C29-1N30-JDG

Flanged External Cage Installation and Operating Manual Float Actuated Liquid Level Switches Read this Manual Before Installing This manual provides information on the Flanged External Cage Liquid Level Switches. 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 Notice of Copyright and Limitations Magnetrol & Magnetrol logotype and are registered trademarks of Magnetrol International. Copyright © 2010 by 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 products 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. 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 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. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Low Voltage Directive For use in Installation Category II, Pollution Degree 2. If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Flanged External Cage Float Actuated Liquid Level Switches Table of Contents 1.0 Installation 1.1 Unpacking ................................................................4 1.2 Critical Alarm Function ............................................4 1.3 Piping .......................................................................4 1.4 Mounting..................................................................5 1.5 Wiring ......................................................................5 2.0 Reference Information 2.1 Description ...............................................................7 2.2 Theory of Operation.................................................7 2.3 Operating Cycle ........................................................7 2.4 Switch Differential Adjustment .................................7 2.4.1 Low level controls...........................................8 2.4.2 High level controls .........................................9 2.5 Replacement of Standard Float and Stem Assembly .................................................10 3.0 Troubleshooting 3.1 Check Switch Mechanism .......................................11 3.2 Check Sensing Unit ................................................12 4.0 Preventive Maintenance 4.1 What To Do............................................................13 4.1.1 Keep control clean........................................13 4.1.2 Inspect switch mechanisms, terminals, and connections monthly....................................13 4.1.3 Inspect entire unit periodically .....................14 4.2 What To Avoid........................................................14 46-605 Flanged External Cage Float Actuated Liquid Level Switches 5.0 Specifications 5.1 Agency Approvals....................................................15 5.2 Physical ...................................................................16 6.0 Replacement Parts 6.1 Standard Flanged External Cage Models .................18 6.1.1 Parts identification .......................................18 6.1.2 Switch and housing reference .......................18 6.1.3 Model C29...................................................18 6.1.4 Models D30, J30 and L30 ...........................19 6.1.5 Models B60 and C60 ...................................19 6.2 Tandem Flanged External Cage Models ..................20 6.2.1 Parts identification .......................................20 6.2.2 Switch and housing reference .......................20 6.2.3 Model C29...................................................21 6.2.4 Models D30, J30 and L30 ...........................21 6.2.5 Models B60 and C60 ...................................21 7.0 Model Numbers.............................................................22 1.0 Installation Caution: If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. 1.1 Unpacking Unpack the instrument carefully. Inspect all units for damage. Report any concealed damage to carrier within 24 hours. Check the contents against the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. Serial # _____________________________________ Caution: Do not discard the shipping container until all parts are accounted for. 1.2 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. 1.3 Piping An instruction tag secured to the control gives dimensional data on switch actuating levels referenced from center line of upper side tank connection. Position control so that actuating levels correspond with the desired liquid level trip points in process vessel. Use pipe of sufficient strength to support the control. If necessary, provide a stand or hanger to help support its weight. All piping should be straight and free of “low spots” or “pockets” so that lower liquid line will drain towards the vessel and upper vapor line will drain toward the control. Shut-off valves are recommended for installation between the vessel and the control. If control is to be used with a low temperature liquid (one which will “boil” in the float chamber if outside heat is absorbed), the chamber and piping should be insulated. Such boiling in the chamber will cause false level indications. Conduit outlet Switch actuating level lreference marks Shutoff valve (if used) Shutoff valve (if used) Optional drain valve Typical Piping Arrangement Caution: DO NOT INSULATE SWITCH MECHANISM HOUSING. For controls equipped with pneumatic switch assemblies, consult bulletin on mechanism furnished for air (or gas) piping instructions. 