Ametek Magnetrol3 Series User manual





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 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 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.
Warranty
All Magnetrol mechanical level and flow controls are war-
ranted free of defects in materials or workmanship for
three 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.
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.
Copyright © 2021 AMETEK Magnetrol USA LLC.
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.

46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
.0 Introduction
1.1 Principle of Operation ..............................................4
1.2 Operating Cycle........................................................4
2.0 Installation
2.1 Unpacking ................................................................4
2.2 Critical Alarm Function ............................................5
2.3 Piping .......................................................................5
2.4 Mounting..................................................................5
2.5 Wiring ......................................................................6
3.0 Switch Differential Adjustment
3.1 Low Level Controls...................................................8
3.2 High Level Controls..................................................9
4.0 Preventive Maintenance
4.1 Recommended Practice...........................................10
4.1.1 Keep Control Clean .....................................10
4.1.2 Inspect Switch Mechanisms Terminals
and Connections Monthly ...........................10
4.1.3 Proof Test Procedure.....................................11
4.1.4 Control Head Removal and Installation .......12
4.2 Troubleshooting ......................................................14
4.2.1 Check Switch Mechanism ............................14
4.2.2 Check Sensing Unit......................................15
4.3 What To Avoid........................................................16
5.0 Reference Information
5.1 Agency Approvals....................................................17
5.2 Specifications ..........................................................18
5.2.1 Dimensional Data — Sealed Cage Models....18
5.2.2 Dimensional Specifications — Sealed
Cage Models ................................................19
5.2.3 Dimensional Data—Flanged Cage Models...21
5.2.4 Dimensional Specifications — Flanged
Cage Models ................................................22
5.2.4.1 150# & 300# ANSI Pressure Ratings......22
5.2.4.2 600# & 900# ANSI Pressure Ratings......23
5.2.5 Actuating Levels Steam Service Ratings
and Specific Gravities ...................................24
5.3 Replacement Parts...................................................25
5.3.1 Sealed Cage Float Models B35 C35 G35
V35 and Z35 Parts Identification.................25
5.3.2 Sealed Cage Float Models B35 C35 G35
V35 and Z35 Part Numbers.........................25
5.3.3 Flanged Cage Float Models B3F G3F K3F
and Z3F Parts Identification ........................26
5.3.4 Flanged Cage Float Models B3F G3F K3F
and Z3F Part Numbers ................................27
5.4 Model Numbers......................................................28
5.4.1 Sealed Cage Models......................................28
5.4.2 Flanged Cage Models ...................................30
Series 3
Liquid Level Switches
ASME B3 . Construction
Table of Co te ts

446-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
Swing in
position
Switch
Return spring
Enclosing tube
(non-magnetic)
Attraction
sleeve
Magnet
HL
1.0 I troductio
The Magnetrol Series 3 level switches are float operated
units suitable for use on clean liquid applications for level
alarm pump control and safety shutdown functions. Units
are designed fabricated and certified to compliance with
ASME B31.1 specifications.
1.1 Pri ciple of Operatio
The design of Magnetrol float-operated level switches is
based upon the principle that a magnetic field will pene-
trate non-magnetic materials such as 316 stainless steel.
The float moves a magnetic attraction sleeve within a non-
magnetic enclosing tube and actuates a switch mechanism.
The enclosing tube provides a pressure seal to the chamber
and therefore to the process.
1.2 Operati g Cycle
As the liquid level rises in the chamber (refer to )
the float moves the magnetic attraction sleeve up within
the enclosing tube and into the field of the switch mecha-
nism magnet. As a result the magnet is drawn in tightly
to the enclosing tube causing the switch to trip “making”
or “breaking” an electrical circuit. As the liquid level falls
the float drops and moves the attraction sleeve out of the
magnetic field releasing the switch at a predetermined
“low level” (refer to ). The tension spring ensures
the return of the switch in a snap action.
2.0 I stallatio
2.1 U packi g
Unpack the instrument carefully. Inspect all units for
damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip and
purchase order. Check and record the serial numbers and
model numbers for future reference when ordering parts.
Serial # _____________________________________
Model # _____________________________________


