Series B, C, D, F, O, Q, R, S, U, W, X, 8 and 9 Installation and Operating Manual Electric switch mechanisms and housings ® UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number to be sure it agrees with the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. These units are in conformity with the provisions of: 1. Directive 2014/34/EU for equipment or protective system intended for use in potentially explosive atmospheres. EC-type examination certificate number ISSeP09ATEX024X (Ex d units; applied standards IEC60079-0:2011 and EN 60079-1:2007) or ISSeP01ATEX027X (Ex i units; applied standards EN50014+A1+A2:1999, EN50020:1994, EN50284:1999). 2. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. 0038 0344 SPECIAL CONDITIONS FOR ATEX INTRINSICALLY SAFE USE When the enclosure is made of aluminium, if it is mounted in an area where the use of category 1G apparatus is required, it must be installed such, that, even in the event of rare incidents, ignition sources due to impact and friction sparks are excluded. PRINCIPLE OF OPERATION Figures 1 & 2 illustrate the simple, reliable operating principle of a float level switch. Switching action is obtained through the use of a magnetic sleeve (4) and a float (3), displacer or flow sensing element and a switching mechanism (2). These two basic component assemblies are sep2 Pivot 5 4 Return Spring 1 3 Process liquid Figure 1 Rising level 2 Process liquid Figure 2 Falling level arated by a non-magnetic, pressure tight enclosing tube (5). The switch (2) and magnet (1) are assembled to a mechanism with a swinging arm which operates on precision stainless steel pivots. As level of a liquid in a vessel rises (Figure 1), the float rides on the liquid surface moving the magnetic sleeve upward in the enclosing tube and into the field of the switch mechanism magnet. As a result, the magnet is drawn in tightly to the enclosing tube moving the switch adjusting screw and allowing the activating arm of the snap switch to move, making or breaking the electrical circuit. As the liquid level recedes (Figure 2), the float and magnetic sleeve moves downward until the switch magnet releases and is drawn outward, away from the enclosing tube by a tension spring. This in turn allows the activating arm of the snap switch to move, thus reversing switch action. Switch mechanisms may include a single switch or multiple switches, depending on operational requirements and switching action desired. DESCRIPTION Magnetrol level controls are available with a range of different switch mechanisms—each designed for specific service conditions. A brief description of the individual switch mechanisms and their applications are given below. Dry contact switches B, C, D, O, Q, S and U • Series B switches are general purpose with a maximum liquid temperature rating of +120 °C (+250 °F), see Figure 3. • Series C switches are general purpose with a maximum liquid temperature rating of +230 °C (+450 °F), see Figure 3. • Series D switches are designed for DC current applications with a maximum liquid temperature rating of +120 °C (+250 °F), see Figure 3. • Series O switches are general purpose with a maximum liquid temperature rating of +150 °C (+300 °F), used only in model C10 and C15 units, see Figure 3. Figure 3 Series B, C, D, O, Q and U Dry contact hermetically sealed switches W and X • Series Q switches are general purpose with a maximum liquid temperature rating of +120 °C (+250 °F), used only in model C10 and C15 units, see Figure 3. • Series S switches are general purpose with a maximum liquid temperature rating of +290 °C (+550 °F), or designed for DC current applications with a maximum liquid temperature of +120 °C (+250 °F), used only in model B40 units, see Figure 4. (= Grp IV switch mech) • Series U switches have gold alloy contacts and are suitable for applications with a maximum liquid temperature of +120 °C (+250 °F). Figure 4 Series S = Grp IV switch mech Hermetically sealed switches are for use in special applications where hermetically sealed contacts are required. • Series W switches are suitable for applications with a maximum liquid temperature of +230 °C (+450 °F). • Series X switches have gold-plated contacts and are suitable for applications with a maximum liquid temperature of +230 °C (+450 °F). Dry contact high temperature switches F, R, 8 and 9 Figure 5 Series W & X • Series 8 and F switches are hermetically sealed and designed for high temperature applications up to +400 °C (+750 °F), see Figure 6. • Series R switches are designed for the highest temperature applications up to +540 °C (+1000 °F) , see Figure 7. • Series 9 switches are hermetically sealed and designed for the highest temperature applications up to +540 °C (+ 1000 °F), see Figure 8. Figure 7 Series R Figure 6 Series 8 & F Figure 8 Series 9 3 MOUNTING Replacing the complete switch mechanisms CAUTION: Before attempting to remove a switch mechanism, be certain to pull disconnect switch or otherwise assure that electrical circuit through control is de-energized. 1. Remove the switch housing cover (see page 14 and up). 2. Disconnect wiring from supply side of terminal block on switch mechanism. Note and record lead wire terminal locations. 3. Loosen screw in split mounting clamp until mechanism slides freely on enclosing tube, refer to Figure 9. 4. Remove small round head screw securing lower switch mechanism to baffle plate, refer to Figure 10. 5. Slide switch mechanism off of enclosing tube. If mechanism is to be reused, ensure that it is placed on a clean surface, free of metallic particles that may be attracted to the switch magnet. Figure 9 Mounting screw 6. Loosen mounting screw so that switch frame will fit over e-tube. Install switch mechanism by sliding it over the enclosing tube. Slide mechanism down until the bottom of the frame and terminal block are resting on the baffle plate. The baffle plate should be resting on the hub of the housing base. 7. Install and tighten baffle plate screw so that the switch mechanism may not be separated from the baffle plate. Tighten the mechanism mounting screw so that the mechanism is firmly clamped to the enclosing tube. Baffle plate screw Figure 10 Baffle plate screw 8. Swing magnet assembly in and out by hand, checking carefully for any signs of binding. 9. Reattached supply-side wiring to the terminal block. 10. Reinstall the switch housing cover (see page 14 and up). 11. Reconnect power supply and test switch action under operating conditions. Replacing the switches only 1. Disconnect control from power supply. 