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Tuffy ® LiquidLevelControls w ithPneumaticSwitch Installation and OperatingMan ual
TuffyLiquidLevelControlwithPneumaticSwitch ReadthisMan ualBefore Installing This m anual providesinformation on the T uffyLiquid LevelControlwith Pneumatic Switch.Itisimportantthat allinstructionsarereadcarefullyand followedinsequence. De tailedinstallationand wiring instructionsareincludedin thism anual. ConventionsUsed in thisMan ual Certain conventions areused in thismanu al to convey specifictypesof information.Generaltechnicalmaterial, support data,and safetyinform ation are presented in narrative form . Th e followingstyles areused for notes, cautions,and warnings. Notes Notescontain inform ation thataugm entsorclarifiesan operating step.No tesdo not normallycontainactions. Th ey follow the proceduralstepstowh ich they refer. C autions Cau tions alertthetechniciantospecialconditions that could injure personnel,dama ge equipment,or reduce a compo nent’sme chanicalintegrity.Cau tions are also used to alertthe technicianto unsafe practices or the need for special protective equipment or specific m aterials.In thisman ual,a caution box indicatesa potentiallyhazardous situation wh ich, ifnot avoided, m ay resultinm inorormo derateinjury. Warnings W arnings identify potentially dangerous situations or serious hazards.In thism anual,a w arningindicatesan imminently hazardous situation w hich,ifnot avoided, couldresultin serious injuryordeath. SafetyMessages Follow allstandard industryproceduresforservicingelec - tricalequipme nt when wo rking with or around high voltage.A lwaysshutoffthe power supplybeforetouching any compo nents. WARN ING! Explosionhazard. Do not connect or dis - connectequipme nt unlesspow erhasbeen switched offor theareaisknown tobe non-hazardous. No ticeofT rademark,C opyright,and Lim itations T uffyisa registered tradem ark ofM agnetrolInternational, Incorporated.T uffyLiquid LevelSwitch isa tradenam e of M agnetrolInternational,Incorporated. © 2010 Magn etrolInternational,Incorporated. All rightsreserved. Magn etrol reserves the right to m ake changes to the product described in thism anual at any time w ithout notice.M agnetrolm akesno w arranty w ith respectto the accuracy ofthe inform ation inthism anual. Wa rranty All Magn etrolm echanicalleveland flow controlsare war - ranted freeofdefectsinmaterialsorw orkman shipforfive fullyearsfrom the date oforiginalfactoryshipment. Ifreturned within thewarrantyperiod;and,upon factory inspection of the control,the cause of the claim is determined to be covered under the warranty;then, M agnetrolwillrepairorreplacethecontrolatno costtothe purchaser(orown er)otherthan transportation. Magn etrol shallnot be liablefor m isapplication, labor claims,direct or consequentialdam ageor expensearising from the installation or use of equipment.T here areno other w arranties expressed or implied, except special written warrantiescovering som e M agnetrolproducts. Q ualityAssurance Th e quality assurance system in place atM agnetrolguar - antees the highest levelofqualitythroughoutthe compa - ny.M agnetroliscomm itted to providing fullcustome rsat - isfactionboth inquality productsand quality service. Magn etrol’s quality assurance system is registered to ISO 9001 affirming its comm itment to know n international quality standards providing the strongest assurance of product/service qualityavailable.
3TuffyLiquidLevelControlwithPneumaticSwitch
1.0 Installation
Thissection providesdetailedproceduresforproperly installing the T uffyLiquid LevelCon trol. Cau tion: Ifequipm entis used in a ma nnernotspecified by m anufacturer,protection provided by equipme nt m ay be im paired.
1.1 Unpa cking
Unp ackthe instrum entcarefully.Inspectallunitsfordam - age.Reportany concealeddamage to thecarrierwithin 24 hours.Che ck thecontentsofthe packing slip and report any discrepanciesto Magn etrol.Check the nameplatemod el numbe rtobe sure itagreesw ith the packing slip and pur - chase order.Che ck and record the serialnumbe rforfuture referencewhen ordering parts. Mode lN um ber SerialNu m ber
1.2 BeforeYou Begin
1.2.1 Site Preparation
- Ensure thatthelength and inside diameterofthe mou nting nozzleare sized correctlyto allowforswitch actuation at designlevels.R eferto Figure 1. 2. Ensure thatthem ounting nozzleorcoupling iswithin 3° ofhorizontal.Ifmou nting the T uffy in an externalcage, ensure thatthecageismo unted w ithin 3° ofhorizontal and thatthetop/bottom piping iswithin3° ofverticalinall directions. 3. Ensure thatthearea isfreeofme tallic particleswhich might be attracted tothe magn etholder/counterbalanceand inter - ferew iththefunctionofthe T uffy.
