FLANGED EXTERNAL CAGE

FLANGED
EXTERNAL CAGE
Liquid float
level switches
®
INSTRUCTION MANUAL AND REPLACEMENT PARTS
DESCRIPTION
External cage type level switches are completely self-contained units designed for side mounting to a tank or vessel
with threaded or flanged pipe connections. These switches
have thoroughly demonstrated their worth for years in hundreds of industrial applications – particularly in the fields of
petroleum refining, petro-chemical production and power
generation.
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.
②
pivot
⑤
return spring
④
①
③
AGENCY APPROVALS
Rising level
Falling level
Agency
Approval
ATEX
II 2G EEx d II C T6, explosion proof
II 1G EEx ia II C T6, intrinsically safe
CENELEC
EEx d II C T6, explosion proof
FM
Class I, Div. 1, Groups C & D
Class II, Div. 1, Groups E, F & G, Type NEMA 7/9
Non-Hazardous area
FM/CSA ➀
Explosion proof area –
Groups B, C, D, E, F & G Type NEMA 4X/7/9
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.
SAA ➀
LRS
Explosion proof area
GOST
Russian Authorisation Standards
Lloyds Register of Shipment (marine applications)
Other approvals are available, consult factory for more details
➀ Consult factory for proper model numbers.
MODEL IDENTIFICATION
A complete flanged external cage float level switch, consists of 1 order code:
1. Order code for liquid float level switches in an external cage
BASIC MODEL NUMBER1
O
B
B
B
A
G
J
J
3
4
4
6
4
3
3
3
0
1
3
0
0
3
1
3
down
down
down
down
down
down
down
down
to
to
to
to
to
to
to
to
S.G.
S.G.
S.G.
S.G.
S.G.
S.G.
S.G.
S.G.
0,84
0,67
0,72
0,69
0,65
0,54
0,50
0,50
up
up
up
up
up
up
up
up
to
to
to
to
to
to
to
to
27,6 bar (400 psi)
19,6 bar (285 psi)
27,6 bar (400 psi)
62 bar (900 psi)
51 bar (740 psi)
51 bar (740 psi)
19,6 bar (285 psi)
27,6 bar (400 psi)
min S.G. varies per material of construction
max pressure varies per material of construction and
temperature
- select as per table on left page -
Code
MATERIALS OF CONSTRUCTION
Cage & process
connection material
A
D
Magnetic sleeve
400 series SST
Carbon steel
B
Float and trim
316 SST (1.4401)
316/316L (1.4401/1.4404)
316 SST (1.4401)
PROCESS CONNECTION – O75, B73 and O30 units are only available with 1"/DN 25 size connections
1"
11/2"
2"
1"
11/2"
2"
DN 25
DN 40
DN 50
Threaded NPT connection
upper side / bottom
B20
C20
D20
Socket weld connection
upper side / bottom
B30
C30
D30
ANSI Flanges
upper side / bottom
side / side
150 lbs RF
300 lbs RF
600 lbs RF
150 lbs RF
300 lbs RF
N30
N40
N50
S30
S40
P30
P40
P50
T30
T40
Q30
Q40
Q50
V30
V40
DIN Flanges - Form to DIN 2526
upper side / bottom
side / side