4 46-605 Flanged External Cage Float Actuated Liquid Level Switches 1.4 Mounting Caution: This instrument is intended for use in Installation Category II, Pollution Degree 2 locations. Adjust piping as required to bring control to a vertical position. Magnetrol controls must be mounted within 3° 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 chamber. Caution: Never insulate the switch housing of the level control. Installation and maintenance of tandem float models are accomplished in much the same manner as described for standard models. Additional consideration must be given to the piping arrangement to allow for alignment of the two switch actuating level marks on the float chamber with the desired levels in the vessel. 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 slowly. 1.5 Wiring Caution: All Flanged Float Cage 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. Flanged float cage controls are shipped with the conduit entry of the switch housing placed 180° opposite the tank connections to simplify most installations. If this configuration 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. Screw Set Screw 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 equipment. Figure 1 1. Loosen set screw(s) at base of switch housing. Refer to Figure 1. 2. Switch housing may be rotated 360° to allow correct positioning of conduit outlet. 3. Tighten set screw(s) at base of switch housing. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 5 4. Unscrew and remove switch housing cover. The threads have been lubricated to facilitate removal. NOTE: For supply connections, use wire with a minimum rating of +167° F (+75° C) as required by process conditions. Use a minimum of 14 AWG wire for power and ground field wires. NOTE: Housing must be grounded via protective ground screw in the base of the housing. Internal Circuit (Left) Switch Internal Circuit (Right) Switch 4 5 6 1 2 3 NOTE: On high temperature applications (above +250° F [+121° C] in float chamber), 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. Close on high level Close on low level Common Load Load Close on high level Close on low level Common Line Load Load Line 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 Figure 2 or your switch bulletin for this information. See Switch and Housing Reference, Section 6.2.2. 6. Dress wiring to ensure no interference or contact with movement of switch, or replacement of switch housing cover. NOTE: It is the responsibility of the customer to comply with applicable installation codes and practices. Class I, Division 1 locations may contain explosive gas mixtures. Appropriate precautions must be taken. Installation should be performed by qualified personnel. Figure 2 Terminal Connections DPDT Switch Mechanism Series A, B, C, D, and E 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 float chamber. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin for additional wiring information on switch mechanism furnished. See Switch and Housing Reference, Section 6.2.2. 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 housings. Caution: In hazardous areas, do not power the unit until the conduit is sealed and the enclosure cover is screwed down securely. 6 46-605 Flanged External Cage Float Actuated Liquid Level Switches 2.0 2.1 Reference Information Description Flanged External Cage liquid level switches are completely self-contained units designed for side mounting to a vessel or tank with threaded or flanged pipe connections. 2.2 Theory of Operation The design of float-operated level switches is based upon the principle that a magnetic field will not be affected by non-magnetic materials such as 316 stainless steel The float moves a magnetic attraction sleeve within a non-magnetic enclosing tube and actuates a magnetic switch mechanism. The enclosing tube provides a pressure seal to the chamber and therefore to the process. Pivot Enclosing tube (non-magnetic) Return Spring 2.3 Operating Cycle As the liquid level rises in the chamber, the float moves the magnetic attraction sleeve up within the enclosing tube and into the field of the switch mechanism magnet. As a result, the magnet is drawn in tightly to the enclosing tube, causing the switch to trip making or breaking an electrical circuit. Refer to Figure 3. As the liquid level falls, the float drops and moves the attraction sleeve out of the magnetic field, releasing the switch mechanism