B60-2C30-JEE

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Installation and Operating Manual

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 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. Notice of Copyright and Limitations Magnetrol & Magnetrol logotype and are registered trade- marks 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 war- ranted 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.

46-605 Flanged External Cage Float Actuated Liquid Level Switches Table of Contents

1.0 Installation

2.0 Reference Information

2.5 Replacement of Standard Float

3.0 T roubleshooting

4.0 Preventive Maintenance

4.1.2 Inspect switch mechanisms, terminals, and

5.0 Specifications

6.0 Replacement Parts

4 46-605 Flanged External Cage Float Actuated Liquid Level Switches Optional drain valve Shutoff valve (if used) Conduit outlet Switch actuating level lreference marks Shutoff valve (if used) Typical Piping Arrangement Caution: If equipment is used in a manner not specified by manu- facturer, 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. 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 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. 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.

46-605 Flanged External Cage Float Actuated Liquid Level Switches 5

1.4 Mounting

Caution: This instrument is intended for use in Installation CategoryII, 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 notice- able 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 con- trol 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 configu- ration 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. 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. 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. Set Screw Screw Figure 1

46-605 Flanged External Cage Float Actuated Liquid Level Switches 7

2.1 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.

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 toFigure 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 hol- low stem. The lower float attaches to the upper attraction sleeve with a solid stem which extends upward through the upper float and stem assembly.

2.4 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. NOTE: This procedure may be applied to single switch models only. Enclosing tube (non-magnetic) Sleeve (magnetic) Float Normal operating level Magnet Return Spring Pivot Figure 3 Low level Swing out position Figure 4

8 46-605 Flanged External Cage Float Actuated Liquid Level Switches 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.

2.4.1 Low level controls

On low level controls the switch trips on the lower actua- tion 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). 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 toFigure 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. NOTE: Level control, connections and pipe lines need not be removed from the tank. 6. Loosen enclosing tube nut with a15⁄16 " wrench. Unscrew enclosing tube counterclockwise (switch and housing base will rotate also), until it is free. Refer toFigure 7. Figure 6 Differential adjustment For access to bottom jam nuts, remove top jam nuts, washer, and attracting sleeve. Slight play (gap) must be allowed (.03" [.8 mm] typical) Position of bottom jam nuts (normal factory setting) Float Sleeve stop strap Replace in same position Drop bottom jam nuts to increase gap setting (see instructions below) 0.50" (13 mm) Maximum gap setting (Applies to models having a single switch mechanism with a single magnet actuator only) Float Sleeve stop strap D Figure 5 Normal Factory Setting (minimum differential)

46-605 Flanged External Cage Float Actuated Liquid Level Switches 9 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 toFigure 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 toFigure 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 toFigure 6. NOTE: Use a new enclosing tube gasket when reassembling enclos- ing 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. 13. Replace enclosing tube, switch, and base on chamber. Screw tube clockwise until tightened to 200–225 foot- pounds 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 1on page 5. 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 inWiring, Section 1.5. 16. T est 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. T o widen the differential by raising the trip point, follow steps 1 through 16 inLow level controls, Section 2.4.1. Enclosing tube nut Conduit connection Switch housing cover Chamber Float Enclosing tube Refer to Figures 6 and 7 Housing base Figure 7

10 46-605 Flanged External Cage Float Actuated Liquid Level Switches

1. Disconnect wiring or medium lines from control and per- form system shutdown. SeeTroubleshooting, 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 enclos- ing tube. NOTE: New float and stem kits are supplied unassembled. Refer to Figure 8for standard jam nut settings (Dimension A). 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. 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. 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Stop tube Sleeve stop strapRetaining screws Float and stem assembly Head flange (ref.) Dim. A .87 (22) Figure 8 Model Flange Bolting Enclosing Tube C29, D30 55–60 ft–lbs 200–225 ft–lbs C60, J30, L30 100–125 ft–lbs 75–100 ft–lbs B60 250–300 ft–lbs 200–225 ft–lbs

