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Installation and Operating Manual Flow Switches Models F10 and F50
Read this Manual Before Installing This manual provides information on Model F10 and F50 Flow 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 box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNINGS Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages Follow all standard industry procedures for servicing elec- trical equipment when working with or around high voltage. Always shut off the power supply before touch- ing any components. WARNING! Explosion hazard. Do not connect or dis- connect 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 the manufacturer, protection provided by the equipment may be impaired. Notice of T rademark, Copyright, and Limitations Magnetrol & Magnetrol logotype are registered trade- marks of Magnetrol International. Copyright © 2010 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 product described in this manual at any time without notice. Magnetrol makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol mechanical level and flow controls are 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 guar- antees the highest level of quality throughout the company. Magnetrol is committed to providing full customer satis- faction 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.
47-602 F10 and F50 Flow Switches Table of Contents
1.0 Introduction
2.3.1 Model F10 Mounting —
2.3.1.2 Positioning Vane Perpendicular
2.3.1.3 T rimming Vane to fit Horizontal
3.1.2 Inspect Switch Mechanisms, T erminals,
4.3.1 Model F10 and F50 Specific Gravity
4.4.3 Model F10 Dimensiona
4.4.4 Model F50 Dimensional
4.5.1.2 Model F10 Switch and
4.5.2.2 Model F50 Switch and
4.5.2.3 Model F50 Bronze Body
4.5.2.4 Model F50 Stainless Steel
4 47-602 F10 and F50 Flow Switches
1.0.1 Model F10
F10 vane-actuated flow switches provide excellent reliabili- ty for a broad spectrum of horizontal pipe flow-sensing applications, including air, oil and petroleum derivatives, corrosive chemicals, and water.
1.0.2 Model F50
F50 Flow Switches are utilized, in horizontal lines, to sense the presence or absence of liquid flow in oil, chemical, gas, and water lines.
1.1 Principle of Operation
1.1.1 Model F10
The flow of liquid or gas through a pipeline applies a force to a flow vane inserted into the pipeline. When flow is sufficient such that the force on the vane moves the vane, it is pivoted up, parallel to the flow. This movement causes an attraction sleeve to move into the field a magnet. The magnet moves toward the sleeve causing actuation of the switch.
1.1.2 Model F50
The flow of liquid through the valve body applies a force to a flow disc. This in turn raises the magnetic sleeve, within its sealed non-magnetic enclosing tube into the field of the switch magnet, located outside the enclosing tube, actuating the attached switch mechanism.
1.2 Operating Cycle
1.2.1 Model F10
Sufficient flow through a pipeline causes the pivoted vane assembly to swing in the direction of the flow. The vane assembly rotates a cam which lifts an attraction sleeve, which in turn causes the magnet to pull in and actuate the switch. The O-ring sealed adjusting screw, in the top of the enclosing tube, compresses the range spring located above the attraction sleeve. T urning the adjusting screw clock- wise, increases the flow rate at which the switch actuates. Adjustments can be made while the flow switch is in service. Actuating vane Adjusting screw Magnetic sleeve Swing out position Return spring Pivot Figure 1—No Flow Position Magnet Return Spring Pivot Figure 2—Position w/Actuating Flow Present
47-602 F10 and F50 Flow Switches 5
1.2.2 Model F50
On an increasing flow rate, the flow disc moves the attrac- tion sleeve up within the field of a switch magnet, drawing it in tightly to the enclosing tube. This causes the switch to make or break an electrical circuit. When the flow rate drops, below the rate for which the flow disc is calibrated, the attraction sleeve is pulled downward until, at a prede- termined low flow rate, the switch magnet releases and swings outward, away from the enclosing tube, causing a reversal of the switching action.
2.0 Installation
This section provides detailed procedures for properly installing Model F10 and F50 Flow Switches.
2.1 Unpacking
Caution: If equipment is used in a manner not specified by the manufacturer, protection provided by the equipment may be impaired. Unpack the instrument carefully, inspecting all compo- nents for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/ crate against those listed on the packing slip, and report any discrepancy to the factory. Check the part number on the nameplate to be certain it agrees with the part number shown on the packing slip and purchase order. Record the serial number for future reference when ordering parts.
2.2 Piping
NOTE: For proper performance, a straight pipe run of 12 pipe diame- ters up stream and 3 pipe diameters downstream of the switch is recommended.
2.2.1 Model F10
The F10 flow switch should be located in a horizontally run pipe with the arrow on the body bushing or mounting flange pointing in the direction of flow.
2.2.2 Model F50
The Model F50 flow switch should be located in a hori- zontal pipe run, with the arrow on the valve body pointing in the direction of flow. The switch housing must always be above the valve body. Figure 3—No Flow Position Figure 4—Position w/Actuating Flow Present Snap switch Swing out position Return spring Pivot Enclosing tube (non-magnetic) Swing in position Sleeve (magnetic) Magnet Flow disc Return Spring Pivot
6 47-602 F10 and F50 Flow Switches
2.3 Mounting
Caution: This instrument is intended for use in Installation Category II, Pollution Degree 2.
