F10 Vane type flow switches ® INSTRUCTION MANUAL AND PARTS LIST DESCRIPTION The F10 is a vane type flow switch designed to be installed in 2" through 30" horizontal pipeline by means of a threaded or flanged connection. OPERATING PRINCIPLE The actuating vane is magnetically linked to a pivoted electric (or pneumatic) switch, which is isolated from the process by a non-magnetic barrier tube. As the actuating vane moves with an increase in flow, it drives a magnetic sleeve ① into the field of a permanent magnet ② located outside the barrier tube ③ which trips the switch. As flow decreases, the actuating vane returns to a vertical position, allowing the magnet and switch assembly to return to the “No Flow” position. Switch mechanism Adjusting screw Magnetic sleeve Magnet Actuating vane NO FLOW POSITION POSITION WITH ACTUATING FLOW PRESENT AGENCY APPROVALS Agency ATEX CCE ➀ FM FM/CSA ➁ IEC LRS Approval II 2G Ex d IIC T6 Gb, flameproof enclosure II 1G EEx ia IIC T6, intrinsically safe explosion proof and intrinsically safe Class I, Div. 1, Groups C & D Class II, Div. 1, Groups E, F & G, Type NEMA 7/9 Non-Hazardous area Explosion proof area – Groups B, C, D, E, F & G Type NEMA 4X/7/9 Ex d IIC T6 Lloyds Register of Shipping (marine applications) Russian Authorisation Standards ➁ Other approvals are available, consult factory for more details ➀ For CCE approved units, use the ATEX model numbers. ➁ Consult factory for proper model numbers and classifications. INSTALLATION UNPACKING Unpack the intrument carefully. Inspect all units for damage. Report any concealed damage to the carrier within 24 hours. Check the content of the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. PIPING The F10 flow switch should be located in a horizontal run pipe with the arrow on the body bushing or mounting flange pointing in the direction of flow. MOUNTING — THREADED CONNECTION A. Installation of F10 IN LINE 1. Insert a length of pipe in 2" 3,000 Ib. Threadolet fitting. 2. Plumb the vertical center line of the fitting and trace around the fitting to locate center line of required 67 mm (2.64") ø hole (Figure 2). Figure 2 2" pipe, ±305 mm (12") long 1.5 mm (0.06") ø spacer wire to provide root cap Air bubble in level position (3000 lb.) 2" threadolet fitting Marker (note A2) Vertical centerline must be plumb 3. Clean-up inside edges of hole and remove any slag on the bottom of line that could interfere with vane. 4. With fitting concentrically positioned over the 67 mm (2.64") ø. hole and the vertical center line held plumb (as shown in Figure 3), tack weld the fitting at 4 equally space points. After tacking, remove 1.5 mm (0.06") ø spacer wire (Figure 2). Air bubble in level position Figure 3 67 ø (2.64") Air bubble in level position Tack weld 4 places (see note below) Vertical centerline must be plumb until one of the 3 decal flow arrows is pointing parallel with flow. 7. Mark the bushing thread even with the top of the threadolet as a reference point for trimming vane to correct length. Remove 2 arrows not parallel with pipe. 8. Remove F10 from pipeline. 9. Check position of arrow stamped on vane support bracket. This arrow should be pointing parallel with the flow arrow on the body bushing (as shown in Figure 4). If arrows are not parallel, remove the three vane support bracket mounting screws and rotate bracket until the stamped arrow is pointing parallel with the flow arrow; replace mounting screws. Figure 4 1/4"NPT plug Adjusting screw safety retainer Adjusting screw Cover Switch (SPDT dry contact shown) Flow arrow must be pointing parallel with the line flow Electrical outlet Body bushing Stamped arrow located on vane support bracket Reference mark (note B8) Vane support bracket with 3 mounting screws Top of 2" threadolet fitting * Pivot pin Small vane Large vane Flow Top of pipeline Dimension C Inside bottom of pipeline 5 (0.19) C. Trimming vane to fit line size 10. The Model F10 is furnished as standard with vanes suitable for use on 2" through 30" pipelines. Assemble vane (or vanes) to F10 and trim according to applicable line size as follows: 2.00" line (SCH.40) – Use small vane only (no cutting should be necessary). 