2. Remove the switch housing cover (see page 14 and up). 3. Disconnect switch leads from terminal block. Note and record terminal connections of switch to be replaced. 4. Remove two mounting screws holding existing switch, refer to Figure 11. 5. Remove existing switch and install replacement switch in the same position, tightening mounting screws securely. NOTE: For proper operation of the replacement switch, it must actuate in the middle portion of the pivoted magnet’s swing. NOTE: If a single switch is being replaced on a DPDT mechanism, lever of second switch must be depressed and held to allow for the audible adjustment of new switch, as described above. d.With new switch in adjustment, release lever of second switch and perform fine-tuning of both switches to provide simultaneous actuation (clicks). 7. Reinstall the switch housing cover (see page 14 and up). 8. Reconnect power supply and test switch action by varying liquid level in the vessel or by “gently blowing down” float chamber. Adjusting screw 6. Check switch action and adjust as follows: a. Slowly rotate the pivoted magnet by hand, back and forth through its angle of swing, listening closely for the actuating click of the switch in each direction. Mounting screw b.Check to see if there is equal overtravel of magnet in its swing after the switch click in either direction. c. If switch actuation is not correct, change adjustment of actuating screw using a 1⁄16" hexagon key wrench, refer to Figure 11. 4 Figure 11 MOUNTING Vibration service adjustment Level controls are frequently used in applications where vibration is encountered, such as on scrubbers or compressors. Switch mechanisms may require repositioning to prevent unwanted magnet movement. This position is usually best at right angles to the direction of vibration. The direction of vibration may be determined by the arrangement of connections to the vessel or the vessels mounting method. Accordingly, the vibration will tend to be in one direction only. Vessel Baffle plate Frame mounting screw Upon determining the vibration direction, switch mechanism(s) may be rotated from an incorrect position (as shown in Figure 12, illustration is shown as looking at a control from above), to a correct position as follows: CAUTION: Before attempting to remove a switch mechanism, be certain to pull disconnect switch or otherwise assure that electrical circuit through control is de-energized. Incorrect Direction of vibration 1. Disconnect control from power supply. 2. Remove the switch housing cover (see page 14 and up). 3. Loosen screw in split mounting clamp until mechanism turns freely on enclosing tube, refer to Figure 9 on page 4. Baffle plate 4. Rotate entire mechanism and bottom baffle plate together to the correct position. CAUTION: Be certain power supply wires retain some slack at new position. Do not pull wires taut. NOTE: Amount of rotation required will vary with each installation and may not be as much as shown in illustration. 5. Check action of switch magnet at new position. When magnet vibrates from side to side, instead of front to back, correct position has been attained. Correct Direction of vibration Swing of magnet Figure 12 Rotation of switch mechanism in vibration 6. Tighten clamp screw on switch mechanism. 7. Reinstall the switch housing cover (see page 14 and up). 8. Reconnect power supply and test switch action under operating conditions. 5 WIRING Circuits shown are for direct-acting level switches and are reversed in side mounting float-in-tank models, which utilize a reversing float pivot. SPDT terminal connections Single float with one switch or single stage displacer 1. Rising level closes contacts 5 & 6, see Figure 13. 1. Rising level closes contacts 5 & 6 and 2 & 3, see Figure 15. 2. Falling level closes contacts 4 & 5. 3. Wiring Diagram is reversed (high level actuation becomes low level actuation, etc.) when this switch mechanism is used on side mounted float switches employing a reversing pivot (Models B40, T52, T62, T63, T64, etc.). Close on low level (NC) Common (C) Close on high level (NO) Line Load Single float with three switches or three stage displacer 2. Falling level closes contacts 4 & 5 and 1 & 2. 3. Unit is shipped with switches positioned for proper function. Do not change switch spacing. Upper stage operates upper switch mechanism Internal circuit 4 Close on low level (NC) 5 Load Common (C) 6 Close on high level (NO) Line Figure 13 Single float with one switch or single stage displacer Middle stage operates middle switch mechanism Single float with two switches or dual stage displacer Close on low level (NC) Common (C) 1. Rising level closes contacts 5 & 6 and 2 & 3, see Figure 14. Close on high level (NO) 2. Falling level closes contacts 4 & 5 and 1 & 2. 3. Wiring diagram is reversed (high level actuation becomes low level actuation, etc.) when this switch mechanism is used on side mounted float switches employing a reversing pivot. (Model T67). Line Lower stage operates lower switch mechanism 4. On units with tandem floats, the top float operates the bottom mechanism while the bottom float actuates the top mechanism (Model T21). Upper stage operates upper switch mechanism Close on low level (NC) Common (C) Close on high level (NO) Line Lower stage operates lower switch mechanism Close on low level (NC) Common (C) Close on high level (NO) Line 6 Load Assem. A 1 Internal circuit Load 3 Assem. B 4 5 Load 6 Figure 14 Single float with two switches or dual stage displacer Common (C) Close on high level (NO) 2 Load Close on low level (NC) Internal circuit Line Load Assem. B 4 Internal circuit 5 Load Load 6 Assem. A 1 Internal circuit 2 Load Load 3 Assem. B 4 5 Load 6 Figure 15 Single float with three switches or three stage displacer Internal circuit WIRING DPDT terminal connections Single float with one switch or single stage displacer 1. Rising level closes contacts 5 & 6 and 2 & 3, see Figure 16. Three Stage Displacer 1. Rising level closes contacts 5 & 6 and 2 & 3, see Figure 18. 2. Falling level closes contacts 4 & 5 and 1 & 2. 2. Falling level closes contacts 4 & 5 and 1 & 2. 3. Double pole action is obtained by simultaneous operation of the right and left side single pole double throw switches. 3. Double pole action is obtained by simultaneous operation of the right and left side single pole switches. 