46-605 Flanged External Cage Float Actuated Liquid Level Switches 11

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 care- fully 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. NOTE: As a matter of good practice spare switches should be kept on hand at all times. Optional drain valve Shutoff valve (if used) Conduit outlet Switch actuating level lreference marks Shutoff valve (if used) Figure 9

12 46-605 Flanged External Cage Float Actuated Liquid Level Switches

3.2 Check Sensing Unit

1. Reconnect power supply. Carefully actuate the switch mechanism manually (use a non-conductive tool on electri- cal 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 corro- sion or solids buildup. Such buildup could restrict move- ment, preventing sleeve(s) from reaching field of switch magnet(s). 10. If differential has been changed in the field by reposition- ing 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 attemptadjustment without first consulting factory for assis- tance in computing level differential change for your control.

46-605 Flanged External Cage Float Actuated Liquid Level Switches 13 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. When inquiring about your control, be certain to always specify the complete Model and Serial numbers. 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.

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 pro- tects 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.

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. A 0.03" Minimum gap setting Top jam nuts Bottom jam nuts Attraction sleeve Enclosing tube (ref.) Stop tube Sleeve stop strapRetaining screws Float and stem assembly Head flange (ref.) Figure 10

14 46-605 Flanged External Cage Float Actuated Liquid Level Switches 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 malad- justed switch mechanisms. Refer to bulletin on switch mechanisms furnished for service instructions. SeeSwitch 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 sub- jected to vibration may eventually crack or become loose at connections causing leakage. Check lines and connec- tions 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 cer- tain 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.

46-605 Flanged External Cage Float Actuated Liquid Level Switches 15

5.1 Agency Approvals

AGENCY APPROVED MODEL AREA CLASSIFICATION FM All with an electric switch mechanism and a housing Non-Hazardous TYPE 4X listed as TYPE 4X All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as TYPE 4X/7/9 ClassII, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as TYPE 4X/7/9 ClassI, Div 1, Group B ClassII, Div 1, Groups E, F & G CSA All with an electric switch mechanism and a Non-Hazardous CSA TYPE 4X housing listed as CSA TYPE 4X All with a Series HS, H1, F , 8 or 9 electric switch ClassI, Div 2, Groups B, C & D mechanism and a housing listed as CSA TYPE 4X All with an electric switch mechanism and a housing Class I, Div 1, Groups C & D listed as TYPE 4X/7/9 ClassII, Div 1, Groups E, F & G All with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D listed as TYPE 4X/7/9 ClassI, Div 1, Group B ClassII, Div 1, Groups E, F & G ATEX / IEC Ex  All with an electric switch mechanism and an ATEX II 2 G EEx d IIC T6 ATEX housing Œ 94/9/EC IEC Ex Ex d IIC T6 IP 66 CE Low Voltage Directive 2006/95/EC Installation CategoryII Per Harmonized Standard: Pollution Degree 2 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 Temperature Classification < 85° C T6 < 100° C T5 < 135° C T4 < 200° C T3 < 300° C T2 < 450° C T1 These units are in conformity with IECEx KEM 05.0020X Classification Ex dIIC T6 Tambient-40° C to +70° C