1.2.2 Equipme ntand Tools
No specialequipment ortoolsarerequired to installthe T uffy LiquidLevelSw itch.T he following items arerecom - me nded:
- Wre nches,flangegasketsand flange bolting appropriatefor processconnection(s).
- Pipe wrench
- Level Figure1 1/4" NPT inlet (A) 1/4" NPT outlet (C) 3.00" maximum nozzle length 1/4" NPT inlet (B) Float must clear inner tank wall Wrench flats Serial number tag
4 TuffyLiquidLevelControlwithPneumaticSwitch
1.3 Mounting
Th e pneumatic T uffyLiquid LevelSw itch isavailable w ith a 2" NP T m ounting bushing,a varietyofflange m ountings and externalcagesformoun ting outsideofthe vessel.
1.3.1 Mountingan NPT Tuffy
- Ap plyeitherT eflon ® tape orPetrolatum to them ounting threadstoprevent galling. 2. Engage the2" NPT by hand to avoid dam aging threads. 3. Using a pipew rench,rotate theunitclockw ise untilthreads aretightinmo unting.Ensure thattheserialnumbe rplateis on top.See Figure 1. Caution: The pneumaticTuffy mu stbe installedwith theserial numb erplateon top to ensure correctswitchingaction.
1.3.2 Mountinga TuffywithFlange
- Have properflangebolting and gasketon hand. 2. Carefullyalignm ountingflange w ith the vesselm ounting flange. 3. Ensure thattheflangegasketisseated properly.Install flangeboltsand nuts. 4. Tighten alternatingflangeboltsin a starpattern. 5. InstallT uffyinto2" NP T ofmou nting flangeasdescribed inSection 1.3.1 above. Cau tion: O peration ofallbuoyancy typeleveldevices should be done insuch a w ay as tom inimize theaction ofdynamic forces on the float or displacer sensing eleme nt.Goo d practice for reducing thelikelihood ofdam age tothecontrolistoequal - izepressureacross thedevice very slowly.
1.3.3 MountingExternalC age Tuffy
A typicalT uffyexternalcageinstallation isshown inFigure2. 1. Installcageso thattappingsarew ithin 3° ofverticalinall directions.Che ck installation w ith a level. 2. Mo unt cageasclose tovesselaspossible,toprovide mor e accurate levelin cage.Long pipe runsmay resultin cooler, denserliquid thanthatin the vesseland cause inaccurate levelin the T uffycage. 3. Use pipe ofsufficientsize and strength to supportthe control.Ifnecessary,provide a hangerorstand to help supportthew eightofthecage. 4. All pipingshouldbe straightand free oflow spotsorpockets. Lower liquidlineshoulddraintoward vesseland upperline towardT uffycage. 5. Shut-offvalvesarerecomme nded forinstallation between thevesseland the cageassem bly. 6. On ceexternalcageismou nted,installpneum atic T uffy into CL Pressure vessel Shut–off valve Safety check valve Shut–off valve Drain valve Switch actuation level 1/4" NPT inlet (A) 1/4" NPT outlet (C) 1/4" NPT inlet (B) Figure 2
5TuffyLiquidLevelControlwithPneumaticSwitch
1.4 AirlineConnections
- Inletairshouldbe filtered with a 5 micron orfinerfilter. Thisw illextend thelife ofthe valveme chanism. 2. Con necttheinletairline to the 1⁄4" NP T connectionfor eitherairinletA orairinletB, depending on the valve action desired (refertoFigure3). Inletairpressure should be between 0–200 psig.R eferto Figure 1 forlocationofair inlets. 3. Con nectoutletairline to the1⁄4" NPT connectionon the bottom ofthevalve.T hisairoutletisdesignated w itha “C”.R efertoFigure 1 forlocation. 4. If3-way function isused,attach theexhaustairlinetothe appropriate 1⁄4" NPT connection basedon valveaction described in Figure 3.
