Top Mounting T20 and T21 Installation and Operating Manual Liquid Level Switches Read this Manual Before Installing This manual provides information on the Top Mounting Liquid Level Switch. It is important that all instructions are read carefully and followed in sequence. Detailed instructions are included in the Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. NOTES Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNINGS Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages Follow all standard industry procedures for servicing electrical equipment when working with or around high voltage. Always shut off the power supply before touching any components. WARNING! Explosion hazard. Do not connect or dis- connect equipment unless power has been switched off or the area is known to be non-hazardous. 2 Low Voltage Directive For use in Category II installations. If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Notice of Trademark, Copyright, and Limitations Magnetrol® & MAGNETROL logotype are registered trademarks of MAGNETROL International. Copyright © 2016 MAGNETROL International, Incorporated. All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. MAGNETROL reserves the right to make changes to the product described in this manual at any time without notice. MAGNETROL makes no warranty with respect to the accuracy of the information in this manual. Warranty All MAGNETROL mechanical level and flow controls are warranted free of defects in materials or workmanship for five full years from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, MAGNETROL will repair or replace the control at no cost to the purchaser (or owner) other than transportation. MAGNETROL shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some MAGNETROL products. Quality Assurance The quality assurance system in place at MAGNETROL guarantees the highest level of quality throughout the company. MAGNETROL is committed to providing full customer satisfaction both in quality products and quality service. MAGNETROL’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. 44-604 Top Mounting Liquid Level Switches Top Mounting Liquid Level Switches Table of Contents 1.0 Introduction 1.1 Principle of Operation...........................................4 2.0 Installation 2.1 Unpacking.............................................................4 2.2 Critical alarm function ..........................................5 2.3 Mounting ..............................................................5 2.4 Wiring...................................................................6 3.0 Switch Differential Adjustment ...................................8 4.0 Preventive Maintenance 4.1 What to do..........................................................10 4.1.1 Keep control clean ....................................10 4.1.2 Inspect switch mechanisms, terminals, and connections monthly .........................10 4.1.3 Inspect entire unit periodically..................11 4.2 What to avoid .....................................................11 44-604 Top Mounting Liquid Level Switches 5.0 Reference Information 5.1 Troubleshooting...................................................12 5.1.1 Check switch mechanism..........................12 5.1.2 Check complete unit ................................13 5.2 Agency Approvals ................................................14 5.3 Specifications.......................................................15 5.3.1 Physical.....................................................15 5.4 Replacement Parts ...............................................16 5.4.1 Model T20 Parts Identification.................16 5.4.1.1 Model T20......................................17 5.4.1.2 Mounting flanges ............................17 5.4.1.3 Switch and housing reference ..........17 5.4.2 Model T21 Parts Identification.................18 5.4.2.1 Model T21......................................19 5.4.2.2 Mounting flanges and guide cage gaskets............................19 5.4.2.3 Switch and housing reference ..........19 5.5 Model Numbers ..................................................20 5.5.1 Model T20 ...............................................20 5.5.2 Model T21 ...............................................22 3 1.0 T20 and T21 level switches are float operated units designed for top mounting to a tank or vessel by means of threaded or flanged pipe connections. T20 standard units are equipped with a single switch mechanism for high or low level alarm or control applications. T21 tandem units are equipped with two switch mechanisms, each operated by a separate float, for applications requiring widely spaced separate high and low level switch actuation. 