PN 16 (DIN 2633) PN 25/40 (DIN 2635) PN 64 (DIN 2636)
PN 16 (DIN 2633) PN 25/40 (DIN 2635)
Form C
Form E
Form C
Form C
Form C
1FA
1HA
1JA
1FB
1HB
2FA
2HA
2JA
2FB
2HB
3HA
3JA
3FB
3HB
3FA
SWITCH MECHANISM & ENCLOSURE
- for all units except B73 and B41
- for B73 and B41 units
- for pneumatic switch mechanisms
complete order code for caged models
2
600 lbs RF
S50
T50
V50
PN 64 (DIN 2636)
Form E
1JB
2JB
3JB
Select electric switch mechanism & enclosure for all models except B41 (see page 4 for switch ratings)
All models with material codes A
qty and
switch
type
A
3
B
C
D
F
HS
U
V
W
X
Weather proof
(IP 66)
cast Aluminium
All models with material codes B and D
ATEX (IP 66)
CENELEC (IP 66)
FM (IP 66)
II 2G EEx d II C T6 II 1G EEx ia II C T6
EEx d II C T6
NEMA 7/9
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
cast Aluminium
cast Aluminium
Weather proof
(IP 66)
cast Aluminium
ATEX (IP 66)
CENELEC (IP 66)
FM (IP 66)
II 2G EEx d II C T6 II 1G EEx ia II C T6
EEx d II C T6
NEMA 7/9
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
1" NPT
cast Aluminium
cast Aluminium
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
1 x SPDT
A2A
AAA
AKC
ACC
-
-
AK7
AU7
AKA
A2B
AAB
AK9
AC9
-
-
AK5
AU5
2 x SPDT
A4A
ABA
ALC
ADC
-
-
AL7
AV7
ALA
A4B
ABB
AL9
AD9
-
-
AL5
AV5
ALB
3 x SPDT
36E
3CA
38E
3EE
-
-
367
377
3ME
A6B
ACB
AM9
AE9
-
-
A65
A75
AMB
1 x DPDT
A8A
ADA
ANC
AFC
-
-
AD7
AW7
ANA
A8B
ADB
AN9
AF9
-
-
AD5
AW5
ANB
2 x DPDT
A1A
AEA
APC
AGC
-
-
AO7
AY7
AOA
A1B
AEB
AP9
AG9
-
-
AO5
AY5
AOB
1 x SPDT
32A
3AA
3KC
3CC
-
-
3K7
3U7
3KA
32B
3AB
3K9
3C9
-
-
3K5
3U5
3KB
2 x SPDT
34E
3BA
39E
3DE
-
-
3L7
3V7
3LE
34B
3BB
3L9
3D9
-
-
3L5
3V5
3LB
3 x SPDT
36E
3CA
38E
3EE
-
-
367
377
3ME
36B
3CB
3M9
3E9
-
-
365
375
3MB
1 x DPDT
38A
3DA
3NC
3FC
-
-
3D7
3W7
3NA
38B
3DB
3N9
3F9
-
-
3D5
3W5
3NB
2 x DPDT
31A
3EA
3PC
3GC
-
-
3O7
3Y7
3OA
31B
3EB
3P9
3G9
-
-
3O5
3Y5
3OB
1 x SPDT
B2A
BAA
BKC
BCC
-
-
BK7
BU7
BKA
B2B
BAB
BK9
BC9
-
-
BK5
BU5
BKB
2 x SPDT
B4A
BBA
BLC
BDC
-
-
BL7
BV7
BLA
B4B
BBB
BL9
BD9
-
-
BL5
BV5
BLB
3 x SPDT
B6A
BCA
BMC
BEC
-
-
B67
B77
BMA
B6B
BCB
BM9
BE9
-
-
B65
B75
BMB
1 x DPDT
B8A
BDA
BNC
BFC
-
-
BD7
BW7
BNA
B8B
BDB
BN9
BF9
-
-
BD5
BW5
BNB
2 x DPDT
B1A
BEA
BPC
BGC
-
-
BO7
BY7
BOA
B1B
BEB
BP9
BG9
-
-
BO5
BY5
BOB
1 x SPDT
C2A
CAA
CKC
CCC
C2X
CAX
CK7
CU7
CKA
C2B
CAB
CK9
CC9
C2T
CAT
CK5
CU5
CKB
2 x SPDT
C4A
CBA
CLC
CDC
C4X
CBX
CL7
CV7
CLA
C4B
CBB
CL9
CD9
C4T
CBT
CL5
CV5
CLB
3 x SPDT
C6A
CCA
CMC
CEC
-
-
C67
C77
CMA
C6B
CCB
CM9
CE9
-
-
C65
C75
CMB
1 x DPDT
C8A
CDA
CNC
CFC
C8X
CDX
CD7
CW7
CNA
C8B
CDB
CN9
CF9
C8T
CDT
CD5
CW5
CNB
2 x DPDT
C1A
CEA
CPC
CGC
C1X
CEX
CO7
CY7
COA
C1B
CEB
CP9
CG9
C1T
CET
CO5
CY5
