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| installation and operating manual liquid level switches asme b31.1 construction series 3 liquid level switches
read this manual before installing this manual provides information on series 3 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 components 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 touching any components. 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 trademark, copyright, and limitations magnetrol & magnetrol logotype are registered trade- marks of magnetrol international, incorporated. copyright ? 2010 magnetrol international. all rights reserved. performance specifications are effective with date of issue and are subject to change without notice. magnetrol reserves the right to make changes to the product described in this manual at any time without notice. magnetrol makes no warranty with respect to the accura- cy 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. repair parts are warranted free of defects in materials and workmanship for one year from the date of shipment. materials, specifications, and contents are subject to change without prior written notice. 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 guaran- tees the highest level of quality throughout the company. magnetrol is committed to providing full customer satis- faction both in quality products and quality service. magnetrols 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. 46-624 series 3 liquid level switches asme b31.1 construction table of contents cer 0ajgbfmdjrba y 6 46-624 series 3 liquid level switches asme b31.1 construction controls should be mounted as close to the vessel as possi- ble. this will result in a more responsive and accurate level change in the control. liquid in a long line may be cooler and more dense than liquid in the vessel causing lower level indication in the control than actual level 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. 2.5 wiring note: a switch or circuit breaker shall be installed in close proximi- ty to equipment and within easy reach of operator. it shall be marked as the disconnecting device for the equipment. note: for supply connections in installations with ambient tempera- ture up to +158 f (+70 c), use wire with a minimum rating of +167 f (+75 c) as required by the process conditions. installations with ambient temperatures up to +176 f (+80 c) require wire with a minimum rating of +185 f (+85 c) as required by the process conditions. use a mini- mum of 14 awg wire for power and ground field wires. 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. series 3 controls are shipped with the conduit entry of the switch housing placed 180 opposite to the tank con- figurations to simplify installation in most cases. if this configuration is appropriate to the installation, proceed to step 4 to begin wiring the unit. if another configuration is desired, the switch housing can be easily rotated by first following steps 1, 2, and 3. 1. loosen set screw(s) at base of switch housing. refer to figure 4 . 2. switch housing may be rotated 360 to allow correct posi- tioning of conduit outlet. 3. tighten set screw(s) at base of switch housing. 4. unscrew and remove switch housing cover. the threads have been lubricated to facilitate removal. note: on high temperature applications (above +250 f [+121 c] in float chamber), high temperature wire should be used between control and first junction box located in a cooler area. on non-hazardous applications, flexible conduit may be used between the control and the first junction box. internal circuit (right) switch 1 2 3 load load close on high level common close on low level line 4 5 6 internal circuit (left) switch load load close on high level common close on low level line set screw screw screw figure 4 nema 4x/7/9 figure 5 wiring diagram for dpdt series a, b, c, d, e & f switches 46-624 series 3 liquid level switches asme b31.1 construction 7 5. the switch terminals are located next to the conduit outlet to facilitate wiring. bring supply wires through conduit outlet. route extra wire around enclosing tube under the baffle plate and connect them to the proper terminals. refer to the wiring diagram in your switch bulletin for this information. refer to chart below for switch instruction manual numbers. note: for models with a series hs or h1 switch with high tempera- ture lead wire, the leads are routed out through the conduit opening by the factory. a suitable conduit box should be pro- vided for the connection of the leads to the control wiring. 6. dress wiring to ensure no interference or contact with actuation of switch, or replacement of switch housing cover. observe all applicable electrical codes and proper wiring procedures. prevent moisture seepage into the enclosure by installing approved seal-drain fittings in the conduit run leading into the unit. caution: in hazardous areas, do not power the unit until the conduit is sealed and the enclosure cover is screwed down securely. 7. replace housing cover. 8. if control has been furnished with an explosion proof or moisture proof (gasketed) switch housing, it must be sealed at the conduit outlet with a suitable compound or non-hardening sealant to prevent entrance of air. 9. test switch action by varying liquid level in float chamber. note: if switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism furnished. 10. check cover-to-base fit to be certain that gasketed joint is tight. a positive seal is necessary to prevent infiltration of moisture-laden air or corrosive gasses into switch housings. switch series description bulletin letter no. b, c, d dry contact switch 42-683 f, 8, 9 high temperature hermetically sealed snap switch 42-799 hs, h1 hermetically sealed snap switch 42-694 r high temperature snap switch 42-799 j bleed type pneumatic switch 42-685 k non-bleed type pneumatic switch 42-686 8 46-624 series 3 liquid level switches asme b31.1 construction 3.0 switch differential adjustment the standard differential of series 3 float models with only one switch mechanism may be field-adjusted. adjustment may be necessary if a wider differential needs to be set to overcome switch chatter caused by the process. 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. caution: maximum differential adjustment is 1 inch (25 mm). 3.1 low level controls on low level controls the switch trips on the lower actuation point and resets on the higher actuation point. widening the differential will allow the switch to trip on the original actuation point and reset at a later, or higher, point. the differential on low level controls may be adjusted by repositioning the lower jam nuts on the float stem. the standard factory setting is for a minimum amount of play (gap) between the top jam nuts and the attraction sleeve as shown in figure 7 on page 9. 