BE44-605-10 TuffyT3

Tuffy® T3
Liquid Level Controls
with Electric Switches
Installation and Operating Manual
Side
Mounted
Float Level
Switch
®
UNPACKING
Unpack the instrument carefully. Make sure all components
have been removed from the foam protection. Inspect all
components for damage. Report any concealed damage to
the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number
to be sure it agrees with the packing slip and purchase
order. Check and record the serial number for future reference when ordering parts.
Cut and remove the plastic shipping straps on flanged units.
0038
0344
Nameplate:
- model number
- serial n°
- tag n°
These units are in conformity with the provisions of:
1. Directive 2014/34/EU for equipment or protective system intended for use in potentially explosive
atmospheres. EC-type examination certificate number ISSeP10ATEX032 (Ex d units; applied standards EN 60079-0:2009, EN 60079-1:2007 and EN 60079-26:2007) or ISSeP00ATEX010X (Ex i
units; applied standards EN 50014:1997 + A1 + A2, EN 50020:1994, EN 50284:1999).
2. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV
module H1.
SPECIAL CONDITIONS FOR ATEX INTRINSICALLY SAFE USE
When the material is equipped with an aluminium enclosure, all precautions shall be taken to avoid all impacts or frictions which
can result in the ignition of the potentially explosive atmosphere.
MOUNTING
Cage
mounted
Air
Threaded
max nozzle length:
84 mm (3.29")
Oil
Flanged
max nozzle length:
85 mm (3.35")
Field adjustable
differential
max nozzle length:
110 mm (4.35")
Interface
max nozzle length:
147 mm (5.80")
Water
Note: min nozzle size is 3" SCH 80 (max nozzle lengths are specified as per this size)
2" NPT Tuffy
Flanged Tuffy
Locking screw, loosen before removing cover
(refasten after replacing)
Locking screw, loosen
before removing cover
(refasten after replacing)
External cage mounted Tuffy
4. Fasten bolts and
studs in a star pattern
Shut-off
valve
Safety
check
valve
Pressure
vessel
CL
M20 x 1.5 or 3/4" NPT
cable entry; should
always be pointing
down
2
Apply Teflon tape
or Petrolatum
Use wrench size 65 mm
3/4"NPT
cable entry
3. M20 x 1.5 or 3/4" NPT
cable entry; should
always be pointing
down
1. Install a proper gasket.
2. Cut and remove the
shipping straps, slide
the control in the
nozzle and align the
bolt holes.
Drain valve
CL
Shut-off
valve
Switch
actuation
level
CL
WIRING
CAUTION: power must be switched OFF before wiring the unit.
Terminal connections
DPDT dry contact switch
with silver contacts
Terminal connections
SPDT dry contact switch
with silver or gold contacts
Internal ground wire
External ground wire
use min. 14 AWG wire
Terminal connections
DPDT dry contact switch
with gold contacts
Allowable operating range
Cast iron housing
with silver switch contacts
with silver/gold contacts HS
Allowable operating range
Aluminium housing
with silver switch contacts
with silver/gold contacts HS
60
Ambient Temperature (°C)
Ambient Temperature (°C)
40
20
0
-20
60
40
20
0
-20
-40
-40
0
50
100
150
200
250
Process Temperature (°C)
300
350
-40
Allowable operating range
Cast iron housing with gold switch contacts
0
50
100
150
200
250
Process Temperature (°C)
300
350
60
Ambient Temperature (°C)
40
20
0
-20
-40
-40
Allowable operating range
Aluminium housing with gold switch contacts
60
Ambient Temperature (°C)
Terminal connections
SPDT HS switch
with silver or gold contacts
40
20
0
-20
-40
0
50
100
150
200
250
Process Temperature (°C)
300
350
-40
-40
0
50
100
150
200
250
Process Temperature (°C)
300
350
3
CALIBRATION
For T31-T35 / T3B / T3D and T3E units
Properly selected TUFFY units do not need any field calibration.
