Series J Pneumatic Switch Mechanism Installation and Operating Manual Bleed Type Valve for Liquid Level Switches Read this Manual Before Installing This manual provides information on the Series J Pneumatic Switch Mechanism. It is important that all instructions are read carefully and followed in sequence. Detailed installation and hook-up instructions are included in 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. Low Voltage Directive For use in Installations Category II, Pollution Degree 2. If equipment is used in a manner not specified by the manufacturer, protection provided by equipment may be impaired. Notice of Copyright, and Limitations Copyright © 2009 Magnetrol International, Incorporated. All rights reserved. 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. 42-685 Series J Pneumatic Switch Mechanism 1.0 Description The Series ‘J’ Pneumatic Switch is a single airline, bleed type valve with a magnetically actuated flapper. The movement of the magnet assembly causes the switch to change state, either moving the flapper away from the nozzle allowing the pressure in the line to vent or moving the flapper against the nozzle causing pressure to build up in the line. 2.0 Principle of Operation Figure 1 shows the attraction sleeve and magnet in the position when the liquid level is such that the attraction sleeve is below the field of the magnet. In this position, the flapper has been drawn away from the nozzle by the fall-out spring; and, air flows faster through the nozzle than it can be supplied through the restriction. The air pressure to the control valve then drops to zero. Figure 2 shows the attraction sleeve when it is within the field of the magnet. When a change in the liquid level moves the attraction sleeve into the field of the magnet, it causes the magnet to pull in against the enclosing tube. In this position, the flapper is held against the nozzle, thus shutting off the bleed of air. The air pressure to the control valve builds up to supply pressure. The switch is reversible with two simple adjustments described on page 4. NOTE: Clean, dry, regulated air should be used with the pneumatic switch. Non-magnetic enclosing tube Non-magnetic enclosing tube D R R Reverse link position for opposite action Attraction sleeve Bleed restriction D Attraction sleeve Reverse link position for opposite action Bleed restriction Air supply Flapper Nozzle To control valve Magnet (swing out position) Falling level Figure 1 Attraction sleeve below field of magnet 42-685 Series J Pneumatic Switch Mechanism Magnet (swing in position) Air supply Nozzle Flapper To control valve Rising level Figure 2 Attraction sleeve in field of magnet 3 3.0 Reversing Pilot Action All Series J Pneumatic Switch Mechanisms are shipped from the factory set-up for direct action; closed at high level. They can be field modified for the reverse (open) position by following the steps below: 1. First remove the upper shoulder screw from the actuator link and move it from the direct (D) position to the reverse (R); refer to Figure 3. 2. Loosen the screw that positions the spring bracket and move it from the direct (D) position to the reverse (R) position; refer to Figure 4. 3. Fasten screw securely. The switch is now setup for reverse action. Enclosing tube Enclosing tube Reverse position Fall out spring Direct position Direct position Spring bracket Upper shoulder screw Air line adapter Actuator link Figure 3 4 Reverse position Air line adapter Figure 4 42-685 Series J Pneumatic Switch Mechanism 4.0 Locating Air Line Connection The air line connection may be rotated a full 360° for your convenience in connecting the instrument air supply. To rotate the switch and base assembly: 1. Loosen both the locking screw above the enclosing tube nut and the frame screw. Refer to Figure 5. 2. Rotate the entire base to the desired position. 3. Tighten both the locking screw and the frame screw. Enclosing tube Fall-out stop Frame screw Air line adapter Magnet 4.0.1 Remove complete mechanism 1. Disconnect air line from air line adapter. 2. Loosen both the locking screw above the enclosing tube nut, and the frame screw approximately 3 to 4 turns. Refer to Figure 5. 