COB
1 x SPDT
D2B
DAB
DK9
DC9
-
-
DK5
DU5
DKB
D2B
DAB
DK9
DC9
-
-
DK5
DU5
DKB
2 x SPDT
D4B
DBB
DL9
DD9
-
-
DL5
DV5
DLB
D4B
DBB
DL9
DD9
-
-
DL5
DV5
DLB
3 x SPDT
-
-
-
-
-
-
-
-
-
D6B
DCB
DM9
DE9
-
-
D65
D75
DMB
1 x DPDT
D8B
DDB
DN9
DF9
-
-
DD5
DW5
DNB
D8B
DDB
DN9
DF9
-
-
DD5
DW5
DNB
2 x DPDT
D1B
DEB
DP9
DG9
-
-
DO5
DY5
DOB
D1B
DEB
DP9
DG9
-
-
DO5
DY5
DOB
1 x SPDT
FCA
FAA
FKC
FCC
-
-
FK7
FU7
FKA
FCB
FAB
FK9
FC9
-
-
FK5
FU5
FKB
2 x SPDT
FFA
FBA
FLC
FDC
-
-
FL7
FV7
FLA
FFB
FBB
FL9
FD9
-
-
FL5
FV5
FLB
1 x DPDT
FGA
FDA
FNC
FFC
-
-
FD7
FW7
FNA
FGB
FDB
FN9
FF9
-
-
FD5
FW5
FNB
AKB
2 x DPDT
FHA
FEA
FPC
FGC
-
-
FO7
FY7
FOA
FHB
FEB
FP9
FG9
-
-
FO5
FY5
FOB
1 x SPDT
H7A
HM2
HFC
HA9
-
-
HB3
HB4
HM3
H7A
HM2
HFC
HA9
-
-
HB3
HB4
HM3
1 x DPDT
H7C
HM6
HGC
HB9
-
-
HB7
HB8
HM7
H7C
HM6
HGC
HB9
-
-
HB7
HB8
HM7
1 x SPDT
U2A
UAA
UKC
UCC
U2X
UAX
UK7
UU7
UKA
U2B
UAB
UK9
UC9
U2T
UAT
UK5
UU5
UKB
2 x SPDT
U4A
UBA
ULC
UDC
U4X
UBX
UL7
UV7
ULA
U4B
UBB
UL9
UD9
U4T
UBT
UL5
UV5
ULB
3 x SPDT
U6A
UCA
UMC
UEC
-
-
U67
U77
UMA
U6B
UCB
UM9
UE9
-
-
U65
U75
UMB
1 x DPDT
U8A
UDA
UNC
UFC
U8X
UDX
UD7
UW7
UNA
U8B
UDB
UN9
UF9
U8T
UDT
UD5
UW5
UNB
2 x DPDT
U1A
UEA
UPC
UGC
U1X
UEX
UO7
UY7
UOA
U1B
UEB
UP9
UG9
U1T
UET
UO5
UY5
UOB
-
-
-
-
-
VJS
VLS
-
-
-
-
-
-
-
VCS
VES
-
-
-
1 x SPDT
W2A
WAA
WKC
WCC
W2X
WAX
WK7
WU7
WKA
W2B
WAB
WK9
WC9
W2T
WAT
WK5
WU5
WKB
2 x SPDT
W4A
WBA
WLC
WDC
W4X
WBX
WL7
WV7
WLA
W4B
WBB
WL9
WD9
W4T
WBT
WL5
WV5
WLB
3 x SPDT
W6A
WCA
WMC
WEC
-
-
W67
W77
WMA
W6B
WCB
WM9
WE9
-
-
W65
W75
WMB
1 x DPDT
W8A
WDB
WN9
WF9
W8T
WDT
WD5
WW5
WNB
W8B
WDB
WN9
WF9
W8T
WDT
WD5
WW5
WNB
2 x DPDT
W1B
WEB
WP9
WG9
W1T
WET
WO5
WY5
WOB
W1B
WEB
WP9
WG9
W1T
WET
WO5
WY5
WOB
1 x SPDT
X2A
XAA
XKC
XCC
X2X
XAX
XK7
XU7
XKA
X2B
XAB
XK9
XC9
X2T
XAT
XK5
XU5
XKB
2 x SPDT
X4A
XBA
XLC
XDC
X4X
XBX
XL7
XV7
XLA
X4B
XBB
XL9
XD9
X4T
XBT
XL5
XV5
XLB
3 x SPDT
X6A
XCA
XMC
XEC
-
-
X67
X77
XMA
X6B
XCB
XM9
XE9
-
-
X65
X75
XMB
1 x DPDT
X8B
XDB
XN9
XF9
X8T
XDT
XD5
XW5
XNB
X8B
XDB
XN9
XF9
X8T
XDT
XD5
XW5
XNB
2 x DPDT
X1B
XEB
XP9
XG9
X1T
XET
XO5
XY5
XOB
X1B
XEB
XP9
XG9
X1T
XET
XO5
XY5
XOB
Select electric switch mechanism & enclosure for B41 models (see page 4 for switch ratings)
All models with material codes A
qty and
switch
type
A
3
B
C
D
F
HS
U
V
W
X
ATEX (IP 66)
Weather proof
(IP 66)
EEx d IIC T6
cast Aluminium
cast Aluminium
All models with material codes B and D
CENELEC (IP 66)
FM (IP 66)
II 1G EEx ia II C T6
EEx d IIC T6
cast Aluminium
ATEX (IP 66)
CENELEC (IP 66)
FM (IP 66)
NEMA 7/9
Weather proof
(IP 66)
EEx d IIC T6
II 1G EEx ia II C T6
EEx d IIC T6
NEMA 7/9
cast Iron
cast Alu.
cast Aluminium
cast Aluminium
cast Aluminium
cast Iron
cast Alu.
