temperatures based on 38°C (100°F) ambient. 3 INSTALLATION CRITICAL ALARM FUNCTION It is recommended that for critical alarm functions, an additional level switch be installed as a high-high or low-low level alarm for maximum protection. PIPING Figure 3 shows a typical piping installation of a Magnetrol Series 75 control to a pressure vessel. Level decals on control identify the actuation levels for a unit with three switches at minimum specific gravity. Refer to the Actuation Level charts on Page 8 for the actuation levels for a unit with one switch at different minimum specific gravities. 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 towards the vessel and upper vapor line will drain toward the control. Shut-off valves are recommended for installation between the vessel and the control. If 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. DO NOT INSULATE SWITCH MECHANISM HOUSING. On controls equipped with pneumatic switch assemblies, consult bulletin on mechanism furnished for air (or gas) piping instructions. Refer to chart below for bulletin numbers for pneumatic switches. Cable entry Switch actuating level reference marks Pressure vessel Shutoff valves Max. 305 mm Drain valve Figure 3 Typical piping arrangement MOUNTING Adjust piping as required to bring control to a vertical position. Magnetrol controls must be mounted within three degrees (3°) of vertical. A three degree slant is noticeable by eye, but installation should be checked with a spirit level on top and/or sides of float chamber. Controls should be mounted as close to the vessel as possible. This will result in a more responsive and accurate level change in the control. Liquid in a long line may be cooler and more dense than liquid in the vessel causing lower level indication in the control than actual level in the vessel. WIRING Most mechanical control switch housings are designed to allow 360° positioning of the cable entries by loosening the set screw(s). See figure 4. 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. (See CAUTION next page) 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. 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. CAUTION: In hazardous area, do not power the unit until the cable gland is sealed and the enclosure cover is screwed down securely. 4 NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation instructions in switch mechanism bulletin. 4. Replace switch housing cover and place control into service. 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. 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 WIRING (cont.) OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES CENELEC/BASEEFA NEMA 4x Figure 4a Set screw Locking screw Figure 4c NEMA 7/9 Set screw CAUTION: - DO NOT attempt to reposition NEMA 4 / NEMA 7/9 housings without loosening the set screws; CENELEC/BASEEFA housings MAY NOT BE REPOSITIONNED. ALWAYS retighten set screw(s) after repositionning. - DO NOT attempt to unscrew cover of CENELEC/BASEEFA housings before loosening locking screw in base of housing. ALWAYS retighten locking screw after replacing cover. Set screw Position screw Figure 4b SWITCH DIFFERENTIAL ADJUSTMENT The standard differential of Series 75 level controls may be field adjusted. Adjustment may be necessary if a wider differential needs to be set to overcome switch chatter caused by the process. The differential, or the amount of level travel between "switch-on” and "switch-off", may be adjusted by repositioning the lower jam nuts on the float stem. This adjustment is different for high level and low level controls. Please refer to the appropriate section below for adjustments instructions. CAUTION: Maximum differential adjustment is 25 mm (1”) LOW LEVEL CONTROLS On low level controls the switch trips on the lower actuation point and resets on the higher actuation point. Widening the differential will allow the switch to trip on the original actuation point and reset at a later, or higher, point. The differential on low level controls may be adjusted by repositioning the lower jam nuts on the float stem. The standard factory setting is for a minimum amount of play (gap) between the top jam nuts and the attraction sleeve as shown in Figure 6. 