3. Lift the entire base and switch assembly straight up and off the enclosing tube. Base Enclosing tube nut Locking screw Figure 5 5.0 Preventive Maintenance 5.0.1 Nozzle cleaning 1. 2. Enclosing tube 3. Flapper adjustment screw 4. ⁄16" Allen wrench 1 Strainer 5. 6. 7. Flapper O-Ring To clean the nozzle, follow the steps below: Unscrew and remove the adapter. Refer to Figure 6. The o-ring and strainer will now fall out when the switch is tipped. Unscrew the flapper adjustment screw with a 1⁄16" Allen wrench. This will prevent damage to the flapper when performing step 4. Insert a 1⁄16" diameter wire into the nozzle from the air line connection side. Refer to Figure 7. The wire may be moved back and forth to clean the opening of any accumulated matter. Reassemble the o-ring, strainer, and air line adapter; insert into nozzle. Refer to Figure 6. Securely tighten the air line adapter. Readjust the flapper to its original position; refer to Section 5.02 Nozzle flapper readjustment on page 6. Nozzle Air line adapter Figure 6 42-685 Series J Pneumatic Switch Mechanism 5 5.0.2 Nozzle flapper readjustment 1. Connect an air line to the adapter. 2. Pressurize the air line. 3. Adjust the flapper adjustment screw for the desired action: Enclosing tube Magnet (yellow or red dot) Direct Action a. Hold the magnet against the enclosing tube. b. Adjust the flapper adjustment screw with a 1⁄16" Allen wrench until the air flow stops, plus an extra one-eighth turn. Floppy adjustment screw 1 ⁄16" Diameter wire Reverse Action a. Hold the magnet against the fall out stop. Refer to Figure 5 on page 5. b. Adjust the flapper adjustment screw with a 1⁄16" Allen wrench until the air flow stops. 4. Manually actuate the switch under pressure to assure its correct actuation. The unit is now ready for service. Flapper Nozzle Figure 7 6.0 Replacement Parts 6.1 J Series pneumatic switch Replacement parts for J Series Pneumatic Switch Mechanisms are available as an assembly only. When ordering an assembly, be certain to specify: 1. The model number of the level control in which the switch was installed, for example B75-1B20-JDE. 2. The serial number of the level control in which the switch was installed. Refer to nameplate attached to control 3. The part number of the replacement switch assembly, for example 89-7501-026. Description Red Dot Yellow Dot Yellow Dot JDG, JGH JEG, JHH JFG, JJH JDE, JGF JEE, JHF JFE, JJF JKE, JNF JLE, JPF JME, JRF Part Number 89-7501-027 89-7501-029 89-7501-031 89-7501-026 89-7501-028 89-7501-030 89-7501-032 89-7501-033 89-7501-034 For models rated below 1480 psig. For models rated above 1480 psig. 6 42-685 Series J Pneumatic Switch Mechanism 6.2 Switch housing replacement assembly Standard carbon steel housing replacement assemblies are available. Refer to Figure 8. Replacement Kit Part Number Description Standard housing cover Gray Cover Blue Cover 89-6509-003 Short 4" (102 mm) 89-6523-002 Tall 6" (152 mm) 89-6523-001 89-6510-003 89-6508-001 89-6508-001 Cover assembly hardware Includes assembly hardware kit 89-6508-001. Figure 8 Carbon steel housing assembly 7.0 Switch Codes Magnetrol level controls are identified by an alpha-numeric numbering system. The last digits describe the type of switch mechanism furnished. SWITCH MECHANISM AND ENCLOSURE Switch Code Red Dot Yellow Dot Maximum Orifice Maximum Process Diameter Supply Temp. in. (mm) Cover Height in. (mm) JDG JDE JKE 100 psig (6 bar) 400° F (204° C) .063 (1) 4 (101) JEG JEE JLE 60 psig (4 bar) 400° F (204° C) .094 (2) 4 (101) JFG JFE JME 60 psig (4 bar) 700° F (371° C) .055 (1) 4 (101) JGH JGF JNF 100 psig (6 bar) 400° F (204° C) .063 (1) 6 (152) JHH JHF JPF 60 psig (4 bar) 400° F (204° C) .094 (2) 6 (152) JJH JJF JRF 60 psig (4 bar) 700° F (371° C) .055 (1) 6 (152) For models rated below 1480 psig. For models rated above 1480 psig. NOTE: Maximum leakage rate is .5 SCFH at maximum supply pressure. Example Model Number: B 7 5 1 B 2 42-685 Series J Pneumatic Switch Mechanism 0 7 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. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 Copyright © 2009 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. BULLETIN: 42-685.4 EFFECTIVE: February 2005 SUPERSEDES: April 1997