1. determine what change in differential is necessary. note: to widen the differential one inch, the lower jam nuts must be set proportionately lower on the stem (i.e., in this example 1 inch). 2. make sure power source is turned off. 3. nema 4x/7/9unscrew and remove switch housing cover. 4. disconnect power supply wires from switch mechanism. pull wires out of conduit connection opening in housing base. refer to figure 6 . 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. refer to figure 3 on page 5. 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. float enclosing tube refer to figures 7 and 8 housing base enclosing tube nut conduit connection switch housing cover chamber figure 6 46-624 series 3 liquid level switches asme b31.1 construction 9 note: level control, connections and pipe lines need not be removed from the tank. 6. loosen enclosing tube nut with a 15 M 16 " wrench. unscrew enclosing tube counterclockwise (switch and housing base will rotate also) until it is free. refer to figure 6 on page 8. 7. lift enclosing tube, switch, and base off float chamber. jam nuts and attraction sleeve are now accessible. 8. measure the distance d from the top edge of the upper jam nuts to the top of the float stem. refer to figure 8 . record this measurement. 9. loosen and remove upper jam nuts, guide washer, and attraction sleeve. 10. loosen and adjust lower jam nuts to the desired position. tighten lower jam nuts securely. refer to figure 8 . 11. replace attraction sleeve on stem. 12. replace upper jam nuts and guide washer on the stem in the position previously noted. tighten upper jam nuts securely. refer to figure 8 . note: using a new enclosing tube gasket when reassembling enclosing tube to the chamber. make certain that all gasket surfaces are thoroughly cleaned to allow proper gasket seating. coat enclosing tube threads with anti-seizing compound. 13. replace enclosing tube, switch, and base on chamber. screw tube clockwise until tightened to 200C225 foot-pounds of torque. 14. rotate switch housing to correct position and tighten set screw at base of switch housing. refer to figure 4 on page 6. 15. bring supply wires through conduit outlet. follow steps 5 through 10 in wiring, section 2.5 on pages 6 and 7. 16. test switch action by varying liquid level in float chamber. note: if switch mechanism fails to function properly, check vertical alignment of control housing and consult installation bulletin on switch mechanism. if the unit still fails to function properly, consult the factory. 3.2 high level controls on high level controls the switch trips on the higher actu- ation point and resets on the lower actuation point. caution: on high level controls, widening the differential requires raising the trip point a proportional amount. the reset point will remain the same. slight play (gap) must be allowed (0.03" typical) position of bottom jam nuts (normal factory setting) replace in same position maximum gap setting (applies to models having a single switch mechanism with a single magnet actuator only) 1.00 (25 mm) drop bottom jam nuts to increase gap setting (refer to above instructions) figure 7 figure 8 d 10 46-624 series 3 liquid level switches asme b31.1 construction to widen the differential by raising the trip point, follow steps 1 through 16 in low level controls, section 3.1 on pages 8 and 9. caution: after increasing gap setting, be certain to check for proper operation of switch mechanism by raising and low- ering float assembly. magnet must "snap" cleanly with additional float movement available after magnet snaps. 4.0 preventive maintenance periodic inspections are necessary to keep your level con- trol 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 implement- ed 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 equip- ment for many years. 4.1 what to do every 6 months (minimum) 4.1.1 switch corrosion inspection for every 6 months in service, conduct the following maintenance and inspection checks. note: conduct this inspection every 3 months for applications where the switches are exposed to corrosive environments. some environments may cause accelerated corrosion on the switch mechanism. to identify switch corrosion prior to failure: 1. disconnect power to the switch. 2. remove switch housing cover to inspect switch mecha- nisms for visible signs of corrosion on terminals and wires. note: when removing switch housing cover, secure housing base to prevent rotation of the base and enclosing tube. if cover proves difficult to remove, loosen housing base set screws before using a crossbar to free the cover. loosening the set screws will prevent accidental rotation of the enclosing tube and possible leakage of process media. 3. 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. 46-624 series 3 liquid level switches asme b31.1 construction 11 4. controls may sometimes be exposed to excessive heat or moisture. under such conditions, insulation on electrical wiring may become brittle, eventually breaking or peeling away. the resulting bare wires can cause short circuits. check wiring carefully and replace at the first sign of brittle insulation. 5. vibration may sometimes cause terminal screws to loosen. check all terminal connections to be certain that screws are tight. 6. conduct a continuity test for switch contacts using a low voltage dc circuit with an indicator. 7. switches that are corroded or that failed the contact continuity test should be replaced. do not operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms for service instructions.) 8. verify that switch housing cover and conduit seal are properly closed after each inspection of the switch mechanism(s). note: in applications with presence of salt-laden air or corrosive vapors, contact magnetrol for possible alternate switch mechanisms. 4.1.2 switch and wiring inspection the switch mechanism and supply wiring need to be in proper position to assure correct switch operation. 1. remove switch housing cover to inspect the supply wires. 2. check that the supply wires are attached to the terminal block and run under the baffle plate. be certain that excess wire does not interfere with the actuation of the switch and that adequate clearance exists for replacement of switch housing cover. 3. manually push on the magnet of the switch mechanism to confirm that the mechanism pivots freely. if it does not, the switch mechanism should be replaced. 