magnet. The tension spring ensures the return of the switch in a snap action. Refer to Figure 4. Tandem float units incorporate two floats which operate independently. They are arranged so that the lower float actuates the upper switch mechanism while the upper float actuates the lower switch mechanism. The upper float is attached to the lower attraction sleeve by means of a hollow stem. The lower float attaches to the upper attraction sleeve with a solid stem which extends upward through the upper float and stem assembly. Magnet Float Sleeve (magnetic) Normal operating level Figure 3 Swing out position 2.4 Low level Switch Differential Adjustment The standard differential of Flanged Cage float models with one switch may be field adjusted. Adjustment may be necessary if a wider differential needs to be set to overcome switch chatter caused by the process. Figure 4 NOTE: This procedure may be applied to single switch models only. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 7 Slight play (gap) must be allowed (.03" [.8 mm] typical) Position of bottom jam nuts (normal factory setting) For access to bottom jam nuts, remove top jam nuts, washer, and attracting sleeve. 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. This adjustment is different for high level and low level controls. Refer to the appropriate section below for adjustment instructions. NOTE: Maximum differential adjustment is 1 inch. Caution: Differential adjustments should NOT be made in the field on tandem float models. Switch actuation levels have been set at the factory to meet customer specifications. Variations in actual conditions from design conditions, usually require special control modifications. Consult the factory or your local representative for assistance. Sleeve stop strap 2.4.1 Low level controls Float On low level controls the switch trips on the lower actuation point and resets on the higher actuation point. Widening the differential will allow the switch to trip on the original actuation point and reset at a later or higher point. The differential on low level controls 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. Refer to Figure 6. 1. Determine what change in differential is necessary. NOTE: To widen the differential by one inch, the lower jam nuts must be set proportionately lower on the stem (i.e., in this example by 1 inch). Figure 5 Normal Factory Setting (minimum differential) D Maximum gap setting 0.50" (Applies to models having (13 mm) a single switch mechanism with a single magnet actuator only) Replace in same position Drop bottom jam nuts to increase gap setting (see instructions below) Sleeve stop strap Float 2. Make sure power source is turned off. 3. Unscrew and remove switch housing cover. 4. Disconnect power supply wires from switch mechanism. Pull wires out of conduit connection opening in housing base. Refer to Figure 7. 5a. Perform system shut-down procedures as required to relieve pressure from float chamber of control. Allow unit to cool. 5b. Close shut-off valves (if so equipped) to isolate control from tank. Drain off liquid in float chamber. 5c. On installations without shut-off valves, relieve pressure from the tank. Drain liquid in tank to a level below the connections of the float chamber. Figure 6 Differential adjustment NOTE: Level control, connections and pipe lines need not be removed from the tank. 6. Loosen enclosing tube nut with a 15⁄16" wrench. Unscrew enclosing tube counterclockwise (switch and housing base will rotate also), until it is free. Refer to Figure 7. 8 46-605 Flanged External Cage Float Actuated Liquid Level Switches Switch housing cover Enclosing tube Refer to Figures 6 and 7 Housing base Conduit connection Enclosing tube nut 7. Lift enclosing tube, switch, and base off float chamber. Jam nuts and attraction sleeve are now accessible. 8. Measure the distance “D” from the top edge of the upper jam nuts to the top of the float stem. Refer to Figure 6. Record this measurement. 9. Loosen and remove upper jam nuts, guide washer and attraction sleeve. 10. Loosen and adjust lower jam nuts to the desired position. Tighten lower jam nuts securely. Refer to Figure 6. 11. Replace attraction sleeve on stem. 12. Replace upper jam nuts and guide washer on the stem in the position previously noted. Tighten upper jam nuts securely. Refer to Figure 6. NOTE: Use a new enclosing tube gasket when reassembling enclosing tube to the chamber. Make certain that all gasket surfaces are thoroughly cleaned to allow proper gasket seating. Coat enclosing tube threads with anti-seizing compound. Chamber Float 13. Replace enclosing tube, switch, and base on chamber. Screw tube clockwise until tightened to 200–225 footpounds of torque. 