1. Determine what change in differential is necessary. NOTE: To widen the differential 25 mm (1"), the lower jam nuts must be set proportionately lower on the stem [i.e. in this example 25 mm (1")]. 2. Make sure power source is turned off. 3a. NEMA 4X/7/9 - Unscrew and remove switch housing cover. 3b. CENELEC and BASEEFA - Loosen cover set screw, unscrew and remove housing cover. 4. Disconnect power supply wires from switch mechanism. Pull wires out of conduit connection opening in housing base. See Figure 5. 5. Perform system shut-down procedures as required to relieve pressure from float chamber of control. Allow unit to cool. a. Close shut-off valves (if so equipped) to isolate control from tank. Drain off liquid in float chamber. See Figure 3 on page 4. b. On installations without shut-off valves, relieve pressure from the tank. Drain liquid in tank to a level below the connections of the float chamber. NOTE: Level control, connections and pipe lines need not be removed from the tank. 6. Loosen enclosing tube nut with a 35 mm wrench. Unscrew enclosing tube counterclockwise (switch and housing base will rotate also), until it is free. See Figure 5. 7. Lift enclosing tube, switch, and base off float chamber. Jam nuts and attraction sleeve are now accessible. 8. Measure the distance “D” from the top edge of the upper jam nuts to the top of the float stem. See Figure 7. Record this measurement. 9. Loosen and remove upper jam nuts, guide washer and attraction sleeve. 10. Loosen and adjust lower jam nuts to the desired position. Tighten lower jam nuts securely. See Figure 7. 11. Replace attraction sleeve on stem. 12. Replace upper jam nuts and guide washer on the stem in the position previously noted. Tighten upper jam nuts securely. See Figure 7. 5 SWITCH DIFFERENTIAL ADJUSTMENT (cont.) NOTE: Use a new enclosing tube gasket when reassembling enclosing tube to the chamber. Coat enclosing tube threads with “anti-seizing” compound. 13. Replace enclosing tube, switch, and base on chamber. Screw tube clockwise until tightened to 10,42 13,90 kgm of torque. 14. Rotate switch housing to correct position and tighten set screw at base of switch housing. See Figure 4. 15. Bring supply wires through conduit outlet. Follow steps 5 through 10 of the “Wiring” section on page 4. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism. If the unit still fails to function properly, consult the factory. HIGH LEVEL CONTROLS On high level controls, the switch trips on the higher actuation point and resets on the lower actuation point. CAUTION: On high level controls, widening the differential requires raising the trip point a proportionate amount. The reset point will remain the same. To widen the differential by raising the trip point, follow steps 1 through 16 under “Low Level Controls”. Switch housing cover Replace in same position Enclosing tube Distance Slight play (gap) must be allowed (0.8 (0.03") typical Position of bottom jam nuts (normal factory setting) Maximum gap setting (applies to models having a single switch mechanism with a single magnet actuator only!) CAUTION: After increasing gap setting, be certain to check for proper operation of switch mechanism by raising and lowering float assembly. Magnet must 