4. make sure the switch mechanism is seated all the way down on the baffle plate. refer to figure 11 . check that the mechanism clamping screw is tightened to assure that the mechanism is secured to the enclosing tube and in proper position on the baffle plate. refer to figure 12 on page 12. the baffle plate should rest on the housing base casting hub. switch wires switch mechanism clamping screw snap switch adjustment screw terminal screws supply wires switch wires switch mechanism clamping screw terminal screws supply wires snap switch adjustment screw figure 9 figure 10 switch mechanism baffle plate housing base enclosing tube housing base casting hub figure 11 12 46-624 series 3 liquid level switches asme b31.1 construction note: hs series switches use a cylindrical spacer in place of the baffle plate. refer to figure 13 . 5. if the above wiring conditions are not met the unit should be rewired. proceed to step 6. 6. disconnect power to the switch. 7. the baffle plate is notched at the front and rear for control wires to pass through. control wires should enter through the conduit entry, pass under the baffle plate to the notch, then proceed through to the terminal block. refer to figure 14 . 8. control wires should not touch moving parts in any way. 9. the control wires should be attached to the terminal block so that they run from the terminal block, down through the notch, and under the baffle plate. note: the control wires must not interfere with the switch mechanism. 10. connect power supply to the control and conduct functional test of unit as described below. 11. replace switch housing cover and place control into service. 4.1.3 functional test of unit this procedure will assure that the complete unit is functioning properly. this test should be conducted after switch and wiring inspections have been completed. 1. adjust piping as required to bring control to a vertical position. control must be mounted within 3 of vertical. installation should be checked with an indicating level on top or sides of float chamber. 2. check the chamber mounting within 3 of vertical after the boiler installation. 3. raise level in the vessel sufficient to raise the float and trip the switch. lower level in the vessel sufficient to lower float and reset the switch. confirm switch trips and resets at expected levels (contact magnetrol for specific information on trip points; have the serial number of the unit readily available). figure 14 placement of supply wires baffle plate conduit entry switch mechanism run wires under baffle plate to terminal block. terminal block assembly notches in baffle plate mechanism clamping screw hs switch mechanism switch spacer housing base enclosing tube switch washer housing base casting hub figure 13 figure 12 46-624 series 3 liquid level switches asme b31.1 construction 13 4.2 what to do every 12 months (minimum) 4.2.1 switch corrosion inspection for every 12 months in service, conduct the following maintenance and inspection checks in addition to cus- tomer specific or code requirements. note: conduct this inspection every 3 months for applications where the switches are exposed to corrosive environments. 1. disconnect power to the switch. 2. remove switch housing cover to inspect switch mecha- nisms for visible signs of corrosion on terminals and wires. note: when removing switch housing cover, secure housing base to prevent rotation of the base and enclosing tube. if cover proves difficult to remove, loosen housing base set screws before using a crossbar to free the cover. loosening the set screws will prevent accidental rotation of the enclosing tube and possible leakage of process media. 3. 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. 4. controls may sometimes be exposed to excessive heat or moisture. under such conditions, insulation on electrical wiring may become brittle, eventually breaking or peeling away. the resulting bare wires can cause short circuits. check wiring carefully and replace at the first sign of brittle insulation. 5. vibration may sometimes cause terminal screws to loosen. check all terminal connections to be certain that screws are tight. refer to figure 15 . 6. conduct a continuity test for switch contacts, using a low voltage dc circuit with an indicator. 7. switches that are corroded or that failed the contact conti- nuity test should be replaced. do not operate your control with defective or maladjusted switch mechanisms (refer to bulletin on switch mechanisms furnished for service instructions.) 8. verify that switch housing cover and conduit seal are properly closed after each inspection of the switch mechanism(s). note: in applications with presence of salt-laden air or corrosive vapors, contact magnetrol for possible alternate switch mechanisms. mechanism clamping screw terminal screws figure 15 14 46-624 series 3 liquid level switches asme b31.1 construction 4.2.2 switch and wiring inspection the switch mechanism and supply wiring need to be in proper position to assure correct switch operation. 1. remove switch housing cover to inspect the supply wires. 2. check that the supply wires are attached to the terminal block and run under the baffle plate. refer to figure 14 on page 12. be certain that excess wire does not interfere with the actuation of the switch and that adequate clearance exists for replacement of switch housing cover. 3. manually push on the magnet of the switch mechanism to confirm that the mechanism pivots freely. if it does not, the switch mechanism should be replaced. 4. make sure the switch mechanism is seated down on the baffle plate. refer to figure 11 on page 11. check that the mechanism clamping screw is tightened to assure that the mechanism is secured to the enclosing tube and in proper position on the baffle plate. refer to figure 16 . the baffle plate should rest on the housing base casting hub. note: hs series switches use a cylindrical spacer in place of the baffle plate. refer to figure 15 on page 13. 5. if the above wiring conditions are not met, the unit should be rewired. proceed to step 6. 6. disconnect power to the switch. 7. the baffle plate is notched at the front and rear for control wires to pass through. control wires should enter through the conduit entry, pass under the baffle plate to the notch, then proceed through to the terminal block. refer to figure 14 on page 12. 8. control wires should not touch moving parts in any way. 9. the control wires should be attached to the terminal block so that they run from the terminal block, down through the notch, and under the baffle plate. note: the control wires must not interfere with the switch mechanism. 10. connect power supply to the control and conduct func- tional test of unit as described below. 11. replace switch housing cover and place control into service. switch wires switch mechanism clamping screw snap switch adjustment screw terminal screws supply wires switch wires switch mechanism clamping screw terminal screws supply wires snap switch adjustment screw figure 17 figure 18 mechanism clamping screw terminal screws figure 16 46-624 series 3 liquid level switches asme b31.1 construction 15 figure 19 4.2.3 control head removal and installation inspection of the interior of the chamber is possible on flanged cage models. to do this, the control head must be removed to provide proper access to the chamber. this procedure will assure that the head assembly is removed and reinstalled properly. 