16 46-605 Flanged External Cage Float Actuated Liquid Level Switches

5.2 Physical

CHAMBERS WITH 1-INCH CONNECTIONS INCHES MILLIMETERS CHAMBERS WITH 2-INCH CONNECTIONS INCHES MILLIMETERS CHAMBERS WITH 1 1⁄2-INCH CONNECTIONS INCHES MILLIMETERS Min. Sp. Gr. 1" NPT Threaded & Socket Weld 1" Flanged Upper Side/Bottom 1" Flanged Side/Side Actuating Levels 1" NPT Threaded & Socket Weld 1" Flanged Upper Side/Bottom 1" Flanged Side/Side Actuating Levels A B C A B C A B C HL LL A B C A B C A B C HL LL J30 .48 2.613.34 258 109 371 331 182 182 348 182 462 66 84 L30 .40 3.24 3.98 82 101 B60 .68 2.773.44 249 96 361 322 169 434 338 169 450 70 87 C60 .55 2.873.60 72 91 Min. Sp. Gr. 11⁄2" NPT Threaded & Socket Weld 11⁄2" Flanged Upper Side/Bottom 11⁄2" Flanged Side/Side Actuating Levels 11⁄2" NPT Threaded & Socket Weld 11⁄2" Flanged Upper Side/Bottom 11⁄2" Flanged Side/Side Actuating Levels A B C A B C A B C HL LL A B C A B C A B C HL LL J30 .48 1.972.70 254 120 382 357 207 485 374 207 501 50 68 L30 .40 2.603.34 66 84 B60 .68 1.462.13 244 107 373 347 195 476 383 195 492 37 54 C60 .55 1.93 2.66 49 67 Min. Sp. Gr. 2" NPT Threaded & Socket Weld 2" Flanged Upper Side/Bottom 2" Flanged Side/Side Actuating Levels 2" NPT Threaded & Socket Weld 2" Flanged Upper Side/Bottom 2" Flanged Side/Side Actuating Levels A B C A B C A B C HL LL A B C A B C A B C HL LL J30 .48 1.602.33 247 123 385 357 207 495 374 207 511 40 59 L30 .40 2.23 2.97 56 75 B60 .68 1.522.19 238 110 376 347 195 485 363 195 501 38 55 C60 .55 1.99 2.72 50 69 Levels ±0.25" (6 mm) Levels ±0.25" (6 mm) Levels ±0.25" (6 mm)

46-605 Flanged External Cage Float Actuated Liquid Level Switches 17 C HL LL D D plugged A B 5.93 (151) 10.12 (257) 3.78 (96) 8.46 (215) C HL LL D D plugged A B 5.93 (151) 10.12 (257) 3.78 (96) 8.46 (215) Side/Bottom FlangedThreaded and Socket Weld C HL LL D D plugged A B 5.93 (151) 10.12 (257) 3.78 (96) 8.46 (215) Side/Side Flanged Conduit Connections D Electrical Switches TYPE 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches TYPE 1: 1⁄4" NPT NOTES: 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. Inches (mm)

18 46-605 Flanged External Cage Float Actuated Liquid Level Switches

6.1.1 Parts identification

6.1.3 Model C29

Housing cover Refer to Section 6.1.2 Housing base Refer to Section 6.1.2 Switch mechanism Refer to Section 6.1.2 Enclosing tube kit: includes items 4 and 5Π089-5933-004 Enclosing tube gasket 012-1204-001 Head flange kit: includes items 5, 6, 7, 8, and 9 089-4203-001 Flange gasket 012-1301-025 Float chamber kit: includes items 7, 8, 9, and 10 089-4603-001 Float and stem assembly: includes items 9, 11, 12, 13, 14, 15, 16, and 17Π089-3257-001 Complete control less float chamber (10), bolts (7), and nuts (8) 089-6567-003 Series Type Bulletin # Dry contact B, C, D 42-683 Hermetically sealed F 42-683 Hermetically sealed HS, H1 42-694 Bleed type pneumatic J 42-685 Non-bleed type pneumatic K 42-686 High temperature 8, 9, R 42-799

6.1.2 Switch and housing reference

IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number.