'snap' cleanly with additional float movement available after magnet snaps. See figures 6 and 7 25 (1") Drop bottom jam nuts to increase gap setting (see instructions above) Conduit connection Housing base Enclosing tube nut Chamber Float Normal factory setting (minimal differential) Figure 6 Differential adjustement Figure 7 Figure 5 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 1. Keep control clean 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. Inspect switch mechanisms, terminals and connections monthly. – 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. – 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 malad6 justed 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. PREVENTIVE MAINTENANCE (cont.) 1. NEVER leave switch housing cover off the control longer than necessary to make routine inspections. 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. 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. 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. WHAT TO AVOID 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) — 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. 3. Inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids build-up which could restrict movement, preventing sleeve(s) from reaching field of magnet(s). 4. If the differential has been changed in the field, check tightness and position of the jam nuts. CHECK SWITCH MECHANISM CHECK COMPLETE UNIT 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. Refer to Figure 3 on page 4). 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. CHECK SENSING UNIT 1. Check to be certain liquid is entering float chamber. A valve may be closed or piping plugged. 2. Proceed to check level sensing action by removing switch housing assembly, as described in Steps 4 through 7 of the “Switch Differential Adjustment” section on Page 5. NOTE: Differential adjustment causes a change in the amount of level travel between “switch-on” and “switch-off” actuations. Refer to Page 5. 5. Fill chamber with liquid at room pressure. Check float(s) to be certain it is buoyant in the liquid (float chamber must have adequate liquid level). If float is determined to be filled with liquid or collapsed, entire float chamber assembly (sensing unit) should be replaced. Reassemble unit. Reconnect 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. If all 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: If difficulties are encountered which can not be identified, consult with the factory or your local representative for assistance. A complete description of the trouble should be provided along with information concerning your piping and mounting arrangement, plus a description of your operation sequence. Sketches or photographs showing the installation are also beneficial. When communicating about your control, be certain always to specify the complete Model and Serial numbers. CAUTION: Unit must be normalized to atmospheric pressure before removing switch housing assembly. 7 ACTUATING LEVELS Actuating levels shown are for single switch units at minimum specific gravity only. Levels will change for multistage units. Consult factory for these units. L L L K K K J F C HL HL LL LL HL LL G D A E B NPT & Socket weld H Upper side/bottom Side/side 1 1/2" and NW 40 (DIN) connections NPT, flanged side - side or side - bottom 2" and NW 50 (DIN) connections NPT, flanged side - side or side - bottom Material code 1 (for minimum specific gravity) 1" and NW 25 (DIN) connections NPT, flanged side - side or side - bottom Part n° code A75 B75 C75 G75 J75 HL 24 76 76 64 79 mm (inches) LL (0.94) (3.00) (3.00) (2.50) (3.12) 47 92 93 81 97 (1.85) (3.62) (3.66) (3.18) (3.81) Part n° code A75 B75 C75 G75 J75 HL 24 59 