14. Loosen the set screws at the base of the switch housing. Rotate switch housing to correct position and tighten set screws. Refer to Figure 1 on page 5. Figure 7 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. Additional float movement will be available after magnet snaps. 15. Bring supply wires through conduit outlet. Follow steps 5 through 10 in Wiring, Section 1.5. 16. Test switch action by varying liquid level in float chamber. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism. If the unit still fails to function properly, consult the factory. 2.4.2 High level controls On high level controls the switch trips on the higher actuation point and resets on the lower actuation point. Caution: In high level controls, widening the differential requires raising the trip point a proportional amount. The reset point will remain the same. To widen the differential by raising the trip point, follow steps 1 through 16 in Low level controls, Section 2.4.1. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 9 2.5 Replacement of Standard Float and Stem Assembly 1. Disconnect wiring or medium lines from control and perform system shutdown. See Troubleshooting, Section 3.0. 2. Remove switch housing assembly from float chamber at head flange. 3. Remove sleeve stop strap from the underside of the head flange and slide the float stem assembly out of the enclosing tube. Dim. A .87 (22) 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Head flange (ref.) NOTE: New float and stem kits are supplied unassembled. Refer to Figure 8 for standard jam nut settings (Dimension A). Retaining screws Sleeve stop strap Stop tube 4. Check new float and stem assembly to be certain it is the correct replacement unit: a. Float should be of same physical size and shape. b. Stem length should match closely. c. Set attraction sleeve per Dimension A as shown in Figure 8. NOTE: If differential adjustment has been altered in the field, disregard Dimension A and readjust new assembly to the previously determined level differential settings. See Switch Differential Adjustment, Section 2.4. Figure 8 Float and stem assembly 5. Replace new float and stem assembly into head flange and install new stop strap with screws included. 6. Remount head flange on float chamber using new gasket provided. Tighten flange nuts evenly, using an alternating pattern typical of standard industry practice. NOTE: Care must be taken during installation to be certain float stem does not bend. 7. With control assembly in place, test switch actuation by varying liquid level in float chamber. NOTE: When reassembling the enclosing tube or the upper flange assembly to the control, tighten according to the following torque values. Model C29, D30 C60, J30, L30 B60 Flange Bolting 55–60 ft–lbs 100–125 ft–lbs 250–300 ft–lbs Enclosing Tube 200–225 ft–lbs 75–100 ft–lbs 200–225 ft–lbs 10 46-605 Flanged External Cage Float Actuated Liquid Level Switches 3.0 Troubleshooting Usually the first indication of improper operation is failure of the controlled equipment to function, i.e., pump will not start (or stop); signal lamps fail to light, etc. When these symptoms occur, whether at time of installation or during routine service thereafter, check the following potential external causes first.  Fuses may be blown.  Reset button(s) may need resetting.  Power switch may be open.  Controlled equipment may be faulty.  Wiring leading to control may be defective. If a thorough inspection of these possible conditions fails to locate the trouble, proceed next to a check of the switch mechanism. 3.1 Check Switch Mechanism 1. Pull 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 3° of vertical. 7. Check microswitch continuity with ohmeter. if switch is damaged, replace immediately. 8. If switch mechanism is operating satisfactorily, proceed to check sensing unit. Conduit outlet Switch actuating level lreference marks Shutoff valve (if used) Shutoff valve (if used) Optional drain valve Figure 9 NOTE: As a matter of good practice spare switches should be kept on hand at all times. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 11 3.2 Check Sensing Unit 1. Reconnect power supply. Carefully actuate the switch mechanism manually (use a non-conductive tool on electrical switch mechanisms) 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). 3. Check to be certain liquid is entering float chamber. A valve may be closed or piping may be 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. 4. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit or operating medium line connections to switch housing. 5. Perform system shutdown to relieve pressure from float chamber of control. Allow unit to cool. 6. Close shutoff valves (if equipped) to isolate control from vessel. Drain off liquid in chamber if necessary. 7. On installations without shutoff valves, relieve pressure from vessel and drain off liquid head above control mounting level. NOTE: Control chamber, connections, and pipe lines need not be removed from vessel or boiler. 