1. vessel should be at a safe temperature and pressure before opening the pressure boundary. 2. power down all wiring to the unit. 3. remove all wiring and conduit from the unit. 4. remove flange bolts. 5. prepare an area where the head assembly can be placed such that it rests on the flange in its normal orientation (two 2 4 boards placed across an open drum work well). refer to figure 19 . 6. carefully lift the head assembly by holding the sides of the flange. maintain the head assembly as much as possible in the vertical position. 16 46-624 series 3 liquid level switches asme b31.1 construction note: care must be taken not to place side force on the float which could bend the stem. 7. with the unit resting in its temporary fixture in an upright position, it can now be inspected or repaired. caution: do not place the unit on its side this could result in damage to the stem. 8. conduct a check for float stem straightness as follows: 8.1 remove the stem assembly including attraction sleeve from the head assembly by removing the two screws holding the stop strap to the bottom of the flange. see figure 20 for assembly schematic. 8.2 check the stem straightness by aligning the stem against a straight edge. stems that are bent in excess of 1 M 8 inch over any 6 inch length should not be used in this condition. replace any bent stems. see replacement parts, section 5.3. 8.3 ensure that the components in the stem assembly are in good condition and surfaces are clear of potential obstructions. the stem assembly is reinstalled by securing the stop strap to the flange. ensure that the attraction sleeve moves freely through the enclosing tube and that the stem assembly surfaces are smooth. note: care must be taken during the straightness check to ensure the attraction sleeve is not removed from the stem and the jam nuts settings are not changed. 9. in the container that the unit is set on, raise the liquid level sufficiently to lift the float and trip the switch mecha- nism. inspect inside of chamber for any obstructions or scale buildup. if excessive buildup is present, the interval between inspections should be shortened. remove old gas- ket such that mating flange surfaces are completely clean. position new gasket on chamber flange before replacing the head assembly. note: the float is restricted from moving laterally by the chamber, in the test configuration the float and stem can move further off center than possible under normal operation. avoid excess movement in this lateral direction during the test. if switch trips, the unit may be reassembled. 10. replace the assembly keeping it as vertical as possible. carefully lower the assembly into the chamber making sure that the stem does not become bent during installa- tion. refer to figure 19 on page 15. 11. tighten flange bolts per torque values as indicated in table on the next page. 0.03" minimum gap setting top jam nuts bottom jam nuts attraction sleeve enclosing tube (ref.) stop tube sleeve stop strap retaining screws float and stem assembly head flange (ref.) dim. a figure 20 46-624 series 3 liquid level switches asme b31.1 construction 17 12. attach wiring and connect power supply as described in switch and wiring inspection, section 4.2.2 on page 14. 4.2.4 functional test of unit this procedure will assure that the complete unit is functioning properly. this test should be conducted after switch and wiring inspections have been completed. 1. adjust piping as required to bring control to a vertical position. control must be mounted within 3 of vertical. installation should be checked with an indicating level on top or sides of float chamber. 2. check the chamber mounting within 3 of vertical after the boiler installation. 3. raise level in the vessel sufficient to raise the float and trip the switch. lower level in the vessel sufficient to lower float and reset the switch. confirm switch trips and resets at expected levels (contact magnetrol for specific information on trip points; have the serial number of the unit readily available). 4.3 troubleshooting usually the first indication of improper operation is failure of the controlled equipment to function, i.e., pump will not start (or stop), signal lamps fail to light, etc. when these symptoms occur, whether at time of 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 control's switch mechanism. model flange bolting enclosing tube b3f C 150# 100 C 120 ft-lbs 200-225 ft-lbs b3f C 300#, g3f C 150#, g3f C 300# 180 C 200 ft-lbs b3f C 600# 300 C 320 ft-lbs g3f C 600#, z3f C 600# 470 C 490 ft-lbs k3f C 600# 675 C 710 ft-lbs z3f C 900# 775 C 850 ft-lbs 18 46-624 series 3 liquid level switches asme b31.1 construction 4.3.1 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 continuity of switch with ohmmeter. 8. if switch mechanism is operating satisfactorily, proceed to check sensing unit. note: spare switches should be kept on hand at all times. 4.3.2 check sensing unit 1. reconnect power supply and carefully, manually actuate switch mechanism (use a non-conductive tool on electrical switch mechanisms) to determine whether controlled equipment will operate. caution: with electrical power on, care should be taken to avoid contact with switch leads and connections at terminal block. 2. if controlled equipment responds to manual switch actua- tion test, trouble may be located in the level sensing portion of the control, float(s), stem(s), and magnetic attraction sleeve(s). 3. check to be certain liquid is entering float chamber. a valve may be closed or piping 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 mecha- nism(s) and remove electrical conduit or operating medi- um line connections to switch housing. 5. perform system shutdown to relieve pressure from float chamber of control and allow unit to cool. 6. close shutoff valves (if equipped) to isolate control from vessel. drain off liquid in chamber if necessary. optional blow-down or drain valve shutoff valve (if used) conduit outlet switch actuating level reference mark optional liquid leg connection to vessel shutoff valve (if used) figure 21 46-624 series 3 liquid level switches asme b31.1 construction 19 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 enclosing tube hex nut, which is located immediately below housing base. refer to figure 6 on page 8. 9. with switch housing assembly removed, inspect attraction sleeve(s) and inside of enclosing tube for excessive corrosion or solids buildup, which could restrict movement, prevent- ing 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. 