2 5 Introduction Pivot 6 4 Return Spring 1 1.1 Principle of Operation The simple and foolproof operation of the top mounted float switches is illustrated in figures 1 and 2. 3 A permanent magnet ➀ is attached to a pivoted switch actuator and adjustment screw ➁. As the float ➂ rises following the liquid level, it raises the attraction sleeve ➃ into the field of the magnet, which then snaps against the non-magnetic enclosing tube ➄, 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. Process Liquid Rising Level Figure 1 2.0 Installation This section provides detailed procedures for properly installing top mounted level switches. Process Liquid Falling Level Figure 2 Caution: If equipment is used in a manner not specified by the manufacturer, protection provided by the equipment may be impaired. 2.1 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 against purchase order. Check and record the model number against serial number for future reference when ordering parts. Model Number Serial Number 4 44-604 Top Mounting Liquid Level Switches 2.2 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. 2.3 Mounting Caution: Operation of all buoyancy type level devices should be done in such a way as to minimize the action of dynamic forces on the float or displacer sensing element. Good practice for reducing the likelihood of damage to the control is to equalize pressure across the device very slowly. Ensure that no tubes, rods, or other obstacles in the tank or vessel which could interfere with the operation of float(s). Caution: This instrument is intended for use in Installation Category II, Pollution Degree 2. Adjust the process connection as required to bring control to a vertical position. MAGNETROL controls must be mounted within three degrees of vertical in all directions. A three degree slant is noticeable by eye, but installation should be checked with a spirit level on top and/or sides of float stem or enclosing tube. NOTE: Do not insulate switch mechanism housing. On controls equipped with pneumatic switch assemblies, consult bulletin on mechanism furnished for air (or gas) piping instructions. Switch Series Letter 44-604 Top Mounting Liquid Level Switches Description B, C, D Dry Contact Switch F Hermetically Sealed Snap Switch HS Hermetically Sealed Snap Switch Bulletin No. 42-683 42-694 J Bleed Type Pneumatic Switch 42-685 K Non-Bleed Type Pneumatic Switch 42-686 R, 8, 9 High Temperature Switch 42-799 5 2.4 Wiring Caution: All Top Mounting units are shipped from the factory with the enclosing tube tightened and the switch housing set screw locked to the enclosing tube. Failure to loosen the set screw prior to repositioning the supply and output connections may cause the enclosing tube to loosen, resulting in possible leakage of the process liquid or vapor. Screw Top mounting controls are shipped with the conduit entry of the switch housing placed 180° opposite the tank connections to simplify installation in most cases. If the location of the conduit entry on the level switch is appropriate to the installation, proceed to Step 4 to begin wiring the unit. If another configuration is desired, the switch housing can be easily rotated by first following Steps 1, 2, and 3. Set Screw Screw Figure 3 Housing Set Screws NOTE: A switch or circuit breaker shall be installed in close proximity to equipment and within easy reach of operator. It shall be marked as the disconnecting device for the equipment. Internal Circuit (Left) Switch 5 4 1 6 Close on high level Load Common Internal Circuit (Right) Switch 2 3 Load Close on high level 1. Loosen set screw(s) at base of switch housing. Refer to Figure 3. 2. Switch housing may be rotated 360° to allow correct positioning of conduit outlet. 3. Tighten set screw(s) at base of switch housing. 