61 46 62 mm (inches) LL (0.94) (2.31) (2.38) (1.81) (2.44) 47 75 78 63 80 (1.85) (2.94) (3.07) (2.48) (3.14) Part n° code A75 B75 C75 G75 J75 HL 24 47 49 38 54 mm (inches) LL (0.94) (1.88) (1.94) (1.50) (2.12) 47 63 66 55 72 (1.85) (2.48) (2.59) (2.16) (2.83) Material code 2 and 4 (for minimum specific gravity) 1" and NW 25 (DIN) connections NPT, flanged side - side or side - bottom Part n° code A75 B75 C75 G75 075 P75 8 HL 25 76 70 64 75 65 mm (inches) LL (0.98) (3.00) (2.77) (2.50) (2.94) (2.56) 52 96 93 84 103 89 (2.05) (3.77) (3.63) (3.30) (4.05) (3.50) 1 1/2" and NW 40 (DIN) connections NPT, flanged side - side or side - bottom Part n° code A75 B75 C75 G75 P75 HL 25 59 53 46 48 mm (inches) LL (0.98) (2.31) (2.08) (1.88) (1.88) 52 79 76 66 72 (2.05) (3.11) (3.00) (2.60) (2.83) 2" and NW 50 (DIN) connections NPT, flanged side - side or side - bottom Part n° code A75 B75 C75 G75 P75 HL 25 47 41 38 36 mm (inches) LL (0.98) (1.88) (1.61) (1.50) (1.41) 52 67 64 58 60 (2.05) (2.63) (2.51) (2.28) (2.36) SEALED CAGE MODEL DIMENSIONAL SPECIFICATIONS in mm (inches) – Only A75 Model – Rotation clearance L NEMA 4X (IP 65) NEMA 7/9 BASEEFA & CENELEC Pneumatic K (NEMA 3R) Pneumatic J (NEMA 3R) Conduit connections K Electrical switches NEMA 4X (IP 65) 109 (4.29) 100 (3.94) 110 (4.33) 130 (5.12) 110 (4.33) NEMA 7/9 BASEEFA & CENELEC Pneumatic switches K Series (Nema 3R) J Series (Nema 3R) All housings rotatable 360° Allow 200 mm (7.87") overhead clearance for cover removal. L 1” NPT, PG 16 or M20 x 1.5 entries (2 entries - one plugged) 1” NPT-F entry M20 x 1.5 or 3/4” NPT-F entry 1/4” NPT-F (two entries) 1/4” NPT-F (one entry) L L K K K C F J HL HL LL HL LL A LL D G B E H Flanged upper side/bottom CENELEC housing Threaded & socket weld upper side/bottom CENELEC housing Flanged side/side CENELEC housing – All models except A75 – Rotation clearance L NEMA 4X (IP 65) NEMA 7/9 BASEEFA & CENELEC Pneumatic K (NEMA 3R) Pneumatic J (NEMA 3R) Conduit connections K Electrical switches NEMA 4X (IP 65) 109 (4.29) 100 (3.94) 110 (4.33) 130 (5.12) 110 (4.33) NEMA 7/9 BASEEFA & CENELEC Pneumatic switches K Series (Nema 3R) J Series (Nema 3R) All housings rotatable 360°. 1” NPT, PG 16 or M20 x 1.5 entries (2 entries - one plugged) 1” NPT-F entry M20 x 1.5 or 3/4” NPT-F entry 1/4” NPT-F (two entries) 1/4” NPT-F (one entry) Allow 200 mm (7.87") over head clearance for cover removal. L L L K K K F J C HL HL LL LL HL LL G D A E B H Flanged upper side/bottom NEMA 4X housing Threaded & socket weld upper side/bottom NEMA 4X housing Flanged side/side NEMA 4X housing 9 SEALED CAGE MODEL DIMENSIONAL SPECIFICATIONS in mm (inches) Carbon steel and Stainless steel chambers with 1" and NW 25 (DIN) connections. mm 1" NPT & socket weld 1" or NW 25 Flanged upper side / bottom 1" or NW 25 Flanged side / side Part n° code A B C (max) D E F (max) G H J (max) A75 222 82 605 356 185 738 356 185 738 B75 222 95 579 356 200 713 356 200 713 C75 222 95 579 356 200 713 356 200 713 G75 242 109 609 356 215 723 356 215 723 J75 242 109 609 356 215 723 356 215 723 P75* 222 82 567 356 185 701 356 185 701 O75* 222 70 561 356 165 695 356 165 695 1" NPT & socket weld inches 1" or NW 25 Flanged upper side / bottom 1" or NW 25 Flanged side / side Part n° code A B C (max) D E F (max) G H J (max) A75 8.74 3.23 23.80 14 7.28 29.05 14 7.28 29.05 B75 8.74 3.74 22.79 14 7.87 28.07 14 7.87 28.07 C75 8.74 3.74 22.79 14 7.87 28.07 14 7.87 28.07 G75 9.53 4.29 23.97 14 8.46 28.46 14 8.46 28.46 J75 9.53 4.29 23.97 14 8.46 28.46 14 8.46 28.46 P75* 8.74 3.23 22.32 14 7.28 27.60 14 7.28 27.60 O75* 8.74 2.75 22.08 14 6.50 27.36 14 6.50 27.36 * 316 / 316L stainless steel only Carbon steel and Stainless steel chambers with 1 1/2" and NW 40 (DIN) connections. 