Swing out
position
LL



46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 5
2.2 Critical Alarm Fu ctio
It is recommended that for critical alarm functions an
additional level switch be installed as a high–high or low–
low level alarm for maximum protection.
2.3 Pipi g
Figure 3 shows a typical piping installation of a
Magnetrol Series 3 control to a pressure vessel. Level decals
on control identify the actuation levels for the bottom
switch mechanism of a unit with three switches at mini-
mum specific gravity. To find the actuation levels for a unit
with one switch at different minimum specific gravities
refer to the charts in Actuation Levels, Steam Service Ratings
and Specific Gravities, Section 5.2.5 on page 24.
Use pipe of sufficient strength to support the control. If
necessary provide a stand or hanger to help support its
weight. All piping should be straight and free of “low
spots” or “pockets” so that lower liquid line will drain
towards the vessel and upper vapor line will drain toward
the control. Shut-off valves are recommended for installa-
tion between the vessel and the control. If control is to be
used with a low temperature liquid (one which will “boil”
in the float chamber if outside heat is absorbed) the
chamber and piping should be insulated. Such boiling
in the chamber will cause false level indications.
DO NOT INSULATE SWITCH MECHANISM
HOUSING.
On controls equipped with pneumatic switch assemblies
consult bulletin on mechanism furnished for air (or gas)
piping instructions. Refer to the chart on page 7 for
bulletin numbers for pneumatic switches.
2.4 Mou ti g
 If equipment is used in a manner not spe ified by the
manufa turer, prote tion provided by the equipment may
be impaired.
 This instrument is intended for use in Installation Category
II, Pollution Degree 2.
Adjust piping as required to bring control to a vertical
position. Magnetrol controls must be mounted within 3°
of vertical. A 3° slant is noticeable by eye but installation
should be checked with a spirit level on top and/or sides of
float chamber.
Shutoff
valve
Drain
valve
Conduit
outlet
Switch
actuating
level
reference
marks
Max. 12"
Pressure
vessel



646-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
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.
 Operation of all buoyan y type level devi es should be
done in su h a way as to minimize the a tion of dynami
for es on the float or displa er sensing element. Good
pra ti e for redu ing the likelihood of damage to the on-
trol is to equalize pressure a ross the devi e slowly.
2.5 Wiri g
NOTE: A swit h or ir uit breaker shall be installed in lose proximi-
ty to equipment and within easy rea h of operator. It shall be
marked as the dis onne ting devi e for the equipment.
NOTE: For supply onne tions 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 pro ess onditions.
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 pro ess onditions. Use a minimum of 14
AWG wire for power and ground field wires.
 Level ontrols are shipped from the fa tory with the
en losing tube tightened and the middle set s rew, on the
housing base, lo ked to the en losing tube. Failure to
loosen the set s rew prior to repositioning the onduit on-
ne tion may ause the en losing tube to loosen, resulting
in the possible leakage of the pro ess 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
.
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 appli ations (above +250 °F [+121 °C] in
float hamber), high temperature wire should be used
between ontrol and first jun tion box lo ated in a ooler
area. On non-hazardous appli ations, flexible onduit may be
used between the ontrol and the first jun tion 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
ScrewScrew






46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 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 swit h with high temperature
lead wire, the leads are routed out through the onduit open-
ing by the fa tory. A suitable onduit box should be provided
for the onne tion of the leads to the ontrol 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.
 In hazardous areas, do not power the unit until the
onduit is sealed and the en losure over is s rewed
down se urely.
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 swit h me hanism fails to fun tion properly, he k verti al
alignment of ontrol housing and onsult installation bulletin
on swit h me hanism 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.
  