6.1 Standard Flanged External Cage Models

1 Housing cover

2 Housing base

3 Switch mechanism

4 Enclosing tube

5 Enclosing tube gasket

6 Head flange

7 Studs

8 Hex nuts

9 Flange gasket

10 Float chamber

11 Stop strap

12 Screws

13 Float and stem assembly

14 Jam nuts

15 Guide washer

16 Attraction sleeve

17 Stop tube (not required for Models C29 and D30)

46-605 Flanged External Cage Float Actuated Liquid Level Switches 19

6.1.4 Models D30, J30 and L30

Housing cover Refer to Section 6.1.2 Housing base Refer to Section 6.1.2 Switch mechanism Refer to Section 6.1.2 Enclosing tube kitŒ  089-5915-001 089-5933-011 includes items 4 and 5 Enclosing tube gasket 012-1204-001 012-1301-002 Head flange kit 089-4204-001 089-4205-001 includes items 5, 6, 7, 8, and 9 Flange gasket 012-1301-023 012-1301-026 Float chamber kitŽ 089-4604-001 089-4605-001 includes items 7, 8, 9, and 10 Float and stem assemblyŒ 089-3204-001 089-3205-001 089-3206-001 includes items 9, 11, 12, 13, 14, 15, 16, and 17 Complete controlŒ  089-6569-002 not available less float chamber (10), bolts (7), and nuts (8) D30 J30 L30

6.1.5 Models B60 and C60

Housing cover Refer to Section 6.1.2 Housing base Refer to Section 6.1.2 Switch mechanism Refer to Section 6.1.2 Enclosing tube kit: includes items 4 and 5Œ 089-5933-004 089-5933-011 Enclosing tube gasket 012-1204-001 012-1301-002 Head flange kit: includes items 5, 6, 7, 8, and 9 089-4206-001 089-4206-002 Flange gasket 012-1204-015 012-1301-024 Float chamber kit:Ž includes items 7, 8, 9, and 10 089-4606-001 089-4606-002 Float and stem assembly: includes items 9, 11, 12, 13, 14, 15, 16, and 17Œ 089-3208-001 089-3209-001 Complete control less float chamber (10), bolts (7), and nuts (8)Œ  089-6568-004 089-6568-003 B60 C60 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.

20 46-605 Flanged External Cage Float Actuated Liquid Level Switches

6.2.1 Parts identification

Series Type Bulletin # Dry contact B, C, D 42-683 Hermetically sealed F 42-683 Hermetically sealed HS, H1 42-694 Bleed type pneumatic J 42-685 Non-bleed type pneumatic K 42-686 High temperature 8, 9, R 42-799

6.2.2 Switch and housing reference

IMPORTANT: When ordering, please specify: A. Model and serial number of control. B. Replacement assembly (kit) part number. //////////// //////////// //////////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// ///////// //// //// //// /// /// /// /// ///// ///// ///// ///// ///// ///// ///// ///// 2 0 Figure 8 //////// //////// //////// //////// //////// //////// //////// //////// //////// ///////// ///////// ///////// ///////// ///////// /// /// /// /// /// ///// ///// /// ///

6.2 Tandem Flanged External Cage Models

7 Studs and bolts

10 Stop strap

11 Screws

12 Upper float and stem assembly

13 Lower attraction sleeve

14 Spacer washer

15 Retaining ring

16 Jam nuts

17 Upper attraction sleeve

18 Lower float and stem assembly

19 Safety stop washer

20 Float chamber

21 Chamber liner (not shown)

46-605 Flanged External Cage Float Actuated Liquid Level Switches 21

6.2.3 Model C29 TDM

Housing kit: includes items 1 and 2 Refer to Section 6.2.2 Switch mechanism Refer to Section 6.2.2 Enclosing tube kit: includes items 4 and 5 89-5909-002 Enclosing tube gasket 12-1204-001 Head flange kit: includes items 5, 6, 7, 8, and 9 89-4203-001 Flange gasket 12-1301-025 Upper float and stem kit: includes items 9, 10, 11, 12, 13, 14 and 15 89-3217-001 Lower float and stem kit: includes items 9, 16, 17, 18 and 19 Special order Œ Float chamber kit: includes items 7, 8, 9, and 20 Special order Œ