M20 x 1,5 3/4" NPT
M20 x 1,5 3/4" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
M20 x 1,5
1" NPT
1 x SPDT
A2P
AAP
AHC
AAC
-
-
AK7
AU7
AKP
A2Q
AAQ
AH9
AA9
-
-
AK5
AU5
AKQ
1 x DPDT
A8P
ADP
AJC
ABC
-
-
AD7
AW7
ANP
A8Q
ADQ
AJ9
AB9
-
-
AD5
AW5
ANQ
1 x SPDT
32P
3AP
3HC
3AC
-
-
3K7
3U7
3KP
32Q
3AQ
3H9
3A9
-
-
3K5
3U5
3KQ
1 x DPDT
38P
3DP
3JC
3BC
-
-
3D7
3W7
3NP
38Q
3DQ
3J9
3B9
-
-
3D5
3W5
3NQ
1 x SPDT
B2P
BAP
BHC
BAC
-
-
BK7
BU7
BKP
B2Q
BAQ
BH9
BA9
-
-
BK5
BU5
BKQ
1 x DPDT
B8P
BDP
BJC
BBC
-
-
BD7
BW7
BNP
B8Q
BDQ
BJ9
BB9
-
-
BD5
BW5
BNQ
1 x SPDT
C2P
CAP
CHC
CAC
C2L
CAL
CK7
CU7
CKP
C2Q
CAQ
CH9
CA9
C2S
CAS
CK5
CU5
CKQ
1 x DPDT
C8P
CDP
CJC
CBC
C8L
CDL
CD7
CW7
CNP
C8Q
CDQ
CJ9
CB9
C8S
CDS
CD5
CW5
CNQ
1 x SPDT
-
-
-
-
-
-
-
-
-
D2Q
DAQ
DH9
DA9
-
-
DK5
DU5
DKQ
1 x DPDT
-
-
-
-
-
-
-
-
-
D8Q
DDQ
DJ9
DB9
-
-
DD5
DW5
DNQ
1 x SPDT
F2P
FAP
FHC
FAC
-
-
FK7
FU7
FKP
F2Q
FAQ
FH9
FA9
-
-
FK5
FU5
FKQ
1 x DPDT
F8P
FDP
FJC
FBC
-
-
FD7
FW7
FNP
F8Q
FDQ
FJ9
FB9
-
-
FD5
FW5
FNQ
1 x SPDT
-
-
-
-
-
-
-
-
-
H7A
HM2
HFC
HA9
-
-
HB3
HB4
HM3
1 x DPDT
-
-
-
-
-
-
-
-
-
H7C
HM6
HGC
HB9
-
-
HB7
HB8
HM7
1 x SPDT
U2P
UAP
UHC
UAC
U2L
UAL
UK7
UU7
UKP
U2Q
UAQ
UH9
UA9
U2S
UAS
UK5
UU5
UKQ
1 x DPDT
U8P
UDP
UJC
UBC
U8L
UDL
UD7
UW7
UNP
U8Q
UDQ
UJ9
UB9
U8S
UDS
UD5
UW5
UNQ
-
-
-
-
-
VFS
VHS
-
-
-
-
-
-
-
V5S
VBS
-
-
-
1 x SPDT
W2P
WAP
WHC
WAC
W2L
WAL
WK7
WU7
WKP
W2Q
WAQ
WH9
WA9
W2S
WAS
WK5
WU5
WKQ
WNQ
1 x DPDT
-
-
-
-
-
-
-
-
-
W8Q
WDQ
WJ9
WB9
W8S
WDS
WD5
WW5
1 x SPDT
X2P
XAP
XHC
XAC
X2L
XAL
XK7
XU7
XKP
X2Q
XAQ
XH9
XA9
X2S
XAS
XK5
XU5
XKQ
1 x DPDT
-
-
-
-
-
-
-
-
-
X8Q
XDQ
XJ9
XB9
X8S
XDS
XD5
XW5
XNQ
3
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.
Shutoff valve
(if used)
PIPING
Figure 3 shows a typical piping installation of a Magnetrol
float cage control to a vessel or boiler. Level decals on control identify the actuation levels for a unit with three switches at minimum specific gravity. Refer to the Actuation Level
charts 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.
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.
Cable connexion
Switch actuating
level reference mark
Optional liquid leg
connexion to vessel
Shutoff valve
(if used)
Optional blow-down
or drain valve
Figure 3
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.
AVAILABLE SWITCH MECHANISMS
Type of switch module ➀
Max. Process Temp. ➁
Switch ratings – A res. ➂
Code
24 V DC 240 V AC 120 V AC
➀
➁
➂
➃
4
Micro switch
max 120 °C (250 °F)
6
15
15
B
Micro switch
max 230 °C (450 °F)
10
15
15
C
Micro switch - DC current
max 120 °C (250 °F)
10
–
10
D
Micro switch with gold alloy contacts
max 120 °C (250 °F)
1
–
1
U
Hermetically sealed micro switch
max 290 °C (500 °F)
5
5
5
HS ➃
Hermetically sealed micro switch with silver plated contacts
max 230 °C (450 °F)
3
1
1
W
Hermetically sealed micro switch with gold plated contacts
max 230 °C (450 °F)
0,5
0,5
0,5
X
Hermetically sealed micro switch
max 400 °C (750 °F)
4
–
2,5
F
Proximity switch - type SJ 3.5 SN
max 100 °C (210 °F)
NA
NA
NA
V
Mercury switch
max 290 °C (500 °F)
10
6,5
13
A
Mercury switch
max 400 °C (750 °F)
10
6,5
13
3
Pneumatic bleed type (open air)
max 200 °C (400 °F)
NA
NA
NA
J
Pneumatic non bleed type (closed circuit)
max 200 °C (400 °F)
NA
NA
NA
K
For applications with heavy vibration, consult factory for suited switch modules.