For T3C: field adjustable differential units
The Adjustable Differential Tuffy II, model T3C, may be set in the field for one of a variety of level differentials. By specific placement of the stops in the holes of the adjustment plate, the level differential may be changed.
D
C
L
B
K
A
H
E
J
G
Partnumber
T3C-4XXX-XXX
Level
Rising
Falling
Rising
Falling
Rising
Falling
T3C-8XXX-XXX
T3C-CXXX-XXX
B
+47
+80
+63
+115
+85
+160
F
To determine the differential
Example: T3C-C unit with stop holes B and G
1. Select the rising level of the upper stop:
example: upper stop = hole B: +85 mm
2. Select the falling level of the lower stop:
example: lower stop = hole G: -205 mm
3. Substract levels:
rising level / upper stop - falling level / lower
stop:
example: +85 mm - (-205 mm) = +290 mm
Example 2:T3C-8 unit: with stop holes D and B:
+183 mm - (+115 mm) = 68 mm
Stop holes in mm (divide by 25,4 to obtain inches)
Upper stops
middle
Lower stops
C
D
K
L
A
E
F
G
H
J
+90 +124 +39 +104 +4 -37 n/a n/a -42 n/a
n/a n/a
+84 n/a +38 -10
-47 -82
+4 -62
+131 +183 +51 +153 -3 -67 n/a n/a -75 n/a
n/a n/a +122 n/a +50 -25
-84 -136
-3 -106
+183 +259 +67 +215 -11 -105 n/a n/a -115 n/a
n/a n/a +170 n/a
66
-43 -128 -205 -11 -106
Impossible stop hole combinations due to the diameter of the stem (of the float):
A and B
A and E
A and H
A and K
B and C
B and K
C and D
C and K
C and L
TROUBLESHOOTING
Symptom
Failure of the controlled equipment
eg. pump does not start,
signal lamps fail to operate etc...
D and L
E and F
E and H
F and H
F and J
F and G
J and G
Cause of malfunction / Action
Check external causes first:
- blown fuses
- tripped reset button
- open power switch.
- controlled equipment fails.
- defective wiring to level switch.
Check wiring as per wiring diagrams on page 3
Check actuating arm and magnet assembly
1. Remove switch mechanism
2. Check for wiring interference or binding of actuating arm. The switch and
magnet must move throughout its entire range of motion without interference.
3. Replace the switch mechanism in case of binding.
Float magnet
Non-magnetic float
holder (pressure
boundary)
Switch magnet
4
Check float assembly
1. Remove the unit from service
2. Clean the mechanism if required
3. Tilt the float, when the unit is limited by its motion:
check differential setting (for T3C units only) – see above
4. Replace the unit in case cleaning and/or resetting did not solve the problem.
Magnet/Switch action
PREVENTIVE MAINTENANCE
Periodic inspections are a necessary means to keep your level control in good working order. This control is a safety device
that protects the valuable equipment it serves. A systematic program of preventive maintenance should be implemented when
the control is placed into service. If the following instructions are observed, your control will provide reliable protection of your
equipment for many years.
What to do
1. Keep control clean.
Be sure the switch housing is always in place. This cover
is designed to keep dust and dirt from interfering with the
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, obtain a replacement immediately.
2. Inspect switch mechanisms, terminals and connections
monthly.
Tuffy T3 level switches 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
loosen. Check all terminal connections to ensure that
screws are tight. Check wiring carefully and repair or
replace if necessary.
Note: It is recommended that spare switches, housing
covers and o-rings be kept on hand at all times.
3. Inspect entire Tuffy T3 unit periodically.
A periodic cleaning of the float and counterweight assembly will ensure continued free movement of the mechanism.
What to avoid
1. NEVER leave the switch housing cover off of the control
longer than is 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,
ensure that it is removed before placing the control into
service.
3. NEVER attempt to make adjustments to or replace
switches without reading instructions carefully. When in
doubt, consult the factory or your local representative.
4. NEVER use in systems containing iron particles. The
magnet in the float assembly can attract the particles and
become jammed.