4. Wiring diagram is reversed (close on high becomes close on low, etc.) when this switch mechanism is used on side mounted float switches employing a reversing pivot. (Models B40, T52, T62, T63, T64 etc.) Internal circuit (left switch) Load Load 4 1 5 2 6 3 Internal circuit (right switch) Close on high level (NO) Close on high level (NO) Common (C) Common (C) Close on low level (NC) Close on low level (NC) Figure 16 Single float with one switch or single stage displacer Load Load 1. Rising level closes contacts 5 & 6 and 2 & 3, see Figure 17. 2. Falling level closes contacts 4 & 5 and 1 & 2. 3. Double pole action is obtained by simultaneous operation of the right and left side single pole switches. 4. Wiring diagram is reversed (close on high becomes close on low, etc.) when this switch mechanism is used on side mounted float switches employing a reversing pivot. (Model T67). 5. On units with tandem floats, the top float operates the bottom mechanism while the bottom float actuates the top mechanism. (Model T21). Load 4 1 5 2 6 3 Close on high level (NO) Common (C) Close on low level (NC) Close on low level (NC) Lower stage operates lower switch mechanism Load Load Close on high level (NO) Common (C) Close on low level (NC) Internal circuit (right switch) Close on high level (NO) Common (C) Internal circuit (left switch) Load 4 1 5 2 6 3 4 1 5 2 6 3 Close on high level (NO) Internal circuit (right switch) Close on high level (NO) Common (C) Common (C) Close on low level (NC) Close on low level (NC) Middle stage operates middle switch mechanism Internal circuit (left switch) Load Load Load 4 1 5 2 6 3 Close on high level (NO) Common (C) Close on low level (NC) Lower stage operates lower switch mechanism Close on high level (NO) Common (C) Close on low level (NC) 4 1 5 2 6 3 Load Load Internal circuit (right switch) Close on high level (NO) Common (C) Close on low level (NC) Internal circuit (left switch) Load Upper stage operates upper switch mechanism Load Internal circuit (left switch) Load Single float with two switches or dual stage displacer Internal circuit (left switch) Upper stage operates upper switch mechanism Load Load Internal circuit (right switch) Close on high level (NO) Common (C) Close on low level (NC) Load Load Figure 18 Three stage displacer Load Load Internal circuit (right switch) Close on high level (NO) Common (C) Close on low level (NC) Figure 17 Single float with two switches or dual stage displacer Load Load 7 PREVENTIVE MAINTENANCE Inspect switch mechanisms, terminals and connections regularly. Proof test interval to be determined by application requirements (required reliability, operating conditions, site requirements, etc). Inspect switch mechanisms, terminals and connections 1. Dry contact switches should be inspected for excessive wear on actuating lever or misalignment of adjustment screw at point of contact between screw and lever. Such wear can cause false switch actuating levels 2. DO NOT operate your control with defective or maladjusted switch mechanisms. 3. Level controls may sometimes be exposed to excessive heat or moisture. Under such conditions, insulation on electrical wiring may become brittle, eventually breaking or peeling away. The resulting “bare” wires can cause short circuits. NOTE: Check wiring carefully and replace at the first sign of brittle insulation. 4. Vibration may sometimes cause terminal screws to loosen. Check all terminal connections to be certain that screws are tight. NOTE: Spare switches should be kept on hand at all times. SWITCHES Switch ratings Process¿ Temperature range °C (°F) SWITCH SERIES SWITCH TYPE B Micro C Micro -40 to +230 (-40 to +450) D Micro -40 to +120 (-40 to +250) F Hermetic O Micro Q Micro R -40 to +120 (-40 to +250) -45 to +400 (-50 to +750) LOAD 15.00 15.00 1/10 15.00 15.00 1/6 Non-Inductive Amp Inductive Amp Horsepower 15.00 15.00 1/8 Non-Inductive Amp 10.00 Non-Inductive Amp Inductive Amp Horsepower Inductive Amp Horsepower Resistive Amp Inductive Amp 3.80 1/8 2.50 2.50 RATING 24 Volts DC 120 15.00 15.00 – 10.00 5.00 – 1.00 0.50 – – – – – 480 15.00 15.00 1/4 15.00 15.00 – – – – – – – Micro VAC-applications 1.00 1.00 1.00 1.00 – – S Micro VDC-applications -40 to +120 (-40 to +250) W Hermetic (Silver contacts) -45 to +230 (-50 to +450) 8 Hermetic X 9 Micro (Gold contacts) Hermetic (Gold contacts) Hermetic Non-Inductive Amp Inductive Amp Horsepower 15.00 15.00 1/10 15.00 15.00 1/6 15.00 15.00 – Inductive Amp Horsepower 3.80 1/8 – – – – Non-Inductive Amp -40 to +120 (-40 to +250) Non-Inductive Amp Inductive Amp -45 to +230 (-50 to +450) Non-Inductive Amp Inductive Amp -45 to +400 (-50 to +750) -45 to +540 (-50 to +1000) Non-Inductive Amp Inductive Amp Non-Inductive Amp Inductive Amp Non-Inductive Amp Inductive Amp ¿ Max. Process Temperature based on +40 °C (+100 °F) ambient temperature. ¡ 28 VDC. 10.00 1.00 1.00 – – – 1.00 – 1.00 0.40 1.00 1.00 – – 0.50 – – – 0.50 – – – – – – – – S Non-Inductive Amp Inductive Amp -40 to +290 (-40 to +550) 0.40 0.40 6.00 5.00 – -40 to +540 (-40 to +1000) 15.00 15.00 1/4 0.50 – – 15.00 15.00 – Micro 15.00 15.00 1/8 1.00 – – 0.30 0.10 15.00 15.00 – – – – 1.00 1.00 0.50 – – 2.20 1/8 4.00¡ 2.00¡ 15.00 15.00 1/6 240 0.25 0.03 – 1.50 min 3.00 max – – – – 15.00 15.00 1/10 Non-Inductive Amp Inductive Amp Horsepower 0.50 0.05 – 10.00 Non-Inductive Amp Inductive Amp Horsepower -40 to +120 (-40 to +250) 6.00 5.00 – 10.00 -40 to +150 (-40 to +300) U 8 120 Volts AC 240 0.50 0.05 – 1.00 0.50 – – – 0.25 0.30 – 0.50 – – – 10.00 10.00 1.50 min 3.00 max – – – – 1.00¡ 0.50¡ 3.00➂ 1.50➂ – – – – – – 3.00 1.00 – – – – – – 0.50 – 0.50 0.50 2.20 1/8 0.50 – 0.50 – – – – – – – – – – – – – – – REPLACEMENT SWITCH MECHANISMS Magnet strength Switch mechanisms are provided with different strength magnets as determined by the characteristics of the level switch. A red, red/yellow or yellow dot is visible on each magnet. When ordering replacement switch mechanisms, be certain to determine the color dot on the magnet. For these types of switches, the tenth digit of the model number identifies the magnet used on the control. The correct magnet dot color may be chosen by finding the tenth digit of your model number at the top of the chart. Any model numbers preceded with an “X” are specially modified controls. Contact the factory for replacement part numbers. Partn°: Digit in partn°: X 1 2 3 4 5 6 7 8 9 10 Serial n°: See nameplate, always provide complete partn° and serial n° when ordering spares. X = product with a specific customer requirement Yellow dot magnet replacement mechanisms Switch Series B C D F 8th, 9th & 10th Digit