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Installation and Operating Manual

Series 3 Liquid Level Switches

ASME B31.1 Construction

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Summary of Contents for 3 Series

Page 1: ...Installation and Operating Manual Series 3 Liquid Level Switches ASME B31 1 Construction ...

Page 2: ... the equipment may be impaired Notice of Trademark Copyright and Limitations Magnetrol MAGNETROL logotype are registered trademarks of MAGNETROL International Incorporated Copyright 2015 MAGNETROL International All rights reserved Performance specifications are effective with date of issue and are subject to change without notice MAGNETROL reserves the right to make changes to the product describe...

Page 3: ...Switch Mechanism 18 4 3 2 Check Sensing Unit 18 4 4 What To Avoid 19 5 0 Reference Information 5 1 Agency Approvals 20 5 2 Specifications 21 5 2 1 Dimensional Data Sealed Cage Models 21 5 2 2 Dimensional Specifications Sealed Cage Models 22 5 2 3 Dimensional Data Flanged Cage Models 24 5 2 4 Dimensional Specifications Flanged Cage Models 25 5 2 4 1 150 300 ANSI Pressure Ratings 25 5 2 4 2 600 900 ...

Page 4: ...1 2 Operating Cycle As the liquid level rises in the chamber refer to Figure 1 the float moves the magnetic attraction sleeve up within the enclosing tube and into the field of the switch mecha nism 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 As the liquid level falls the float drops and moves the attra...

Page 5: ...the control Shut off valves are recommended for installa tion 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 DO NOT INSULATE SWITCH MECHANISM HOUSING On controls equipped with pneuma...

Page 6: ...ed and the middle set screw on the housing base locked to the enclosing tube Failure to loosen the set screw prior to repositioning the conduit con nection may cause the enclosing tube to loosen resulting in the possible leakage of the process liquid or vapor Series 3 controls are shipped with the conduit entry of the switch housing placed 180 opposite to the tank con figurations to simplify insta...

Page 7: ...in fittings in the conduit run leading into the unit Caution In hazardous areas do not power the unit until the conduit is sealed and the enclosure cover is screwed down securely 7 Replace housing cover 8 If control has been furnished with an explosion proof or moisture proof gasketed switch housing it must be sealed at the conduit outlet with a suitable compound or non hardening sealant to preven...

Page 8: ... be adjusted by repositioning the lower jam nuts on the float stem The standard factory setting is for a minimum amount of play gap between the top jam nuts and the attraction sleeve as shown in Figure 7 on page 9 1 Determine what change in differential is necessary NOTE To widen the differential one inch the lower jam nuts must be set proportionately lower on the stem i e in this example 1 inch 2...

Page 9: ...at enclosing tube threads with anti seizing compound 13 Replace enclosing tube switch and base on chamber Screw tube clockwise until tightened to 200 225 foot pounds of torque 14 Rotate switch housing to correct position and tighten set screw at base of switch housing Refer to Figure 4 on page 6 15 Bring supply wires through conduit outlet Follow steps 5 through 10 inWiring Section 2 5 on pages 6 ...

Page 10: ...tch Corrosion Inspection For every 6 months in service conduct the following maintenance and inspection checks NOTE Conduct this inspection every 3 months for applications where the switches are exposed to corrosive environments Some environments may cause accelerated corrosion on the switch mechanism To identify switch corrosion prior to failure 1 Disconnect power to the switch 2 Remove switch ho...

Page 11: ...ms 4 1 2 Switch and Wiring Inspection The switch mechanism and supply wiring need to be in proper position to assure correct switch operation 1 Remove switch housing cover to inspect the supply wires 2 Check that the supply wires are attached to the terminal block and run under the baffle plate Be certain that excess wire does not interfere with the actuation of the switch and that adequate cleara...

Page 12: ... place control into service 4 1 3 Functional Test of Unit This procedure will assure that the complete unit is functioning properly This test should be conducted after switch and wiring inspections have been completed 1 Adjust piping as required to bring control to a vertical position Control must be mounted within 3 of vertical Installation should be checked with an indicating level on top or sid...

Page 13: ...ween screw and lever Such wear can cause false switch actuating levels Adjust switch mechanism to compensate if possible or replace switch 4 Controls may sometimes be exposed to excessive heat or moisture Under such conditions insulation on electrical wiring may become brittle eventually breaking or peeling away The resulting bare wires can cause short circuits Check wiring carefully and replace a...

Page 14: ...g base casting hub NOTE HS series switches use a cylindrical spacer in place of the baffle plate Refer to Figure 15 on page 13 5 If the above wiring conditions are not met the unit should be rewired Proceed to step 6 6 Disconnect power to the switch 7 The baffle plate is notched at the front and rear for control wires to pass through Control wires should enter through the conduit entry pass under ...