2.3.1 Model F10 Mounting – Threaded Connection
2.3.1.1 Installation of F10 in Horizontal Line
- Insert a length of pipe in two inch, 3,000 lb. threadolet fitting. 2. Plumb the vertical center line of the fitting and trace around the fitting to locate center line of required 2.62 inch (67 mm) diameter hole. Refer to Figure 5. 3. Clean up inside edges of hole, and remove any slag on the bottom of line that could interfere with vane. 4. With fitting concentrically positioned over the 2.62 inch (67 mm) diameter hole, and the vertical center line held plumb (refer to Figure 6), tack weld the fitting at four equally space points. After tacking, remove .06 inch (2 mm) diameter spacer wire. Refer to Figure 5. NOTE: A hole in the pipeline less than 2.62 inches (67 mm) in diame- ter will limit travel of the pivoted vane. If this condition cannot be avoided, the width of the vane should be reduced to 1.50 inches (38 mm) maximum. IMPORTANT: For installation in 2.00 inch pipe lines, disregard 2.62 inch (67 mm) dimension and use inside of threadolet as template. 5. Proper operation of the F10 depends upon the vertical center line of the 2" NPT coupling being plumb within 3°. Keep fitting plumb while welding the continuous passes, according to threadolet manufacturers installation procedure.
2.3.1.2 Positioning Vane Perpendicular to Flow
- With large and small vanes unassembled, tighten the F10 body bushing into the coupling on the pipeline, until one of the three decal flow arrows is pointing parallel with flow. 2. Mark the bushing thread, even with the top of the thread- olet, as a reference point for trimming vane to correct length. Remove two arrows not parallel with the pipe. 3. Remove the F10 from pipeline. Figure 5 2 3 4 5 6 7 8 9 10 11 Air bubble in level position 2'' diameter pipe, approx. 12''long .06 (2)dia. spacer wire to provide root gap 3,000 lb. 2" threadolet fitting Marker Vertical centerline must be plumb 1 2 3 4 5 6 7 10 11 2 3 4 5 6 7 8 9 10 11 Air bubble in level position Air bubble in level position Tack weld four places 2.62 (67) dia. Vertical centerline must be plumb (See Note following Item 4) Figure 6
- Check position of the arrow stamped on vane support
2.3.1.3 Trimming Vane to Fit Horizontal Line Size
trimmed to dimension “C” less .19 inch (5 mm). Figure 8. Upon final assembly of trimmed vanes, be peened over on the threaded end.
2.3.1.4 Final Mounting
- Apply sealing compound to body bushing threads.
- Thread F10 into threadolet fitting and tighten body bush-
Section 2.3.1.2,Positioning Vane Perpendicular to Flow.
- Connect conduit and power lines.
8 47-602 F10 and F50 Flow Switches
2.3.2 Model F10 — Flanged Connection
NOTE: For proper performance, a straight pipe run of 12 pipe diame- ters up stream and 3 pipe diameters downstream of the switch is recommended. Figure 9 shows one method which may be used to mount the F10 flow switch to 2.50 to 30.00 inch run pipes. Before final welding, alignment of mounting flange should be checked to be certain it is plumb. Finished mounting must allow control switch housing to be within three degrees of vertical for proper operation. A three-degree slant is noticeable by eye, but installation should be checked with a spirit level.
2.3.3 Model F50 Mounting
2.3.3.1 Installation of Model F50
- When installing, use wrenches on valve body only. Do not attempt to tighten or draw-up valve body on the pipe by pulling or pushing on switch housing cover. 2. Adjust pipe alignment, as required, to bring switch hous- ing to a vertical position above pipeline. F50 flow switches must be mounted within three degrees of vertical. Three degree slant is noticeable to the eye, but installation should be check with a spirit level on the side of the enclosing tube at two places, 90 degrees apart. NOTE: On flow switches using pneumatic switch assemblies, con- sult bulletin on mechanism furnished for air (or gas) piping instructions. NOTE: For proper performance, a straight pipe run (12 pipe diameters upstream, and three pipe diameters downstream of the switch), is recommended.