BAB, BAQ, BA9, BC9, BH9, BKB, BKQ, BK5, BK9, BU5, B2B, B2Q BBB, BBN, BD9, BLB, BL5, BL9, BV5, B4B, B4N BCB, BE9, BMB, BM9, B6B, B65, B75 BB9, BDB, BDQ, BD5, BF9, BJ9, BNB, BNQ, BN9, BW5, B8B, B8Q BEB, BEN, BG9, BOB, BO5, BP9, BY5, B1B, B1N CAB, CAQ, CAS, CAT, CA9, CC9, CH9, CKB, CKQ, CK5, CK9, CU5, C2B, C2Q, C2S, C2T CBB, CBT, CD9, CLB, CL5, CL9, CV5, C4B, C4T CCB, CE9, CMB, CM9, C6B, C65, C75 CB9, CDB, CDQ, CDS, CDT, CD5, CF9, CJ9, CNB, CNQ, CN9, CW5, C8B, C8Q, C8S, C8T CEB, CET, CG9, COB, CO5, CP9, CY5, C1B, C1T DAB, DAQ, DA9, DC9, DH9, DKB, DKQ, DK5, DK9, DU5, D2B, D2Q DBB, DD9, DLB, DL5, DL9, DV5, D4B DCB, DE9, DMB, DM9, D6B, D65, D75 DB9, DDB, DDQ, DD5, DF9, DJ9, DNB, DNQ, DN9, DW5, D8B, D8Q DEB, DG9, DOB, DO5, DP9, DY5, D1B FAB, FAQ, FA9, FCB, FC9, FH9, FKB, FKQ, FK5, FK9, FU5, F2Q FBB, FD9, FFB, FLB, FL5, FL9, FV5 FB9, FDB, FDQ, FD5, FF9, FGB, FJ9, FNB, FNQ, FN9, FW5, F8Q FEB, FG9, FHB, FOB, FO5, FP9, FY5 FMB, FM9, FSB, FWB, FY9 CStl or Cast Iron Housing FE9, FTB, FVB, FYB, FZ9 CStl or Cast Iron Housing Switch Contacts SPDT DPDT SPDT Set points 1 2 3 1 2 1 2 Bottom Mech 089-7401-104 089-7401-122 089-7401-110 3 DPDT SPDT DPDT SPDT DPDT SPDT Group IV DPDT Group IV 1 2 1 2 3 1 2 1 2 1 2 Middle Mech Top Mech - - - 089-7401-103 - - 089-7401-103 - 089-7401-122 - - - 089-7401-109 - - - 089-7401-125 - 089-7401-105 - - 089-7401-109 089-7401-125 089-7401-106 089-7401-123 089-7401-095 089-7401-098 - 089-7401-105 - - - - 089-7401-220 - 089-7401-216 089-7401-123 - 089-7401-096 - - 1 1 089-7401-106 - - 089-7401-214 - 089-7401-098 089-7401-218 - 089-7101-020 089-7101-020 089-7101-022 089-7401-110 - 1 1 089-7401-104 Switch Only - - - 089-7101-022 089-7101-024 089-7101-024 089-7101-041 089-7101-041 089-7101-041 9 REPLACEMENT SWITCH MECHANISMS Yellow dot magnet replacement mechanisms Switch Series O Q Switch Contacts Set points Bottom Mech Middle Mech Top Mech OEB, OKB, O1B SPDT DPDT 3 089-7401-110 QEB, QKB, Q1B DPDT 3 089-7401-125 089-7401-109 SPDT 3 089-7401-110 3 089-7401-104 089-7401-122 089-7401-103 8th, 9th & 10th Digit OCB, OMB, O6B QCB, QMB, Q6B RA9, RC9, RH9, RKB, RKQ, RK5, RK9, RU5, R1B, R1M, R1Q, R1Y, R2B, R2Q RD9, RLB, RL5, RL9, RV5, R3B, R3M, R4B R RB9, RDB, RDM, RDQ, RDY, RF5, RF9, RGB, RJ9, RNB, RNQ, RN5, RN9, R8Q REB, REM, RG5, RG9, RHB, ROB, RO5, RP9 2 089-7401-181 089-7401-203 RFB, RJB, RM9, RSB, RS9 DPDT Group IV 1 089-7401-204 SAB, SA9, SH9, SKB, S2B SPDT Group IV SAM 1 1 1 SB9, SDB, SJ9, SNB, S8B DPDT Group IV 1 SBB, SC9, SK9, SLB, S2R SPDT Group IV 1 SBM SEB, SF9, SN9, SOB, S8R SEM UAB, UAQ, UAS, UAT, UA9, UC9, UH9, UKB, UKQ, UK5, UK9, UU5, U2B, U2Q, U2S, U2T UBB, UBT, UD9, ULB, UL5, UL9, UV5, U4B, U4T DPDT Group IV SPDT UCB, UE9, UMB, UM9, U6B, U65, U75 UB9, UDB, UDQ, UDS, UDT, UD5, UF9, UJ9, UNB, UNQ, UN9, UW5, U8B, U8Q, U8S, U8T UEB, UET, UG9, UOB, UO5, UP9, UY5, U1B, U1T 10 1 1 SDM U 2 089-7401-179 SPDT Group IV RJM, RM5, RS5 S (DC Volt) DPDT 1 RW9, RYB, RY9, R5B, R6B RW5, RY5, R5M S (AC Volt) SPDT DPDT 1 1 089-7401-180 089-7401-182 089-7401-161 089-7401-126 089-7401-163 089-7401-128 089-7401-162 089-7401-129 089-7401-164 089-7401-127 089-7401-125 089-7401-125 089-7401-122 089-7401-122 089-7401-104 - - - 089-7401-178 - - - 089-7401-181 - - - - - - - - - - - - - - - - - - - - 089-7101-045 089-7101-045 089-7101-045 089-7101-022 089-7101-024 - 3 189-9107-901 189-9107-901 1 - - - 189-9111-901 2 089-7101-045 - - 189-9111-901 089-7101-020 - - 189-9109-901 089-7101-022 - - 2 Switch Only 189-9105-901 189-9109-901 189-9105-901 REPLACEMENT SWITCH MECHANISMS Yellow dot magnet replacement mechanisms Switch Series W 8th, 9th & 10th Digit WAB, WAQ, WAS, WAT, WA9, WC9, WH9, WKB, WKQ, WK5, WK9, WU5, W2B, W2Q, W2S, W2T WBB, WBT, WD9, WLB, WL5, WL9, WV5, W4B, W4T WCB, WE9, WMB, WM9, W6B, W65, W75 WB9, WDB, WDQ, WDS, WDT, WD5, WF9, WJ9, WNB, WNQ, WN9, WW5, W8B, W8Q, W8S, W8T WEB, WET, WG9, WOB, WO5, WP9, WY5, W1B, W1T X 8 XAB, XAQ, XAS, XAT, XA9, XC9, XH9, XKB, XKQ, XK5, XK9, XU5, X2B, X2Q, X2S, X2T XBB, XBT, XD9, XLB, XL5, XL9, XV5, X4B, X4T XCB, XE9, XMB, XM9, X6B, X65, X75 XB9, XDB, XDQ, XDS, XDT, XD5, XF9, XJ9, XNB, XNQ, XN9, XW5, X8B, X8Q, X8S, X8T XEB, XET, XG9, XOB, XO5, XP9, XY5, X1B, X1T 8AB, 8AQ, 8A9, 8C9, 8H9, 8KB, 8KQ, 8K5, 8K9, 8U5, 82B, 82Q 8BB, 8D9, 8LB, 8L5, 8L9, 8V5, 84B 8CB, 8E9, 8MB, 86B, 865, 875, 889 8B9, 8DB, 8DQ, 8D5, 8F9, 8J9, 8NB, 8NQ, 8N9, 8W5, 88B, 88Q 8EB, 8G9, 8OB, 8O5, 8P9, 8Y5, 81B 8FB, 8SB, 8M9, 8Y9, 83B 8HM, 8M5, 8N5 8GB, 8S9, 8TB, 8Z9, 87B 8JM, 8P5, 8Z5 9AB, 9AM, 9AQ, 9AY, 9A9, 9C9, 9H9, 9KB, 9KQ, 9K5, 9K9, 9U5, 92B, 92Q 9 9BB, 9BM, 9D9, 9LB, 9L5, 9L9, 9V5, 94B 9CB, 9CM, 9E9, 9MB, 96B, 965, 975, 989 9B9, 9DB, 9DM, 9DQ, 9DY, 9D5, 9F9, 9J9, 9NB, 9NQ, 9N9, 9W5, 98B, 98Q 9EB, 9EM, 9G9, 9OB, 9O5, 9P9, 9Y5, 91B 9FB, 9M9, 9SB, 9Y9, 93B 9HM, 9M5, 9N5 9GB, 9S9, 9TB, 9Z9, 97B 9JM, 9P5, 9Z5 Switch Contacts SPDT DPDT SPDT Set points Middle Mech Top Mech - - 3 - 089-7410-003 089-7410-003 1 - - - 089-7410-005 - - - 089-7412-003 - - - 089-7412-005 - - 1 2 2 1 2 Bottom Mech 089-7410-004 089-7410-005 089-7412-004 3 DPDT SPDT DPDT SPDT Group IV DPDT Group IV SPDT 1 2 1 2 3 1 2 089-7412-003 089-7412-005 089-7401-185 089-7401-192 1 089-7401-206 1 089-7401-208 1 1 1 2 089-7401-188 089-7401-190 SPDT Group IV DPDT Group IV 1 2 1 1 1 1 - 089-7401-185 - 089-7401-192 - - - - - - - - - 089-7401-199 - - - 089-7401-200 089-7401-201 - - 089-7401-202 - - 089-7401-198 3 DPDT - - 089-7401-199 089-7401-200 089-7401-211 089-7401-212 - - 089-7411-001 089-7413-001 089-7412-004 089-7401-186 - 089-7411-001 089-7410-004 - 089-7401-186 Switch Only 089-7413-001 037-4632-001 037-4632-001 037-4632-001 037-4632-001 037-4633-001 089-7401-198 - - 037-4633-001 037-4633-001 037-4633-001 11 REPLACEMENT SWITCH MECHANISMS Red dot magnet replacement mechanisms Switch Series B 8th, 9th & 10th Digit BAA, BAC, BAP, BCC, BHC, BKA, BKC, BKP, BK7, BU7, B2A, B2P BBA, BBP, BDC, BLA, BLC, BL7, BV7, B4A, B4P BCA, BEC, BMA, BMC, B6A, B67, B77 BBC, BDA, BDP, BD7, BFC, BJC, BNA, BNC, BNP, BW7, B8A, B8P BEA, BEP, BGC, BOA, BO7, BPC, BY7, B1A, B1P CAA, CAC, CAL, CAP, CAX, CCC, CHC, CKA, CKC, CKP, CK7, CU7, C2A, C2L, C2P, C2X C CBA, CBX, CDC, CLA, CLC, CL7, CV7, C4A, C4X FBC, FDA, FDP, FD7, FFC, FGA, FJC, FNA, FNC, FNP, FW7, F8P DPDT UBA, UBX, UDC, ULA, ULC, UL7, UV7, U4A, U4X SPDT UCA, UEC, UMA, UMC, U6A, U67, U77 UBC, UDA, UDL, UDP, UDX, UD7, UFC, UJC, UNA, UNC, UNP, UW7, U8A, U8L, U8P, U8X WAA, WAC, WAL, WAP, WAX, WCC, WHC, WKA, WKC, WKP, WK7, WU7, W2A, W2L, W2P, W2X WBA, WBX, WDC, WLA, WLC, WL7, WV7, W4A, W4X WCA, WEC, WMA, WMC, W6A, W67, W77 1 2 Bottom Mech 