4. Unscrew and remove switch housing cover. The threads have been lubricated to facilitate removal. Common Close on low level Load Close on Load low level Line Line Figure 4 Terminal Connections DPDT Switch Mechanism Series B, C, and D NOTE: For supply connections use wire with a minimum rating of 75 °C, as required by process conditions. Use a minimum of 14 AWG wire for power and ground field wires. On high temperature applications (above 250 °F [121 °C] at mounting flange or bushing), high temperature wire should be used between control and first junction box located in a cooler area. On non-hazardous applications, flexible conduit may be used between the control and the first junction box. 5. The switch terminals are located next to the conduit outlet to facilitate wiring. Bring supply wires through conduit outlet. Route extra wire around enclosing tube under the baffle plate, and connect them to the proper terminals. Refer to the wiring diagram, Figure 4, or your switch bulletin for this information. 6 44-604 Top Mounting Liquid Level Switches 6. Dress wiring to ensure no interference or contact with the switch actuation arm, or replacement of switch housing cover. NOTE: Observe all applicable electrical codes and proper wiring procedures. Prevent moisture seepage into the enclosure by installing approved seal-drain fittings in the conduit run leading into the unit. Caution: In hazardous areas, do not power the unit until the conduit is sealed and the enclosure cover is screwed down securely. 7. Replace housing cover. 8. If control has been furnished with an explosion proof or moisture proof switch housing, it must be sealed at the conduit outlet with a suitable compound or non-hardening sealant to prevent entrance of air. 9. Test switch action by varying liquid level in the tank or vessel. The upper switch on Model T21 units is actuated by movement of the lower float, while the lower switch is actuated by the upper float. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism furnished. 10. 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 gasses into switch housing. 44-604 Top Mounting Liquid Level Switches 7 3.0 Switch Differential Adjustment The standard differential of the single float Model T20 may be field adjusted. Adjustment may be necessary if a wider differential needs to be set to overcome switch chatter caused by the process. The differential, or the amount of level travel between switch-on and switch-off, may be adjusted by repositioning the lower jam nuts on the float stem. The standard factory setting is for a minimum amount of play (gap) between the top jam nuts and the attraction sleeve as shown in Figure 6. NOTE: For assistance in computing level differential change for a specific control, consult the factory giving the model and serial numbers of the control. Caution: Maximum differential adjustment is 0.50 inch. NOTE: To widen the differential 0.50 inch, the lower jam nuts must be set proportionately lower on the stem (i.e., in this example 0.50 inch). Switch housing cover Enclosing tube Refer to Figures 6 and 7 Conduit connection Housing base Enclosing tube nut 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. 2. 3. 4. Float Figure 5 Determine what change in differential is necessary. Make sure power source is turned off. Unscrew and remove switch housing cover. Disconnect power supply wires from switch mechanism. Pull wires out of conduit connection opening in housing base. Refer to Figure 5. 5. Perform system shut-down procedures as required to relieve pressure from tank or vessel and drain off liquid head, if required. Allow unit to cool. NOTE: The amount of level travel between switch-on and switch-off actuation (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 6. This setting may be increased to a maximum of 0.50" (13 mm), as shown in Figure 7. 6. Remove switch housing assembly by loosening the enclosing tube nut, which is located immediately below housing base. Refer to Figure 5. 8 44-604 Top Mounting Liquid Level Switches 7. With switch housing and enclosing tube 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. 8. Loosen and adjust lower jam nuts to desired position. Make certain jam nuts are retightened securely. NOTE: Use new enclosing tube gasket in assembly of switch housing to the mounting bushing or flange. Refer to Sections 5.4.1.1 and 5.4.2.1 for enclosing tube gasket part numbers. 