 
B, C, D Dry Conta t Swit h 42-683
F, 8, 9 High Temperature Hermeti ally Sealed
Snap Swit h 42-799
HS Hermeti ally Sealed Snap Swit h 42-694
R High Temperature Snap Swit h 42-799
J Bleed Type Pneumati Swit h 42-685
K Non-Bleed Type Pneumati Swit h 42-686

846-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
3.0 Switch Differe tial Adjustme t
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.
 Maximum differential adjustment is 1 in h (25 mm).
3.1 Low Level Co trols
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  on page 9.
1. Determine what change in differential is necessary.
NOTE: To widen the differential one in h, the lower jam nuts must be
set proportionately lower on the stem (i.e., in this example
1 in h).
2. Make sure power source is turned off.
3. NEMA 4X/7/9—Unscrew and remove switch housing
cover.
4. Disconnect power supply wires from switch mechanism.
Pull wires out of conduit connection opening in housing
base. Refer to .
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
 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


46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 9
NOTE: Level ontrol, onne tions and pipe lines need not be
removed from the tank.
6. Loosen enclosing tube nut with a 15⁄16" wrench. Unscrew
enclosing tube counterclockwise (switch and housing base
will rotate also) until it is free. Refer to  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 .
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 .
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 .
NOTE: Using a new en losing tube gasket when reassembling
en losing tube to the hamber. Make ertain that all gasket
surfa es are thoroughly leaned to allow proper gasket
seating. Coat en losing tube threads with “anti-seizing”
ompound.
13. Replace enclosing tube switch and base on chamber. Screw
tube clockwise until tightened to 200–225 foot-pounds
of torque.
14. Rotate switch housing to correct position and tighten set
screw at base of switch housing. Refer to  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 swit h me hanism fails to fun tion properly, he k verti al
alignment of ontrol housing and onsult installation bulletin
on swit h me hanism. If the unit still fails to fun tion properly,
onsult the fa tory.
3.2 High Level Co trols
On high level controls the switch trips on the higher actu-
ation point and resets on the lower actuation point.
 On high level ontrols, widening the differential requires
raising the trip point a proportional amount. The reset
point will remain the same.




























 


10 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
To widen the differential by raising the trip point follow
steps 1 through 16 in Low Level Controls Section 3.1,
pages 8–9).
 After in reasing gap setting, be ertain to he k for
proper operation of swit h me hanism by raising and low-
ering float assembly. Magnet must “snap” leanly with
additional float movement available after magnet snaps.
4.0 Preve tive Mai te a ce
Periodic inspections are a necessary means to keep your
level control in good working order. This control is a safety
device to protect the valuable equipment it serves. A sys-
tematic program of “preventive maintenance” must be
implemented when the control is placed into service. If the
following sections on “what to do” and “what to avoid” are
observed your control will provide reliable protection of
your equipment for many years.
4.1 Recomme ded Practice
 
Be sure the switch housing cover is always in place on the
control. This cover is designed to keep dust and dirt from
interfering with switch mechanism operation. 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.
 

1. Dry contact switches should be inspected for excessive
wear on actuating lever or misalignment of adjustment
screw at point of contact between screw and lever. Such
wear can cause false switch actuating levels. See switch
mechanism bulletin supplied with control should switch
adjustment or replacement be necessary.
2. DO NOT operate your control with defective or mal-
adjusted switch mechanisms. Refer to the Switch
Instruction Reference Bulletins chart on page 7 to find
appropriate bulletins for service instructions.
3. Level controls may sometimes be exposed to excessive
heat or moisture. Under such conditions insulation on
electrical wiring may become brittle eventually breaking
or peeling away. The resulting “bare” wires can cause
false trip.

46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 11
4. Vibration may sometimes cause terminal screws to loosen.
Check all terminal connections to be certain that screws
are tight.
5. On units with pneumatic switches air (or gas) lines
subjected to vibration may eventually crack or loosen at
connections causing leakage. Check lines and connections
carefully and repair or replace if necessary.
NOTE: Spare swit hes should be kept on hand at all times.
 