2.50" line – Use small vane with large vane trimmed to 38 mm (1.50") wide (same as small vane) and length trimmed to dimension C less 5 mm (0.19"), as shown in Figure 5. 3.00" line and larger – Use small vane with large vane length trimmed to dimension C less 5 mm (0.19"), as shown in Figure 5. Upon final assembly of trimmed vanes, firmly tighten 2 screws (item 27, page 7). It is recommended that the lower retaining screw be peened over on the threaded end. NOTE: A hole in the pipeline less than 67 mm (2.64") in diameter will limit travel of the pivoted vane. If this condition cannot be avoided, the width of the vane should be reduced to 38 mm (1.50") maximum. Top of threadolet 40 (1.56) IMPORTANT: For installation in 2.00" pipe lines, disregard 67 mm (2.64") dimension and use inside of Threadolet as template. 5. Proper operation of the model F10 depends upon the vertical center line of the 2" NPT coupling being plumb within 3°; keep fitting plumb while welding the continuous passes according to threadolet manufacturers installation procedure. B. Positioning vane perpendicular to flow 6. With large and small vanes unassembled, tighten thread the F10 body bushing into the coupling on the pipeline 2 * 40 ± 0.06 (1.56 ± 2) Dim. C Reference mark (note B8 & D11) 13 (0.50) 6 (0.25) 5 (0.19) (5) min. * Dimension C * 19 (0.75) Figure 5 Bottom of pipeline INSTALLATION (cont.) D. Final Mounting of F10 11. Apply sealing compound to body bushing threads. 12. Thread F10 into threadolet fitting and tighten body bushing to the same seal tight position as in note B6, so that the flow arrow is pointing parallel with the line flow. 13. Connect power lines. MOUNTING — FLANGED CONNECTIONS Figure 6 shows 1 method which may be used to mount the Model F10 flow switch to 2 1/2" through 30" run pipes. Before final welding, alignment of mounting flange should be checked to be certain it is plumb. Finished mounting must allow control switch housing to be within 3° degrees of vertical for proper operation. A 3° slant is noticeable by eye, but installation should be checked with a spirit level. Vertical centerline must be plumb 2 1/2" ANSI mounting flange ① WIRING NOTE: All Model F10 switch housings are designed to allow 360° positioning of the electrical outlet(s) for wiring convenience by loosening the set screw(s) located under the housing base. 1. On high temperature applications (above 120°C (250°F) in pipeline), high temperature wire should be used between Magnetrol control and first junction box located in a cooler area. 2. To gain access to switch mechanism, remove switch housing cover. 3. Pull in supply wires (conductors), wrap them around enclosing tube beneath the baffle plate and connect to proper terminals. Check to be certain that excess wire does not interfere with “tilt” of switch and that adequate clearance exists for replacement of switch housing cover. 4. Connect power supply to control and test switch actuation by varying flow rate within pipeline. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and refer to installation bulletin on mechanism furnished, as listed below. 5. Replace switch housing cover. NOTE: NEMA 7/9 housings, the housings must be “sealed” at the electrical outlet with suitable compound 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. 6. Place flow switch into service. 2 1/2" PS ANSI flange 133 (2.25) ② 2 1/2" PS pipe nipple (Sched. 