9. Test switch actuation by varying liquid level in tank or vessel. Caution: Instructions given are for standard base model units which use a single magnet switch mechanism only. No differential adjustment should be attempted on tandem float models in the field. Switch actuation levels have been set at the factory to meet specific customer specifications. Variations in actual conditions from design conditions usually requires special control modifications. Consult with the factory or local representative for assistance. For access to bottom jam nuts, mark position, remove top jam nuts, Replace in washer, and attracting same position sleeve. Slight play (gap) must be allowed (.03" [.8 mm] typical) Position of bottom jam nuts (normal factory setting) Maximum gap setting (Applies to models having 0.50" a single switch mechanism (13 mm) with a single magnet actuator only) Drop bottom jam nuts to increase gap setting (see instructions below) 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. Float Figure 6 Normal Factory Setting (minimum differential) 44-604 Top Mounting Liquid Level Switches Figure 7 Differential adjustment 9 4.0 Preventive Maintenance Periodic inspections are a necessary means to keep your level control in good working order. This control is a safety device to protect the valuable equipment it serves. Therefore, a systematic program of “preventive maintenance” must be implemented when the 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 equipment for many years. 4.1 What to do 4.1.1 Keep control clean Be sure the switch housing cover is always in place on 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 or any seals become damaged or misplaced, obtain a replacement immediately. 4.1.2 Inspect switch mechanisms, terminals, and connections monthly 1. 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. See switch mechanism bulletin supplied with control should switch adjustment or replacement be necessary. 2. DO NOT operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms furnished for service instructions.) 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 pealing 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 work loose. Check all terminal connections to be certain that screws are tight. 10 44-604 Top Mounting Liquid Level Switches 5. On units with pneumatic switches, air (or gas) 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. NOTE: As a matter of good practice, spare switches should be kept on hand at all times. 4.1.3 Inspect entire unit periodically Isolate control from vessel. Raise and lower liquid level to check for switch contact and reset. 4.2 What to avoid 1. Never leave switch housing cover off the control longer than necessary to make routine inspections. 2. Never place a jumper wire across terminals to “cut-out” the control. If a “jumper” is necessary for test purposes, be certain it is removed before placing control into service. 3. Never attempt to make adjustments or replace switches without reading instructions carefully. Certain adjustments provided for in level controls should not be attempted in the field. When in doubt, consult the factory or your local representative. 4. Never use lubricants on pivots of switch mechanisms. A sufficient amount of lubricant has been applied at the factory to ensure a lifetime of service. Further oiling is unnecessary and will only tend to attract dust and dirt which can interfere with mechanism operation. 44-604 Top Mounting Liquid Level Switches 11 5.0 Reference Information 5.1 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. a. Fuses may be blown. b. Reset button(s) may need resetting. c. Power switch may be open. d. Controlled equipment may be faulty. e. 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. 5.1.1 Check switch mechanism 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 degrees of vertical. (Use spirit level on side of enclosing tube in two places, 90° apart. 7. Check the continuity of the microswitch with ohmmeter. Replace immediately if found defective. 8. If switch mechanism is operating satisfactorily, proceed to check sensing unit. 12 44-604 Top Mounting Liquid Level Switches 5.1.2 Check complete unit 1. 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. 2. If controlled equipment responds to manual actuation test, trouble may be located in the level sensing portion of the control–float(s), stem(s), and magnetic attraction sleeve(s). NOTE: Ensure that liquid is entering the storage tank or vessel. A valve may be closed or a pipe line plugged. Caution: Be certain to pull disconnect switch or otherwise ensure that electrical circuit(s) through control is deactivated. Close operating medium supply valve on controls equipped with pneumatic switch mechanisms. 3. With liquid in tank or vessel, raise the liquid level above the set points. Magnets should “pull-in” on rising level. On Model T21 the lower float actuates the upper switch, and the upper float actuates the lower switch. If magnets fail to “pull-in”, lower the level and purge pressure. a. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit or operating medium line connections to switch housing. b. Remove switch housing assembly by loosening hex nut, which is located immediately below housing base. 4. With switch housing assembly removed, inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids buildup, which could restrict movement, preventing sleeve(s) from reaching field of switch magnet(s). 5. If differential has been changed in the field by repositioning the lower jam nuts on the float stem, check tightness and position of the jam nuts. Refer to Figure 6. NOTE: Differential adjustment affects a change in the amount of level travel between switch-on and switch-off actuation. Do not attempt adjustment without first consulting factory for assistance in computing level differential change for your control. 44-604 Top Mounting Liquid Level Switches 13 6. Check float to be certain it is buoyant in the liquid (tank or vessel must have adequate liquid level). If float is determined to be filled with liquid, or it is collapsed, it must be replaced immediately. Do not attempt to repair a float. 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. When communicating about your control, be certain to always specify the complete Model and Serial numbers. 5.2 Agency Approvals AGENCY MODEL APPROVED APPROVAL CLASSES FM All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Groups C & D Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Group B Class I, Div 1, Groups B, C & D Class II, Div 1, Groups E, F & G All with a Series HS, F, 8 or 9 electric switch mechanism and a housing listed as CSA TYPE 4X Class I, Div 2, Groups A, B, C & D All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Groups C & D Class II, Div 1, Groups E, F & G All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Group B Class I, Div 1, Groups B, C & D Class II, Div 1, Groups E, F & G All with an electric switch mechanism and an ATEX housing ➀ ATEX II 2 G EEx d IIC T6 94/9/EC IEC Ex Ex d IIC T6 IP 66 Low Voltage Directives 2006/95/EC Per Harmonized Standard: EN 61010-1/1993 & Amendment No. 1 Installation Category II Pollution Degree 2 CSA ATEX / IEC Ex ➁ CE ➀ Dual stage units with ‘HS’ switches are not ATEX approved. ➁ IEC Installation Instructions: The cable entry and closing devices shall be Ex d certified suitable for the conditions of use and correctly installed. For ambient temperatures above +55 °C or for process temperatures above +150 °C, suitable heat resistant cables shall be used. Heat extensions (between process connection and housing) shall never be insulated. Special conditions for safe use: When the equipment is installed in process temperatures higher than +85 °C the temperature classification must be reduced according to the following table as per IEC60079-0. 14 Maximum Process Temperature Temperature Classification < 85 °C T6 < 100 °C T5 < 135 °C T4 < 200 °C T3 < 300 °C T2 < 450 °C T1 These units are in conformity with IECEx KEM 05.0020X Classification Ex d IIC T6 Tambient -40 °C to +70 °C 44-604 Top Mounting Liquid Level Switches 5.3 Specifications 5.3.1 Physical inches (mm) B B A A 6.25* (158) 6.25* (158) 7.94* (201) 7.94* (201) 2.44 (61) 1.81 (45) Ref. 1" NPT Distance to actuating level (4" min. Distance to actuating level (4" min) Actuating level Actuating level Model T20 with flange Model T20 with 1" NPT * These dimensions increase by 2.19 (55) when unit is supplied with an HS switch with terminal block. B A 8.46 (214) Housing ➀ A B Conduit Connections TYPE 4X/7/9, Group B 5.93 (151) 3.87 (98) 1" NPT dual entry 4.70 (119) 5.00 (127) NEMA 1 ➁ Pneumatics 10.12 (257) 1 ⁄4" NPT single entry ➀ All housings rotatable 360°. ➁ Pneumatic switches available with Series T20 units only. 1.81 (45) Ref. Distance to upper actuating level (4" min.) Actuating level 8" min. Actuating level Distance to lower actuating level Distance To Maximum Minimum Upper level 40" (1016) 4" (102) Lower level 48" (1219) 12" (305) NOTE: On Model T21 the lower float actuates upper switch mechanism. The upper float actuates the lower switch mechanism. Model T21 with flange 44-604 Top Mounting Liquid Level Switches 15 5.4 Replacement Parts 1 5 3 6 4 2 11 10 9 12 7 8 5.4.1 Model T20 Parts Identification Item 1 2 3 4 5 6 7 8 9 10 11 12 16 Description Housing cover Housing base Switch mechanism Attraction sleeve Jam nuts Guide washer(s) Float