2.4 Wiring
Caution: Level controls are shipped from the factory with the enclosing tube tightened 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. 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 the equipment. Figure 9 Vertical centerline must be plumb 21/2" ANSI mounting flange21/2" P.S. ANSI flange 21/2" P.S. pipe nipple (sched. 80 max. wall thickness) 1/2"- 3000 lb. sockolet fitting 0.19 minimum 3.00 dia. hole in run pipe Top of run pipe Inside bottom of run pipe Actuating vane FLOW 4 5.25 (133) Standoffs (Qty. 3) NOTES: Conduit outlet may be rotated 360° for wiring convenience. Flange to match flange of F10 flow switch and positioned with bolt holes straddling center lines. For proper attachment procedure, refer to fitting manufacturer’s recommendation. Dimension shown is for use with 0.06 inch (2 mm) thick flange gasket. If thicker gasket is used, reduce dimension amount equal to addi- tional thickness. For run pipe sizes over 2.50 inch P .S. only. For installation on 2.50 inch run pipes, disregard 3.00 inch dimension and use inside of adaptor fitting as template. Follow appropriate sections under threaded connection mounting to position the vane per- pendicular to the flow and trim vane to size.
47-602 F10 and F50 Flow Switches 9 1. On high temperature applications, above +250° F (+121° C), high temperature wire should be used between the control and first junction box located in a cooler area. 2. Remove switch housing to gain access to switch mechanism. NOTE: For supply connections in installations with ambient tempera- ture up to +70° C, use wire with a minimum rating of +75° C as required by the process conditions,. Installations with ambient temperatures up to +80° C require wire with a mini- mum rating of +85° C as required by the process conditions. Use a minimum of 14 AWG wire for power and ground field wires. 3. Pull in supply wires (conductors), wrap them around enclosing tube beneath the baffle plate, and connect to proper terminals. Ensure excess wire does not interfere with actuation of the switch, and that adequate clearance exists for replacement of switch housing cover. 4. Connect power supply to control and test switch actuation by varying flow rate within pipeline. NOTE: If switch mechanism fails to function properly, check vertical alignment of control housing. Refer to installation bulletin of mechanism furnished, as listed in the switch mechanism chart on page 21. 5. Replace switch housing cover. NOTE: NEMA 4X/7/9 housings must be sealed at the conduit outlet with suitable compound to prevent entrance of air. 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 gases into switch housing. 6. Place flow switch into service.
2.4.1 Model F10 Switch Actuation Adjustment
The F10 flow switch is factory set to actuate at the mini- mum flow rate. Actuation flow rate can be increased while the unit is in service, under pressure, by removing the 1⁄4" NPT plug to gain access to the O-ring sealed adjusting screw. Each clockwise turn of the adjusting screw increases the actuating flow rate approximately 10% of the range of the specific flow vane being used. See pages 16–18 for flow rate adjustability. Caution: The safety retainer above the adjusting screw is placed there to help prevent the accidental removal of the adjust- ing screw. Do not defeat its purpose by forcefully backing out the adjustment screw. Be sure to replace the 1⁄4" NPT plug and tighten it firmly. Set Screw ScrewScrew Figure 10
10 47-602 F10 and F50 Flow Switches
3.0 Preventive Maintenance
Periodic inspections are a necessary means to keep your flow switch 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 is observed, your control will provide reliable protection of your capital equipment for many years.
3.1 What To Do
3.1.1 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 the switch mechanism operation. In addition, it 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.
3.1.2 Inspect Switch Mechanisms, Terminals, and
a. 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. Such wear can cause false switch actuating levels. Adjust switch mechanism to compensate (if possible) or replace switch. b. DO NOT operate your control with defective or maladjusted switch mechanism (refer to bulletin on switch mechanisms furnished for service instructions). c. 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 it at the first sign of brittle insulation. d. Vibration may sometimes cause terminal screws to work loose. Check all terminal connections to be certain that screws are tight. e. On units with pneumatic switches, air (or gas) operating medium 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.
47-602 F10 and F50 Flow Switches 11 NOTE: As a matter of good practice, spare switches should be kept on hand at all times.
3.1.3 Inspect Entire Unit Periodically
Increase and decrease liquid flow through the pipeline to check for switch contact and reset.
3.2 What To Avoid
- NEVER leave switch housing cover off the control longer than necessary to make routine inspection. 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 flow switches 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 lubrication is unnecessary, and will only tend to attract dust and dirt which can interfere with mechanism operation.
12 47-602 F10 and F50 Flow Switches
4.0 Reference Information
4.1 Troubleshooting
Usually the first indication of improper operation is fail- ure of the controlled equipment to function, i.e., pump will not start (or stop), signal lights 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. a. Fuses may be blown. b. Reset button(s) may need resetting. c. Power switch may be open. d. Controlled equipment may be faulty. If a thorough inspection of these possible conditions fails to locate the trouble, proceed to a check of the control's switch mechanism.