5. NEVER put insulation over the switch housing.
SPECIFICATIONS
PHYSICAL SPECIFICATIONS
Description
Measured variable
Physical range
Ambient temperature
Process temperature
Process pressure
Wetted parts
Flange materials
Housing materials
ELECTRICAL SPECIFICATIONS
Description
Switch ratings
Signal output
Switch types
Approvals
Cable entries
Specification
Liquid level
Narrow differential: 13 mm (0.5")
Adjustable differential: up to 464 mm (18.26")
Interface Service Differential: 44 mm (1.72")
Interface: min S.G. difference between both liquids: 0,1
-40 °C to + 70 °C (-40 °F to +160 °F)
From -55 °C (-65 °F) up to 400 °C (750 °F) depending switch/housing selection
Standard models: up to 50 bar abs. (720 psi)
High pressure models: up to 150 bar abs. (2160 psi)
316/316L (1.4401/1.4404) or Hastelloy C (2.4819)
Carbon steel
316/316L (1.4401/1.4404) or Carbon steel with 316/316L (1.4401/1.4404) cladding
Hastelloy C (2.4819) or Carbon steel with Hastelloy C (2.4819) cladding
Cast aluminium or cast iron
Specification
Up to 10 A @ 240 V AC
Up to 6.0 A @ 24 V DC
Single SPDT or single DPDT contacts
Dry contact with silver or gold plated contacts
Hermetically sealed for corrosive environment
ATEX II 1/2 G / IECEx Ex d IIC T6 Ga/Gb, explosion proof
ATEX II 1G EEx ia II C T6, intrinsically safe
NEMA 4X/7/9, Class 1, Div 1, Groups B, C & D
3/4" NPT or M20 x 1,5
5
REPLACEMENT PARTS
Partn°:
Digit in partn°:
X 1 2 3
4 5 6 7
8 9 10
Serial n°:
See nameplate, always provide complete partn° and
serial n° when ordering spares.
X = product with a specific customer requirement
EXPEDITE SHIP PLAN (ESP)
Several parts are available for quick shipment, within max. 1 week after factory receipt of purchase order, through the
Expedite Ship Plan (ESP).
Parts covered by ESP service are conveniently grey coded in the selection tables.
¡
Digit 9
0
1
2
3
4
6
6
¬
¿
(1) Switch assembly
Replacement part
031-5144-001
031-5146-001
031-5144-002
031-5146-002
031-5145-001
031-5145-002
Digit 10
1 or 3
2, 4, N or R
M or P
(3) "O"-ring
(2) Housing cover
Replacement part
004-9197-011
004-9197-002
004-9197-005
Replacement part
012-2201-240
DIMENSIONS in mm (inches)
T31 and T35: threaded narrow differential
211
(8.29)
84
(3.29)
T31: 220 (8.66)
T35: 200 (7.86)
T31: 91 (3.59)
T35: 85 (3.33)
112
(4.39)
2" NPT
Cable entries: M20 x 1.5 or 3/4" NPT
T31, T33 and T35: flanged narrow differential
211
(8.29)
85
(3.35)
T31: 221 (8.72)
T33: 190 (7.50)
T35: 201 (7.92)
112
(4.39)
T31/T33: 91 (3.59)
T35: 85 (3.33)
Cable entries: M20 x 1.5 or 3/4" NPT
T32: flanged high pressure narrow differential
211
(8.29)
85
(3.35)
204
(8.02)
112
(4.39)
85
(3.35)
Cable entries: M20 x 1.5 or 3/4" NPT
T3C: adjustable wide differential
209
(8.23)
85
(3.35)
Stem length (code 4): 327 (12.86)
Stem length (code 8): 422 (16.61)
Stem length (code C): 543 (21.36)
112
(4.39)
Stem length (code 4): 346 (13.62)
Stem length (code 8): 471 (18.54)
Stem length (code C): 629 (24.76)
Cable entries: M20 x 1.5 or 3/4" NPT
Stem le
Stem le ngth (code 4
Stem le ngth (code 8):): 95 (3.75)
ngth (c
ode C): 190 (7.50)
311 (12
.25)
7
DIMENSIONS in mm (inches)
T3B: interface
209
(8.23)
112
(4.39)
Cable entries: M20 x 1.5 or 3/4" NPT
8
85
(3.35)
448
(17.62)
172
(6.78)
MODEL IDENTIFICATION
T
T
T
T
T
T
3
3
3
3
3
3
1
2
3
5
B
C
Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,4 / max 50 bar abs (720 psi)
Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 150 bar abs (2160 psi)
Tuffy with Hastelloy C (2.4819) float - min S.G. 0,65 / max 50 bar abs. (720 psi)
Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 103 bar abs (1500 psi)
Interface Tuffy with 316/316L (1.4401/1.4404) float - max 50 bar abs (720 psi)
Adjustable diff. Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,78 / max 50 bar abs (720 psi)
NARROW DIFFERENTIAL UNITS - T31, T32, T33 AND T35
0
Standard level differential of 13 mm (0,5")
SPECIFIC GRAVITY OF LOWER LIQUID FOR T3B
0,81 0,82 0,83 0,84 0,85 0,86 0,87 0,88
A
B
C
D
E
F
G
H
0,91 0,92
L
M
0,93
N
0,94
P
0,95
R
0,96
S
0,97
T
0,98
U
0,89
J
0,99
V
0,90
K
1
W
Specific Gravity
Code
Specific Gravity
Code
STEM EXTENSION LENGTH FOR T3C - DIMENSION "A"
4
95 mm (3.75") stem extension / 346 mm (13.62") differential
8
190 mm (7.50") stem extension / 471 mm (18.54") differential
C
311 mm (12.25") stem extension / 629 mm (24.76") differential
PROCESS CONNECTION – ANSI Flanges
3 A
3" 150 lbs RF ANSI Flange
3 B
3" 300 lbs RF ANSI Flange
3 C
3" 600 lbs RF ANSI Flange
3 D
3" 900 lbs RF ANSI Flange
4 A
4" 150 lbs RF ANSI Flange
4 B
4" 300 lbs RF ANSI Flange
4 C
4" 600 lbs RF ANSI Flange
4 D
4" 900 lbs RF ANSI Flange
5 A
5" 150 lbs RF ANSI Flange
5 B
5" 300 lbs RF ANSI Flange
6 A
6" 150 lbs RF ANSI Flange
6 B
6" 300 lbs RF ANSI Flange
PROCESS CONNECTION – THREADED
2 N
2" NPT connection
PROCESS CONNECTION – EN/DIN Flanges
A 1
DN 80, PN 16
EN 1092-1 Type B1
A 2
DN 80, PN 25/40 EN 1092-1 Type B1
A 3
DN 80, PN 63
EN 1092-1 Type B2
A 4
DN 80, PN 100 EN 1092-1 Type B2
A 5
DN 80, PN 160 DIN 2527 Form E flange
B 1
DN 100, PN 16
EN 1092-1 Type B1
B 2
DN 100, PN 25/40 EN 1092-1 Type B1
B 3
DN 100, PN 63
EN 1092-1 Type B2
B 4
DN 100, PN 100 EN 1092-1 Type B2
B 5
DN 100, PN 160 DIN 2527 Form E flange
C 1
DN 125, PN 16
EN 1092-1 Type B1
C 2
DN 125, PN 25/40 EN 1092-1 Type B1
D 1
DN 150, PN 16
EN 1092-1 Type B1
D 2
DN 150, PN 25/40 EN 1092-1 Type B1
SEE PAGE 10
T 3
0
complete code for TUFFY® T3
9
MODEL IDENTIFICATION
SEE PAGE 9
DESIGN CODE AND FLANGE MATERIAL
Design codes
Standard
ANSI/
NACE
ANSI/ASME
ASME B31.3
B31.3 & NACE
1
2
3¿
4¿
A
E
J
N
B
F
K
P
C
G
L
R
H
M
T
D
¿
Not for all models
Flange material
Carbon steel
Carbon steel w. 316/316L cladding
316/316L (1.4401/1.4404) stainless steel
Carbon steel w. Hastelloy C cladding
Hastelloy C (2.4819)
SWITCH TYPE (see table below - "SWITCH MECHANISMS")
0
SPDT with silver contacts
1
DPDT with silver contacts
2
SPDT with gold plated contacts
3
DPDT with gold plated contacts
4
Hermetically sealed, SPDT with silver contacts
6
Hermetically sealed, SPDT with gold plated contacts
HOUSING MATERIALS AND CABLE ENTRY
Consult factory for proper partnumbers for FM/CSA approved units
1
2
3
4
M
N
P
R
T 3
Cast
Cast
Cast
Cast
Cast
Cast
Cast
Cast
aluminium, single 3/4" NPT cable entry,
iron, single 3/4" NPT cable entry,
aluminium, single M20 x 1,5 cable entry,
iron, single M20 x 1,5 cable entry,
aluminium, single 3/4" NPT cable entry,
iron, single 3/4" NPT cable entry,
aluminium, single M20 x 1,5 cable entry,
iron, single M20 x 1,5 cable entry,
ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb
ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb
ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb
ATEX II 1/2G / IECEx Ex d II C T6 Ga/Gb
ATEX II 1G EEx ia II C T6
ATEX II 1G EEx ia II C T6
ATEX II 1G EEx ia II C T6
ATEX II 1G EEx ia II C T6
complete code for TUFFY® T3
SWITCH MECHANISMS
All TUFFY® are available with a selection of switch modules that vary in switch rating (Amp) and max process temperature
allowance. The max temperature is dependent upon the housing material selected. Consult table below, before selecting the
proper module in the order number structure on pages 9 or 10.
10
Code
0
1
2
3
4
6
Electric switch rating
V AC
V DC
Contacts and type
120 240 24 120
SPDT with silver contacts
10.0 10.0 6.0 0.6
DPDT with silver contacts
10.0 10.0 6.0 0.6
SPDT with gold plated contacts
0.1 0.1 DPDT with gold plated contacts
0.1 0.1 HS SPDT with silver contacts
1.0 1.0 3.0 0.5
HS SPDT with gold plated contacts 0.5 0.5 0.5 0.5
Process temperature range
@ 40 °C (100 °F) ambient temp.
Cast Iron
Cast Aluminium
-40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F)
-40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F)
-40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F)
-40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F)
-55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F)
-55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F)
Notes
11
IMPORTANT
SERVICE POLICY
Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or
replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner) other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
and the parts required to rebuild or replace the equipment.
In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the
original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the
control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of
our warranty.
No claims for misapplication, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrol’s local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number and Ref Number
4. Desired Action
5. Reason for Return
6. Process details
Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards
applicable by the owner, before it is returned to the factory.
A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box.
All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments.
All replacements will be shipped Ex Works.
BULLETIN N°:
EFFECTIVE:
SUPERSEDES:
UNDER RESERVE OF MODIFICATIONS
BE 44-605.10
APRIL 2015
February 2014
www.m a gne tr ol.c om
BENELUX
FRANCE
Heikensstraat 6, 9240 Zele, België -Belgique
Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected]
DEUTSCHLAND
Alte Ziegelei 2-4, D-51491 Overath
Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: [email protected]
INDIA
B-506, Sagar Tech Plaza, Saki Naka Junction, Andheri (E), Mumbai - 400072
Tel. +91 22 2850 7903 • Fax. +91 22 2850 7904 • E-Mail: [email protected]
ITALIA
Via Arese 12, I-20159 Milano
Tel. +39 02 607.22.98 • Fax. +39 02 668.66.52 • E-Mail: [email protected]
RUSSIA
198095 Saint-Petersburg, Marshala Govorova street, house 35, office 427
Tel. +7 812 320 70 87 • E-Mail: [email protected]
U.A.E.
DAFZA Office 5EA 722 • PO Box 293671 • Dubai
Tel. +971-4-6091735 • Fax +971-4-6091736 • E-Mail: [email protected]
UNITED
KINGDOM
Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
Tel. +44 (0)1444 871313 • Fax +44 (0)1444 871317 • E-Mail: [email protected]