1. Bypass the logic controller or take other action to avoid a
false trip.
2. Perform a detailed inspection of the unit inside and out
for physical damage that may impact the structural
integrity and for evidence of environmental or process
leaks. Repair or replace the unit if needed.
3. Using a calibrated multimeter set to measure electrical
resistance (ohms) at the field connections measure and
record the resistances across the Common (C) and the
Normally Closed (NC) contacts and the Common (C)
and the Normally Open (NO) contacts.
4. Change the process level to cause the switch mechanism to
change states.
5. Again measure and record the resistances across the
Common (C) and the Normally Closed (NC) contacts
and the Common (C) and the Normally Open (NO) contacts.
6. Ensure with the multimeter readings that the switch mech-
anism did in-fact change states. A closed switch contact
should measure less than 1 ohm and an open contact
should measure greater than 5 megaohms.
7. Repeat steps 3 through 6 for all other sets of switch
contacts (if any).
8. Restore the installation to normal operation.

12 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
 
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. Allow vessel to get to 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 .
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.
NOTE: Care must be taken not to pla e side for e on the float whi h
ould bend the stem.
7. With the unit resting in its temporary fixture in an upright
position it can now be inspected or repaired.
 Do not pla e the unit on its side — this ould result in
damage to the stem.

 

46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 13
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  for assembly schematic.
8.2 Check the stem straightness by aligning the stem
against a straight edge. Stems that are bent in excess of
1⁄8inch over any 6 inch length should not be used
in this condition. Replace any bent stems. See
Replacement Parts, Section 5.3 beginning on page 25.
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 he k to be er-
tain that the attra tion sleeve is not removed from the stem
and jam nuts settings are not hanged.
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 restri ted from moving laterally by the hamber, in
the test onfiguration the float and stem an move further off
enter than possible under normal operation. Avoid ex ess
movement in this lateral dire tion during the test. If swit h
trips, the unit may be reassembled.
10. Replace the assembly onto the float cage keeping it as
vertical as possible. Carefully lower the assembly into the
chamber making sure that the stem does not become bent
during installation. Refer to  on page 12.
11. Tighten flange bolts per torque values as indicated in table below.
12. Attach wiring and connect power supply as described in
Wiring, Section 2.5 on page 6.
  
B3F – 150# 100 – 120 ft-lbs
200–225 ft-lbs
B3F – 300#, G3F – 150#, G3F – 300# 180 – 200 ft-lbs
B3F – 600# 300 – 320 ft-lbs
G3F – 600#, Z3F – 600# 470 – 490 ft-lbs
K3F – 600# 675 – 710 ft-lbs
Z3F – 900# 775 – 850 ft-lbs
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


14 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
4.2 Troubleshooti g
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.
 
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. Examine the switch closely as described in Inspect Switch
Mechanisms, Terminals, and Connections Monthly, Section
4.1.2 step 1 on page 10. Check continuity of switch with
ohmmeter. If switch does not function properly replace it
immediately.
8. If switch mechanism is operating satisfactorily proceed to
check sensing unit.
NOTE: Spare swit hes should be kept on hand at all times.

46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 15
 
1. Reconnect power supply. Carefully actuate the switch
mechanism manually (use a non-conductive tool on elec-
trical switch mechanisms) to determine whether controlled
equipment will operate.
 With ele tri al power on, avoid onta t with swit h leads
and onne tions at terminal blo k.
2. If controlled equipment responds to manual switch actua-
tion test trouble may be located in the level sensing por-
tion of the control float(s) stem(s) and magnetic attrac-
tion sleeve(s).
3. Check to be certain liquid is entering float chamber.
A valve may be closed or piping plugged.
 Be ertain to pull dis onne t swit h or otherwise ensure
that ele tri al ir uit(s) through ontrol is dea tivated.
Close operating medium supply valve on ontrols
equipped with pneumati swit h me hanisms.
4. Disconnect wiring from supply side of switch mechanism(s)
and remove electrical conduit or operating medium line
connections to switch housing.
5. Perform system shutdown to relieve pressure from float
chamber of control and allow unit to cool.
6. Close shutoff valves (if equipped) to isolate control from
vessel. Drain off liquid in chamber if necessary
7. On installations without shutoff valves relieve pressure
from vessel and drain off liquid head above control
mounting level.
NOTE: Control hamber, onne tions, 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  on 6.
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.
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)