Page 15: ...d reinstalled properly 1 Vessel should be at a safe temperature and pressure before opening the pressure boundary 2 Power down all wiring to the unit 3 Remove all wiring and conduit from the unit 4 Remove flange bolts 5 Prepare an area where the head assembly can be placed such that it rests on the flange in its normal orientation two 2 4 boards placed across an open drum work well Refer to Figure...

Page 16: ...ooth NOTE Care must be taken during the straightness check to ensure the attraction sleeve is not removed from the stem and the jam nuts settings are not changed 9 In the container that the unit is set on raise the liquid level sufficiently to lift the float and trip the switch mecha nism Inspect inside of chamber for any obstructions or scale buildup If excessive buildup is present the interval b...

Page 17: ...onfirm switch trips and resets at expected levels contact MAGNETROL for spe cific information on trip points have the serial number of the unit readily available 4 3 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 installa...

Page 18: ...trical 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 switch actua tion 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 ...

Page 19: ...epair a float See Section 5 3 Replacement Parts If all components in the control are in operating condition the trouble must be located external to the control Repeat inspection of external conditions 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 pr...

Page 20: ...95 EC per Harmonized Standard EN 61010 1 1993 Amendment No 1 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 5 0 Reference Information 5 1 Agency Approvals Controls with two or m...

Page 21: ...Ref K HL LL A K M Plugged L Figure 24 Flanged Side Side Figure 23 Flanged Upper Side Bottom Figure 22 Threaded Socket Weld Upper Side Bottom Conduit Connections K Actuation levels Allow 8 203 mm over head clearance for cover removal All housings rotatable 360 Electrical Switches NEMA 4X 7 9 1 NPT Group B 1 NPT Pneumatic Switches NEMA 1 1 4 NPT Outline Dimensions L M NEMA 4X 7 9 3 87 5 93 NEMA 4X 7...

Page 22: ... 92 227 4 22 107 15 12 384 12 56 319 14 00 356 7 69 195 18 76 477 20 20 513 13 21 336 14 00 356 7 69 195 19 41 493 20 20 513 C35 8 92 227 4 22 107 15 12 384 12 56 319 14 00 356 7 69 195 18 76 477 20 20 513 13 21 336 14 00 356 7 69 195 19 41 493 20 20 513 G35 9 80 249 4 75 121 16 17 410 13 31 338 14 00 356 8 19 208 19 68 500 20 36 517 13 96 355 14 00 356 8 19 208 20 33 516 20 36 517 V35 8 92 227 4 ...

Page 23: ...H J 14 16 14 16 14 16 14 16 B35 8 92 227 4 34 110 15 12 384 14 00 356 9 00 229 20 20 513 14 00 356 9 00 229 20 20 513 C35 8 92 227 4 34 110 15 12 384 14 00 356 9 00 229 20 20 513 14 00 356 9 00 229 20 20 513 G35 9 80 249 4 88 124 16 17 410 16 00 406 10 00 254 22 36 568 16 00 406 10 00 254 22 36 568 V35 8 92 227 4 34 110 15 12 384 14 00 356 10 00 254 20 20 513 14 00 356 10 00 254 20 20 513 Z35 9 80...

Page 24: ...d K L K HL LL J G M Ref Plugged K H HL LL D E F M Ref K Plugged K L Figure 27 Flanged Upper Side Bottom Figure 26 Flanged Side Side Conduit Connections K Actuation levels Allow 8 203 mm over head clearance for cover removal All housings rotatable 360 Electrical Switches NEMA 4X 7 9 1 NPT Group B 1 NPT Pneumatic Switches NEMA 1 1 4 NPT Outline Dimensions L M NEMA 4X 7 9 3 87 5 93 NEMA 4X 7 9 98 151...

Page 25: ... Std 14 Std 14 B3F 150 9 12 232 3 69 94 16 64 423 13 06 332 14 00 356 7 13 181 20 58 523 21 51 546 13 71 348 14 00 356 7 13 181 21 23 539 21 51 546 300 9 12 232 3 69 94 17 32 440 13 06 332 14 00 356 7 13 181 21 26 540 22 19 564 13 71 348 14 00 356 7 13 181 21 91 556 22 19 564 G3F 150 10 12 257 4 75 121 18 30 465 14 06 357 14 00 356 8 19 208 22 25 565 22 19 564 14 71 374 14 00 356 8 19 208 22 89 58...

Page 26: ...18 39 467 14 00 356 9 00 229 23 32 592 14 00 356 9 00 229 23 32 592 A B C D E F g H J Std 16 Std 16 Std 16 Std 16 G3F 600 10 12 257 4 75 121 20 51 521 16 00 406 10 00 254 26 44 672 16 00 406 10 00 254 26 43 671 Z3F 600 10 12 257 4 75 121 20 19 513 16 00 406 10 00 254 26 08 662 16 00 406 10 00 254 26 08 662 900 10 12 257 4 75 121 21 13 537 16 00 406 10 00 254 26 08 662 16 00 406 10 00 254 26 08 662...