4.1.1 Check Switch Mechanism
- Pull disconnect switch, or otherwise assure that electrical circuit(s) of control are deactivated. 2. Remove switch housing cover. 3. Swing magnet assembly in and out by hand, checking carefully for any sign of binding. Assembly should require minimal force to move it through its full swing. 4. If binding exists, magnet may be rubbing enclosing tube. If magnet is rubbing, loosen magnet clamp screw, and shift magnet position. 5. If switch magnet assembly swings freely, and mechanism still fails to actuate, check installation of control to be certain it is within the specified three degrees of vertical. Use a spirit level on side of enclosing tube in two places, 90 degrees apart. NOTE: As a matter of good practice, spare switches should be kept on hand at all times. If switch mechanism is operating satisfactorily, a test of the complete control’s performance is the next likely step.
47-602 F10 and F50 Flow Switches 13
4.1.2 Test Control’s Performance
If switch mechanism is operating satisfactorily, a test of the complete control’s performance is the next likely step. 1. Reconnect power supply, and carefully actuate switch mechanism manually, using a non-conductive tool, 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 flow sensing portion of the control. NOTE: Check first to be certain liquid is flowing through pipeline. A valve may be closed, or pipeline may be plugged. 3. If magnet fails to pull in on increasing flow: a. Disk or vane may not be sized properly for required actuation flow rate. b. Check for hang-up or deposits in disk seat or at vane pivot. c. Check for malfunctioning by manually moving magnet carriage. 4. If magnet fails to pull out on decreasing flow: a. Disk or vane may not be sized properly for required actuation flow rate. b. Check for hang-up or deposits in disk seat or at vane pivot. c. Check for malfunctioning by manually moving magnet carriage. If all components in the unit are in operating condition, the trouble must be located external to the unit. Repeat inspection of external conditions previously described.
14 47-602 F10 and F50 Flow Switches
4.2 Agency Approvals
AGENCY MODEL APPROVAL CATEGORIES FM F10-XXXX-XXX with an electric switch mechanism and a housing Class I, Div 1, Groups C & D F50-XXXX-XXX listed as Type 4X/7/9 Class II, Div 1, Groups E, F & G F10-XXXX-XXX with an electric switch mechanism and a housing Class I, Div 1, B, C & D F50-XXXX-XXX listed as Type 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G CSA F10-XXXX-XXX with a Series F or HS electric switch Class I, Div 2, Group B F50-XXXX-XXX mechanism and a housing listed as CSA Type 4X F10-XXXX-XXX with an electric switch mechanism and a housing Class I, Div 1, Groups C & D F50-XXXX-XXX listed as Type 4X/7/9 Class II, Div 1, Groups E, F & G F10-XXXX-XXX with an electric switch mechanism and a housing Class I, Div 1, Groups B, C & D F50-XXXX-XXX listed as Type 4X/7/9 Class I, Div 1, Group B Class II, Div 1, Groups E, F & G ATEX/IEC Ex F10-XXXX-XXX with an electric switch mechanism and an ATEX II 2 G EEx d IIC T6 F50-XXXX-XXX ATEX housing 94/9/EC IEC Ex Ex d IIC T6 IP66 CE F10-XXXX-XXX Low Voltage Directives 2006/95/EC Installation Category II F50-XXXX-XXX Per Harmonized Standard: Pollution Degree 2 EN 61010-1/1993 & Amendment No. 1 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 d IIC T6 Tambient-40° C to +70° C
47-602 F10 and F50 Flow Switches 15
4.3.1 Model F10 and F50 Specific Gravity Correction
To determine the actuating flow rates for liquids other than water (approximate viscosity of 20 centistokes or less), a specific gravity correction factor must be applied to the water flow rates given in the table. Example: The maximum adjustment for an increasing flow rate with a liquid specific gravity of .70 in an 8" line is: 230 GPM x 1.20 = 276 GPM. Specific Gravity Multiplication Factor Specific Gravity Multiplication Factor .40 1.58 .95 1.03 .45 1.49 1.00 1.00 .50 1.41 1.05 .98 .55 1.35 1.10 .95 .60 1.29 1.15 .93 .65 1.24 1.20 .91 .70 1.20 1.25 .89 .75 1.15 1.30 .88 .80 1.12 1.35 .86 .85 1.08 1.40 .85 .90 1.05 1.45 .83
4.3 Specific Gravity
16 47-602 F10 and F50 Flow Switches
4.4 Specifications
4.4.1 Model F10 Actuating Flow Rates
Model F10 units may be adjusted in service to actuate within the minimum and maximum flow rates given below. A specific gravity correction factor is applied for liquids other than water (1.00 specific gravity). A vane length equal to the line size of the horizontal pipe is required. Pipe Line Size Flow Increase (GPM) Flow Decrease (GPM) Inches Minimum Maximum Minimum Maximum 2 21 63 16 48 21⁄2 26 74 20 56 3 32 88 24 65 31⁄2 38 100 28 75 4 45 120 33 85 5 61 150 43 110 6 79 180 55 130 8 120 230 82 160 10 170 310 110 210 12 230 380 150 250 14 270 430 170 280 16 340 510 220 320 18 430 590 270 370 20 520 690 320 430 22 620 780 380 480 24 730 900 450 550 26 850 1030 520 620 28 980 1160 590 700 30 1110 1290 670 780 Based upon Sch 40 pipe. For higher flow rates consult factory.