089-7401-102 1 2 1 2 1 2 1 2 1 2 1 2 089-7401-121 089-7401-108 1 2 089-7401-124 089-7401-093 089-7401-097 189-9108-901 2 3 - - - 089-7401-101 - - - 089-7401-121 - - - 089-7401-107 - - - 089-7401-124 - - - 089-7401-094 - - - 089-7401-097 - - - 189-9106-901 - - - 189-9110-901 - - - 089-7410-001 089-7410-001 089-7410-002 189-9106-901 189-9110-901 1 SPDT Top Mech 089-7401-107 3 DPDT Middle Mech 089-7401-101 3 SPDT UEA, UEX, UGC, UOA, UO7, UPC, UY7, U1A, U1X 12 SPDT FAA, FAC, FAP, FCA, FCC, FHC, FKA, FKC, FKP, FK7, FU7, F2P UAA, UAC, UAL, UAP, UAX, UCC, UHC, UKA, UKC, UKP, UK7, UU7, U2A, U2L, U2P, U2X W DPDT DPDT FBA, FDC, FFA, FLA, FLC, FL7, FV7 Set points 3 CBC, CDA, CDL, CDP, CDX, CD7, CFC, CJC, CNA, CNC, CNP, CW7, C8A, C8L, C8P, C8X FEA, FGC, FHA, FOA, FO7, FPC, FY7 U SPDT CCA, CEC, CMA, CMC, C6A, C67, C77 CEA, CEX, CGC, COA, CO7, CPC, CY7, C1A, C1X F Switch Contacts 089-7410-002 Switch Only 089-7101-020 089-7401-102 089-7101-020 089-7101-022 089-7401-108 089-7101-022 089-7101-041 089-7101-041 189-9105-901 189-9108-901 189-9105-901 089-7411-001 REPLACEMENT SWITCH MECHANISMS Red dot magnet replacement mechanisms Switch Series X 8th, 9th & 10th Digit XAA, XAC, XAL, XAP, XAX, XCC, XHC, XKA, XKC, XKP, XK7, XU7, X2A, X2L, X2P, X2X XBA, XBX, XDC, XLA, XLC, XL7, XV7, X4A, X4X Switch Contacts SPDT XCA, XEC, XMA, XMC, X6A, X67, X77 8AA, 8AC, 8AP, 8CC, 8HC, 8KA, 8KC, 8KP, 8K7, 8U7, 82A, 82P 8BA, 8DC, 8LA, 8LC, 8L7, 8V7, 84A SPDT 8CA, 8EC, 8MA, 86A, 867, 877, 88C 8 8BC, 8DA, 8DP, 8D7, 8FC, 8JC, 8NA, 8NC, 8NP, 8W7, 88A, 88P 8EA, 8GC, 8OA, 8O7, 8PC, 8Y7, 81A 8FA, 8SA, 8MC, 8YC, 83A 8HD, 8M7, 8N7 8GA, 8SC, 8TA, 8ZC, 87A 8JD, 8P7, 8Z7 9AA, 9AC, 9AD, 9AP, 9AR, 9CC, 9HC, 9KA, 9KC, 9KP, 9K7, 9U7, 92A, 92P 9BA, 9BD, 9DC, 9LA, 9LC, 9L7, 9V7, 94A 9 9EA, 9ED, 9GC, 9OA, 9O7, 9PC, 9Y7, 91A 9FA, 9MC, 9SA, 9YC, 93A 9HD, 9M7, 9N7 9GA, 9SC, 9TA, 9ZC, 97A 9JD, 9P7, 9Z7 Middle Mech Top Mech - - 3 - 089-7412-001 089-7412-001 1 - - - 089-7401-184 - - - 089-7401-191 - - 1 2 2 Bottom Mech 089-7412-002 089-7401-183 3 DPDT SPDT Group IV DPDT Group IV SPDT 9CA, 9CD, 9EC, 9MA, 96A, 967, 977, 98C 9BC, 9DA, 9DD, 9DP, 9DR, 9D7, 9FC, 9JC, 9NA, 9NC, 9NP, 9W7, 98A, 98P Set points DPDT SPDT Group IV DPDT Group IV 1 2 089-7401-184 089-7401-191 1 089-7401-205 1 089-7401-207 1 1 1 089-7401-187 089-7401-189 - - - - - - 3 - 089-7401-194 089-7401-194 1 - - - 089-7401-195 089-7401-196 - - 089-7401-197 - - 2 089-7401-195 1 089-7401-209 1 089-7401-210 1 1 - - 037-4632-001 089-7401-183 - 089-7401-193 089-7413-001 089-7412-002 - 2 Switch Only 037-4632-001 037-4632-001 037-4632-001 037-4633-001 089-7401-193 - - 037-4633-001 037-4633-001 037-4633-001 13 REPLACEMENT SWITCH HOUSINGS (standard, NOT for use with group IV switch mechanism) Switch housing replacement assemblies When ordering replacement parts for an existing Magnetrol instrument, please specify: 1. Model and serial numbers of control. 2. Description and part number of replacement kit. The proper replacement switch housing kit and parts can be determined by the last three characters of the model number. Cast aluminum housings (short and tall) Die cast aluminum TYPE 4X housing replacements are available for general purpose or weatherproof installations. Explosion proof NEMA 7/9 and ATEX housing replacements are available for hazardous atmosphere locations. Die cast aluminum housings are finished with a baked-on polyester powder coat paint. 10 1 9 8 2 3 4 7 1. Housing cover 2. Baffle plate 3. Housing base 4. Stopping plug 5. Base lock screw 6 5 6. Base lock screw 7. Base O-ring 8. Cover lock screw 9. Cover O-ring 10. Caution tag Figure 19 Standard cast aluminium housing (short and tall) Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. In case of ATEX Ex d approved housing, first unlock cover lock screw (8) before unscrewing the cover (1) counterclockwise. Lift housing cover straight upwards to avoid damaging the inside switch mechanism. 3. Replacement of housing base (3) and/or base O-ring (7). 3.1 First remove housing cover (1) - see 1-2. 3.2 Remove entire switch mechanism (see page 4). 3.3 Loosen base lock screws (5) & (6). 3.4 Slide housing base (3) of enclosing tube. 3.5 O-ring (7) can be accessed/replaced. 4. Replace part and mount in opposite order. 5. Close housing cover (1) clockwise and tighten cover lock screw (8) in case of ATEX Ex d approved housing. 14 Replacement housing kits Table with switch & housing model codes: Column header Data Switch contacts "SPDT" or "DPDT" Housing height "Short" or "Tall" Housing type Weatherproof (IP 66) Switch & housing code e.g. B2Q, BAQ, B2P, BAP, ... Description Kit contains part(s) Replacement part Cover kit for short housing 1, 9, 10 089-6582-034 Cover kit for tall housing 1, 9, 10 089-6582-031 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 9 089-6582-039 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-030 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 Housing type ATEX Ex d, flameproof Switch & housing code e.g. BH9, BA9, BHC, BAC, ... Description Kit contains part(s) Replacement part Cover kit for short housing 1, 8, 9, 10 089-6582-035 Cover kit for tall housing 1, 8, 9, 10 089-6582-037 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 9 089-6582-040 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-041 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 Housing type ATEX Ex i, intrinsically safe Switch & housing code e.g. C2S, CAS, C2L, CAL, ... Description Kit contains part(s) Replacement part Cover kit for short housing 1, 9, 10 089-6582-036 Cover kit for tall housing 1, 9, 10 089-6582-038 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 9 089-6582-042 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-043 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 Housing type FM NEMA 7/9, explosion proof Switch & housing code e.g. BKQ, BKP, ... Description Kit contains part(s) Replacement part Cover kit for short housing 1, 9, 10 089-6582-034 Cover kit for tall housing 1, 9, 10 089-6582-031 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-030 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 REPLACEMENT SWITCH HOUSINGS (standard, NOT for use with group IV switch mechanism) Extra tall cast aluminum housings Die cast aluminum TYPE 4X housing replacements are available for general purpose or weatherproof installations. Explosion proof NEMA 7/9 housing replacements are available for hazardous atmosphere locations. Die cast aluminum housings are finished with a baked-on polyester powder coat paint. 