80 max. wall thickness) ④ 2 1/2" 3000 lb. sockolet fitting Top of run pipe Switch mechanism Dry contact switches Bleed type pneumatic valve Non-bleed type pneumatic valve Bulletin n° B, C, D, U, W,X J K Series ref. 42-783 42-685 42-686 ③ 76 (3) ø hole in run pipe Flow ⑤ Actuating vane 5 (0.19) min. Inside bottom of run pipe Figure 6 ① Electrical outlet may be rotated 360° for wiring convenience. ② Flange to match flange of F10 flow switch and positioned with bolt holes straddling center lines. ③ For proper attachment procedure, refer to fitting manufacturer’s recommendation. ④ Dimension shown is for use with 1.5 mm (0.06") thick flange gasket. If thicker gasket is used, reduce dimension amount equal to additional thickness. ⑤ For run pipe sizes over 2 1/2" P.S. only. For installation on 2 1/2" run pipes, disregard 3" dimension and use inside of adaptor fitting as template. ⑥ Follow sections B and C of MOUNTING — THREADED CONNECTION to position the vane perpendicular to the flow and trim the vane to size. SWITCH ACTUATION ADJUSTMENT The Model F10 flow switch is factory set to actuate at the minimum flow rate. Actuation flow rate can be increased while the unit is in service (under pressure) by removing the 1/4” NPT plug to gain access to the “O” ring sealed adjusting screw. Each clockwise turn of the adjusting screw increases the actuating flow rate approximately 10% of the range of the specific flow vane being used. CAUTION: The safety retainer above the adjusting screw is there to help prevent the accidental removal of the adjusting screw. Do not defeat its purpose by forcefully backing out the adjustment screw. Be sure to replace 1/4” NPT plug and tighten firmly. 3 SELECTION DATA A complete measuring system consists of: 1. Code for F10 models 2. Code for modified models or adders: put an "X" in front of the closest matching order code and specify the modifications/adders separately eg. XF10-AD22-BK9 X = with material certification EN 10204 / DIN 50049-3.1.B 1. Code for F10 flow switch BASIC MODEL NUMBER F 1 0 vane actuated flow switch – field adjustable setpoint Consult factory for steam applications. MATERIALS OF CONSTRUCTION Code Process connection material Carbon steel 316 SST (1.4401) A D Vane Trim and magnetic sleeve 302 SST (1.4300) or 304 SST (1.4301) 316 SST (1.4401) PIPE SIZE AND PROCESS CONNECTION D 2 2 D 2 4 Pipe size Process connection 2" 4" D 2 6 D 2 0 10" E 5 8 8" E 5 4 4" E 5 6 6" E 5 0 2 E 6 0 10" E 7 6 6" E 6 8 2" NPT E 7 4 - 150 lbs RF 2 1/2" - 150 lbs RF 10" 2 1/2" E 7 8 - 150 lbs RF E 7 0 SWITCH MECHANISM & ENCLOSURE B C D HS U V W X 4 1 x DPDT Weather proof (IP 66) cast Aluminium 1 x SPDT 1 x DPDT – 8" 2 1/2" - 600 lbs RF 10" 2 1/2" - 600 lbs RF ATEX/IEC (IP 66) II 2G Ex d II C T6 Gb cast Aluminium ATEX (IP 66) II 1G EEx ia II C T6 cast Aluminium II 2G Ex d II C T6 Gb cast Iron 1" NPT M20 x 1,5 3/4" NPT B8B BDB BN9 BF9 – – BD5 BW5 B2B BAB CAB C8B CDB H7A HM2 D2B H7C U2B U8B – W2B 1 x DPDT X8B 1 x SPDT 2 1/2" - 600 lbs RF M20 x 1,5 1 x SPDT 1 x DPDT 2 1/2" - 600 lbs RF 1" NPT D8B 1 x SPDT 4" M20 x 1,5 1 x DPDT 1 x DPDT 2 1/2" - 300 lbs RF 1" NPT C2B 1 x SPDT 2 1/2" - 300 lbs RF M20 x 1,5 1 x SPDT 1 x DPDT 6" 2 1/2" - 300 lbs RF - for electric switch mechanisms (see below) - for pneumatic switch mechanisms (see next page) Select electric switch mechanism & enclosure 1 x SPDT 4" complete code for F10 models F 1 0 qty and switch type 2 1/2" - 300 lbs RF 2" NPT E 6 6 2 1/2" - 150 lbs RF 1/2" 8" E 6 4 2" NPT 8" Process connection 2" NPT 2" NPT 6" D 2 8 Pipe size W8B X2B DAB DDB HM6 UAB UDB – WAB WDB XAB XDB BK9 BC9 – CK9 CC9 C2T DN9 DF9 – CN9 DK9 HFC HGC CF9 DC9 HA9 HB9 – – HB3 HB4 HM3 – – XN9 XF9 X8T XK9 WF9 XC9 CKB CNB W2T WN9 BKB BNB CW5 WC9 – CU5 1" NPT CD5 WK9 – CK5 BU5 cast Alu. CDT UC9 UF9 CAT BK5 NEMA 7/9 C8T UK9 UN9 – FM (IP 66) U2T U8T VCS W8T X2T – – – UAT UDT VES WAT WDT XAT XDT DK5 DD5 HB7 UK5 DU5 DW5 HB8 UU5 UD5 UW5 WD5 WW5 – WK5 XK5 XD5 – WU5 XU5 XW5 