2.0 Reference Information
2.1 Description
T uffy liquidlevelswitchesaredesigned forhorizontal mo unting in a tankorvesselthrough threaded orflanged pipe connections.Standardmo delsare equipped w itha three-port/two-position valveactuated by a m agnetically actuated pivoted cam mec hanism .T hisinstruction manual coversT uffylevelcontrolsw hich havepneumaticswitches. ForT uffy controlsw ith electric switches,please consult Bulletin 44-607.
2.2 Theory ofO peration
At a “lowoperating level”ofliquid in a tank orvessel(refer toFigure4),thefloatmove sthem agnetupw ardand into thefieldofthe switch me chanism m agnet.A sa result,the magn etsrepelcausing the pivotarm and valveplungerto mo ve so thatairisallow ed to passfrom airinletA toair outletC. As liquid levelrises,the floatmo vesthe magne t downw arduntilthe switch m echanism m agnetreverses position,allowing the valveplungerto mo ve so thatairis allowed topassfrom airinletB toairoutletC (referto Figure 5). Fordirectacting low leveloperation,airinletA isclosed off when liquid levelincreases.Co nversely,forhigh levelopera - tion,airinletB isclosed offw hen liquid levelrecedes. Forreverseacting operation,airinletA isusedforhigh level and airinletB isused forlow level.Plug the airinletthatis notin use topreventforeign materialsfrom entering. Figure 3 N .O.—Directacting:Airsupplyon switch condition. N .C.—Re verseacting:Aircut-offon sw itchcondition. 2-Way 2-Way 3-Way 3-Way (direct) (reverse) (direct) (reverse) A Inlet Plug Inlet Exhaust Outlet Outlet B Plug Inlet Exhaust Inlet Outlet Inlet C O utlet O utlet Outlet Outlet Inlet Outlet Float Tuffy body (Non-magnetic) Magnet Pivot Falling level Air inlet (B) (no air flow) Air inlet (A) Air outlet (C) Pivot arm Magnet pivot Spring Valve plunger Valve body FloatPivot Rising level Tuffy body (Non-magnetic)Air inlet (B) Air inlet (A) (no air flow) Air outlet (C) Spring Valve plunger Valve body Magnets Pivot arm Magnet pivot Figure 4 Low LevelOp eration—DirectActing Figure5 High LevelOp eration—DirectActing
6 TuffyLiquidLevelControlwithPneumaticSwitch
2.3 PreventiveM aintenance
Periodicinspections are a necessarymean sto keep your Magne trollevelcontrolin good wo rking order.T hiscontrol isa safetydevice toprotectthe valuableequipme nt itserves. A system atic program ofpreventive m aintenanceshouldbe impleme nted w hen thecontrolisplaced intoservice.Based on utilizing a preventative m aintenance program and observing thefollow ing section on “w hattoavoid”,your T uffy willprovide reliableprotection ofyour capitalequip - me nt forman y years. WHAT T O AV OID 1. Use onlythe2" wrench flatsto installorremovethe unit. RefertoFigure1. Use ofany othersurfacecouldchange the calibration.The valvebody iscalibrated atthe factoryand locked in place. 2. NEV ER attemp tto make adjustme ntsw ithoutreading the instructions carefully.W hen indoubt,consultthefactoryor yourlocalrepresentative. 3. NEV ER use insystems w hich haveexcessiron particlesin thesolution.T he m agnetatthe counterweightend ofthe floatcan attractthe particlesw hich couldcausethe floatrod tojam.
2.4 Troubleshooting
IfT uffyfailstoshutofforturn on inletair: 1. Check floatforfullrangeoftravel;clicking ofmec hanism shouldbe heard. 2. Ifthecom pleteT uffy mec hanism operatesproperlyw hen rem oved from service,check to be certain thatliquidis entering the storagetank orvessel.A valvemay be closed ora pipe line clogged. 3. Ifthefloatisdeterm inedto be filled w ith liquid oris collapsed,the entire levelswitch m ustbe replaced.D o notattemp tto repairthe float. 4. The factorycalibration setting shouldnotrequireany adjustme nt in thefield.Check to see thattheunitis installed properlywith the serialnumber tagpositioned on thetop ofthe unit.Ifthe unitisstillnotoperating correctly,please contactthe factory. NOT E: When in doubtaboutthecondition orperformance ofa control,please contactthefactory forassistance.