6.2.4 Models D30 TDM, J30 TDM and L30 TDM

Housing kit: includes items 1 and 2 Refer to Section 6.2.2 Switch mechanism Refer to Section 6.2.2 Enclosing tube kit 089-5909-002 includes items 4 and 5 Enclosing tube gasket 012-1204-001 Head flange kit 089-4204-001 089-4205-001 includes items 5, 6, 7, 8, and 9 Flange gasket 012-1301-023 012-1301-026 Upper float and stem kit 089-3218-001 089-3219-001 089-3220-001 includes items 9,10,11,12,13,14, and 15 Lower float and stem kit Special order Œ includes items 9, 16, 17, 18, and 19 Float chamber kit Special order Œ includes items 7,8 9, and 20 D30 TDM  J30 TDM L30 TDM

6.2.5 Models B60 TDM and C60 TDM

Housing kit: includes items 1 and 2 Refer to Section 6.2.2 Switch mechanism Refer to Section 6.2.2 Enclosing tube kit: includes items 4 and 5 089-5933-004 089-5933-011 Enclosing tube gasket 012-1204-001 012-1204-001 Head flange kit: includes items 5, 6, 7, 8, and 9 089-4206-001 089-4206-002 Flange gasket 012-1204-015 012-1301-024 Upper float and stem kit: includes items 9, 10, 11, 12, 13, 14, and 15 089-3222-001 089-3223-001 Lower float and stem kit: includes items 9, 16, 17, 18, and 19 Special order Œ Float chamber kit: includes items 7, 8, 9, and 20 Special order Œ B60 TDM C60 TDM 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.

22 46-605 Flanged External Cage Float Actuated Liquid Level Switches Minimum Specific Gravity  Œ for Models with Pressure Rating Model Material of Construction Code psig @ ° F bar @ ° C No. 12 100 750 900 1000 38 399 482 538 C29 0.76 0.81 500 403 388 383 34 28 27 26 D30 Ž 0.65 0.69 250 201 194 191 17 14 13 13 J30 0.48 0.51 400  322  310 167 28  22  21 12 L30 0.40 0.42 300  242  233 167 21  17  16 12 B60 0.68 0.71 900 725 496 182 62 50 34 13 C60 0.55 0.59 500 403 388 182 34 28 27 13 Maximum Maximum Bleed Models with Supply Process Orifice Material of Construction Switch Pressure Temperature Diameter Code 1 Code 2Description psig bar ° F ° C inches mm NEMA 1 NEMA 1 Series J 100 7 +400 +204 .063 1.6 JDG JDE Bleed Type 60 4 +400 +204 .094 2.3 JEG JEE Series K 100 7 +400 +204 —— KOE KOE Non-Bleed 40 3 +400 +204 —— KOG — Connection Connection Size Type 1" 11⁄2" 2" Threaded B20 C20 D20 Socket Weld B30 C30 D30 Cage Mounting Flange Rating (lbs.) 150 300 600 150 300 600 150 300 600 Flanged Upper N30 N40 N50 P30 P40 P50 Q30 Q40 Q50Side/Bottom Flanged S30 S40 S50 T30 T40 T50 V30 V40 V50Side/Side

1 Carbon Steel Chamber, 316 SS Float, 400 Stainless Steel Sleeve

2 Carbon Steel Chamber, 316 SS Float, 316 Stainless Steel Sleeve

7.0 Model Numbers

TANK CONNECTION TYPE AND SIZE PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Connection flanges are ASME B16.5 raised face. 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.

46-605 Flanged External Cage Float Actuated Liquid Level Switches 23 ELECTRIC SWITCH MECHANISM AND ENCLOSURE Switch

Description

Process  Temperature Range °F (°C) Contacts Set Points All models with Material of Construction Code 1 All models with Material of Construction Code 2 TYPE 4X/7/9 Aluminum Enclosure ‘ Class I, Div 1 Groups C&D Class I, Div 1 Group B ATEX Ex II 2 G EEx d IIC T6 Class I, Div 1 Groups C&D Class I, Div 1 Group B ATEX Ex II 2 G EEx d IIC T6 Series B Snap Switch -40 to +250 (-40 to +121) SPDT