8. Remove switch housing assembly by loosening hex nut, which is located immediately below housing base. 9. With switch housing assembly removed, inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids buildup. Such buildup could restrict movement, preventing sleeve(s) from reaching field of switch magnet(s). 10. 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. NOTE: Differential adjustment affects a change in the amount of level travel between switch-on and switch-off actuations. Do not attempt adjustment without first consulting factory for assistance in computing level differential change for your control. 12 46-605 Flanged External Cage Float Actuated Liquid Level Switches A 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Head flange (ref.) 11. Check float to be certain it is buoyant in the liquid (float chamber 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. Caution: Do not attempt to repair a float. See Replacement of Standard Float and Stem Assembly, Section 2.5. If all components in the control are in operating condition, the trouble is likely located external to the control. Repeat inspection of external conditions as previously described. NOTE: If difficulties are encountered which cannot be identified, consult the factory or your local representative for assistance. A complete description of the trouble should be provided along with information concerning your piping and mounting arrangement, plus a description of your operating sequence. Sketches or photographs showing the installation are also beneficial. Retaining screws Sleeve stop strap Stop tube When inquiring about your control, be certain to always specify the complete Model and Serial numbers. 4.0 Float and stem assembly Preventive Maintenance Periodic inspections are necessary to keep your level control in good working order. This control is a safety device to protect the valuable equipment it serves. 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. Figure 10 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. It also 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. Dry contact switches should be inspected for excessive wear on actuating lever or misalignment of adjustment screw at point of contact between screw and lever. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 13 Such wear can cause false switch actuating levels. See switch mechanism bulletin supplied with control should switch adjustment or replacement become necessary. 2. DO NOT operate your control with defective or maladjusted switch mechanisms. Refer to bulletin on switch mechanisms furnished for service instructions. See Switch and Housing Reference, Section 6.2.2. 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 cause terminal screws to loosen. Check all terminal connections to be certain that screws are tight. 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. 14 46-605 Flanged External Cage Float Actuated Liquid Level Switches 5.0 5.1 Specifications Agency Approvals APPROVED MODEL AREA CLASSIFICATION AGENCY FM All with an electric switch mechanism and a housing listed as TYPE 4X All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Group B Non-Hazardous TYPE 4X Class I, Div 1, Groups C & D Class II, Div 1, Groups E, F & G Class I, Div 1, Groups B, C & D Class II, Div 1, Groups E, F & G Non-Hazardous CSA TYPE 4X Class I, Div 2, Groups B, C & D Class I, Div 1, Groups C & D Class II, Div 1, Groups E, F & G Class I, Div 1, Groups B, C & D Class II, Div 1, Groups E, F & G ATEX II 2 G EEx d IIC T6 94/9/EC IEC Ex Ex d IIC T6 IP 66 Installation Category II Pollution Degree 2 CSA All with an electric switch mechanism and a housing listed as CSA TYPE 4X All with a Series HS, H1, F, 8 or 9 electric switch mechanism and a housing listed as CSA TYPE 4X All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 All with an electric switch mechanism and a housing listed as TYPE 4X/7/9 Class I, Div 1, Group B All with an electric switch mechanism and an ATEX housing Œ ATEX / IEC Ex  CE Low Voltage Directive 2006/95/EC Per Harmonized Standard: EN 61010-1/1993 & Amendment No. 1 Œ Dual stage units with “HS” or “H1” switches are not ATEX approved.  