Max process temperature is specified at 40 °C (100 °F) ambient temperature and for non condensing applications.
For more details - see bulletin BE 42-120.
For condensing applications, max process temperature is down-rated to 200 °C (400 °F) @ 40 °C (100 °F) ambient.
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.
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.
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 propre 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
Reference series
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
E
OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES
CENELEC
Weatherproof
ATEX
FM
Set screw
Locking screw
Figure 4a
Figure 4c
CAUTION:
- DO NOT attempt to reposition NEMA 4 /
NEMA 7/9 housings without loosening the
set screws; CENELEC housings MAY NOT
BE REPOSITIONNED. ALWAYS retighten
set screw(s) after repositionning.
- DO NOT attempt to unscrew cover of CENELEC housings before loosening locking
screw in base of housing. ALWAYS retighten
locking screw after replacing cover.
NEMA 7/9
CAST IRON
Set screw
Set screw
Position
screw
Figure 4b
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
WHAT TO AVOID
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.
1. NEVER leave switch housing cover off the control longer
than necessary to make routine inspections.
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 maladjusted switch mechanisms (refer to bulletin on switch
mechanism furnished for service instructions).
– Magnetrol controls may sometimes be exposed to
excessive heat or moisture. Under such conditions,
insulation on electrical wires may become brittle,
eventually breaking or peeling away. The resulting
"bare" wires can cause short circuits.
Check wiring carefully and replace at first sign of brittle
insulation.
– Vibration may sometimes cause terminal screws to
work loose. Check all terminal connections to be certain that screws are tight. Air (or gas) operating medium lines subjected to vibration may eventually crack
or become loose at connections causing leakage.
Check lines and connections carefully and repair or
replace, if necessary.
– On units with pneumatic switches, air (or gas) operating medium lines subjected to vibration, may eventually crack or become loose at connections carefully
and repair or replace, if necessary.
NOTE: As a matter of good practice, spare switches should
be kept on hand at all times.
3. Inspect entire unit periodically
Isolate control from vessel. Raise and lower liquid level
to check for switch contact and reset.
6
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.
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.
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.
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 8.
NOTE: Differential adjustment causes a change in the
amount of level travel between “switch-on” and “switch-off”
actuations. Refer to Page 8.
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
SWITCH DIFFERENTIAL ADJUSTMENT
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For access to bottom
jam nuts, remove top
jam nuts, washer, and
attracting sleeve.
Slight play (gap)
must be allowed
(0.8 mm (0.03") typical)
Position of bottom
jam nuts (normal
factory setting)
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Maximum gap setting
(Applies to models having
13 mm a single switch mecha(0.50") nism with a single magnet
actuator only)
Replace in
same position
Drop bottom jam nuts to
increase gap setting
(see instructions below)
Sleeve stop
strap
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.
Figure 5
Normal Factory Setting
(minimum differential)
Figure 6
Differential adjustment
The amount of level travel between switch-on and switchoff actuations (differential) may be field 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 5. This setting may be increased to a
maximum of 0.50" (13 mm), as shown in Figure 6.
2. Perform system shutdown as required to relieve pressure from float chamber of control and allow unit to
cool.
NOTE: For assistance in computing level differential
change for a specific control, consult the factory giving the
model and serial numbers of the control.
With level change specifications determined, proceed as
follows:
CAUTION: Before attempting any work on the control,
pull disconnect switch, or otherwise assure that electrical circuit(s) through the control is deactivated. Close
operating medium supply valve on controls equipped
with pneumatic switch mechanisms.
1. Disconnect wiring from supply side of switch mechanism(s) and electrical conduit or operating medium line
connections to switch housing.
8
NOTE: Control chamber, connections, or pipe lines need
not be removed from vessel or boiler.
3. Remove switch housing assembly by loosening hex
nut, which is located immediately below housing base
(refer to Figure 8).
4. With switch housing removed, jam nuts and attraction
sleeve are accessible. Measure position of upper jam
nuts from stem end; then loosen and remove upper
jam nuts, guide washer, and attraction sleeve.
5. Loosen and adjust lower jam nuts to desired position.
Make certain jam nuts are retightened securely.
NOTE: Use new gasket in assembly of switch housing to
chamber.
6. Test switch actuation by varying liquid level in float
chamber.