47-602 F10 and F50 Flow Switches 17 Water Service m3/h Model F10 units may be adjusted in service to actuate within the minimum and maximum flow rates given below. A specific gravity correction factor is applied for liquids other than water (1.00 specific gravity). Pipe Line Size Flow Increase (m 3/h) Flow Decrease (m 3/h) Inches Minimum Maximum Minimum Maximum 2 4.8 14.3 3.6 10.9 21⁄2 5.2 16.8 4.5 12.7 3 7.3 20.0 5.4 14.8 31⁄2 8.6 22.7 6.4 17.0 4 10.2 27.2 7.5 19.3 5 13.8 34.1 9.8 25.0 6 17.9 40.9 12.5 29.5 8 27.2 52.2 18.6 36.3 10 38.6 70.4 25.0 47.7 12 52.2 86.3 34.1 56.8 14 61.3 97.6 38.6 63.6 16 77.2 115.8 49.9 72.6 18 97.6 133.8 61.3 84.0 20 118.0 156.6 72.6 97.6 22 140.7 177.1 86.3 109.0 24 165.7 204.3 102.2 124.9 26 193.0 233.8 118.0 140.7 28 222.5 263.3 133.9 158.9 30 252.0 292.8 152.1 177.1 4.4.1 Model F10 Actuating Flow Rates (cont.) Based upon Sch 40 pipe. For higher flow rates consult factory.
18 47-602 F10 and F50 Flow Switches
4.4.2 Model F50 Actuating Flow Rates
Pipe Actuating Flow Rate, GPM Water Flow Size Increasing and Decreasing Rate (NPT) AB C D E F
47-602 F10 and F50 Flow Switches 19
4.4.3 Model F10 Dimensional Specifications
NOTE: For proper performance, a straight pipe run of 12 pipe diameters upstream and 3 pipe diameters downstream of the switch is recommended. Vane length dependent upon line size 1.75 (44) 1.50 (38) 3" Pipe and Up 2" and 2 1/2" Pipe 2" NPT 3000# Bonney Threadolet or Equal (Supplied by Customer) Pipe Line Size (Horizontal Lines Only) Vane Width FLOW A 5.93 (150) 3.87 (98) 8.46 (214) A plugged B 1.56 (40) 2.50 (63) 10.12 (257) CONDUIT CONNECTIONS A Electrical Switches: NEMA 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches: NEMA 1: 1/4" NPT All housings rotatable 360° Line Dim. B Equivalent Size Max. Max. Wall Schedule 2" 1.81 (46) 80 3" 1.88 (48) 80 31⁄2" 1.88 (48) 80 4" 2.00 (51) 120 5" 2.06 (52) 120 6" 2.12 (54) 120 8" 2.19 (56) 100 Over 2.31 (59) —8" 3.00 (76) Diameter 2 1/2" ANSI Flange□ (to match F10) 2 1/2" ANSI□ Mounting Flange Flow Vane 0.19 (5) Minimum 5.93 (150)□ □3.87 (98)□ 8.46□ (214)□ 10.12□ (257)□ plugged 5.25□ (133) Top of □ pipe run 7.38□ (187) A A Standoffs (Qty. 3) Notes: 1. Allow the following for overhead clearance for cover removal: NEMA 1 — 8.00 (203) NEMA 4X/7/9 — 10.00 (254) Group B — 10.00 (254) F10 with Flanged Connection F10 with 2" NPT Connection Inches (mm)
20 47-602 F10 and F50 Flow Switches
4.4.4 Model F50 Dimensional Specifications
Inches (mm) F50 Flow Switch with 3⁄4" or 1" NPT Internal Pipe, Bronze or Stainless Steel Body F50 Flow Switch with 11⁄2" or 2" NPT Internal Pipe, Bronze or Stainless Steel Body Outline Dimensions Housing AB C* D 5.93 4.29NEMA 4X/7/9 (151) (108) NEMA 4X/7/9 5.93 4.29 9.75 3.60 Group B (151) (108) (247) (91) NEMA 1 4.70 5.00 8.44 3.44 Pneumatic (119) (127) (214) (87) Conduit Connections E Electrical Switches NEMA 4X/7/9: 1" NPT Group B: 1" NPT Pneumatic Switches NEMA 1: 1/4" NPT Outline Dimensions Housing AB C * D 5.93 4.29NEMA 4X/7/9 (151) (108) NEMA 4X/7/9 5.93 4.29 10.75 4.60 Group B (151) (108) (273) (116) NEMA 1 4.70 5.00 9.44 4.44 Pneumatic (119) (127) (240) (113) NOTE: 1. For proper performance, a straight pipe run of 12 pipe diameters upstream and 3 pipe diameters downstream of the switch is recommended. 2. For NEMA 4X/7/9 allow 8.00 (203) overhead clearance for cover removal. 6.25□ (158) 3.87□ (98) 5.93 (150) 7.94□ (201) 3.00□ (76) 2.00□ (25) 5.75□ (1.46) Horizontal□ lines only Plugged A A Connection size NPT□ (both ends) 6.25□ (158) 3.87□ (98) 5.93 (150) 7.94□ (201) 3.18□ (80) 1.19 (30) 3.81□ (97) Horizontal□ lines only Plugged A A Connection size NPT□ (both ends) * This dimension increases by 2.19" (55) when the unit is supplied with an HS hermetically sealed switch with terminal block * This dimension increases by 2.19" (55) when the unit is supplied with an HS hermetically sealed switch with terminal block
47-602 F10 and F50 Flow Switches 21
4.5 Replacement Parts
4.5.1 Model F10
Figure 11 — F10 with Flange Connection Figure 12 — F10 with Threaded Connection ////