1 1/2" NPT mm 1 1/2" socket weld Part n° code A B C (max) A A75 222 84 605 B75 217 98 584 C75 217 98 G75 236 J75 P75* 1 1/2" or NW 40 Flanged upper side / bottom 1 1/2" or NW 40 Flanged side / side B C (max) D E F (max) G H J (max) 222 93 605 356 200 738 356 200 738 225 108 592 356 215 723 356 215 723 584 225 108 592 356 215 723 356 215 723 114 613 243 122 620 356 230 733 356 230 733 236 114 613 243 122 620 356 230 733 356 230 733 217 84 573 224 93 580 356 200 712 356 200 712 1 1/2" NPT inches 1 1/2" socket weld 1 1/2" or NW 40 Flanged upper side / bottom 1 1/2" or NW 40 Flanged side / side Part n° code A B C (max) A B C (max) D E F (max) G H J (max) A75 8.74 3.30 23.80 8.74 3.66 23.80 14 7.87 29.05 14 7.87 29.05 B75 8.56 3.88 23.00 8.84 4.25 23.30 14 8.46 28.46 14 8.46 28.46 C75 8.56 3.88 23.00 8.84 4.25 23.30 14 8.46 28.46 14 8.46 28.46 G75 9.29 4.49 24.13 9.56 4.80 24.40 14 9.05 28.85 14 9.05 28.85 J75 9.29 4.49 24.13 9.56 4.80 24.40 14 9.05 28.85 14 9.05 28.85 P75* 8.56 3.30 22.56 8.84 3.66 22.83 14 7.87 28.03 14 7.87 28.03 * 316 / 316L stainless steel only Carbon steel and Stainless steel chambers with 2" and NW 50 (DIN) connections. 2" NPT mm 2" or NW 50 Flanged upper side / bottom 2" or NW 50 Flanged side / side Part n° code A B C (max) A B C (max) D E F (max) G H J (max) A75 222 84 605 222 101 605 356 200 738 356 200 738 B75 211 98 584 228 115 601 356 220 729 356 220 729 C75 211 98 584 228 115 601 356 220 729 356 220 729 G75 231 115 614 248 132 631 356 235 739 356 235 739 J75 231 115 614 248 132 631 356 235 739 356 235 739 P75* 211 84 576 228 101 593 356 200 721 356 200 721 2” NPT inches 2" socket weld 2" or NW 50 Flanged upper side / bottom 2" or NW 50 Flanged side / side Part n° code A B C (max) A B C (max) D E F (max) G H J (max) A75 8.74 3.31 23.80 8.74 3.97 23.80 14 7.87 29.05 14 7.87 29.05 B75 8.33 3.88 23.00 9.00 4.55 23.66 14 8.66 28.70 14 8.66 28.70 C75 8.33 3.88 23.00 9.00 4.55 23.66 14 8.66 28.70 14 8.66 28.70 G75 9.11 4.53 24.17 9.78 5.20 24.84 14 9.25 29.09 14 9.25 29.09 J75 9.11 4.53 24.17 9.78 5.20 24.84 14 9.25 29.09 14 9.25 29.09 P75* 8.33 3.31 22.67 9.00 3.97 23.34 14 7.87 28.38 14 7.87 28.38 * 316 / 316L stainless steel only 10 2" socket weld REPLACEMENT PARTS Item Models with mat’l code 1 Description Models with mat’l code 2 A, B, C, G, J75 1 Housing cover 2 Housing base 3 Switch mechanism 4 Jam nuts 5 Guide washer 6 Attraction sleeve 7 Stop tube (not shown) 8 9 Enclosing tube Housing kits A, B, C, G, J75 Refer to bulletin 42-780 for switch housing cover and base assemblies Refer to bulletin on switch mechanism furnished (listed on page 4) Sleeve kits 089-3410-001 089-3409-009 NEMA 4X, 7/9 032-6302-033 Pneumatic SW. HSG. 032-6302-031 BASEEFA & CENELEC 032-6344-002 012-1204-001 (B, G75) E-tube gasket 012-1301-002 (A, C, J75) 10 Chamber assemblies are available as complete sensing units only with all parts listed under items 4 through 10 assembled. When ordering specify model & serial number of control. Chamber assembly Item Models with mat’l code 4 Description A, B, C, G, J, O, P75 1 Housing cover 2 Housing base 3 Switch mechanism 4 Jam nuts 5 Guide washer 6 Attraction sleeve 7 Stop tube (not shown) 8 9 Enclosing tube Housing kits Refer to bulletin 42-780 for switch housing cover and base assemblies Refer to bulletin on switch mechanism furnished (listed on page 4) Sleeve kits 089-3410-001 NEMA 4X, 7/9 032-6302-037 Pneumatic SW. HSG. 032-6302-036 BASEEFA & CENELEC 032-6344-001 012-1204-001 (B, G75) E-tube gasket 012-1301-002 (A, C, J75) ,,,, ,,,, ,,,, ,,,, ,, ,,,, ,,,, ,, ,,,, ,,,, ,,,, ,,,, ,,,, Chamber assemblies are available as complete sensing units only with all parts listed under items 4 through 10 assembled. When ordering specify model & serial number of control. 