REPLACEMENT OF STANDARD FLOAT AND STEM ASSEMBLY
1. Disconnect wiring or medium lines from control and
perform system shutdown as previously described in
Troubleshooting and Differential Adjustment Sections.
A
2. Remove switch housing assembly from float chamber
at head flange.
3. Remove sleeve stop strap from the underside of the
head flange and slide the float stem assembly out of
the enclosing tube.
Bottom jam nuts
0.03"
Minimum
gap setting
Attraction sleeve
Enclosing tube (ref.)
NOTE: New float and stem kits are supplied unassembled.
Refer to standard lower jam nut settings chart (below) and
to Figure 7 for dimension A.
4. Check new float and stem assembly to be certain it is
the correct replacement unit:
a. Float should be of same physical size and shape.
Retaining
screws
b. Stem length should match closely.
;
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Top jam nuts
Head
flange
(ref.)
Stop tube
Sleeve
Stop strap
c. Set attraction sleeve per dimension A as shown in
the chart below.
NOTE: If differential adjustment has been altered in the
field, disregard dimension A and readjust new assembly to
the previously determined level differential settings per
instructions on page 8.
5. Replace new float and stem assembly into head flange
and install new stop strap with screws included.
6. Remount head flange on float chamber, using new
gasket provided. Tighten flange nuts evenly, using an
alternating pattern typical of standard industry practice.
Float and stem
assembly
Figure 7
NOTE: Care must be taken during installation to be certain
float stem does not become bent.
7. With control assembly in place, test switch actuation by
varying liquid level in float chamber.
1
STANDARD LOWER JAM NUT SETTINGS
Model
B24, C24, A40, B41, B43,
J31, J33, G33, B60, O30
Dimension A
inches
3
mm
16
51
2
2
17
6
9
11
10
18
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4
14
15
5
7
8
9
6
12
10
13
Figure 8
9
REPLACEMENT PARTS
Standard Replacement Assembly Kits
No.
Description
B24
C24
➀
A40
➀
B41
B43
J31
J33
1
2
3
4
Housing cover
Housing base
Switch mechanism
Enclosing tube
5
E-Tube gasket
—
121204001
6
7
8
9
7
8
9
10
9
11
12
Head
Flange
Kits
894201001
Consult Factory
Float
Chamber
Kits
894601001
Consult Factory
13
Head flange
Studs/Bolts
Hex nuts
Flange gasket
Studs/Bolts
Hex nuts
Flange gasket
Float Chamber
Flange gasket
Stop Strap
Screws
Float and
stem assembly
14
15
16
17
Jam nuts
Guide washer
Attraction sleeve
Stop tube (if used)
Float
and
Stem
Kits
893201001
➀
18
Chamber liner ➀
—
Flange gasket
—
9
Housing
Kits
4
Enclosing
Tube
O30
B24
055524001
121301003
896564003 ➁
Cast aluminium
housing
Cast iron
housing
Pneumatic
switch housing
Refer to bulletin on Switch Mechanism Furnished (listed on page 3)
See table below
1212-1301-002
1204001
IMPORTANT:
When ordering, please specify:
A. Model and serial number of control.
B. Replacement assembly (kit) part number.
121301002
Consult Factory
Consult Factory
121301015
121301014
121301015
121301009
12-1301-006
121204015
121301018
Consult Factory
Models with mat’l code A & B
032-6302-033
032-6302-031 (B/C 24 & B 41)
Models with mat’l code D
032-6302-037
032-6302-036 (B 41)
032-6344-002
032-6344-001
032-6302-031
032-6302-036
Notes:
➀ Cast float cage models used on boiler service require brass
chamber liner. Refer to bulletin 46-625 for replacement instructions.
10
B60
Refer to Bulletin 42-683 for Switch Housing Cover
and Base Assemblies
—
—
Complete Control
Less Float Chamber,
Bolts, and Nuts
G33
➁ Furnished with one Series A, SPDT Mercury Switch and standard
switch housing.
TANDEM FLOAT MODELS
DESCRIPTION
Models with tandem style floats are used on applications
where widely spaced high and low switching functions can
be accomplished with a single control. The 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 attraction sleeve by
means of a hollow stem. The lower float attaches to the
upper attraction sleeve with a solid stem that extends
upward, through the upper float and stem assembly.
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16
3
17
14
15
2
1
13
INSTALLATION, PREVENTATIVE
MAINTENANCE, AND TROUBLESHOOTING
Installation and maintenance of tandem float models is
accomplished in much the same manner as for standard
models previously described. 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 or boiler. When troubleshooting the level sensing portion of the
control, additional checks may be made of the following:
1. Inspect for binding of solid (lower) float stem within hollow (upper) float stem due to corrosion or possible damage incurred during shipment or previous maintenance.
4
9
11
10
2. Make certain that retaining (snap) rings, used to locate
lower attraction sleeve, are locked in place. An extreme
shock or hammer, such as during blow-down on a
water column boiler control, may have damaged a ring
causing it to snap out of its retaining groove in the hollow (upper) float stem.