1 Housing cover
2 Housing base
3 Switch mechanisms
4 Baffle plate
7 Safety retainer
8 Washer
9 O-ring
10 Adjustment screw
11 Enclosing tube
12 Enclosing tube gasket
13 Body bushing or stem, cam follower & flange assy.
14 Flow arrow
15 Upper spring guide
16 Range spring
18 Lower spring guide
19 Attraction sleeve
20 Washer
21 Stem assembly
22 Cam assembly
23 No. 8 lock washer 24 8-32 fillister head screw 25 8-32 round head screw
26 Small vane
27 Large vane
4.5.1.1 Model F10 Parts Identification
Series Type Bulletin # Dry contact B, C, D 42-683 Hermetically sealed HS 42-694 Bleed type pneumatic J 42-685 Non-bleed type pneumatic K 42-686
4.5.1.2 Model F10 Switch and Housing Reference
IMPORTANT: When ordering replacement parts, please specify: A. Model and serial number of control. B. Name and number of replacement part.
22 47-602 F10 and F50 Flow Switches
4.5.1 Model F10 (continued)
4.5.1.3 Model F10 Threaded Mounting
Carbon Steel 304 SS 316 SS Housing cover See Switch and housing reference on previous page Housing base See Switch and housing reference on previous page Switch mechanism See Switch and housing reference on previous page Baffle plate 036-5303-001 6-32 round head screw 010-1409-005 Enclosing tube kit: includes items 6 through 11 089-5912-001 089-5913-001 089-5914-001 Enclosing tube gasket 012-1204-001 Body bushing 089-5704-001 089-5705-001 089-5706-001 Flow arrow 005-9822-001 Stem assembly kit: includes items 14 through 24 089-5541-001 089-5542-001 Vane kit: includes items 25 through 27 089-6703-001 — Consult factory for pipe runs over 8"
4.5.1.4 Model F10 Flanged Mounting
Forged Steel 304 SS 316 SS Housing cover See Switch and housing reference on previous page Housing base See Switch and housing reference on previous page Switch mechanism See Switch and housing reference on previous page Baffle plate 036-5303-001 6–32 round head screw 010-1409-005 Enclosing tube kit: includes items 6 through 11 089-5928-001 089-5929-001 089-5930-001 Enclosing tube gasket 012-1204-001 Stem, cam follower, and flange assy. 150 lb. 032-7203-001 032-7204-001 032-7205-001 300 lb. 032-7203-002 032-7204-002 032-7205-002 600 lb. 032-7203-003 032-7204-003 032-7205-003 Attraction sleeve and spring kit: includes items 14 through 20 089-5544-001 089-5545-001 Vane kit: includes items 25 through 27 089-6703-001 — Consult factory for pipe sizes over 8"
47-602 F10 and F50 Flow Switches 23 IMPORTANT: When ordering replacement parts, please specify: A. Model and serial number of control. B. Name and number of replacement part.
4.5.2 Model F50
3 Switch mechanism
4 Switch
5 Enclosing tube
6 E-tube gasket
7 O-ring (not shown)
8 Body adaptor (not shown)
9 Threaded body
10 Flow piston stop
11 Flow piston assy
12 Lock nut
13 Flow disc
4.5.2.1 Model F50 Parts Identification
Series Type Bulletin # Dry contact B, C, D 42-683 Hermetically sealed F 42-683 Hermetically sealed HS 42-694 Bleed type pneumatic J 42-685 Non-bleed type pneumatic K 42-686
4.5.2.2 Model F50 Switch and Housing Reference
Highly corrosive applications use piston assembly with sheathed attraction sleeve. Consult local representative for ordering assistance. Use insoluble adhesive on nut when attaching new flow disc. When actuated flow rate is critical, the entire control must be returned to the factory for replacement and recalibration of flow disc.