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. Maximum Process Temperature < 85° C < 100° C < 135° C < 200° C < 300° C < 450° C Temperature Classification T6 T5 T4 T3 T2 T1 These units are in conformity with IECEx KEM 05.0020X Classification Ex d IIC T6 Tambient -40° C to +70° C 46-605 Flanged External Cage Float Actuated Liquid Level Switches 15 5.2 Physical CHAMBERS WITH 1-INCH CONNECTIONS INCHES 1" Flanged Min. 1" NPT Threaded & Socket Weld Upper Side/Bottom Sp. Gr. A B C A B C C29 .76 D30 .65 J30 .48 L30 .40 B60 .68 C60 .55 9.81 3.80 14.25 12.68 6.68 17.12 13.33 6.68 17.75 1" Flanged Side/Side A B C MILLIMETERS Actuating 1" NPT Threaded 1" Flanged Levels & Socket Weld Upper Side/Bottom HL LL A B 76 83 109 C 342 323 371 A 325 306 331 B 149 155 182 C 417 155 182 1" Flanged Side/Side A B C Actuating Levels HL LL 97 84 84 101 87 91 9.94 3.02 13.50 12.81 5.87 16.44 13.46 5.87 17.06 2.95 3.85 252 9.19 3.27 12.75 12.06 6.12 15.63 12.71 6.12 16.25 2.50 3.33 233 10.19 4.33 14.63 13.06 7.18 17.50 13.71 7.18 18.19 2.61 3.34 3.24 3.98 2.77 3.44 2.87 3.60 249 258 341 149 433 74 322 155 412 63 348 182 462 66 82 70 96 361 322 169 434 338 169 450 72 Levels ± 0.25" (6 mm) CHAMBERS WITH 11⁄2-INCH CONNECTIONS INCHES 1 11⁄2" Flanged Min. 1 ⁄2" NPT Threaded & Socket Weld Upper Side/Bottom Sp. Gr. A B C A B C MILLIMETERS Actuating 11⁄2" NPT Threaded 11⁄2" Flanged 11⁄2" Flanged Actuating Levels & Socket Weld Upper Side/Bottom Side/Side Levels HL LL A B 87 93 120 C 365 333 382 A 350 331 357 B 174 180 207 C 466 436 485 A B C HL LL 74 68 68 84 54 67 367 174 484 51 348 180 454 47 374 207 501 50 66 37 244 107 373 347 195 476 383 195 492 49 11⁄2" Flanged Side/Side A B C C29 .76 D30 .65 J30 .48 L30 .40 B60 .68 C60 .55 9.75 3.44 14.38 13.81 6.87 18.38 14.46 6.87 19.06 2.02 2.92 247 9.00 3.69 13.12 13.06 7.12 17.19 13.71 7.12 17.88 1.87 2.70 228 10.00 4.75 15.06 14.06 8.18 19.12 14.71 8.18 19.75 1.97 2.70 2.60 3.34 1.46 2.13 9.62 4.22 14.69 13.68 7.68 18.75 14.33 7.68 19.38 1.93 2.66 254 Levels ± 0.25" (6 mm) CHAMBERS WITH 2-INCH CONNECTIONS INCHES 2" Flanged Min. 2" NPT Threaded & Socket Weld Upper Side/Bottom Sp. Gr. A B C A B C 2" Flanged Side/Side A B C MILLIMETERS Actuating 2" NPT Threaded 2" Flanged Levels & Socket Weld Upper Side/Bottom HL LL A B 90 96 123 C 366 336 385 A 350 331 357 B 174 180 207 C 463 446 495 2" Flanged Side/Side A B C Actuating Levels HL LL 75 59 59 75 55 69 C29 .76 10.00 3.56 14.44 13.81 6.87 18.25 14.46 6.87 18.94 2.07 2.97 254 D30 .65 J30 .48 L30 .40 B60 .68 C60 .55 9.38 4.34 14.81 13.68 7.68 19.12 14.33 7.68 19.75 8.75 3.81 13.25 13.06 7.12 17.56 13.71 7.12 18.25 1.50 2.33 222 9.74 4.87 15.19 14.06 8.18 19.50 14.71 8.18 20.12 1.60 2.33 2.23 2.97 1.52 2.19 1.99 2.72 238 247 367 174 481 52 348 180 463 38 374 207 511 40 56 38 110 376 347 195 485 363 195 501 50 Levels ± 0.25" (6 mm) 16 46-605 Flanged External Cage Float Actuated Liquid Level Switches Inches (mm) 5.93 (151) 5.93 (151) 3.78 (96) 3.78 (96) 10.12 (257) 8.46 (215) 10.12 (257) 8.46 (215) D D plugged D D plugged HL LL HL LL C A C A B B Threaded and Socket Weld Side/Bottom Flanged 5.93 (151) 3.78 (96) Conduit Connections D Electrical Switches TYPE 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches 1 TYPE 1: ⁄4" NPT 10.12 (257) 8.46 (215) D D plugged NOTES: HL LL C A 1. Switch actuating levels (HL & LL) are given for minimum specific gravity conditions. Levels will be lower in the float chamber for higher specific gravities. 2. Standard process connections are a combination of 1" NPT and 1" socket weld coupling. 3. Allow overhead clearance of 10" (254 mm) for NEMA 4X/7/9 housing. B Side/Side Flanged 46-605 Flanged External Cage Float Actuated Liquid Level Switches 17 6.0 6.1 1 3 2 17 16 Replacement Parts Standard Flanged External Cage Models 6.1.1 Parts identification 4 14 15 5 8 7 6 12 9 11 10 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Housing cover Housing base Switch mechanism Enclosing tube Enclosing tube gasket Head flange Studs Hex nuts Flange gasket Float chamber Stop strap Screws Float and stem assembly Jam nuts Guide washer Attraction sleeve Stop tube (not required for Models C29 and D30) IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number. 6.1.2 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, H1 J K 8, 9, R Bulletin # 42-683 42-683 42-694 42-685 42-686 42-799 6.1.3 Model C29 Housing cover Housing base Switch mechanism Enclosing tube kit: includes items 4 and 5 Œ Enclosing tube gasket Head flange kit: includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit: includes items 7, 8, 9, and 10 Float and stem assembly: includes items 9, 11, 12, 13, 14, 15, 16, and 17 Complete control less float chamber (10), bolts (7), and nuts (8) 18 Œ Refer to Section 6.1.2 Refer to Section 6.1.2 Refer to Section 6.1.2 089-5933-004 012-1204-001 089-4203-001 012-1301-025 089-4603-001 089-3257-001 089-6567-003 46-605 Flanged External Cage Float Actuated Liquid Level Switches 6.1.4 Models D30, J30 and L30 D30 Housing cover Housing base Switch mechanism Enclosing tube kit Œ  includes items 4 and 5 Enclosing tube gasket Head flange kit includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit Ž includes items 7, 8, 9, and 10 Float and stem assembly Œ includes items 9, 11, 12, 13, 14, 15, 16, and 17 Complete control Œ  less float chamber (10), bolts (7), and nuts (8) J30 L30 089-5915-001 012-1204-001 089-4204-001 012-1301-023 089-4604-001 089-3204-001 089-6569-002 Refer to Section 6.1.2 Refer to Section 6.1.2 Refer to Section 6.1.2 089-5933-011 012-1301-002 