REPLACEMENT OF FLOAT
AND STEM ASSEMBLIES
Should replacement of either upper or lower float and stem
assembly be required, instructions previously given for
standard units (page 9) may be followed with additional
consideration as follows:
1. New float and stem assemblies are available in separate replacement kits, with attraction sleeve parts furnished loose, to allow for field assembly with existing
serviceable components. Consult factory.
5
8
7
12
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 require special control
modifications. Consult factory or local representative
for assistance.
6
20
19
18
Figure 9
Typical tandem float model
2. Dimension A, referred to in standard instructions, must
be arrived at by direct measurement from old assembly.
NOTE: Disregard dimension A figures shown in chart on
page 9. If in doubt, or unable to get an accurate measurement from old assembly, consult factory or local representative for assistance.
3. Lower attraction sleeve locks in place on hollow
(upper) float stem with external type snap rings. Care
must be taken to be certain rings are properly
installed. If available, use the correct type external
snap ring pliers.
NOTE: Model shown has fabricated steel float cage; models W25 and W24 have cast iron float cage.
11
FLANGED CAGE MODEL DIMENSIONAL SPECIFICATIONS in mm (inches)
– Only A40 Model –
X
Y
X
Y
X
Y
V
Z
Z
V
W
V
Z
W
W
C
C
C
A
A
A
B
B
B
Threaded & socket weld
upper side/bottom
cast iron housing
Flanged
upper side/bottom
cast iron housing
Flanged
side/side
cast iron housing
– All models except A40 –
X
Y
X
X
Y
Y
V
Z
V
V
Z
Z
W
W
W
C
C
C
A
A
A
B
B
B
Flanged
side/side
aluminium housing
Flanged
upper side/bottom
aluminium housing
Threaded & socket weld
upper side/bottom
aluminium housing
Housing type
Models
WeatherproofFM (NEMA 7/9) ATEX (Cast Alu)
CENELEC (Cast Iron)
V
W
mm
inches
B73/B41 with HS-switch
All other models
257
10.12
B73/B41 excl. HS-switch
202
7.94
All
249
All
165
Pneumatics
Switch Module J
Pneumatics
Switch Module K
øX
Y
Z
mm
inches
mm
inches
mm
inches
42
1.66
151
5.93
109
4.29
M20 x 1,5 (*) or 1" NPT
(2 entries - 1 plugged)
(*) not for FM (NEMA 7/9)
9.80
45
1.77
143
5.63
110
4.33
M20 x 1,5 or 3/4" NPT
(single entry - 2 entries at request)
110
4.33
6.50
39
1.54
118
4.65
130
5.12
1/4" NPT
Allow 200 mm (7.87") overhead clearance / All housings are 360 ° rotatable
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.
LL
HL
NPT & Socket weld
12
LL
HL
Upper side/bottom
LL
HL
Side/side
FLANGED CAGE MODEL DIMENSIONAL SPECIFICATIONS in mm (inches)
Dimensions
Process
connection
size
Mounting configuration
1" - DN 25
Model
1" - DN 25
1" - DN 25
1" - DN 25
Model
A
B
C
mm
inches
mm
inches
mm
inches
mm
inches
mm
inches
threaded / socket welded
222
8.74
82
3.23
391
15.39
250
9.84
96
3.78
408
16.06
flanged upper side / bottom
356
14
185
7.28
525
20.67
356
14
200
7.87
514
20.24
flanged side/side
356
14
185
7.28
525
20.67
356
14
200
7.87
514
20.24
threaded / socket welded
222
8.74
94
3.70
391
15.39
260
10.24
107
4.21
418
16.46
356
14
200
7.87
525
20.67
356
14
215
8.46
514
20.24
flanged side/side
356
14
200
7.87
525
20.67
356
14
215
8.46
514
20.24
threaded / socket welded
222
8.74
97
3.82
391
15.39
262
10.31
110
4.33
420
16.54
flanged upper side / bottom
356
14
200
7.87
525
20.67
356
14
220
8.66
514
20.24
flanged side/side
356
14
200
7.87
525
20.67
356
14
220
8.66
514
20.24
threaded / socket welded
250
9.84
82
3.23
411
16.18
250
9.84
82
3.23
419
16.50
flanged upper side / bottom
356
14
185
7.28
517
20.35
356
14
185
7.28
525
20.67
flanged side/side
356
14
185
7.28
517
20.35
356
14
185
7.28
525
20.67
threaded / socket welded
260
10.24
94
3.70
421
16.57
260
10.24
94
3.70
429
16.89
381
15
200
7.87
542
21.34
381
15
200
7.87
550
21.65
flanged side/side
356