DKB DNB HM7 UKB UNB – WKB WNB XKB XNB Select pneumatic switch mechanism & enclosure Pneumatic switch type Max supply pressure bar (psi) Max liquid temperature °C (°F) Bleed orifice Ø mm (inches) NEMA 3R (IP 53) 6,9 (100) +200 (+400) 1,60 (0.063) JGF 4,1 (60) +200 (+400) 2,39 (0.094) JHF 6,9 (100) +200 (+400) – KOF Series J (open air) Series K (closed circuit) X SPECIFICATIONS V Z W FLOW A Pipe size (horizontal lines only) Pipe size 2" Dim. A max. 46 (1.81) 67 ø ± 1,5 (2.64 ø ± 0.06) Equivalent max. wall schedule 2 1/2" 49 (1.94) 3" 48 (1.88) 3 1/2" 48 (1.88) 4" 5" 6" 8" 10" 51 (2.00) 52 (2.06) 54 (2.12) 56 (2.19) 59 (2.31) over 10" 59 (2.31) 180 63 (2.50) 2" NPT 3000# bonney threadolet or equal (supplied by customer) 44 (1.75) Vane width 38 (1.50) 94 (3.69) 100 254 (10.00) Housing type Flow vane 2" and 2 1/2" pipe 76 ø (3.00) 5 (0.19) minimum 79 (3.12) 118 (4.66) - 3" pipe and up 68 (2.66) 120 100 133 (5.25) 187 (7.38) Dim "B" 40 (1.59) 120 120 W Dim. B 53 (2.09) 180 Y V Z 2" NPT 160 180 X Y 145 (5.72) 195 (7.69) V W øX Y Z mm inches mm inches mm inches mm inches WeatherproofFM (NEMA 7/9) ATEX (Cast Alu) 257 10.12 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) ATEX (Cast Iron) 249 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) Pneumatics Switch Module J Pneumatics Switch Module K 216 8.50 110 4.33 39 1.54 118 4.65 130 5.12 216 8.50 Allow 200 mm (7.87") overhead clearance / All housings are 360 ° rotatable 1/4" NPT 5 REPLACEMENT PARTS Item no. Description Qty. 1 Switch housing cover 6 Switch mechanism 1 1/4-20 NPT plug 1 4 5 7 8 9 10 11 12 13 14 15 16a 16b 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 Switch housing base 1 1/4-20 set screw 1 Baffle plate assembly 6-32 round head screw Safety retainer Washer follower, and flange assembly Flow arrow Upper spring guide T316 SS mounting 1 150 lb. 300 lb. 600 lb. Range spring 10-32 hex nut Lower spring guide Attraction sleeve 1 1 1 1 3 1 1 Drain washer 1 8-32 fil. hd. screw 3 Stem assembly No. 8 lockwasher 8-32 rd. hd. screw Small vane Large vane Instruction tag (not shown) 2 1 1 T316 SS flange (item 2: head screw — item 3: retaining washer) See appropriate bulletin on switch mechanism (listed on page 4) E-tube kit E-tube kit 36-5303-001 10-1409-005 E-tube kit 89-5912-001 89-5913-001 189-5914-001 089-5704-001 089-5705-001 189-5706-001 — 05-9822-001 Stem kit 89-5541-001 E-tube kit 189-5928-001 12-1204-001 Stem 32-7204-001 32-7203-002 32-7204-002 32-7203-003 kit 189-5542-001 E-tube kit 89-5929-001 — 32-7203-001 1 3 T304 SS flange see bulletin 42-680. 1 1 Forged steel flange See bulletin 42-780 for switch housings, items 2 & 3 only applicable on steel NEMA 4 housing, 32-7204-003 — Attraction sleeve and spring kit 189-5544-001 Vane kit 89-6703-001 Vanes for pipe runs over 8" are special order items. See important order note below. When ordering, please specify: A. Model and serial number of control. B. Name and Number of replacement assembly. NOTE: Consult factory for cast iron housing. 05-9816-001 E-tube kit 189-5930-001 32-7205-001 32-7205-002 32-7205-003 Attraction sleeve and spring kit 189-5545-001 — IMPORTANT: 6 T304 SS mounting 1 Enclosing tube Stem. cam 1 1 Adjustment screw Body bushing 1 1 “O” ring Enclosing tube gasket 1 Carbon steel mounting REPLACEMENT PARTS (cont.) Serial number tage (ref.) Threaded mounting Flanged mounting 7 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. 2. 3. 4. 5. 6. Purchaser Name Description of Material Serial Number and Ref Number Desired Action Reason for Return Process details Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards applicable by the owner, before it is returned to the factory. A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box. All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped Ex Works. 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