24 47-602 F10 and F50 Flow Switches
4.5.2 Model F50 (continued)
Housing cover See Switch and housing reference on previous page Housing base See Switch and housing reference on previous page Switch mechanism See Switch and housing reference on previous page Switch See Switch and housing reference on previous page Enclosing tube Z32-6325-002 Enclosing tube gasket 012-1204-001 O-ring Not required 012-1204-036 Body adaptor Not required 004-0481-001 Threaded body 002-5703-003 002-5703-004 002-5705-003 002-5705-004 Flow piston stop 005-5420-121 Not required Flow piston assembly 032-7127-001 032-7127-003 032-7127-002 Lock nut 010-2107-002 010-2107-003 Flow disc Specify model number and serial number
4.5.2.4 Model F50 Stainless Steel Body Replacement Parts
Housing cover See Switch and housing reference on previous page Housing base See Switch and housing reference on previous page Switch mechanism See Switch and housing reference on previous page Switch See Switch and housing reference on previous page Enclosing tube Z32-6325-002 Enclosing tube gasket 012-1204-001 O-ring Not required 012-1204-036 Body adaptor Not required 004-0481-001 Threaded body 002-5703-001 002-5703-002 002-5705-001 002-5705-002 Flow piston stop 005-5420-121 Not required Flow piston assembly 032-7108-001 032-7109-001 032-7109-002 Lock nut 010-2107-002 010-2107-003 Flow disc Specify model number and serial number Use insoluble adhesive on nut when attaching new flow disc. When actuation flow rate is critical, the entire control must be returned to the factory for replacement and recalibration of flow disc.
4.5.2.3 Model F50 Bronze Body Replacement Parts
47-602 F10 and F50 Flow Switches 25
4.6 Model Numbers
4.6.1 Model F10
Maximum Supply Maximum Process Bleed Orifice Switch Pressure Temperature Diameter Description psig bar ° F ° C inches mm NEMA 1 Series J 100 7 +400 +204 .63 1.6 JGF 60 4 +400 +204 .94 2.3 JHFBleed Type 60 4 +400 +204 .55 1.4 JJF Series K 100 7 +400 +204 —— KOF Non-Bleed 40 3 +400 +204 —— KOH Vane Sized for Flow Line Connection Type 2" 4" 6" 8" 10" 2" NPT D22 D24 D26 D28 D20 21⁄2" 150 lb. ANSI raised face flange n/a E54 E56 E58 E50 21⁄2" 300 lb. ANSI raised face flange n/a E64 E66 E68 E60 21⁄2" 600 lb. ANSI raised face flange n/a E74 E76 E78 E70 Mounting Connection Trim Magnetic Sleeve Pressure F10-1 Carbon Steel 304 and 316 Stainless Steel 316 Stainless Steel 1000 psig @ +450° F (69 bar @ +232° C) F10-3 304 Stainless Steel 304 and 316 Stainless Steel 316 Stainless Steel 1000 psig @ +450° F (69 bar @ +232° C) F10-4 316 Stainless Steel 316 Stainless Steel 316 Stainless Steel 1000 psig @ +450° F (69 bar @ +232° C) MODEL NUMBER CODE PIPELINE CONNECTION PNEUMATIC SWITCH MECHANISM AND ENCLOSURE Consult factory for flow lines above 10" or larger flange sizes. ELECTRIC SWITCH MECHANISM AND ENCLOSURE Process temperatures based on +100° F (+38° C) ambient. Uncontrolled housing heater or drain available in NEMA 4X/7/9 enclosures. Consult factory for NEMA 4X/7/9 cast iron housings. On flanged models, standoffs are carbon steel with Model F10-1 and 316 stainless steel on Models F10-3 and F10-4. NEMA 4X/7/9 Maximum Aluminum Process One Class I, Class I, Temperature Set Div.1 Div. 1 Switch Description ° F (° C) Point Grps C & D Grp B ATEX Series B snap +250 (+121)SPDT BKB BKK BC9 DPDT BNB BNK BF9 Series C snap +450 (+232)SPDT CKB CKK CC9 DPDT CNB CNK CF9 Series D snap +250 (+121)SPDT DKB DKK DC9 for DC current applications DPDT DNB DNK DF9 Series HS 5 amp SPDT HMJ HMK n/ahermetically sealed snap +450 (+232) with wiring leads DPDT HMS HMT n/a Series HS 5 amp SPDT HM3 HM4 HA9hermetically sealed snap +450 (+232) with terminal block DPDT HM7 HM8 HB9
26 47-602 F10 and F50 Flow Switches