7TuffyLiquidLevelControlwithPneumaticSwitch
2.6 Parts
2.6 .1 Physical Pneumaticswitchmodels 3.75 (95) Float minimum□ clearance 2" NPT 2.50 (64) Dia. .75 (19)C L 3.00 (76) max.□ Nozzle length Float size = 2.00 (51) Dia. x 4.57 (116) long Float size = 2.00 (51) Dia. x 5.12 (130) long Switch actuates□ Rising level Falling level Switch actuates 12.00 (304) [Sp.Gr. 0.6 Min] 1/4" NPT inlet (A) 1/4" NPT outlet (C) 1/4" NPT inlet (B) Pressure: 0 .6SG 1500 psigat+300° F (103barat+149° C)
0.4 SG 500 psigat+300 ° F (34 barat+149° C )
Process Temperature: -40° F to+300° F (-40° C to+149° C) AmbientTemperature: Max .+100° F (+38°C) withmaximum processtemperature PneumaticSw itchSup ply Pressure: Vacuum to200 psig(13.8bar)maxim um Max imum Leakage Rate: 0 .5SCF H (0.015 SCMH @ 100 psig(6.9bar)) Max imum AirFlow: 12.0 SCF H (0.34SCMH @ 100 psig(6.9bar)) SpecificGravity: 0 .6minimum or0.4 minimum MaterialsofCo nstruction: 316/316L SS we ttedcompon entsincludingNACE and ASME B31.3 Ho using: 316 stainless steel
2.5 Specifications
2.5.1 M echanicalSpecifications
6 Pneumatic
0 316 Stainlesssteelw ith1/4"NP T airline connec tions SP ECIFIC GR AVITY AND PRESSURE RATINGS 0 0.60 m inimum S.G.,1500 psima ximum pressure 4 0.40 m inimum S.G.,500 psima ximum pressure
2.7 Mod elNumbers
Owners ofM agnetrolma y requestthe return ofa control orany partofa controlforcomp leterebuildingorreplace - m ent.Th eyw illbe rebuiltorreplaced promp tly.Controls returned under our servicepolicy mu stbe returnedby Prepaidtransportation. Magne trol w illrepairor replace thecontrolatno costto the purchaser(or owner)other than transportation if: 1 . R eturnedwithinthew arrantyperiod;and 2 . Th e factoryinspection findsthe causeoftheclaimto be covered underthew arranty. Ifthe trouble istheresultofconditions beyond our con - trol;or,isN OT covered by the warranty,therewillbe charges forlabor and the partsrequired to rebuildor replacethe equipment. In some cases itmay be expedient to shipreplacement parts;or,in extreme cases a comp lete new control,to replacethe originalequipment before itisreturned.Ifthis isdesired,notifythefactory ofboth themodel and serial numbers ofthe controltobe replaced.In suchcases,cred - itforthe materials returned w illbe determined on the basisofthe applicability ofourwarranty. No claimsfor misapplication,labor,director consequen - tialdam agewillbe allowed. Low Voltage Directive For use in Installations Category II,PollutionDegree2. Ifequipment isused in a manne r not specifiedby the m anufacturer,protection providedby equipment may be impaired. Return Ma terialProcedure So thatwe may efficientlyprocess any materialsthatare returned, it is essential that a “Return Ma terial Auth orization”(R MA )numbe rbe obtained from the fac - tory,prior to the m aterial'sreturn. Th is is available throughM agnetrol’slocalrepresentative orby contacting the factory.Pleasesupplythe follow ing inform ation: 1. Compan y Name 2. De scription ofM aterial 3. SerialNum ber 4. Reason forR eturn 5. Application An y unitthat w as used in a processm ust be properly cleaned inaccordancew ith O SHA standards,before itis returned tothe factory. A M aterialSafety Data Sheet (M SD S) m ustaccompany materialthatw asusedinany m edia. All shipmentsreturned to the factorym ustbe by prepaid transportation. All replacem entsw illbe shippedF .O.B.factory. AS SURED Q UA LITY & SER VICE C OS T LESS BULLETIN: 44- 606.11 EFFECTIVE: M ay 2010 SU PERSEDE S: M ay 2006 5300 Belmont Road • Downers Grove, Illinois 60515-4 499 • 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 Internatio nal, Incorporated. All rights reserved. Printed in the USA. Performance specifications are effective with date of issue and are subject to change without notice. Ma gnetrol& Ma gnetrollogotypeareregisteredtrademarksofMagnetrolInternational. Teflon isa registeredtradem arkofD uPont.