Page 27: ... 4 62 117 5 06 129 600 819 psig 56 bar 523 F 271 C 0 76 4 29 109 5 00 127 K3F 600 1123 psig 77 bar 559 F 293 C 0 73 4 21 107 4 65 118 Z3F 600 1132 psig 78 bar 560 F 293 C 0 73 3 50 89 4 09 104 900 1564 psig 108 bar 602 F 317 C 0 68 3 18 81 3 84 98 5 2 5 Actuating Levels Steam Service Ratings and Specific gravities For float operated units minimum specific gravities and actuating levels vary depend...

Page 28: ...model and serial number of control when ordering Figure 28 Housing and Switch Mechanism 1 1 2 3 5 3 2 Sealed Cage Float Models B35 C35 g35 v35 Z35 Part Numbers B35 7 B35 C35 g35 v35 Z35 Material Code 7 Material Code P Material Code P Housing kit Refer to bulletin on switch mechanism and housing base includes items 1 and 2 assembly furnished see page 7 Switch mechanism Refer to bulletin on switch m...

Page 29: ...P Material Code P Material Code P Material Code P Housing kit Refer to bulletin on switch mechanism and housing base includes items 1 and 2 assembly furnished see page 7 Switch mechanism Refer to bulletin on switch mechanism and housing base assembly furnished see page 7 Enclosing tube Z32 6346 002 Z32 6346 002 Z32 6346 003 Z32 6346 003 E tube gasket 12 1204 001 Head flange gasket B3F 12 1204 024 ...

Page 30: ...6 V56 V66 Switch Description Maximum Supply Pressure Maximum Process Temperature Bleed Orifice Diameter Models B35 C35 g35 Models v35 Z35 psig bar F C inches mm NEMA 1 NEMA 1 Series J Bleed Type 100 7 400 204 063 1 6 JGH JGF 60 4 400 204 094 2 3 JHH JHF 60 4 700 371 055 1 3 JJH JJF Series K Non Bleed 100 7 400 204 KOF 40 3 400 204 KOH Models are limited to maximum temperature rating of selected sw...

Page 31: ... A HMJ HMK N A 2 HMN HMP HMN HMP DPDT 1 HMS HMT HMS HMT 2 HMY HMZ HMY HMZ Series HS Hermetically Sealed 5 amp Snap Switch with Terminal Block 50 to 400 46 to 204 SPDT 1 HM3 HM4 HA9 HM3 HM4 HA9 DPDT 1 HM7 HM8 HB9 HM7 HM8 HB9 Series R High Temperature Snap Switch 40 to 750 40 to 399 SPDT 1 RKB RKK RC9 RKB RKK RC9 2 RLB RLK RD9 RLB RLK RD9 DPDT 1 RNB RNK RF9 RNB RNK RF9 2 ROB ROK RG9 ROB ROK RG9 Seri...

Page 32: ...6 9 Z3F 600 0 67 1480 1170 1015 825 102 0 80 7 70 0 56 9 900 1875 1875 1426 1184 129 3 129 3 98 3 81 7 Connection Type Connection Size C C 1 11 2 2 ANSI Head Flange Rating lbs 150 300 600 900 150 300 600 900 150 300 600 900 Threaded Std B20 B60 B80 B40 C20 C60 C80 C40 D20 D60 D80 D40 Socket Weld Std B30 B70 B90 B50 C30 C70 C90 C50 D30 D70 D90 D50 Flanged Upper Side Bottom Std N30 N40 P30 P40 Q30 Q...

Page 33: ...ads 50 to 400 46 to 204 SPDT 1 HMJ HMK N A HMJ HMK N A 2 HMN HMP HMN HMP DPDT 1 HMS HMT HMS HMT 2 HMY HMZ HMY HMZ Series HS Hermetically Sealed 5 amp Snap Switch with Terminal Block 50 to 400 46 to 204 SPDT 1 HM3 HM4 HA9 HM3 HM4 HA9 DPDT 1 HM7 HM8 HB9 HM7 HM8 HB9 Series R High Temperature Snap Switch 40 to 750 40 to 399 SPDT 1 RKB RKK RC9 RKB RKK RC9 2 RLB RLK RD9 RLB RLK RD9 DPDT 1 RNB RNK RF9 RN...

Page 34: ...34 46 624 Series 3 Liquid Level Switches ASME B31 1 Construction NOTES ...

Page 35: ...46 624 Series 3 Liquid Level Switches ASME B31 1 Construction 35 NOTES ...

Page 36: ... 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 cred it for the materials returned will be determined on the basis of the applicability of our warranty No claims for misapplication labor direct or consequen tial damage will...

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