stem Float Adaptor bushing/guide tube assembly Enclosing tube gasket Enclosing tube Mounting flange 44-604 Top Mounting Liquid Level Switches 5.4.1.1 Model T20 T20-1 Housing cover Housing base Switch mechanism Stem kit: includes items 4, 5, 6, & 7 Float: 3.00" ¥ 5.00" T20-4 See below See below See below Consult factory Z07-1202-003 3.50" ¥ 6.00" Z07-1202-009 4.00" 4.50" Adaptor bushing/guide tube assembly Float stem Enclosing tube gasket Enclosing tube Mounting flange Z07-1102-008 Z07-1102-009 Consult factory Consult factory 012-1301-002 Z32-6325-001 Z32-6325-002 See below 5.4.1.2 Mounting flanges 4" 5" 6" 8" flange flange flange flange 125 lb cast iron Z04-5840-001 Z04-5840-002 Z04-5840-003 Z04-5840-004 150 lb forged steel 300 lb forged steel 150 lb forged 304 Z04-5840-011 Z04-5840-016 004-5840-021 Z04-5840-012 Z04-5840-017 004-5840-022 Z04-5840-013 Z04-5840-018 004-5840-023 Z04-5840-014 Z04-5840-019 004-5840-024 150 lb forged 316 004-5840-026 004-5840-027 004-5840-028 004-5840-029 5.4.1.3 Switch and housing reference Dry contact Hermetically sealed Hermetically sealed Bleed type pneumatic Non-bleed type pneumatic High Temperature Series Type B, C, D F HS J K R, 8, 9 Bulletin# 42-683 42-683 42-694 42-685 42-486 42-799 Important: When ordering spare parts, please specify: A. Model and serial numbers. B. Name and part number of replacement part or assembly. All replacement parts are for standard models only. Consult your local representative for ordering assistance on all specially modified models (model numbers preceded by an X). 44-604 Top Mounting Liquid Level Switches 17 5.4 Replacement Parts 1 3 5 6 4 10 9 2 14 13 12 15 17 11 16 7 8 18 5.4.2 Model T21 Parts Identification Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Housing cover Housing base Switch mechanism Upper attraction sleeve Jam nuts Guide washer(s) Upper stem assembly Lower float Lower attraction sleeve, stop tube, and washers Retaining rings Upper float and tube assembly Adaptor bushing Enclosing tube gasket Enclosing tube Mounting flange Float guide cage (optional) Float guide cage gasket (optional) 44-604 Top Mounting Liquid Level Switches 5.4.2.1 Model T21 T21-1 Housing cover Housing base T21-4 See below See below Switch mechanism Float stem kit: includes items 4, 5, 6, & 7 Lower float: 3" ¥ 5" See below Consult factory Z07-1201-003 Z07-1202-003 4.00" 4.50" Upper float and tube assembly kit: includes items 9, 10, & 11 Adaptor bushing Enclosing tube gasket Enclosing tube Mounting flange Guide cage kits: includes items 16 & 17 Z07-1101-015 Z07-1102-008 Z07-1102-009 Consult factory Z04-5734-110 004-5734-123 012-1301-002 Z32-6325-004 Z32-6325-005 See below Consult factory 5.4.2.2 Mounting flanges 4" 5" 6" 8" flange flange flange flange 125 lb cast iron Z04-5840-001 Z04-5840-002 Z04-5840-003 Z04-5840-004 150 lb forged steel 300 lb forged steel 150 lb forged 304 Z04-5840-011 Z04-5840-016 004-5840-021 Z04-5840-012 Z04-5840-017 004-5840-022 Z04-5840-013 Z04-5840-018 004-5840-023 Z04-5840-014 Z04-5840-019 004-5840-024 150 lb forged 316 004-5840-026 004-5840-027 004-5840-028 004-5840-029 5.4.2.3 Switch and housing reference Dry contact Hermetically sealed Hermetically sealed Bleed type pneumatic Non-bleed type pneumatic High Temperature Snap Series Type B, C, D F HS J K R, 8, 9 Bulletin# 42-683 42-683 42-694 42-685 42-486 42-799 Important: When ordering spare parts, please specify: A. Model and serial numbers. B. Name and part number of replacement part or assembly. All replacement parts are for standard models only. Consult your local representative for ordering assistance on all specially modified models (model numbers preceded by an X). 44-604 Top Mounting Liquid Level Switches 19 5.5 Model Numbers 5.5.1 Model T20 IMPORTANT: Actuating level(s), in either the rising or falling state, and specific gravity must be provided upon placement of order. MODEL NUMBER CODE AND MATERIALS OF CONSTRUCTION Model No. T20-1 T20-4 Set Points Tank Connection Carbon steel 316 SS 1—Single float Float and Trim 300 Series SS 316 SS Sleeve 400 Series SS 316 SS IMPORTANT: The maximum available insertion depth is governed by the liquid specific gravity and selected float size as given in the table below. The minimum insertion depth is four inches. MAXIMUM INSERTION LENGTH inches (mm) Liquid Specific Gravity 1.00 0.90 0.80 0.70 0.60 3.00 x 5.00 (76 x 127) 39 (991) 20 (508) — — — Float Size 4.00 (102) 48 (1219) 33 (838) 11 (279) — — FLOAT PRESSURE RATINGS Float