10 9 1 8 12 2 11 3 4 7 1. Housing cover 2. Baffle plate 3. Housing base 4. Stopping plug 5. Base lock screw 6. Base lock screw 6 5 7. Base O-ring 8. Cover lock screw (not applicable) 9. Cover O-ring 10. Caution tag 11. Cover extension O-ring 12. Housing extension Figure 20 Extra tall cast aluminium housing Replacement housing kits Table with switch & housing model codes: Column header Data Switch contacts "SPDT" or "DPDT" Housing height "X-Tall" Housing type Weatherproof (IP 66) Switch & housing code e.g. O6B, OCB, O1B, OEB, ... Description Kit contains part(s) Replacement part Cover kit for tall housing 1, 9, 10 089-6582-031 Housing extension 12 004-9175-002 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 11 089-6582-039 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 11 089-6582-030 Cover extension 'O'-ring 11 012-2201-253 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 Housing type FM NEMA 7/9, explosion proof Switch & housing code e.g. OMB, OKB, ... Description Kit contains part(s) Replacement part Cover kit for tall housing 1, 9, 10 089-6582-031 Housing extension 12 004-9175-002 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 11 089-6582-030 Cover extension 'O'-ring 11 012-2201-253 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Baffle plate 2 005-6657-001 Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. Unscrew the cover (1) and housing extension (12) counterclockwise and lift housing cover straight upwards to avoid damaging the inside switch mechanism. 3. Replacement of housing base (3) and/or base O-ring (7). 3.1 First remove housing cover (1) and housing extension (12) - see 1-2. 3.2 Remove entire switch mechanism (see page 4). 3.3 Loosen base lock screws (5) & (6). 3.4 Slide housing base (3) of enclosing tube. 3.5 O-ring (7) can be accessed/replaced. 4. Replace part and mount in opposite order. 5. Close housing cover (1) and housing extension (12) clockwise. 15 REPLACEMENT SWITCH HOUSINGS (standard, NOT for use with group IV switch mechanism) Cast iron housings Cast iron ATEX Exd housing replacements are available for hazardous atmosphere locations. The cast iron cover and base are finished with an epoxy paint. 6 Aluminium / Carbon steel housings Carbon steel TYPE 4X switch housings are available for general purpose and weatherproof installations. The housing base is cast from aluminum while the cover is made from cold rolled steel. The housings are finished with a baked-on polyester powder coat paint. 6 4 1 2 Housing cover Baffle plate Housing base Cover lock screw 3 5. 6. 7. 8. 2 9 1. Housing cover 2. Baffle plate 3. Housing base 4. Acorn nut 5. Washer Base lock nut Caution tag Nameplate Cover gasket 8 10 7 6. Seal washer 7. Base O-ring 8. Base lock screw 9. Cover O-ring 10. Nameplate Figure 22 Standard aluminium /carbon steel housing (short and tall) Figure 21 Standard cast iron housing Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. First unlock cover lock screw (4) before unscrewing the cover (1) counterclockwise. 3. Lift housing cover straight upwards to avoid damaging the inside switch mechanism. 4. Replacement of housing base (3). 4.1 First remove housing cover (1) - see 1-3. 4.2 Remove entire switch mechanism (see page 4). 4.3 Loosen base lock nut (5) counterclockwise. 4.4 Unscrew housing base (3) counterclockwise. 5. Replace and mount in opposite order. 6. Close housing cover (1) clockwise and tighten cover lock screw (4). Replacement housing kits Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. Loosen acorn nut (4) or cover screw (model F10 & F50) and remove washers (5) & (6). Lift housing cover straight upwards to avoid damaging the inside switch mechanism. 3. Replacement of housing base (3) and/or base O-ring (7). 3.1 First remove housing cover (1) - see 1-2. 3.2 Remove entire switch mechanism (see page 4). 3.3 Loosen base lock screw (8). 3.4 Slide housing base (3) of enclosing tube. 3.5 O-ring (7) can be accessed/replaced. 4. Replace part and mount in opposite order. 5. Replace housing cover (1), reinstall washers (6) & (5) and fix with acorn nut (4) or cover screw (model F10 & F50). Replacement housing kits Table with switch & housing model codes: Table with switch & housing model codes: Column header Data Switch contacts "SPDT" or "DPDT" Housing height "Tall" Housing type ATEX Ex d, flameproof Switch & housing code e.g. BK5, BU5, BK7, BU7, ... Description Kit contains part(s) Replacement part Cover kit 1, 6, 8 189-9122-001 Base kit for M20 x 1,5 cable entry 3, 4, 5, 7 189-9126-002 Base kit for 3/4" NPT-F cable entry 3, 4, 5, 7 189-9126-001 Cover gasket 8 012-1301-005 Baffle plate assembly 2 036-5303-003 16 3 7 5 1. 2. 3. 4. 1 4 8 5 Column header Data Switch contacts "SPDT" or "DPDT" Housing height "Short" or "Tall" Housing type Weatherproof (IP 65) Switch & housing code e.g. R1Y, R1M, ... Description Kit contains part(s) Replacement part Cover kit for short housing 1, 4, 5, 6, 7, 9 189-6509-001 Cover kit for tall housing 1, 4, 5, 6, 7, 9 189-6510-001 Base kit for 3/4" NPT-F cable entry 3, 7, 8, 9, 10 089-6505-003 Washer + 'O'-ring kit 4, 5, 6, 7, 9 189-6508-001 Cover 'O'-ring 9 012-1318-001 Base 'O'-ring 7 012-2201-116 Baffle plate assembly 2 036-5303-003 REPLACEMENT SWITCH HOUSINGS (for use with group IV switch mechanism) Cast aluminum housings Die cast aluminum TYPE 4X housing replacements are available for general purpose or weatherproof installations. Explosion proof NEMA 7/9 and ATEX housing replacements are available for hazardous atmosphere locations. Die cast aluminum housings are finished with a baked-on polyester powder coat paint. 10 13 11 12 1 9 2 8 14 3 4 7 1. Housing cover 2. Switch mechanism 3. Housing base 4. Stopping plug 5. Base lock screw 6. Base lock screw 7. Base O-ring 6 5 8. Cover lock screw 9. Cover O-ring 10. Caution tag 11. Screw 12. Lock washer 13. Top insulator 14. Base insulator Figure 23 Cast aluminium housing for use with group IV switch mechanism (high temp.) Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. In case of ATEX Ex d approved housing, first unlock cover lock screw (8) before unscrewing the cover (1) counterclockwise. Lift housing cover straight upwards to avoid damaging the inside switch mechanism (2). 3. Replacement of switch mechanism (2) and/or insulators (13) & (14). 3.1 First remove housing cover (1) - see 1-2. 3.2 Loosen screw (11), remove lock washer (12) and lift switch mechanism (2). 3.3 Reinstall/Replace insulators (13) & (14) and mount in opposite order. 4. Replacement of housing base (3) or base O-ring (7). 