089-4205-001 012-1301-026 089-4605-001 089-3205-001 089-3206-001 not available 6.1.5 Models B60 and C60 B60 Housing cover Housing base Switch mechanism Enclosing tube kit: includes items 4 and 5 Œ Enclosing tube gasket Head flange kit: includes items 5, 6, 7, 8, and 9 Flange gasket Float chamber kit: Ž includes items 7, 8, 9, and 10 Float and stem assembly: includes items 9, 11, 12, 13, 14, 15, 16, and 17 Complete control less float chamber (10), bolts (7), and nuts (8) Œ  C60 Œ Refer to Section 6.1.2 Refer to Section 6.1.2 Refer to Section 6.1.2 089-5933-004 089-5933-011 012-1204-001 012-1301-002 089-4206-001 089-4206-002 012-1204-015 012-1301-024 089-4606-001 089-4606-002 089-3208-001 089-3209-001 089-6568-004 089-6568-003 NOTE: All replacement assemblies listed are furnished in kit form for standard base models. Consult local representative for ordering assistance on all special model replacement parts or accessories not included in above listing. Œ For models with -2 material codes, consult factory for spare parts.  Model D30 unit is specially designed for Dowtherm “A” service only, with Hastelloy C enclosing tube. Ž Kits are units with 1” NPT or SW side/bottom connections. For other configurations, consult factory.  Furnished with one Series 3, SPDT Mercury Switch and standard switch housing. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 19 6.2 Tandem Flanged External Cage Models 6.2.1 Parts identification 14 2 3 16 17 15 13 1 9 4 6 5 8 10 12 7 11 19 20 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Housing cover Housing base Switch mechanism Enclosing tube Enclosing tube gasket Head flange Studs and bolts Hex nuts Flange gasket Stop strap Screws Upper float and stem assembly Lower attraction sleeve Spacer washer Retaining ring Jam nuts Upper attraction sleeve Lower float and stem assembly Safety stop washer Float chamber Chamber liner (not shown) IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number. Figure 8 6.2.2 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, H1 J K 8, 9, R Bulletin # 42-683 42-683 42-694 42-685 42-686 42-799 20 46-605 Flanged External Cage Float Actuated Liquid Level Switches 6.2.3 Model C29 TDM Housing kit: includes items 1 and 2 Switch mechanism Enclosing tube kit: includes items 4 and 5 Enclosing tube gasket Head flange kit: includes items 5, 6, 7, 8, and 9 Flange gasket Upper float and stem kit: includes items 9, 10, 11, 12, 13, 14 and 15 Lower float and stem kit: includes items 9, 16, 17, 18 and 19 Float chamber kit: includes items 7, 8, 9, and 20 Refer to Section 6.2.2 Refer to Section 6.2.2 89-5909-002 12-1204-001 89-4203-001 12-1301-025 89-3217-001 Special order Œ Special order Œ 6.2.4 Models D30 TDM, J30 TDM and L30 TDM Housing kit: includes items 1 and 2 Switch mechanism Enclosing tube kit includes items 4 and 5 Enclosing tube gasket Head flange kit includes items 5, 6, 7, 8, and 9 Flange gasket Upper float and stem kit includes items 9,10,11,12,13,14, and 15 Lower float and stem kit includes items 9, 16, 17, 18, and 19 Float chamber kit includes items 7,8 9, and 20 D30 TDM  J30 TDM Refer to Section 6.2.2 Refer to Section 6.2.2 089-5909-002 L30 TDM 089-4204-001 012-1301-023 089-3218-001 012-1204-001 089-4205-001 012-1301-026 089-3219-001 089-3220-001 Special order Œ Special order Œ 6.2.5 Models B60 TDM and C60 TDM Housing kit: includes items 1 and 2 Switch mechanism Enclosing tube kit: includes items 4 and 5 Enclosing tube gasket Head flange kit: includes items 5, 6, 7, 8, and 9 Flange gasket Upper float and stem kit: includes items 9, 10, 11, 12, 13, 14, and 15 Lower float and stem kit: includes items 9, 16, 17, 18, and 19 Float chamber kit: includes items 7, 8, 9, and 20 B60 TDM C60 TDM Refer to Section 6.2.2 Refer to Section 6.2.2 089-5933-004 089-5933-011 012-1204-001 012-1204-001 089-4206-001 089-4206-002 012-1204-015 012-1301-024 089-3222-001 089-3223-001 Special order Œ Special order Œ NOTE: All replacement assemblies listed are furnished in kit form for standard base models. Consult local representative for ordering assistance on all special model replacement parts or accessories not included in above listing. Œ Specify model and serial number when ordering special order items.  