Size 4.50 (114) 48 (1219) 48 (1219) 48 (1219) 38 (965) 6 (152) Inches (mm) 3.00 x 5.00 (76 x 127) 4.00 (102) 3.50 x 6.00 (89 x 152) 4.50 (114) Pressure Rating PSIG (bar) 100° F (38° C) 500 (34) 600 (41) 500 (34) 500 (34) 750° F (399° C) 377 (26) 483 (33) 403 (27) 403 (28) 900° F (482° C) 353 (24) 465 (32) 388 (26) 388 (27) 1000° F (538° C) 335 (23) 459 (32) 383 (26) 383 (26) TANK CONNECTION AND FLOAT SIZE Tank Connection ➀ Float Diameter 3.50 x 6.00 (89 x 152)» 3.00 x 5.00 (76 x 127) 4.00 (102) 4.50 (114) 4" 125 lb. C.I. flange ➁ ➂ B2A B2B B2C B2D H2A — — H2D 4" 150 lb. F.S. flange H3A — — H3D 4" 300 lb. F.S. flange H4A — — H4D 1" NPT 5" 125 lb. C.I. flange ➁ ➂ J2A J2B J2C J2D 5" 150 lb. F.S. flange J3A J3B J3C J3D 5" 300 lb. F.S. flange 6" 125 lb. C.I. flange ➁ ➂ J4A J4B J4C J4D K2A K2B K2C K2D 6" 150 lb. F.S. flange K3A K3B K3C K3D 6" 300 lb. F.S. flange K4A K4B K4C K4D ➀ Flanges are ANSI standard threaded onto 1" NPT bushing. Forged steel flanges have standard raised face. ➁ Not available with Model T20-4. ➂ Available only in cast iron. ➃ Process temperature based on +100 °F (+38 °C) ambient. ➄ Uncontrolled housing heater or drain available in TYPE 4X/7/9 enclosure. ≈ Consult factory for TYPE 4X/7/9 cast iron housings. ➆ On steam applications, temperature down-rated to +400 °F (+204 °C) process at +100 °F (+38 °C) ambient. ➇ CSA approval does not apply to Series HE switches. » Not available when 4" nozzle is sch 160 or greater. 20 44-604 Top Mounting Liquid Level Switches ELECTRIC SWITCH MECHANISM AND ENCLOSURE Switch Description Series B Snap Switch Series C Snap Switch Series D DC Current Snap Switch T20-1 Models T20-4 Models Process ➃ TYPE 4X/7/9 Aluminum Enclosure ƒ≈ Temperature Set Contacts Range ATEX ATEX Points Class I, Div 1 Class I, Div 1 Class I, Div 1 Class I, Div 1 Ex II 2 G EEx Ex II 2 G EEx °F (°C) Groups C&D Group B Groups C&D Group B d IIC T6 d IIC T6 BKP BKT BAC BKQ BKS BA9 SPDT 1 -40 to +250 (-40 to +121) DPDT 1 BNP BNT BBC BNQ BNS BB9 SPDT 1 CKP CKT CAC CKQ CKS CA9 -40 to +450 (-40 to +232) DPDT 1 CNP CNT CBC CNQ CNS CB9 SPDT 1 DKQ DKS DA9 DKQ DKS DA9 -40 to +250 (-40 to +121) DPDT 1 DNQ DNS DB9 DNQ DNS DB9 Series F Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Series HS Hermetically Sealed 5-amp Snap Switch with Wiring Leads -50 to +550 ∆ (-46 to +288) Series HS Hermetically Sealed 5-amp Snap Switch with Terminal Block -50 to +550 ∆ (-46 to +288) Series R High Temperature Snap Switch -40 to +750 (-40 to +399) Series 8 Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Series 9 High Temperature Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Switch Description SPDT 1 FKP FKT FAC FKQ FSS FA9 DPDT 1 FNP FNT FBC FNQ FNS FB9 SPDT 1 HMC HEK « HMC HEK « HET « — HMF DPDT 1 HMF HET « — SPDT 1 HM3 HM4 HA9 HM3 HM4 HA9 DPDT 1 HM7 HM8 HB9 HM7 HM8 HB9 SPDT 1 RKQ RKS RA9 RKQ RKS RA9 DPDT 1 RNQ RNS RB9 RNQ RNS RB9 SPDT 1 8KP 8KT 8AC 8KQ 8KS 8A9 DPDT 1 8NP 8NT 8BC 8NQ 8NS 8B9 SPDT 1 9KP 9KT 9AC 9KQ 9KS 9A9 DPDT 1 9NP 9NT 9BC 9NQ 9NS 9B9 Process ➃ CS/Aluminum CS/Aluminum Cast Iron Cast Iron Set Temp. Range Contacts Class I, Div 1 Class I, Div 1 Class I, Div 1 Class I, Div 1 Points NEMA 4X NEMA 4X °F (°C) Groups C&D Group B Groups C&D Group B Series R High Temperature Snap Switch -40 to +1000 (-40 to +538) Series 9 High Temperature Hermetically Sealed Snap Switch -50 to +1000 (-46 to +538) SPDT 1 R1Y RKY RKW R1Y RKY RKW DPDT 1 RDY RNY RNW RDY RNY RNW SPDT 1 9AR 9KR 9KV 9AY 9KY 9KW DPDT 1 9DR 9NR 9NV 9DY 9NY 9NW PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Switch Description Series J Bleed Type Series K Non-Bleed Maximum Maximum Supply Process Pressure Temperature 100 psig (7 bar) 400° F (204° C) 60 psig (4 bar) 60 psig 700° F (4 bar) (371° C) 100 psig (7 bar) 400° F (204° C) 40 psig (3 bar) Bleed Orifice NEMA 1 Diameter 44-604 Top Mounting Liquid Level Switches .063 (1.6 mm) .094 (2.4 mm) .055 (1.4 mm) JDE JEE JFE — KOE — KOG 21 5.5 Model Numbers 5.5.2 Model T21 IMPORTANT: Actuating level(s), in either the rising or falling state, and specific gravity must be provided upon placement of order. MODEL NUMBER CODE AND MATERIALS OF CONSTRUCTION Model No. T21-1 T21-4 Set Points Tank Connection Carbon steel 316 SS 2—Tandem float Float and Trim 300 Series SS 316 SS Sleeve 400 Series SS 316 SS IMPORTANT: The maximum available insertion depth is governed by the liquid specific gravity and selected float size as given in the table below. The minimum insertion depth is four inches. The minimum