4.1 First remove housing cover (1) and switch mechanism (2) – see 1-3. 4.2 Loosen base lock screws (5) & (6). 4.3 Slide housing base (3) of enclosing tube. 4.4 O-ring (7) can be accessed/replaced. 5. Replace part and mount in opposite order. 6. Close housing cover (1) clockwise and tighten cover lock screw (8) in case of ATEX Ex d approved housing. Replacement housing kits Table with switch & housing model codes: Column header Data Switch contacts "SPDT Grp IV" or "DPDT Grp IV" Housing height "Tall" Housing type Weatherproof (IP 66) Switch & housing code e.g. FWB, FMB, FWA, FMA, ... Description Kit contains part(s) Replacement part Cover kit 1, 9, 10 089-6582-031 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 9 089-6582-039 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-030 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Screw 11 010-1402-015 Lock washer 12 010-3101-003 Ring gasket 13 012-1301-013 Base insulator 14 012-9307-001 Housing type ATEX Ex d, flameproof Switch & housing code e.g. FY9, FM9, FYC, FMC Description Kit contains part(s) Replacement part Cover kit 1, 8, 9, 10 089-6582-037 Base kit for M20 x 1,5 cable entry 3, 4, 5, 6, 7, 9 089-6582-040 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-041 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Screw 11 010-1402-015 Lock washer 12 010-3101-003 Ring gasket 13 012-1301-013 Base insulator 14 012-9307-001 Housing type FM NEMA 7/9, explosion proof Switch & housing code e.g. FSB, FSA Description Kit contains part(s) Replacement part Cover kit 1, 9, 10 089-6582-031 Base kit for 1" NPT-F cable entry 3, 4, 5, 6, 7, 9 089-6582-030 Cover 'O'-ring 9 012-2201-253 Base 'O'-ring 7 012-2201-116 Screw 11 010-1402-015 Lock washer 12 010-3101-003 Ring gasket 13 012-1301-013 Base insulator 14 012-9307-001 17 REPLACEMENT SWITCH HOUSINGS (for use with group IV switch mechanism) Cast iron housings Cast iron ATEX Exd housing replacements are available for hazardous atmosphere locations. The cast iron cover and base are finished with an epoxy paint. 6 11 8 9 Data Switch contacts "SPDT Grp IV" or "DPDT Grp IV" Housing height "Tall" Housing type ATEX Ex d, flameproof 2 Switch & housing code e.g. RY5, RW5, RS5, RM5, ... Description Kit contains part(s) Replacement part 4 Cover kit 1, 6, 8 189-9122-001 Base kit for M20 x 1,5 cable entry 3, 4, 5, 7 189-9126-002 10 1 12 3 7 7. Nameplate 8. Cover gasket 9. Screw 10. Lock washer 11. Top insulator 12. Base insulator Figure 24 Cast iron housing for use with group IV switch mechanism (high temp.) Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. First unlock cover lock screw (4) before unscrewing the cover (1) counterclockwise. Lift housing cover straight upwards to avoid damaging the inside switch mechanism (2). 3. Replacement of switch mechanism (2) and/or insulators (11) & (12). 3.1 First remove housing cover (1) - see 1-2. 3.2 Loosen screw (9), remove lock washer (10) and lift switch mechanism (2). 3.3 Reinstall/Replace insulators (11 & 12) and mount in opposite order. 4. Replacement of housing base (3). 4.1 First remove housing cover (1) and switch mechanism (2) – see 1-3. 4.2 Loosen base lock nut (5) counterclockwise. 4.3 Unscrew housing base (3) counterclockwise. 5. Replace part and mount in opposite order. 6. Close housing cover (1) clockwise and tighten cover lock screw (4). 18 Table with switch & housing model codes: Column header 5 1. Housing cover 2. Switch mechanism 3. Housing base 4. Cover lock screw 5. Base lock nut 6. Caution tag Replacement housing kits Base kit for 3/4" NPT-F cable entry 3, 4, 5, 7 189-9126-001 Cover gasket 8 012-1301-005 Screw 9 010-1402-015 Lock washer 10 010-3101-003 Ring gasket 11 012-1301-013 Base insulator 12 012-9307-001 REPLACEMENT SWITCH HOUSINGS (for use with group IV switch mechanism) Aluminium / Carbon steel housings Carbon steel TYPE 4X switch housings are available for general purpose and weatherproof installations. The housing base is cast from aluminum while the cover is made from cold rolled steel. The housings are finished with a baked-on polyester powder coat paint. 9 7 6 4 5 10 8 1 2 3 14 11 13 1. Housing cover 2. Switch mechanism 3. Housing base 4. Acorn nut 5. Washer 6. Seal washer 7. Stud 8. Hex nut 12 Replacement housing kits Table with switch & housing model codes: Column header Data Switch contacts "SPDT Grp IV" or "DPDT Grp IV" Housing height "Tall" Housing type Weatherproof (IP 65) Switch & housing code e.g. R5M, RJM, ... Description Kit contains part(s) Cover kit 1, 4, 5, 6, 14 189-6510-001 Base kit for 3/4" NPT-F cable entry 3 002-6101-736 Washer, insulation + 'O'-ring kit 4, 5, 6, 10, 11, 12, 14 189-6508-002 Base lock srew 13 010-1202-007 Cover 'O'-ring 14 012-1318-001 Replacement part 15 9. Lock washer 10. Top insulator 11. Base insulator 12. Base insulator 13. Base lock screw 14. Cover O-ring 15. Nameplate Figure 25 Aluminium /carbon steel housing for use with group IV switch mechanism Assemble / Disassemble instructions 1. Disconnect control from power supply before opening. 2. Loosen acorn nut (4) and remove washers (5) & (6). Lift housing cover straight upwards to avoid damaging the inside switch mechanism (2). 3. Replacement of switch mechanism (2) and/or top insulator (10). 3.1 First remove housing cover (1) - see 1-2. 3.2 Loosen hex nut (8), remove lock washer (9) and lift switch mechanism (2). 3.3 Reinstall/Replace top insulator (10) and mount in opposite order. 4. Replacement of housing base (3) and/or base insulators (11) & (12). 4.1 First remove housing cover (1) and switch mechanism (2) – see 1-3. 4.2 Loosen base lock screw (13). 4.3 Slide housing base (3) of enclosing tube. 4.4 Base insulators (11) & (12) can be accessed/replaced. 5. Replace part and mount in opposite order. 6. Replace housing cover (1), reinstall washers (6) & (5) & fix with acorn nut (4). 