16 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
 Do not attempt to repair a float. See Replacement Parts,
Section 5.3 beginning on page 25.
If all components in the control are in operating condition
the trouble is likely located external to the control. Repeat
inspection of external conditions previously described.
NOTE: If diffi ulties are en ountered whi h annot be identified,
onsult the fa tory or your lo al representative for assistan e.
A omplete des ription of the trouble should be provided
along with information on erning your piping and mounting
arrangement, plus a des ription of your operating sequen e.
Sket hes or photographs showing the installation are also
benefi ial.
When communicating about your control be certain to
always specify the complete Model and Serial numbers.
4.3 What To Avoid
1. Never leave switch housing cover off the control longer
than necessary to make routine inspections.
2. Never place a jumper wire across terminals to “cut-out”
the control. If a “jumper” is necessary for test purposes be
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.
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.
 Operation of all buoyan y type level devi es should be
done in su h a way as to minimize the a tion of dynami
for es on the float or displa er sensing element. Good
pra ti e for redu ing the likelihood of damage to the
ontrol is to equalize pressure a ross the devi e very
slowly.

46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 17
  
 All with an ele tri swit h me hanism 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 ele tri swit h me hanism 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
 All with a Series HS, F, 8 or 9 ele tri swit h Class I, Div 2, Groups A, B, C & D
me hanism and a housing listed as CSA TYPE 4X
All with an ele tri swit h me hanism 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 ele tri swit h me hanism 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
➁All with an ele tri swit h me hanism and an ATEX II 2 G EEx d IIC T6
ATEX housing ➀94/9/EC
IEC Ex Ex d IIC T6
IP 66
 All models Installation Category II
Pollution Degree 2
Low Voltage Dire tives
2006/95/EC
per Harmonized Standard
EN 61010-1/1993 & Amendment No. 1
5.0 Refere ce I formatio
5.1 Age cy Approvals
➀Controls with two or more HS swit hes are not ATEX approved.
➁IEC Installation Instru tions:
The able entry and losing devi es shall be Ex d ertified suitable for the onditions of use and orre tly installed.
For ambient temperatures above +55 °C or for pro ess temperatures above +150 °C, suitable heat resistant ables shall be
used.
Heat extensions (between pro ess onne tion and housing) shall never be insulated.

When the equipment is installed in pro ess temperatures higher than +85 °C the temperature lassifi ation must be redu ed
a ording to the following table as per IEC60079-0.




< 85 °C T6
< 100 °C T5
< 135 °C T4
< 200 °C T3
< 300 °C T2
< 450 °C T1
These units are in onformity with IECEx KEM 05.0020X
Classifi ation Ex d IIC T6
Tambient -40 °C to +70 °C

18 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
5.2 Specificatio s
 
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









Allow 8" (203 mm) over head
learan e for over removal.
All housings rotatable 360°.
Ele tri al Swit hes
NEMA 4X/7/9: 1" NPT
Group B: 1" NPT
Pneumati Swit hes
NEMA 1: 1⁄4" NPT

 
NEMA 4X/7/9 3.87 5.93
NEMA 4X/7/9, (98) (151)
Group B
NEMA 1 5.00 4.62
(127) (117)


46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion 19
 











     
       
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)








     
       
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)








     
       
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)


20 46-624 Series 3 Liquid Level Swit hes ASME B31.1 Constru tion
 










     
       
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)








     
       
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)









     
       
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)