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 section 5.3, replacement parts . if all components in the control are in operating condition, the trouble must be located external to the control. repeat inspection of external conditions previously described. note: if difficulties are encountered which cannot be identified, consult the factory or your local representative for assistance. a complete description of the trouble should be 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 communicating about your control, be certain to always specify the complete model and serial numbers. 4.4 what to avoid 1. never leave switch housing cover removed from the con- trol longer than necessary to make routine inspections. 2. never place a jumper wire across terminals to cut-out the control. if a jumper is necessary for test purposes, be certain it is removed before placing control into service. 3. never attempt to make adjustments or replace switches without reading instructions carefully. certain adjustments provided for in level controls should not be attempted in the field. when in doubt, consult the factory or your local representative. 20 46-624 series 3 liquid level switches asme b31.1 construction agency approved model approval classes fm all with an electric switch mechanism and a housing class i , div 1, groups c & d listed as nema 4x/7/9 class ii , 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 nema 4x/7/9 class i , div 1, group b class ii , div 1, groups e, f & g csa all with a series hs, h1, f, 8 or 9 electric switch class i , 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 nema 4x/7/9 class ii , 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 nema 4x/7/9 class i , div 1, group b class ii , div 1, groups e, f & g atex / iec ex all with an electric switch mechanism and an atex ii 2 g eex d ii c t6 atex housing 94/9/ec iec ex ex d ii c t6 ip 66 ce all models installation category ii pollution degree 2 low voltage directives 2006/95/ec per harmonized standard en 61010-1/1993 & amendment no. 1 4. never use lubricants on pivots of switch mechanisms. a sufficient amount of lubricant has been applied at the factory to ensure a lifetime of service. further oiling is unnecessary and will only tend to attract dust and dirt which can interfere with mechanism operation. 5.0 reference information 5.1 agency approvals controls with two or more 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 d ii c t6 t ambient -40 c to +70 c 46-624 series 3 liquid level switches asme b31.1 construction 21 5.2 specifications 5.2.1 dimensional data sealed cage models k m plugged k l hl ll g j (ref) h k m plugged k l hl ll d e f (ref) nema 1: 8.50 (216) nema 4x/7/9: 10.12 (257) group b: 10.12 (257) c b (ref) k hl ll a k m plugged l figure 24 flanged side/side figure 23 flanged upper side/bottom figure 22 threaded & socket weld upper side/bottom conduit connections k actuation levels allow 8" (203 mm) over head clearance for cover removal. all housings rotatable 360. electrical switches nema 4x/7/9: 1" npt group b: 1" npt pneumatic switches nema 1: 1 M 4 " npt outline dimensions lm nema 4x/7/9 3.87 5.93 nema 4x/7/9, (98) (151) group b nema 1 5.00 4.62 (127) (117) inches (mm) 22 46-624 series 3 liquid level switches asme b31.1 construction 5.2.2 dimensional specifications C sealed cage models chambers with 1-inch connections 150 lb. and 300 lb. ansi class chambers with 1 1 M 2 -inch connections 150 lb. and 300 lb. ansi class chambers with 2-inch connections 150 lb. and 300 lb. ansi class model code 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b35 8.92 (227) 4.15 (105) 15.12 (384) 11.56 (294) 14.00 (356) 6.69 (170) 17.76 (451) 20.20 (513) 12.21 (310) 14.00 (356) 6.69 (170) 18.41 (468) 20.20 (513) c35 8.92 (227) 4.15 (105) 15.12 (384) 11.56 (294) 14.00 (356) 6.69 (170) 17.76 (451) 20.20 (513) 12.21 (310) 14.00 (356) 6.69 (170) 18.41 (468) 20.20 (513) g35 9.80 (249) 4.69 (119) 16.17 (410) 12.31 (313) 14.00 (356) 7.19 (183) 18.68 (474) 20.36 (517) 12.96 (329) 14.00 (356) 7.19 (183) 19.33 (490) 20.36 (517) v35 8.92 (227) 4.15 (105) 15.12 (384) 11.56 (294) 14.00 (356) 6.69 (170) 17.76 (451) 20.20 (513) 12.21 (310) 14.00 (356) 6.69 (170) 18.41 (468) 20.20 (513) z35 9.80 (249) 4.69 (119) 16.17 (410) 12.31 (313) 14.00 (356) 7.19 (183) 18.68 (474) 20.36 (517) 12.96 (329) 14.00 (356) 7.19 (183) 19.33 (490) 20.36 (517) model code 1 1 M 2 " npt threaded & socket weld 1 1 M 2 " flanged upper side/bottom 1 1 M 2 " flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b35 8.92 (227) 4.22 (107) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) c35 8.92 (227) 4.22 (107) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) g35 9.80 (249) 4.75 (121) 16.17 (410) 13.31 (338) 14.00 (356) 8.19 (208) 19.68 (500) 20.36 (517) 13.96 (355) 14.00 (356) 8.19 (208) 20.33 (516) 20.36 (517) v35 8.92 (227) 4.22 (107) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) z35 9.80 (249) 4.75 (121) 16.17 (410) 13.31 (338) 14.00 (356) 8.19 (208) 19.68 (500) 20.36 (517) 13.96 (355) 14.00 (356) 8.19 (208) 20.33 (516) 20.36 (517) model code 2" npt threaded & socket weld 2" flanged upper side/bottom 2" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b35 8.92 (227) 4.34 (110) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) c35 8.92 (227) 4.34 (110) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) g35 9.80 (249) 4.88 (124) 16.17 (410) 13.31 (338) 14.00 (356) 8.19 (208) 19.68 (500) 20.36 (517) 13.96 (355) 14.00 (356) 8.19 (208) 20.33 (516) 20.36 (517) v35 8.92 (227) 4.34 (110) 15.12 (384) 12.56 (319) 14.00 (356) 7.69 (195) 18.76 (477) 20.20 (513) 13.21 (336) 14.00 (356) 7.69 (195) 19.41 (493) 20.20 (513) z35 9.80 (249) 4.88 (124) 16.17 (410) 13.31 (338) 14.00 (356) 8.19 (208) 19.68 (500) 20.36 (517) 13.96 (355) 14.00 (356) 8.19 (208) 20.33 (516) 20.36 (517) inches (mm) 46-624 series 3 liquid level switches asme b31.1 construction 23 5.2.2 dimensional specifications C sealed cage models (cont.) chambers with 1 1 M 2 -inch connections 600 lb. & 900 lb. ansi class chambers with 2-inch connections 600 lb. & 900 lb. ansi class model code 1 1 M 2 " npt threaded & socket weld 1 1 M 2 " flanged upper side/bottom 1 1 M 2 " flanged side/side a b c d e f g h j 14" 16" 14" 16" 14" 16" 14" 16" b35 8.92 (227) 4.22 (107) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) c35 8.92 (227) 4.22 (107) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) g35 9.80 (249) 4.75 (121) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) v35 8.92 (227) 4.22 (107) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) z35 9.80 (249) 4.75 (121) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) model code 2" npt threaded & socket weld 2" flanged upper side/bottom 2" flanged side/side a b c d e f g h j 14" 16" 14" 16" 14" 16" 14" 16" b35 8.92 (227) 4.34 (110) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) c35 8.92 (227) 4.34 (110) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) g35 