14
200
7.87
517
20.35
356
14
200
7.87
525
20.67
threaded / socket welded
261
10.28
97
3.82
422
16.61
261
10.28
97
3.82
430
16.93
flanged upper side / bottom
381
15
200
7.87
542
21.34
381
15
200
7.87
550
21.65
flanged side/side
381
15
200
7.87
542
21.34
381
15
200
7.87
550
21.65
threaded / socket welded
250
9.84
109
4.29
429
16.89
250
9.84
109
4.29
418
16.46
flanged upper side / bottom
356
14
215
8.46
535
21.06
356
14
215
8.46
524
20.63
flanged side/side
356
14
215
8.46
535
21.06
356
14
215
8.46
524
20.63
threaded / socket welded
261
10.28
121
4.76
440
17.32
261
10.28
121
4.76
429
16.89
381
15
230
9.06
560
22.05
381
15
230
9.06
549
21.61
flanged side/side
356
14
230
9.06
535
21.06
356
14
230
9.06
524
20.63
threaded / socket welded
262
10.31
124
4.88
441
17.36
262
10.31
124
4.88
430
16.93
flanged upper side / bottom
381
15
235
9.25
560
22.05
381
15
235
9.25
549
21.61
flanged side/side
381
15
235
9.25
560
22.05
381
15
235
9.25
549
21.61
threaded / socket welded
222
8.74
70
2.76
353
13.90
flanged upper side / bottom O30 (*)
356
14.02
165
6.50
487
19.17
flanged side/side
356
14.02
165
6.50
487
19.17
1 1/2" - DN 40 flanged upper side / bottom
2" - DN 50
C
inches
1 1/2" - DN 40 flanged upper side / bottom
2" - DN 50
Dimensions
B
mm
1 1/2" - DN 40 flanged upper side / bottom A40 (*)
2" - DN 50
A
B41
G33
J33
B60 (*)
B43 (*)
J31 (*)
(*) Add 33 mm (1.30") to C-dimension for cast iron
EEx d II C T6 housings.
Actuation levels in mm (inches) for minimum specific gravity and as per selected material of construction
(see selection data)
1" / DN 25
Material code A
Model
1 1/2" / DN 40
Material code B & D
Material code A
2" / DN 50
Material code B & D
Material code A
Material code B & D
High
Low Level
High
Low Level
High
Low Level
High
Low Level
High
Low Level
High
Low Level
Level (HL)
(LL)
Level (HL)
(LL)
Level (HL)
(LL)
Level (HL)
(LL)
Level (HL)
(LL)
Level (HL)
(LL)
A40
34 (1.34)
56 (2.20)
32 (1.26)
59 (2.32)
34 (1.34)
56 (2.20)
32 (1.26)
59 (2.32)
34 (1.34)
56 (2.20)
32 (1.26)
59 (2.32)
B41
23 (0.91)
45 (1.77)
25 (0.98)
51 (2.01)
23 (0.91)
45 (1.77)
25 (0.98)
51 (2.01)
23 (0.91)
45 (1.77)
25 (0.98)
51 (2.01)
B43
53 (2.09)
77 (3.03)
60 (2.36)
90 (3.54)
46 (1.81)
70 (2.76)
53 (2.09)
83 (3.27)
38 (1.50)
62 (2.44)
45 (1.77)
75 (2.95)
B60
76 (2.99)
94 (3.70)
81 (3.19) 102 (4.02) 57 (2.24)
75 (2.95)
62 (2.44)
83 (3.27)
49 (1.93)
67 (2.64)
54 (2.13)
75 (2.95)
G33
65 (2.56)
83 (3.27)
66 (2.60)
58 (2.28)
76 (2.99)
59 (2.32)
80 (3.15)
50 (1.97)
68 (2.68)
51 (2.01)
72 (2.83)
J31/J33 74 (2.91)
93 (3.66)
80 (3.15) 103 (4.06) 55 (2.17)
74 (2.91)
61 (2.40)
84 (3.31)
47 (1.85)
66 (2.60)
53 (2.09)
76 (2.99)
-
-
-
-
-
-
-
O30
-
-
57 (2.24)
87 (3.43)
85 (3.35)
-
13
14
15
IMPORTANT
SERVICE POLICY
Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or
replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner) other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
and the parts required to rebuild or replace the equipment.
In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the
control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of our
warranty.
No claims for misapplication, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number
4. Desired Action
5. Reason for Return
6. Process details
All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments.
All replacements will be shipped FOB factory.
BULLETIN N°:
EFFECTIVE:
SUPERSEDES:
UNDER RESERVE OF MODIFICATIONS
BENELUX
®
DEUTSCHLAND
FRANCE
ITALIA
UNITED
KINGDOM
INDIA
BE 46-605.5
JUNE 2002
March 1997
Heikensstraat 6, 9240 Zele, België
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
Le Vinci 6 - Parc d’activités de Mitry Compans,
1, rue Becquerel, 77290 Mitry Mory
Tél. 01.60.93.99.50
Fax. 01.60.93.99.51
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