1 4 5 3 2 8 6 9 10 ,, Figure 8 , , Chamber assembly ,, ,, ,, ,, 10 11 SERIES 75 TANDEM FLOAT UNITS 1. Inspect for binding of solid (lower) float stem within hollow (upper) float stem due to corrosion or possible damage incurred in shipment. 2. Make certain that retaining “snap” rings, used to locate lower attracting sleeve, are locked in place. An extreme shock or hammer may have damaged a ring causing it to snap out of its retaining groove in the hollow (upper) float stem. DESCRIPTION Series 75 units with tandem style floats are used on applications where widely spaced high and low switching functions can be accomplished with a single control. These units incorporate two floats which operate independently and are arranged so that the lower float actuates the upper switch mechanism and the upper float actuates the lower switch mechanism. The upper float is attached to the lower attracting sleeve by means of a hollow stem. The lower float attaches to the upper attracting sleeve with a solid stem which extends upward through the upper float and stem assembly. DIFFERENTIAL ADJUSTMENT CAUTION: No differential adjustment should be made on tandem float models in the field. Switch actuation levels have been set at the factory to meet specific customer specifications. Variations in actual conditions from design conditions usually requires special control modifications. Consult the factory or your local representative for assistance. INSTALLATION, PREVENTATIVE MAINTENANCE AND TROUBLE SHOOTING Installation and maintenance of tandem float models is accomplished in much the same manner as previously described for standard models. Some additional consideration must be given to the piping arrangement to allow for alignment of the two switch actuating level marks on the float chamber with the desired levels in the vessel. When trouble-shooting the level sensing portion of the control, additional checks may be made of the following : REPLACEMENT OF FLOAT AND STEM ASSEMBLIES Should replacement of either upper or lower float and stem assembly be required, entire float chamber assembly (sensing unit) should be replaced. REPLACEMENT PARTS ,,,, ,,,, ,,,, ,,,, ,,,, ,, ,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, 3 1 10 4 8 ,,, ,,, 5 ,, ,, ,, ,, 2 Standard Replacement Assembly Kits Item ,, ,, 11 Figure 9 6 Description 1 Housing Cover (Tall) 2 Housing Base 3 Switch Mechanisms 4 Jam Nuts 5 Upper Attraction Sleeve 6 Lower Attraction Sleeve 7 Spacer Washer 8 Retaining Ring 9 E-Tube Gasket B75, C75, G75, J75 Housing Kits See bulletin 42-780 for reference switch housing replacement assemblies - See bulletin on mechanism furnished (listed on Page 4) Sleeve Kits ➀ 089-3411-001 (Std.) 089-3412-001 (SST) Gasket 9 10 11 Enclosing Tube Chamber Assembly E-Tube 012-1204-001 Nema 4X, Nema 7/9 032-6302-037 BASEEFA & CENELEC 032-6344-001 Sensing Unit ➁ NOTES: ① Sleeve kit part numbers denote “SST” include sheathed type attraction sleeves used on models specified for corrosive service. Standard kit part numbers denoted “Std.” include attraction sleeves of type 400 series stainless steel. ➁ Chamber assemblies are available as complete sensing units only with all parts listed under items 4 through 11 assembled. See important note following. IMPORTANT: When ordering, please specify: A. Model and Serial Number of control. B. Name and/or Number of replacement assembly. IMPORTANT: Many model 75 controls are specially tailored to meet specific customer specifications and therefore may contain special parts. When ordering, always give Serial Number of control. 12 13 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 46-620.5 EFFECTIVE: NOVEMBER 1996 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