Model D30 unit is specially designed for Dowtherm “A” service only, with Hastelloy® C enclosing tube. 46-605 Flanged External Cage Float Actuated Liquid Level Switches 21 7.0 Model Numbers Minimum Specific Gravity  for Models with Material of Construction Code 1 0.76 0.65 0.48 0.40 0.68 0.55 2 0.81 0.69 0.51 0.42 0.71 0.59 100 500 250 400  300  900 500 MODEL NUMBER CODE Œ Model No. C29 D30 Ž J30 L30 B60 C60 Pressure Rating psig @ ° F 750 403 201 322  242  725 403 900 388 194 310 233 496 388 1000 383 191 167 167 182 182 38 34 17 28  21  62 34 bar @ ° C 399 28 14 22  17  50 28 482 27 13 21 16 34 27 538 26 13 12 12 13 13 MATERIALS OF CONSTRUCTION 1 2 Carbon Steel Chamber, 316 SS Float, 400 Stainless Steel Sleeve Carbon Steel Chamber, 316 SS Float, 316 Stainless Steel Sleeve TANK CONNECTION TYPE AND SIZE Connection Type Threaded Socket Weld 150 Flanged Upper Side/Bottom Flanged Side/Side N30 S30 1" B20 B30 300 N40 S40 Connection Size 11⁄2" C20 C30 Cage Mounting Flange Rating (lbs.) 600 150 300 600 150 N50 S50 P30 T30 P40 T40 P50 T50 Q30 V30 2" D20 D30 300 Q40 V40 600 Q50 V50 Connection flanges are ASME B16.5 raised face. PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Switch Description Series J Bleed Type Series K Non-Bleed Maximum Supply Pressure psig bar 100 60 100 40 7 4 7 3 Maximum Process Temperature °F °C +400 +400 +400 +400 +204 +204 +204 +204 Bleed Orifice Diameter inches mm .063 .094 — — 1.6 2.3 — — Models with Material of Construction Code 1 Code 2 NEMA 1 NEMA 1 JDG JEG KOE KOG JDE JEE KOE — Electric switch mechanism and enclosure codes on next page Œ Models are limited to maximum temperature rating of selected switch mechanisms.  For single stage models only. Consult factory for multiple stages. Ž Model D30 recommended for Dowtherm applications.  Float cage rated 600 psig @ +100° F (41 bar @ +38° C) and 340 psig @ +750° F (23 bar @ +399° C).  Process temperature based on +100° F (+38° C) ambient. ‘ Consult factory for NEMA 4X//9 cast iron housing codes. ’ On condensing applications, temperature down-rated to +400° F (+209° C) process at +100° F (+38° C) ambient. 22 46-605 Flanged External Cage Float Actuated Liquid Level Switches ELECTRIC SWITCH MECHANISM AND ENCLOSURE Process  Temperature TYPE 4X/7/9 Aluminum Enclosure ‘ Set Contacts Range Points ATEX ATEX °F (°C) 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 Groups C&D Group B Groups C&D Group B d IIC T6 d IIC T6 SPDT DPDT SPDT DPDT SPDT DPDT Series F Hermetically Sealed Snap Switch Series HS ’ Hermetically Sealed 5-amp Snap Switch with Wiring Leads Series HS ’ Hermetically Sealed 5-amp Snap Switch with Terminal Block Series H1 Hermetically Sealed 1-amp Snap Switch with Wiring Leads Series R High Temperature Snap Switch -50 to +750 (-46 to +399) SPDT DPDT SPDT DPDT SPDT DPDT 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 1 2 1 2 1 2 1 2 1 1 1 SPDT 2 SPDT DPDT SPDT DPDT SPDT DPDT 1 2 1 2 1 2 3 1 2 1 2 3 1 2 HKN RKB RLB RNB ROB 8KA 8LA 8MA 8NA 8OA 9KA 9LA 9MA 9NA 9OA CS/Aluminum NEMA 4X Series R High Temperature Snap Switch Series 9 High Temperature Hermetically Sealed Snap Switch -40 to +1000 (-46 to +538) SPDT DPDT SPDT DPDT 1 2 1 2 1 2 3 1 2 R1M R3M RDM REM 9AD 9BD 9CD 9DD 9ED HKP RKK RLK RNK ROK 8KJ 8LJ 8MJ 8NJ 8OJ 9KJ 9LJ 9MJ 9NJ 9OJ RC9 RD9 RF9 RG9 8CC 8DC 8EC 8FC 8GC 9CC 9DC 9EC 9FC 9GC BKA BLA BMA BNA BOA CKA CLA CMA CNA COA DKB DLB DNB DOB FKA FLA FNA FOA HMJ HMN HMS HMY HM3 HM7 HKJ BKJ BLJ BMJ BNJ BOJ CKJ CLJ CMJ CNJ COJ DKK DLK N/A DNK DOK FKJ FLJ FNJ FOJ HMK HMP HMT HMZ HM4 HM8 HKK N/A HKN RKB RLB RNB ROB 8KB 8LB 8MB 8NB 8OB 9KB 9LB 9MB 9NB 9OB CS/Aluminum NEMA 4X R1M R3M RDM REM 9AM 9BM 9CM 9DM 9EM HKP RKK RLK RNK ROK 8KK 8LK 8MK 8NK 8OK 9KK 9LK 9MK 9NK 9OK RC9 RD9 RF9 RG9 8C9 8D9 8E9 8F9 8G9 9C9 9D9 9E9 9F9 9G9 BCC BDC BEC BFC BGC CCC CDC CEC CFC CGC DC9 DD9 DF9 DG9 FCC FDC FFC FGC N/A BKB BLB BMB BNB BOB CKB CLB CMB CNB COB DKB DLB DMB DNB DOB FKB FLB FNB FOB HMJ HMN HMS HMY HM3 HM7 HKJ BKK BLK BMK BNK BOK CKK CLK CMK CNK COK DKK DLK DMK DNK DOK FKK FLK FNK FOK HMK HMP HMT HMZ HM4 HM8 HKK N/A BC9 BD9 BE9 BF9 BG9 CC9 CD9 CE9 CF9 CG9 DC9 DD9 DE9 DF9 DG9 FC9 FD9 FF9 FG9 N/A All models with Material of Construction Code 1 All models with Material of Construction Code 2 Switch Description Series B Snap Switch -40 to +250 (-40 to +121) Series C Snap Switch -40 to +450 (-40 to +232) Series D DC Current Snap Switch -40 to +250 (-40 to +121) -50 to +550 (-46 to +288) -50 to +550 (-46 to +288) HA9 HB9 HA9 HB9 -50 to +750 (-46 to +399) -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) -50 to +1000 (-46 to +538) Cast Iron Class I, Div 1 Class I, Div 1 Groups C&D Group B RKM RKW RLM RLW RNM RNW ROM ROW 9KD 9KV 9LD 9LV 9MD 9MV 9ND 9NV 9OD 9OV Cast Iron Class I, Div 1 Class I, Div 1 Groups C&D Group B RKM RKW RLM RLW RNM RNW ROM ROW 9KM 9KW 9LM 9LW 9MM 9MW 9NM 9NW 9OM 9OW 46-605 Flanged External Cage Float Actuated Liquid Level Switches 23 ASSURED QUALITY & SERVICE COST LESS Service Policy 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: 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. No claims for misapplication, labor, direct or consequential damage will be allowed. Return Material Procedure 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. 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. 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 © 2010 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Hastelloy® is a registered trademark of Haynes International, Inc. BULLETIN: 46-605.17 EFFECTIVE: August 2010 SUPERSEDES: July 2009