distance between the top and bottom insertion depths is eight inches. MAXIMUM INSERTION LENGTH inches (mm) Float Size Liquid 3.00 x 5.00 4.00 (76 x 127) (102) Specific Gravity Upper Lower Upper Lower 21 48 32 48 1.00 (533) (1219) (813) (1219) 9 30 18 44 0.90 (229) (762) (457) (1118) 4 21 0.80 — — (102) (533) 0.70 — — — — 4.50 (114) Upper Lower 40 48 (1016) (1219) 40 48 (1016) (1219) 40 48 (1016) (1219) 21 48 (533) (1219) FLOAT PRESSURE RATINGS Float Size Inches (mm) 3.00 x 5.00 (76 x 127) 4.00 (102) 4.50 (114) 100 °F (38 °C) 500 (34) 600 (41) 500 (34) Pressure Rating PSIG (bar) 750 °F 900 °F 1000 °F (399 °C) (482 °C) (538 °C) 377 (26) 483 (33) 403 (28) 353 (24) 465 (32) 388 (27) 335 (23) 459 (32) 383 (26) TANK CONNECTION AND FLOAT SIZE Tank Connection ➀ 4" 125 lb. C.I. flange ➁ ➂ 4" 150 lb. F.S. flange 5" 125 lb. C.I. flange ➁ ➂ 5" 150 lb. F.S. flange 6" 125 lb. C.I. flange ➁ ➂ 6" 150 lb. F.S. flange 6" 300 lb. F.S. flange 3.00 x 5.00 (76 x 127) H2A H3A J2A J3A K2A K3A — Float Diameter 4.00 (102) — — J2B J3B K2B K3B — 4.50 (114) — — J2C J3C K2C K3C K4C ➁ ➀ Flanges are ANSI standard. Forged steel flanges have standard raised face. ➁ Not available with -4 Materials of Construction. ➂ Available only in cast iron. ➃ Process temperature based on +100 °F (+38 °C) ambient. ➄ Uncontrolled housing heater or drain available in TYPE 4X/7/9 enclosure. ≈ Consult factory for TYPE 4X/7/9 cast iron housings. ➆ On steam applications, temperature down-rated to +400 °F (+204 °C) process at +100 °F (+38 °C) ambient. 22 44-604 Top Mounting Liquid Level Switches ELECTRIC SWITCH MECHANISM AND ENCLOSURE Switch Description Series B Snap Switch Series C Snap Switch Series D DC Current Snap Switch T21-1 Models T21-4 Models Process ➃ TYPE 4X/7/9 Aluminum Enclosure ➄≈ Temperature Set Contacts Range ATEX ATEX Points Class I, Div 1 Class I, Div 1 Class I, Div 1 Class I, Div 1 Ex II 2 G EEx Ex II 2 G EEx °F (°C) Groups C&D Group B Groups C&D Group B d IIC T6 d IIC T6 SPDT 2 BLA BLJ BDC BLB BLK BD9 -40 to +250 (-40 to +121) DPDT 2 BOA BOJ BGC BOB BOK BG9 SPDT 2 CLA CLJ CDC CLB CLK CD9 -40 to +450 (-40 to +232) DPDT 2 COA COJ CGC COB COK CG9 SPDT 2 DLB DLK DD9 DLB DLK DD9 -40 to +250 (-40 to +121) DPDT 2 DOB DOK DG9 DOB DOK DG9 Series F Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Series HS Hermetically Sealed 5-amp Snap Switch with Wiring Leads -50 to +550 ➆ (-46 to +288) Series R High Temperature Snap Switch -40 to +750 (-40 to +399) Series 8 Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Series 9 High Temperature Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) Switch Description SPDT 2 FLA FLJ FDC FLB FLK FD9 DPDT 2 FOA FOJ FGC FOB FOK FG9 SPDT 2 HMN HMP HMN HMP HMY HMZ — — DPDT 2 HMY HMZ SPDT 2 RLB RLK RD9 RLB RLK RD9 DPDT 2 ROB ROK RG9 ROB ROK RG9 SPDT 2 8LA 8LJ 8DC 8LB 8LK 8D9 DPDT 2 8OA 8OJ 8GC 8OB 8OK 8G9 SPDT 2 9LA 9LJ 9DC 9LB 9LK 9D9 DPDT 2 9OA 9OJ 9GC 9OB 9OK 9G9 Process ➃ Cast Iron Cast Iron CS/Aluminum CS/Aluminum Set Temp. Range Contacts Class I, Div 1 Class I, Div 1 Class I, Div 1 Class I, Div 1 Points NEMA 4X NEMA 4X °F (°C) Groups C&D Group B Groups C&D Group B Series R High Temperature Snap Switch -40 to +1000 (-40 to +538) Series 9 High Temperature Hermetically Sealed Snap Switch -50 to +1000 (-46 to +538) SPDT 2 R3M RLM RLW R3M RLM RLW DPDT 2 REM ROM ROW REM ROM ROW SPDT 2 9BD 9LD 9LV 9BM 9LM 9LW DPDT 2 9ED 9OD 9OV 9EM 9OM 9OW 44-604 Top Mounting Liquid Level Switches 23 ASSURED QUALITY & SERVICE COST LESS Service Policy Return Material Procedure Owners of MAGNETROL 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. Controls returned under our service policy must be returned by Prepaid transportation. MAGNETROL will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material's return. This is available through MAGNETROL’s local representative or by contacting the factory. Please supply the following information: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor 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. 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory. No claims for misapplication, labor, direct or consequential damage will be allowed. 705 Enterprise Street • Aurora, Illinois 60504-8149 • 630-969-4000 • Fax 630-969-9489 [email protected] • www.magnetrol.com Copyright © 2016 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. CSA logotype is a registered trademark of Canadian Standards Association BULLETIN: 44-604.18 EFFECTIVE: March 2016 SUPERSEDES: January 2015