the lack & gas people INSTRUCTION MANUAL 40H-235/46 (1) FLOAT OPERATED MAGNETIC LEVEL SWITCHES: MODEL 40H-2, 40H-3, 40H-5, 60S & 80S (2) DISPLACER OPERATED MAGNETIC LEVEL ‘SWITCHES MODEL 40H-4 & 40H-6 ‘Supersedes : Dec. 01 Fig. 4 This instruction manuel gives maintenance detalls of float operated level switches model 40H-2, (side mounted), 40H-3 (top mounted), 40H-5, 605 & 80S (external cage). along with displacer operated level switch 40H-4 (intemal Mounted) and 40H-6 (ExternalTYPICAL PIPING ARRANGMENT rm t 1) | "eae Il) INSTALLATION PIPING Figure 2 shows a typical piping installation of a magnetic level switch, Centre of liquid chamber should be aligned to correspond with liquid level in vessel at which switch control is desired. Use pipe of sufficient strength to support the Instrument. If necessary, provide a stand or hanger to help support i's weight. All piping should be straight & free of "Low Spot’ or “Pockets” so that lower liquid line will drain the liquid chamber. Shut-off valves are recommended for installation between vessel & the liquid chamber. | magnetic level switch is to be used with a low temperature liquid (one which will “boil” in the liquid chamber if outside heat is absorbed), the chamber and the piping should be insulated. Such bolling in the chamber will cause false level indications. DO NOT insulate switch mechanism housing4 T roa puscaan a FLOAT OPERATED LEVEL SWITCH MI) WIRING ‘All magnetic level switch housings are designed to allow 360° positioning of the conduit outlet by loosening the set screw(s) located under the housing base. On high, tamperature applications {above 150°C in chamber) asbestos covered wire should be used between chamber and first junction box. Conduit should have sufficient slack to permit removal ofswtch housing assembly. 41. To gain access to switch mechanism(s) remove switch housing cover. 2. Pullin supply wires (conductors), wrap them around enclosing {ube and connect to proper terminals. Be certain that excess wire does not interfere with tit’ of switch and that adequate Clearance exists fr replacement of switch housing cover. 3. Connect power supply to magnetic level switch, Test switch action by varying liquid level in chamber or by changing position offloat/Displacer. NOTE: Ifswitch mechanism falis to function properly, check vertical aligamentof magneticlevel switch housing. 4. Replace switch housing cover and place magnetic level switch into service. Hf magnetic level switch has been furnished with an explosion proof switch housing, check the following: 1. After wiring connections have been completed, housings must be sealed at the conduit outlet with a suitable air compound or “dope” to prevent entrance ofa. Pg.2. Check cover to base fitment to be certain that gasketed Joint is tight. A positive seal is necessary to prevent infiltration of ‘moisture laden air or corrosive gases into switch housing ‘The amount of level travel between “switch ON" and “switch-OFF" actuations (differential) may be field adjusted by repositioning the lower jam nuts on the floatDisplacer 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 diagram "“C Fig. 3 (Page 3). This setting may be increased as shown in diagram *D’ Fig. 3. (Page 3). Differential of level switch can be adjusted as und 41. Disconnect wiring from supply side of switch mechanism(s) and remove electrical conduit or operating medium line connections to switch housing 2. Relieve pressure from liquid chamber of magnetic level switch and allow unit to cool, Close shut-off valves to isolate from vessel. Drain off excess liquid from chamber. 3. Remove switch housing assembly by loosening bottom jam nut located immediately below the housing base. 4, With switch housing removed, attraction sleeve and jamnuts are accessible. Measure position of upper jam nuts from stem fend, then loosen and remove upper jam nuts, guide washer andattraction sleeve, 5. Loosen and adjust lower jam nuts to desired position 6. Make certain that jam nuts are tightened securely after performing above functions, 7. Reassemble magnetic level switch in reverse steps 1 through 4 ‘making certain upper jam nuts are locked in original position. Replace gasketifdamaged. 