19 SWITCH AND HOUSING MODEL CODES The following charts identify the switch and housing model codes used with the buoyancy products. The eighth, ninth and tenth digit combinations may be used to identify the type and number of switches, number of contacts, switch magnet strength as well as housing type, size and options. Weather proof (IP 66) Cast aluminium M20x1.5 1" NPT 20 ATEX - IP 66 II 2G Ex d IIC T6 Gb Carbon steel Cast aluminium Cast iron 3/4" NPT M20x1.5 1" NPT M20x1.5 3/4" NPT Weather proof (IP 65) II 1G EEx ia IIC T6 Cast aluminium M20x1.5 1" NPT FM NEMA 7/9 Cast alu 1" NPT Magnet dot color B2Q B2P B2B B2A B4B B4A B6B B6A B8Q B8P B8B B8A B1B B1A BAQ BAP BAB BAA BBB BBA BCB BCA BDQ BDP BDB BDA BEB BEA - BH9 BHC BK9 BKC BL9 BLC BM9 BMC BJ9 BJC BN9 BNC BP9 BPC BA9 BAC BC9 BCC BD9 BDC BE9 BEC BB9 BBC BF9 BFC BG9 BGC BK5 BK7 BL5 BL7 B65 B67 BD5 BD7 BO5 BO7 BU5 BU7 BV5 BV7 B75 B77 BW5 BW7 BY5 BY7 - - BKQ BKP BKB BKA BLB BLA BMB BMA BNQ BNP BNB BNA BOB BOA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red C2Q C2P C2B C2A C4B C4A C6B C6A C8Q C8P C8B C8A C1B C1A CAQ CAP CAB CAA CBB CBA CCB CCA CDQ CDP CDB CDA CEB CEA - CH9 CHC CK9 CKC CL9 CLC CM9 CMC CJ9 CJC CN9 CNC CP9 CPC CA9 CAC CC9 CCC CD9 CDC CE9 CEC CB9 CBC CF9 CFC CG9 CGC CK5 CK7 CL5 CL7 C65 C67 CD5 CD7 CO5 CO7 CU5 CU7 CV5 CV7 C75 C77 CW5 CW7 CY5 CY7 C2S C2L C2T C2X C4T C4X C8S C8L C8T C8X C1T C1X CAS CAL CAT CAX CBT CBX CDS CDL CDT CDX CET CEX CKQ CKP CKB CKA CLB CLA CMB CMA CNQ CNP CNB CNA COB COA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red D2Q D2B D4B D6B D8Q D8B D1B DAQ DAB DBB DCB DDQ DDB DEB - DH9 DK9 DL9 DM9 DJ9 DN9 DP9 DA9 DC9 DD9 DE9 DB9 DF9 DG9 DK5 DL5 D65 DD5 DO5 DU5 DV5 D75 DW5 DY5 - - DKQ DKB DLB DMB DNQ DNB DOB Yellow F2Q F2P FCB FCA FFB FFA FWB FWA F8Q F8P FGB FGA FHB FHA FYB FYA FAQ FAP FAB FAA FBB FBA FMB FMA FDQ FDP FDB FDA FEB FEA FVB FVA - FH9 FHC FK9 FKC FL9 FLC FY9 FYC FJ9 FJC FN9 FNC FP9 FPC FE9 FEC FA9 FAC FC9 FCC FD9 FDC FM9 FMC FB9 FBC FF9 FFC FG9 FGC FZ9 FZC FK5 FK7 FL5 FL7 FD5 FD7 FO5 FO7 - FU5 FU7 FV5 FV7 FW5 FW7 FY5 FY7 - - - FKQ FKP FKB FKA FLB FLA FSB FSA FNQ FNP FNB FNA FOB FOA FTB FTA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red O6B O1B OCB OEB - - - - - - - OMB OKB Q6B Q1B QCB QEB - - - - - - - QMB QKB R2Q R2B R4B R6B R8Q RGB RHB RJB R1Q R1B R3B R5B RDQ RDB REB RFB R1Y R1M R3M R5M RDY RDM REM RJM RH9 RK9 RL9 RY9 RJ9 RN9 RP9 RS9 RA9 RC9 RD9 RW9 RB9 RF9 RG9 RM9 RK5 RL5 RY5 RN5 RO5 RS5 RU5 RV5 RW5 RF5 RG5 RM5 - - RKQ RKB RLB RYB RNQ RNB ROB RSB Yellow S2B S8B S2R S8R SAB SDB SBB SEB SAM SDM SBM SEM SH9 SJ9 SK9 SN9 SA9 SB9 SC9 SF9 - - - - SKB SNB SLB SOB Yellow Set points Switch contacts 1 SPDT Housing height Switch type Short Tall 2 SPDT Tall 3 SPDT Tall 1 DPDT Dry contact Short Tall 2 DPDT 1 SPDT Tall Short Tall 2 SPDT Tall 3 SPDT Tall 1 DPDT Dry contact Short Tall 2 DPDT Tall 1 SPDT Short Tall 2 3 SPDT 1 DPDT 2 DPDT 1 SPDT Tall Short Tall Tall DC voltage dry contact Short Tall 2 SPDT Tall 1 SPDT Grp IV Tall 1 DPDT Short High temp. herm. sealed dry contact Tall 2 DPDT Tall 1 DPDT Grp IV Tall 3 SPDT DPDT 3 SPDT DPDT 1 SPDT Short Tall 2 1 SPDT SPDT Grp IV Tall 1 DPDT Short Tall 2 1 DPDT DPDT Grp IV Tall SPDT Grp IV DPDT Grp IV SPDT Grp IV DPDT Grp IV Tall Yellow 1 1 X-Tall Dry contact for C10/C15 High temp. dry contact Dry contact for B40 SWITCH AND HOUSING MODEL CODES Weather proof (IP 66) Cast aluminium M20x1.5 1" NPT ATEX - IP 66 II 2G Ex d IIC T6 Gb Carbon steel Cast aluminium Cast iron 3/4" NPT M20x1.5 1" NPT M20x1.5 3/4" NPT Weather proof (IP 65) II 1G EEx ia IIC T6 Cast aluminium M20x1.5 1" NPT FM NEMA 7/9 Cast alu 1" NPT Magnet dot color U2Q U2P U2B U2A U4B U4A U6B U6A U8Q U8P U8B U8A U1B U1A UAQ UAP UAB UAA UBB UBA UCB UCA UDQ UDP UDB UDA UEB UEA - UH9 UHC UK9 UKC UL9 ULC UM9 UMC UJ9 UJC UN9 UNC UP9 UPC UA9 UAC UC9 UCC UD9 UDC UE9 UEC UB9 UBC UF9 UFC UG9 UGC UK5 UK7 UL5 UL7 U65 U67 UD5 UD7 UO5 UO7 UU5 UU7 UV5 UV7 U75 U77 UW5 UW7 UY5 UY7 U2S U2L U2T U2X U4T U4X U8S U8L U8T U8X U1T U1X UAS UAL UAT UAX UBT UBX UDS UDL UDT UDX UET UEX UKQ UKP UKB UKA ULB ULA UMB UMA UNQ UNP UNB UNA UOB UOA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red W2Q W2P W2B W2A W4B W4A W6B W6A W8Q W8B W1B WAQ WAP WAB WAA WBB WBA WCB WCA WDQ WDB WEB - WH9 WHC WK9 WKC WL9 WLC WM9 WMC WJ9 WN9 WP9 WA9 WAC WC9 WCC WD9 WDC WE9 WEC WB9 WF9 WG9 WK5 WK7 WL5 WL7 W65 W67 WD5 WO5 WU5 WU7 WV5 WV7 W75 W77 WW5 WY5 W2S W2L W2T W2X W4T W4X W8S W8T W1T WAS WAL WAT WAX WBT WBX WDS WDT WET WKQ WKP WKB WKA WLB WLA WMB WMA WNQ WNB WOB Yellow Red Yellow Red Yellow Red Yellow Red X2Q X2P X2B X2A X4B X4A X6B X6A X8Q X8B X1B XAQ XAP XAB XAA XBB XBA XCB XCA XDQ XDB XEB - XH9 XHC XK9 XKC XL9 XLC XM9 XMC XJ9 XN9 XP9 XA9 XAC XC9 XCC XD9 XDC XE9 XEC XB9 XF9 XG9 XK5 XK7 XL5 XL7 X65 X67 XD5 XO5 XU5 XU7 XV5 XV7 X75 X77 XW5 XY5 X2S X2L X2T X2X X4T X4X X8S X8T X1T XAS XAL XAT XAX XBT XBX XDS XDT XET XKQ XKP XKB XKA XLB XLA XMB XMA XNQ XNB XOB Yellow Red Yellow Red Yellow Red Yellow Red 82Q 82P 82B 82A 84B 84A 86B 86A 83B 83A 88Q 88P 88B 88A 81B 81A 87B 87A 8AQ 8AP 8AB 8AA 8BB 8BA 8CB 8CA 8FB 8FA 8DQ 8DP 8DB 8DA 8EB 8EA 8GB 8GA 8HM 8HD 8JM 8JD 8H9 8HC 8K9 8KC 8L9 8LC 889 88C 8Y9 8YC 8J9 8JC 8N9 8NC 8P9 8PC 8S9 8SC 8A9 8AC 8C9 8CC 8D9 8DC 8E9 8EC 8M9 8MC 8B9 8BC 8F9 8FC 8G9 8GC 8Z9 8ZC 8K5 8K7 8L5 8L7 865 867 8N5 8N7 8D5 8D7 8O5 8O7 8P5 8P7 8U5 8U7 8V5 8V7 875 877 8M5 8M7 8W5 8W7 8Y5 8Y7 8Z5 8Z7 - - 8KQ 8KP 8KB 8KA 8LB 8LA 8MB 8MA 8SB 8SA 8NQ 8NP 8NB 8NA 8OB 8OA 8TB 8TA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red 92Q 92P 92B 92A 94B 94A 96B 96A 93B 93A 98Q 98P 98B 98A 91B 91A 97B 97A 9AQ 9AP 9AB 9AA 9BB 9BA 9CB 9CA 9FB 9FA 9DQ 9DP 9DB 9DA 9EB 9EA 9GB 9GA 9AY 9AR 9AM 9AD 9BM 9BD 9CM 9CD 9HM 9HD 9DY 9DR 9DM 9DD 9EM 9ED 9JM 9JD 9H9 9HC 9K9 9KC 9L9 9LC 989 98C 9Y9 9YC 9J9 9JC 9N9 9NC 9P9 9PC 9S9 9SC 9A9 9AC 9C9 9CC 9D9 9DC 9E9 9EC 9M9 9MC 9B9 9BC 9F9 9FC 9G9 9GC 9Z9 9ZC 9K5 9K7 9L5 9L7 965 967 9N5 9N7 9D5 9D7 9O5 9O7 9P5 9P7 9U5 9U7 9V5 9V7 975 977 9M5 9M7 9W5 9W7 9Y5 9Y7 9Z5 9Z7 - - 9KQ 9KP 9KB 9KA 9LB 9LA 9MB 9MA 9SB 9SA 9NQ 9NP 9NB 9NA 9OB 9OA 9TB 9TA Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Yellow Red Set points Switch contacts 1 SPDT Housing height Switch type Short Tall 2 SPDT Tall 3 SPDT Tall 1 DPDT Dry gold contact Short Tall 2 DPDT 1 SPDT Tall Short Tall 2 SPDT Tall 3 SPDT Tall Yellow 1 DPDT Yellow 2 DPDT 1 SPDT Herm. sealed dry silver contact Short Tall Tall Short Tall 2 SPDT Tall 3 SPDT Tall Yellow 1 DPDT Yellow 2 DPDT 1 SPDT Herm. sealed dry gold contact Short Tall Tall Short Tall 2 SPDT Tall 3 SPDT Tall 1 SPDT Grp IV Tall 1 DPDT High temp. herm. sealed dry contact Short Tall 2 DPDT Tall 1 DPDT Grp IV Tall 1 SPDT Short Tall 2 SPDT Tall 3 SPDT Tall 1 SPDT Grp IV Tall 1 DPDT High temp. herm. sealed dry contact Short Tall 2 DPDT Tall 1 DPDT Grp IV Tall 21 Notes 22 Notes 23 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 and Ref Number 4. Desired Action 5. Reason for Return 6. Process details Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards applicable by the owner, before it is returned to the factory. A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box. All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped Ex Works. 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