1 BKA BKJ BCC BKB BKK BC9

2 BLA BLJ BDC BLB BLK BD9

3 BMA BMJ BEC BMB BMK BE9

DPDT 1 BNA BNJ BFC BNB BNK BF9

2 BOA BOJ BGC BOB BOK BG9

-40 to +450 (-40 to +232) SPDT

1 CKA CKJ CCC CKB CKK CC9

2 CLA CLJ CDC CLB CLK CD9

3 CMA CMJ CEC CMB CMK CE9

DPDT 1 CNA CNJ CFC CNB CNK CF9

2 COA COJ CGC COB COK CG9

-40 to +250 (-40 to +121) SPDT

1 DKB DKK DC9 DKB DKK DC9

2 DLB DLK DD9 DLB DLK DD9

3 N/A DMB DMK DE9

DPDT 1 DNB DNK DF9 DNB DNK DF9

2 DOB DOK DG9 DOB DOK DG9

-50 to +750 (-46 to +399) SPDT 1 FKA FKJ FCC FKB FKK FC9

2 FLA FLJ FDC FLB FLK FD9

DPDT 1 FNA FNJ FFC FNB FNK FF9

2 FOA FOJ FGC FOB FOK FG9

Series HS ’ Hermetically Sealed 5-amp Snap Switch with Wiring Leads -50 to +550 (-46 to +288) SPDT 1 HMJ HMK N/A HMJ HMK N/A2 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 +550 (-46 to +288) SPDT 1 HM3 HM4 HA9 HM3 HM4 HA9 DPDT 1 HM7 HM8 HB9 HM7 HM8 HB9 Series H1 Hermetically Sealed 1-amp Snap Switch with Wiring Leads -50 to +750 (-46 to +399) SPDT

1 HKJ HKK

2 HKN HKP HKN HKP

-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

-50 to +750 (-46 to +399) SPDT 1 8KA 8KJ 8CC 8KB 8KK 8C9 2 8LA 8LJ 8DC 8LB 8LK 8D9 3 8MA 8MJ 8EC 8MB 8MK 8E9 DPDT 1 8NA 8NJ 8FC 8NB 8NK 8F9 2 8OA 8OJ 8GC 8OB 8OK 8G9 Series 9 High Temperature Hermetically Sealed Snap Switch -50 to +750 (-46 to +399) SPDT 1 9KA 9KJ 9CC 9KB 9KK 9C9 2 9LA 9LJ 9DC 9LB 9LK 9D9 3 9MA 9MJ 9EC 9MB 9MK 9E9 DPDT 1 9NA 9NJ 9FC 9NB 9NK 9F9 2 9OA 9OJ 9GC 9OB 9OK 9G9 CS/Aluminum Cast Iron CS/Aluminum Cast Iron NEMA 4X Class I, Div 1 Groups C&D Class I, Div 1 Group B NEMA 4X Class I, Div 1 Groups C&D Class I, Div 1 Group B Series R High Temperature Snap Switch -40 to +1000 (-46 to +538) SPDT 1 R1M RKM RKW R1M RKM RKW

2 R3M RLM RLW R3M RLM RLW

DPDT 1 RDM RNM RNW RDM RNM RNW

2 REM ROM ROW REM ROM ROW

-50 to +1000 (-46 to +538) SPDT 1 9AD 9KD 9KV 9AM 9KM 9KW 2 9BD 9LD 9LV 9BM 9LM 9LW 3 9CD 9MD 9MV 9CM 9MM 9MW DPDT 1 9DD 9ND 9NV 9DM 9NM 9NW 2 9ED 9OD 9OV 9EM 9OM 9OW

BULLETIN: 46-605.17 EFFECTIVE: August 2010 SUPERSEDES: July 2009 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. 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 con- trol; 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 consequen- tial 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. Company Name 2. Description of Material 3. Serial Number 4. Reason for Return 5. 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. ASSURED QUALITY & SERVICE COST LESS Hastelloy® is a registered trademark of Haynes International, Inc.