4.6.2 Model F50
PNEUMATIC SWITCH MECHANISM AND ENCLOSURE PIPE SIZE Process temperatures based on -40° to +160° F (-40° to +71° C). Bronze models are rated to a maximum process temperature of +500° F (+260° C). Stainless steel models are limited to the maximum temperature of the selected switch mechanism. On steam applications, temperature down-rated to +400° F (+204° C) process at +100° F (+40° C) ambient. On models with bronze bodies 3⁄4" or 1" NPT pipe sizes, consult factory for HS switches. Body Trim Magnetic Sleeve Pressure Ratings F50-1 Bronze 300 Series 400 Series 400 psi @ +100° F (27.6 bar @ 38° C) Stainless Steel Stainless Steel 200 psi @ +500° F maximum (13.8 bar @ 260° C maximum) F50-4 316 Stainless Steel 316 Stainless Steel 316 Stainless Steel 1150 psi @ +100° F (79.2 bar @ 38° C) 600 psi @ +750° F maximum (41.3 bar @ 399° C maximum) A2 3⁄4" pipe size with 3⁄4" NPT connections B2 1" pipe size with 1" NPT connections C2 1 1⁄2" pipe size with 11⁄2" NPT connections D2 2" pipe size with 2" NPT connections Actuating Flow Rate, GPM Water Flow, Increasing and Decreasing Rate Pipe size AB C D E F Max. Process Maximum Bleed Temp. Supply Orifice Body Pipe Size Switch Description ° F (° C) Pressure Diameter Material (NPT) Flow Rate NEMA 1 3⁄4" or 1" A thru F JDG100 psig 0.63" Bronze 11⁄2" or 2" A thru D (7 bar) (1.6 mm) E and F JDE Series J bleed type +550 Stainless Steel3⁄4" thru 2" A thru F (+288) 3⁄4" or 1" A thru F JEG60 psig 0.94" Bronze 11⁄2" or 2" A thru D (4 bar) (2.4 mm) E and F JEEStainless Steel3⁄4" thru 2" A thru F 100 psig n/a Bronze 1 1⁄2" or 2" E and F KOE Series K non-bleed type +550 (7 bar) Stainless Steel3⁄4" thru 1" A thru F (+288) 40 psig n/a Bronze 3⁄4" thru 1" A thru F KOG(3 bar) 11⁄2" or 2" A thru D
47-602 F10 and F50 Flow Switches 27 ELECTRIC SWITCH MECHANISM AND ENCLOSURE
4.6.2 Model F50 (continued)
° F (° C) One Set Point Body Material Pipe Size (NPT) Flow Rate TYPE 4X/7/9 Aluminum Class I, Div 1 Class I, Div 1 Grps C & D Grp B ATEX Series B snap -40 to +250 (-40 to +121) SPDT Bronze 3⁄4" or 1" A thru F BKP BKT BAC 11⁄2" or 2" A thru D E and F BKQ BKS BA9Stainless Steel3⁄4" thru 2"A thru F DPDT Bronze 3⁄4" or 1" A thru F BNP BNT BBC 11⁄2" or 2" A thru D E and F BNQ BNS BB9Stainless Steel3⁄4" thru 2"A thru F Series C snap -40 to +450 (-40 to +232) SPDT Bronze 3⁄4" or 1" A thru F CKP CKT CAC 11⁄2" or 2" A thru D E and F CKQ CKS CA9Stainless Steel3⁄4" thru 2"A thru F DPDT Bronze 3⁄4" or 1" A thru F CNP CNT CBC 11⁄2" or 2" A thru D E and F CNQ CNS CB9Stainless Steel3⁄4" thru 2"A thru F Series D snap for DC current applications -40 to +250 (-40 to +121) SPDT Stainless Steel3⁄4" thru 2"A thru F DKQ DKS DA9 DPDT DNQ DNS DB9 Series F snap -40 to +750 (-40 to +399) SPDT Bronze 3⁄4" or 1" A thru F FKP FKT FAC 11⁄2" or 2" A thru D E and F FKQ FKS FA9Stainless Steel3⁄4" thru 2"A thru F DPDT Bronze 3⁄4" or 1" A thru F FNP FNT FBC 11⁄2" or 2" A thru D E and F FNQ FNS FB9Stainless Steel3⁄4" thru 2"A thru F Series HS snap 5 amp hermetically sealed w/wiring leads -50 to +550 (-46 to +288) SPDT Bronze 11⁄2" thru 2" A thru F HMC HEK n/a DPDT Bronze 11⁄2" thru 2" A thru F HMF HET n/a Series HS snap 5 amp hermetically sealed w/terminal block -50 to +550 (-46 to +288) SPDT Bronze 11⁄2" thru 2" A thru F HM3 HM4 HA9 DPDT Bronze 11⁄2" thru 2" A thru F HM7 HM8 HB9
BULLETIN: 47-602.26 EFFECTIVE: August 2010 SUPERSEDES: August 2008 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. 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 replace- ment. 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 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. CSA logotype is a registered trademark of Canadian Standards Association