9.80 (249) 4.88 (124) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) v35 8.92 (227) 4.34 (110) 15.12 (384) 14.00 (356) 10.00 (254) 20.20 (513) 14.00 (356) 10.00 (254) 20.20 (513) z35 9.80 (249) 4.88 (124) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) chambers with 1-inch connections 600 lb. & 900 lb. ansi class model code 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j 14" 16" 14" 16" 14" 16" 14" 16" b35 8.92 (227) 4.15 (105) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) c35 8.92 (227) 4.15 (105) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) g35 9.80 (249) 4.69 (119) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) v35 8.92 (227) 4.15 (105) 15.12 (384) 14.00 (356) 9.00 (229) 20.20 (513) 14.00 (356) 9.00 (229) 20.20 (513) z35 9.80 (249) 4.69 (119) 16.17 (410) 16.00 (406) 10.00 (254) 22.36 (568) 16.00 (406) 10.00 (254) 22.36 (568) inches (mm) 24 46-624 series 3 liquid level switches asme b31.1 construction 5.2.3 dimensional data flanged cage models figure 25 threaded & socket weld upper side/bottom l hl ll c a b nema 1: 8.50 (216) nema 4x/7/9: 10.12 (257) group b: 10.12 (257) m (ref) k plugged k l k hl ll j g m (ref) plugged k h hl ll d e f m (ref) k plugged k l figure 27 flanged upper side/bottom figure 26 flanged side/side conduit connections k actuation levels allow 8" (203 mm) over head clearance for cover removal. all housings rotatable 360. electrical switches nema 4x/7/9: 1" npt group b: 1" npt pneumatic switches nema 1: 1 M 4 " npt outline dimensions lm nema 4x/7/9 3.87 5.93 nema 4x/7/9, (98) (151) group b nema 1 5.00 4.62 (127) (117) inches (mm) 46-624 series 3 liquid level switches asme b31.1 construction 25 5.2.4 dimensional specifications C flanged cage models 5.2.4.1 150# & 300# ansi pressure ratings inches (mm) chambers with 1-inch connections model code fig. size (lbs.) 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 150 9.12 (232) 3.63 (92) 16.64 (423) 12.06 (306) 14.00 (356) 6.13 (156) 19.58 (497) 21.51 (546) 12.71 (323) 14.00 (356) 6.13 (156) 20.23 (514) 21.51 (546) 300 9.12 (232) 3.63 (92) 17.32 (440) 12.06 (306) 14.00 (356) 6.13 (156) 20.26 (515) 22.19 (564) 12.71 (323) 14.00 (356) 6.13 (156) 20.91 (531) 22.19 (564) g3f 150 10.12 (257) 4.69 (119) 18.30 (465) 13.06 (332) 14.00 (356) 7.19 (183) 21.25 (540) 22.19 (564) 13.71 (348) 14.00 (356) 7.19 (183) 21.89 (556) 22.19 (564) 300 10.12 (257) 4.69 (119) 19.12 (486) 13.06 (332) 14.00 (356) 7.19 (183) 22.06 (560) 23.00 (584) 13.71 (348) 14.00 (356) 7.19 (183) 22.71 (577) 23.00 (584) chambers with 1 1 M 2 -inch connections model code fig. size (lbs.) 1 1 M 2 " npt threaded & socket weld 1 1 M 2 " flanged upper side/bottom 1 1 M 2 " flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 150 9.12 (232) 3.69 (94) 16.64 (423) 13.06 (332) 14.00 (356) 7.13 (181) 20.58 (523) 21.51 (546) 13.71 (348) 14.00 (356) 7.13 (181) 21.23 (539) 21.51 (546) 300 9.12 (232) 3.69 (94) 17.32 (440) 13.06 (332) 14.00 (356) 7.13 (181) 21.26 (540) 22.19 (564) 13.71 (348) 14.00 (356) 7.13 (181) 21.91 (556) 22.19 (564) g3f 150 10.12 (257) 4.75 (121) 18.30 (465) 14.06 (357) 14.00 (356) 8.19 (208) 22.25 (565) 22.19 (564) 14.71 (374) 14.00 (356) 8.19 (208) 22.89 (581) 22.19 (564) 300 10.12 (257) 4.75 (121) 19.12 (486) 14.06 (357) 14.00 (356) 8.19 (208) 23.06 (586) 23.00 (584) 14.71 (374) 14.00 (356) 8.19 (208) 23.71 (602) 23.00 (584) chambers with 2-inch connections model code fig. size (lbs.) 2" npt threaded & socket weld 2" flanged upper side/bottom 2" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 150 9.12 (232) 3.81 (97) 16.64 (423) 13.06 (332) 14.00 (356) 7.13 (181) 20.58 (523) 21.51 (546) 13.71 (348) 14.00 (356) 7.13 (181) 21.23 (539) 21.51 (546) 300 9.12 (232) 3.81 (97) 17.32 (440) 13.06 (332) 14.00 (356) 7.13 (181) 21.26 (540) 22.19 (564) 13.71 (348) 14.00 (356) 7.13 (181) 21.91 (556) 22.19 (564) g3f 150 10.12 (257) 4.88 (124) 18.30 (465) 14.06 (357) 14.00 (356) 8.19 (208) 22.25 (565) 22.19 (564) 14.71 (374) 14.00 (356) 8.19 (208) 22.89 (581) 22.19 (564) 300 10.12 (257) 4.88 (124) 19.12 (486) 14.06 (357) 14.00 (356) 8.19 (208) 23.06 (586) 23.00 (584) 14.71 (374) 14.00 (356) 8.19 (208) 23.71 (602) 23.00 (584) 26 46-624 series 3 liquid level switches asme b31.1 construction 46-624 series 3 liquid level switches asme b31.1 construction 24 g3f with 600# flanges available in 16" centerlines only. chambers with 1-inch connections model code fig. size (lbs.) 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 600 9.12 (232) 3.63 (92) 18.39 (467) 14.00 (356) 9.00 (229) 23.32 (592) 14.00 (356) 9.00 (229) 23.32 (592) a b c d e f g h j std. 16" std. 16" std. 16" std. 16" g3f 600 10.12 (257) 4.69 (119) 20.51 (521) 16.00 (406) 10.00 (254) 26.44 (672) 16.00 (406) 10.00 (254) 26.43 (671) z3f 600 10.11 (257) 4.68 (119) 20.19 (513) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) 900 10.11 (257) 4.68 (119) 21.13 (537) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) a b c d e f g h j std. 18" std. 18" std. 18" std. 18" k3f 600 11.62 (295) 5.69 (145) 22.89 (581) 18.00 (457) 11.00 (279) 29.32 (745) 18.00 (457) 11.00 (279) 29.32 (745) chambers with 1 1 M 2 -inch connections model code fig. size (lbs.) 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 600 9.12 (232) 3.69 (94) 18.39 (467) 14.00 (356) 9.00 (229) 23.32 (592) 14.00 (356) 9.00 (229) 23.32 (592) a b c d e f g h j std. 16" std. 16" std. 16" std. 16" g3f 600 10.12 (257) 4.75 (121) 20.51 (521) 16.00 (406) 10.00 (254) 26.44 (672) 16.00 (406) 10.00 (254) 26.43 (671) z3f 600 10.12 (257) 4.75 (121) 20.19 (513) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) 900 10.12 (257) 4.75 (121) 21.13 (537) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) a b c d e f g h j std. 18" std. 18" std. 18" std. 18" k3f 600 11.62 (295) 5.75 (146) 22.89 (581) 18.00 (457) 11.00 (279) 29.32 (745) 18.00 (457) 11.00 (279) 29.32 (745) chambers with 2-inch connections model code fig. size (lbs.) 1" npt threaded & socket weld 1" flanged upper side/bottom 1" flanged side/side a b c d e f g h j std. 14" std. 14" std. 14" std. 14" b3f 600 9.12 (232) 3.81 (97) 18.39 (467) 14.00 (356) 9.00 (229) 23.32 (592) 14.00 (356) 9.00 (229) 23.32 (592) a b c d e f g h j std. 16" std. 16" std. 16" std. 16" g3f 600 10.12 (257) 4.88 (124) 20.51 (521) 16.00 (406) 10.00 (254) 26.44 (672) 16.00 (406) 10.00 (254) 26.43 (671) z3f 600 10.12 (257) 4.88 (124) 20.19 (513) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) 900 10.12 (257) 4.88 (124) 21.13 (537) 16.00 (406) 10.00 (254) 26.08 (662) 16.00 (406) 10.00 (254) 26.08 (662) a b c d e f g h j std. 18" std. 18" std. 18" std. 18" k3f 600 11.62 (295) 5.88 (149) 22.89 (581) 18.00 (457) 11.00 (279) 29.32 (745) 18.00 (457) 11.00 (279) 29.32 (745) 5.2.4.2 600# & 900# ansi pressure ratings inches (mm) 46-624 series 3 liquid level switches asme b31.1 construction 27 sealed cage float models sealed cage