8. Testswitch actuation by varying liquid levelin vessel, 8. Adjust gap to achieve desired differential IV) PREVENTIVE MAINTENANCE 4. SWITCHHOUSING NEVER leave switch housing cover off the magnetic level switch. This cover is designed to keep dust and dit from interfering with ‘switch mechanism operation.INSPECT SWITCH MECHANISMS, TERMINALS & CONNECTIONS MONTHLY Micro 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 (ifpossible) or replace switch. Magnetic level switch may sometimes be exposed to excessive heat or moisture. Under such conditions, insulation on electrical wires may become brite, eventually breaking or peeling away. The resulting "bare" wires can cause short circuits. Check wiring carefully and replace at first sign of bitle insulation Vibrations may sometimes cause terminal screws to become loose. Check all terminal connections to be certain that screws are tight, AVOID FOLLOWING NEVER eave switch housing cover off the magneticlevel ‘switch longer than necessary to make routine inspections. NEVER use lubricants on pivots of switch mechanisms. NEVER place ajumperwire across terminals to "cut-out" the magneticlevel switch. NEVER attemptto make adjustments or replace switches withoutreading instructions carefully. V) TROUBLE SHOOTING Usually the first indication of improper operation is failure of the ‘magnetic level switch to function ie pump will not start (or stop)/ signal lamps fail to light, etc. When these symptoms occur, check the following: = Fusesmay be blown. + Power switch may be open. = Controlled equipment may be fauity = Wiring leading to magnetic level switch may be defective, {fa thorough inspection of these possible conditions failto locate the trouble, proceed next to.a check of the control's switch mechanism. Pg.|. Disconnect supply wires. 2. Remove switch housing cover. 3. Swing magnet assembly in and outby hand to check carefully forany sign of binding. Assembly should require no force, however slight, to move itthrough its full swing 4, Ifbinding exists, magnet may be rubbing the enclosing tube ‘magnetis rubbing, loosen magnet clamp screw and shift ‘magnet position 5 If'switch magnet assembly swings freely and mechanism stil fails to actuate, check installation of control to be certain itis within specified three (3) degrees of vertical (use spiitevel on side of enclosing tube in two places, 90° apart) 6. Ifswitchis damaged, replace itimmediately. it If switch mechanism is operating satisfactorily, a test of the complete control's performance is the nextlikely step. 1, Reconnect power supply and carefully actuate switch ‘mechanism manually (using non-conductive tool) to determine whether controlled equipment ill operate. 2. If controlled equipment responds to manual actuation test, trouble may be located in the level sensing portion of the ‘control {floatidisplacer(s), stem(s) and, magnetic attracting sleeve(s)} NOTE: Check first to be certain that the liquid is entering liquid chamber. Ifnota valve may be closed or pipeline may be plugged. 3. With liquid in chamber, proceed to check level sensing action by removing switch housing assembly, as described in “Differential Adjustment” instructions in page 4. 4, Inspect attracting sleeves) and inside of enclosing tube for ‘excessive corrosion or solids build-up which could restrict movement, preventing sleeve(s) from reaching field of ‘magnet( s). 5. Ifthe differential as been changed in the field, check tightness. and position of the jam nuts. 6. Check float/aisplacer(s) to be certain itis buoyant in the liquid {liquid chamber must have adequate liquid level). Ifnot, check Ifthe Noatidisplacers collapsed or filed with water.Vi) MOUNTING ‘Adjust piping as required to bring control to a vertical position, Magnetic level switch must be mounted within three (3) degree of vertical. A three degree slant is noticeable by eye, but installation should be checked with a spirit level on top andlor sides ofthe liquid chamber. Control should be mounted as close to the vessel as, possible. This will result in a more responsive and accurate le\BILL OF MATERIAL FOR FLOAT OPERATED LEVEL SWITCH 'SINO. | ITEM DESCRIPTION PART NO. 7 _ | HOUSINGCOVER, AlAloy ‘0H501 2__ | HOUSINGBASE,AlAloy Oro 3 __ | CHAMBER, CSISS 0H503 a | FLOATS “OHO 5_| ENCLOSINGTUBE, SS OHO © _| GAGEFLANGE, CSISS 40H506 7_ | LEVEL SWITCHFLANGE, CSISS_| 40H507, | FLOATROD.SS OHEO8 | ATTRACTIONSLEEVE, SS 4OHE08 70 | SWITCHMECHANISM, SSIAT__| 40HS10 TT __| JAMNUTS, 55 “Ort T2_| GASKET Asbestos ‘Ore 13 _| GUIDEWASHER, SS HES Important: ‘When ordering forspares, please specify ‘A. Model Number and Serial Number of Magnetic Level Switch B. Name and/or PartNumber ofreplacementassembly. Automat reserves the right, without notice, to alter or improve the design. specifications or dimensions of product described herein.DISPLACER OPERATED MAGNETIC LEVEL SWITCHES MODEL 40H-4 & 40H-6 _pwssenve MICRO SWITCH — + armorgn se6ve } mmoene LM gen , CF ‘sme out exc.oeso uae —— seaeey one , : DIAGRAMA DIAGRAM B NOTE: Model 40H-4 is without cage and model 40H-6 is with flanged cage. Refer bulletin No. 600 for more details. DESCRIPTION: These pages gives maintenance details of Displacer operated Level Switches model 40H-4 (Top Mounted without cage) and 40H- 6 (Top External mounted with flanged cage). INSTALLATION Refer (ll) on Page No.2 WIRING Refer ll) on Page No. 3MAINTENANCE, Spring Tension: In case of displacer operated level switch, setting of tension of spring is important. In case the switch malfunctions, bring the level to centre of displacer and adjust the tension of spring to achieve desired result. “A DIFFERENTIAL ADJUSTMENTS If Level Switch functions at desired level, do not adjust spring tension and proceed for Differential Adjustments, MODEL 411 : This model has got one displacer and one Switch Assembly. Factory set differential is within 7mm mm at S.G. of 1. It ‘canbe varied by 10% by adjusting gap between the jam nuts. 1. Disconnect wiring from supply side of switch mechanism, 2. Relieve pressure from displacer chamber of magnetic level switch and allow unitto cool (Model 40H-6) -Close shut-off valves and isolate from vessel. Drain the liquid in chamber. 3. Remove switch housing assembly by looseing bottom jam nut locatedimmediately below the housing base. 4. With switch housing removed, jamnuts and attracting sleeve are accessible, Measure position of upper jam nuts from stem end then loosen and remove upper jam nuts, quide washer and attraction sieeve. 5. Loosen and adjust lower jam nuts to desired position. Make certain that jam nuts are tightened securely, after performing above functions 6. Reassemble magnetic level switch in reverse steps 1 through 4 making certain that upper jam nuts are locked in original position Replace gasket if'damaged. 7. Testswitch actuation by varying liquid levelin vessel Pg. 10MODEL 412: This model has got two displacers and one Switch Assembly. In this case, the distance between two displacers is the differential. For adjusting the differential, adjust location of displacers by loosening Ring Stoppers. MODEL 422 : This model has got two displacers and two Switch assemblies, This models similar to model 411 but with 2 displacers and 2 switch assemblies. Each displacer operates individual switch assembly. Narrow differential of each displacer is adjusted as in ‘model 411 and wide differential is adjusted by adjusting distance between displacers by loosening Ring Stoppers. PREVENTIVE MAINTENANCE. Refer (IV)on Page No.4 TROUBLE SHOOTING Refer (V) onPageNo. 5 MOUNTING Refer (Vion Page No.7BILL OF MATERIAL FOR DISPLACER OPERATED LEVEL SWITCH 'SINO] ITEM DESCRIPTION [PART NO, 1 [mouse cover, aiaioy —_[aoiior 2 | HOUSING BASE, AA onto 3 cuamaer, csiss 4on103 4__ | DISPLACER, SS oH 104 [ENCLOSING TUBE, SS | 4oHT05 | CAGE FLANGE, CSISS__[onT08 7_| HEVEL SWITOR FLANGE, GOSS [4OHTOT @__ | SPRING GUIDE, Ss orto 2 _| SPRING. SS aoHt03 40_| biseLACER ROD, 85) aon vi Arrraction steeve, ss [ont 12_[ swrrch mecHawism, ssIAi | 4oHI12 13 [ saw NuTS, ss aon 14_| GASKET, Asbestos aorta T5_[ DISPLAGER STOPPER 8S_[a0HTTS IMPORTANT: ‘When ordering for spares, please specify ‘A. Mode! Number and Serial Number of Magnetic Level Switch B. Name and/or part Number ofreplacementassembly. Automat reserves the right, without notice, to alter or improve the design. specifications or dimensions of product described herein. V. AUTOMAT & INSTRUMENTS (P) LTD. AUTOWAT HOUSE, F61, kha Indusia Area, Phased, New Dlh- 10020, OA Phone: 476270040 Lines) Fax 051-126819640 Grams: SWITCH Ema: avtometBarsrosbandin;automtGvenicom Website: nmevautonstnds com BRANCHES IN BARODA MOVE, KOLKATA, JAMSHEDPUR: SECUNDERABAD & CHENNAL See Webste for edcress(Specifcatons con change witout po: noice