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 ;;; ;; ; ;; ;; ;; ;;;; ;;;; 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) ;; ;; ;; ;; ;; ;;;; ;;;; 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. ; ; ;; ; ; ;; ; ; ;; ;;; ;; 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 ;;;;;;; ;;;;;;; ; ; ; ; ; ; ; ;;;;;;; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;;;;;; ;;;;;;;;; ;;;;;; ; ; ; ;;;;;;;;; ;;;;;;;; ; ; ; ;;;;;;;;; ;;;;;;;;; ;;; ;;;; ;;;;;; ;;; ;;; ;;;;;;; ;;; ;;; ;; ; ; ; ;; ;;; ;; ; ; ; ;; ;; ;;;; ;; ; ;;; ; ;;; ; ;;; ; ;;; ; ;;; ;; ; ;;; ;; ;;;;; 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. ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ;;;;;;;;; ;;;;;;;;; ;;; ;;;;;;; ;;;;; ;;;;;;;;; ;;; ; ; ;;;;; ;;;;;;; ;;; ;;;;; ;;;;; ; ; ;;;; ;;; ;;; ;;;;;;;; ; ; ; ;;;;;;;;;; ; ;;; ;;;;;;;; ;;;;;;;; ;; ;;;;;;;; ;; ;;;;;;;; ;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ; ;;;;;;;; ;; ;; ; 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