actuation levels models pressure temperature specific gravity hl ll b35 812 psig (56 bar) +520 f (+271 c) 0.76 3.33 (85) 3.91 (99) c35 379 psig (26 bar) +443 f (+227 c) 0.83 4.05 (103) 4.57 (116) g35 546 psig (38 bar) +476 f (+247 c) 0.80 4.33 (110) 4.77 (121) v35 1044 psig (72 bar) +550 f (+288 c) 0.74 3.19 (81) 3.81 (97) z35 1113 psig (77 bar) +558 f (+292 c) 0.73 3.39 (86) 3.97 (101) flanged head flange actuation levels cage models lbs. pressure temperature specific gravity hl ll 150 201 psig (14 bar) +388 f (+199 c) 0.87 3.32 (84) 4.13 (105) b3f 300 601 psig (41 bar) +489 f (+254 c) 0.79 2.82 (72) 3.53 (90) 600 819 psig (56 bar) +523 f (+271 c) 0.77 2.67 (68) 3.57 (91) 150 201 psig (14 bar) +388 f (+199 c) 0.87 5.32 (135) 5.75 (146) g3f 300 557 psig (38 bar) +481 f (+249 c) 0.80 4.62 (117) 5.06 (129) 600 819 psig (56 bar) +523 f (+271 c) 0.76 4.29 (109) 5.00 (127) k3f 600 1123 psig (77 bar) +559 f (+293 c) 0.73 4.21 (107) 4.65 (118) z3f 600 1132 psig (78 bar) +560 f (+293 c) 0.73 3.50 (89) 4.09 (104) 900 1564 psig (108 bar) +602 f (+317 c) 0.68 3.18 (81) 3.84 (98) 5.2.5 actuating levels*, steam service ratings and specific gravities for float operated units, minimum specific gravities and actuating levels vary depending upon the material of construction code used with the unit. note: the minimum specific gravities and actuating levels shown are for single switch units with 1" process connections only. minimum specific gravities and levels will change for multistage units and levels will change for units with 1 1 M 2 or 2" process connections. consult factory for these changes. *the level decals on the control identify the actuation levels for units with three switches at the corre- sponding minimum specific gravity of the three switch configuration. inches (mm) flanged cage float models levels 0.25" (6 mm) levels 0.25" (6 mm) 28 46-624 series 3 liquid level switches asme b31.1 construction 5.3 replacement parts 5.3.1 sealed cage float models b35, c35, g35, v35 & z35 parts identification item description 1 housing cover 2 housing base 3 switch mechanism 4 jam nuts (qty. 4) 5 washer 6 attraction sleeve 7 stop tube 8 enclosing tube 9 e-tube gasket 10 chamber assembly figure 29 sealed cage models b35, c35, g35 4 5 6 8 7 9 10 an enclosing tube order must also include an e-tube gasket order. specify model and serial number of control when ordering. figure 28 housing and switch mechanism 1 1 2 3 5.3.2 sealed cage float models b35, c35, g35, v35 & z35 part numbers b35-7 b35, c35 & g35 v35 & z35 material code C7 material code C p material code C p housing kit refer to bulletin on switch mechanism and housing base (includes items 1 and 2) assembly furnished (see page 7) switch mechanism refer to bulletin on switch mechanism and housing base assembly furnished (see page 7) sleeve kit 89-3426-001 89-3426-001 89-3426-005 (includes items 4 through 7) enclosing tube z32-6357-001 z32-6346-002 z32-6346-003 e-tube gasket 12-1204-001 chamber assembly available as complete sensing units only 46-624 series 3 liquid level switches asme b31.1 construction 29 5.3.3 flanged cage float models b3f, g3f, k3f and z3f parts identification item description 1 housing cover 2 housing base 3 switch mechanism 4 enclosing tube 5 e-tube gasket 6 jam nuts (qty. 4) 7 washer (qty. 2) 8 attraction sleeve 9 stop tube 10 stop strap 11 screws (qty. 2) 12 float & stem assembly 13 head flange gasket 14 head flange 15 chamber assembly an enclosing tube order must also include an e-tube gasket order. a head flange order must also include a head flange gasket order. specify model and serial number of control when ordering. figure 30 flanged cage models b3f, g3f, k3f 6 7 8 4 5 9 10 13 14 11 12 15 5.3.4 flanged cage float models b3f, g3f, k3f and z3f part numbers 150# head flange 300# head flange 600# head flange 900# head flange material code C p material code C p material code C p material code C p housing kit refer to bulletin on switch mechanism and housing base (includes items 1 and 2) assembly furnished (see page 7) switch mechanism refer to bulletin on switch mechanism and housing base assembly furnished (see page 7) enclosing tube z32-6346-002 z32-6346-002 z32-6346-003 z32-6346-003 e-tube gasket 12-1204-001 head flange gasket b3f 12-1204-024 12-1204-012 12-1204-002 n/a g3f 12-1204-025 12-1204-013 12-1204-028 n/a k3f 12-1204-026 12-1204-027 12-1204-029 n/a z3f n/a n/a 12-1204-028 12-1204-047 float and stem kits b3f 89-3258-005 89-3258-008 89-3258-011 n/a (includes items g3f 89-3258-006 89-3258-009 89-3258-012 n/a 6 through 13) k3f 89-3258-007 89-3258-010 89-3258-013 n/a z3f n/a n/a 89-3258-023 89-3258-024 head flange b3f z04-8637-001 z04-8637-002 z04-8637-003 n/a g3f z04-8637-004 z04-8637-005 z04-8637-006 n/a k3f z04-8637-007 z04-8637-008 z04-8637-009 n/a z3f n/a n/a z04-8637-006 z04-8637-013 chamber assembly available as complete sensing units only 30 46-624 series 3 liquid level switches asme b31.1 construction 5.4 model numbers 5.4.1 sealed cage models model number code sealed cage size and tank connection type materials of construction pneumatic switch mechanism and enclosure model code minimum specific gravity pressure rating psig @ f bar @ c 100 550 750 800 38 288 399 427 b35 0.69 830 830 716 594 57.2 57.2 49.6 41.0 c35 0.57 500 435 400 395 34.5 30.0 27.6 27.2 g35 0.54 750 653 600 593 51.7 45.0 41.4 40.9 v35 0.71 1680 1680 1455 1210 115.8 115.8 100.3 83.4 z35 0.66 1645 1645 1425 1185 113.4 113.4 98.3 81.7 type connection size c/c 1" 1 1 M 2 " 2" threaded std. b20 c20 d20 socket weld std. b30 c30 d30 cage mounting ansi flange rating (lbs.) 150 300 600 900 150 300 600 900 150 300 600 900 flanged upper side/ bottom std. n30 n40 p30 p40 q30 q40 14" n34 n44 n54 n64 p34 p44 p54 p64 q34 q44 q54 q64 16" n56 n66 p56 p66 q56 q66 flanged side/side std. s30 s40 t30 t40 v30 v40 14" s34 s44 s54 s64 t34 t44 t54 t64 v34 v44 v54 v64 16" s56 s66 t56 t66 v56 v66 switch description maximum supply pressure maximum process temperature bleed orifice diameter models b35, c35, & g35 models v35 & z35 psig bar f c inches mm nema 1 nema 1 series j bleed type 100 7 400 204 .063 1.6 jgh jgf 60 4 400 204 .094 2.3 jhh jhf 60 4 700 371 .055 1.3 jjh jjf series k non-bleed 100 7 400 204 kof 40 3 400 204 koh models are limited to maximum temperature rating of selected switch mechanism. minimum specific gravity ratings apply to single stage units only. consult factory for two or three stage units. models v35 and z35 contain 17C7 ph stainless steel floats. codes for a 16-inch center to center dimension are applicable to models g35 with 600# flanges and z35 with 600 & 900# flanges only. process temperature based on +100 f (+38 c) ambi- ent. for models built to asme b31.1 in applications over +750 f (+399c), 100% radiographic examination is required. consult factory for pricing. hs & h1 switches can be used with only materials of construction code 1 on models v35 & z35 p carbon steel chamber, 316l stainless steel float, 400 series stainless steel sleeve, asme b31.1 construction 7 p22/f22 chrome-moly chamber, 347 ss float, 400 series ss sleeve, asme b31.1 construction, model b35 only 46-624 series 3 liquid level switches asme b31.1 construction 31 electric switch mechanism and enclosure switch description process temperature range f (c) contacts set points models b35, c35 & g35 models v35 & z35 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 series c snap switch -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 series d dc current snap switch -40 to +250 (-40 to +121) spdt 1 dkb dkk dc9 dkb dkk dc9 2 dlb dlk dd9 dlb dlk dd9 3 dmb dmk de9 dmb dmk de9 dpdt 1 dnb dnk df9 dnb dnk df9 2 dob dok dg9 dob dok dg9 series f hermetically sealed snap switch -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 +400 (-46 to +204) spdt 1 hmj hmk n/a hmj hmk n/a 2 hmn hmp hmn hmp dpdt 1 hms hmt hms hmt 2 hmy hmz hmy hmz series hs hermetically sealed 5-amp snap switch with terminal block -50 to +400 (-46 to +204) spdt 1 hm3 hm4 ha9 hm3 hm4 ha9 dpdt 1 hm7 hm8 hb9 hm7 hm8 hb9 series h1 hermetically sealed 1-amp snap switch with wiring leads -50 to +750 (-46 to +399) spdt 1 hkj hkk n/a hkj hkk n/a dpdt 2 hkn hkp hkn hkp series r high temperature snap switch -40 to +750 (-40 to +399) spdt 1 rkb rkk rc9 rkb rkk rc9 2 rlb rlk rd9 rlb rlk rd9 dpdt 1 rnb rnk rf9 rnb rnk rf9 2 rob rok rg9 rob rok rg9 series 8 hermetically sealed snap switch -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 switch description process temp. range f (c) contacts set points 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 (-40 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 series 9 high temperature hermetically sealed snap switch -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 32 46-624 series 3 liquid level switches asme b31.1 construction 5.4.2 flanged cage models switch description maximum supply pressure maximum process temperature bleed orifice diameter all models except: b3f, g3f, k3f & z3f with 600 lb. head flanges models b3f, g3f, k3f & z3f with 600 & 900 lb. head flanges psig bar f c inches mm nema 1 nema 1 series j bleed type 100 7 400 204 .063 1.6 jgh jgf 50 4 400 204 .094 2.3 jhh jhf 60 4 700 371 .055 1.3 jjh jjf series k non-bleed 100 7 400 204 kof 40 3 400 204 koh model number code cage size and tank connection type p carbon steel chamber, 316l stainless steel float, 400 stainless steel sleeve, asme b31.1 construction materials of construction pneumatic switch mechanism and enclosure model code head flange ansi class minimum s.g. gravity pressure rating psig @ f bar @ c 1 100 550 750 800 38 288 399 427 b3f 150# 0.78 285 155 95 80 19.6 10.7 6.5 5.5 300# 0.66 740 588 505 410 51.0 39.6 34.8 28.3 600# 0.66 960 870 800 790 66.1 60.1 55.6 54.5 g3f 150# 0.41 285 155 95 80 19.6 10.7 6.5 5.5 300# 0.55 740 588 505 410 51.0 45.0 41.4 28.3 600# 0.70 1000 870 800 790 68.9 60.0 55.6 54.5 k3f 600# 0.60 1410 1147 1010 825 97.2 79.1 69.6 56.9 z3f 600# 0.67 1480 1147 1010 825 102.0 79.1 69.6 56.9 900# 1645 1645 1425 1185 151.2 113.4 98.3 81.7 connection type connection size c/c 1" 1 1 M 2 " 2" ansi head flange rating (lbs.) 150 300 600 900 150 300 600 900 150 300 600 900 threaded std. b20 b60 b80 b40 c20 c60 c80 c40 d20 d60 d80 d40 socket weld std. b30 b70 b90 b50 c30 c70 c90 c50 d30 d70 d90 d50 flanged upper side/ bottom std. n30 n40 p30 p40 q30 q40 14" n34 n44 n54 n64 p34 p44 p54 p64 q34 q44 q54 q64 16" n56 n66 p56 p66 q56 q66 18" n58 p58 q58 flanged side/side std. s30 s40 t30 t40 v30 v40 14" s34 s44 s54 s64 t34 t44 t54 t64 v34 v44 v54 v64 16" s56 s66 t56 t66 v56 v66 18" s58 t56 q58 minimum specific gravity ratings apply to single stage units only. consult factory for two or three stage units. models are limited to maximum temperature rating of selected switch mechanism. models z3f & k3f contain 7C17 ph stainless steel floats. codes for a 16 inch center to center dimension are applicable to models g3f and z3f with 600# flanges only. codes for an 18-inch center to center dimension are applicable to k3f model only. process temperature based on +100 f (+38 c) ambient. for models built to asme b31.1 in applications over +750 f (+399c), 100% radiographic examination is required. consult factory for pricing. hs & h1 switches can be used with only materials of construction code 1 on all models with 600# or 900# ansi rating. 46-624 series 3 liquid level switches asme b31.1 construction 33 electric switch mechanism and enclosure switch description process temperature range f (c) contacts set points all models except b3f, g3f, k3f & z3f with 600# or 900# ansi ratings models b3f, g3f, k3f & z3f with 600# or 900# ansi ratings 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 series c snap switch -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 series d dc current snap switch -40 to +250 (-40 to +121) spdt 1 dkb dkk dc9 dkb dkk dc9 2 dlb dlk dd9 dlb dlk dd9 3 dmb dmk de9 dmb dmk de9 dpdt 1 dnb dnk df9 dnb dnk df9 2 dob dok dg9 dob dok dg9 series f hermetically sealed snap switch -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 +400 (-46 to +204) spdt 1 hmj hmk n/a hmj hmk n/a 2 hmn hmp hmn hmp dpdt 1 hms hmt hms hmt 2 hmy hmz hmy hmz series hs hermetically sealed 5-amp snap switch with terminal block -50 to +400 (-46 to +204) spdt 1 hm3 hm4 ha9 hm3 hm4 ha9 dpdt 1 hm7 hm8 hb9 hm7 hm8 hb9 series h1 hermetically sealed 1-amp snap switch with wiring leads -50 to +750 (-46 to +399) spdt 1 hkj hkk n/a hkj hkk n/a dpdt 2 hkn hkp hkn hkp series r high temperature snap switch -40 to +750 (-40 to +399) spdt 1 rkb rkk rc9 rkb rkk rc9 2 rlb rlk rd9 rlb rlk rd9 dpdt 1 rnb rnk rf9 rnb rnk rf9 2 rob rok rg9 rob rok rg9 series 8 hermetically sealed snap switch -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 switch description process temp. range f (c) contacts set points 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 (-40 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 series 9 high temperature hermetically sealed snap switch -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 34 46-624 series 3 liquid level switches asme b31.1 construction notes: 46-624 series 3 liquid level switches asme b31.1 construction 35 notes: bulletin: 46-624.5 effective: august 2010 supersedes: october 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. 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, cred- it for the materials returned will be determined on the basis of the applicability of our warranty. no claims for misapplication, labor, direct or consequen- tial damage will 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 materials return. this is available through magnetrols 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 |
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