Magnetrol Tuffy T3 series User manual

®
Side
Mounted
Float Level
Switch
Installation and Operating Manual
Tuffy®T3
Liquid Level Controls
with Electric Switches

2
UNPACKING
Unpack the instrument carefully. Make sure all components
have been removed from the foam protection. Inspect all
components for damage. Report any concealed damage to
the carrier within 24 hours. Check the contents of the car-
ton/crates against the packing slip and report any discrep-
ancies to Magnetrol. Check the nameplate model number
(Model number/approvals as per inserted separate sheet) to
be sure it agrees with the packing slip and purchase order.
Check and record the serial number for future reference
when ordering parts.
MOUNTING
These units have been tested and
are in compliance with the
Directive 94/9/EC for equipment
or protective system for use in
potentially explosive atmospheres
(EEx d/EEx i units)
Nameplate:
- partnumber
- switch
- serial n°
- tag n°
For flanged units
2" NPT Tuffy External cage mounted TuffyFlanged Tuffy
Cut and remove the plastic shipping straps on flanged units.
Flanged
max nozzle length:
85 mm (3.35")
Field adjustable
differential
max nozzle length:
110 mm (4.35")
Interface
max nozzle length:
147 mm (5.80")
Threaded
max nozzle length:
84 mm (3.29")
Cage
mounted
Air
Oil
Water
Locking screw, loosen before removing cover
(refasten after replacing)
Locking screw, loosen
before removing cover
(refasten after replacing)
M20 x 1.5 or 3/4" NPT
cable entry; should
always be pointing
down
Apply Teflon tape
or Petrolatum
Use wrench size 65 mm
1. Install a proper
gasket.
2. Cut and remove
the shipping
straps, slide the
control in the
nozzle and align
the bold holes.
3. M20 x 1.5 or 3/4" NPT
cable entry; should
always be pointing
down
4. Fasten bolts and
studs in a star pattern
C
LC LC L
Pressure
vessel
Switch
actuation
level
Drain valve
3/4"NPT
cable entry
Safety
check
valve
Shut-off
valve
Shut-off
valve
Note: min nozzle size is 3" SCH 80 (max nozzle lengths are specified as per this size)

3
WIRING
CAUTION: power must be switched OFF before wiring the unit.
Allowable operating range
Cast iron housing with silver switch contacts
with silver/gold contacts HS
Internal ground wire
use min. 14 AWG wire
External ground wire
Terminal connections
DPDT dry contact switch
with silver contacts
Terminal connections
DPDT dry contact switch
with gold contacts
Terminal connections
SPDT dry contact switch
with silver or gold contacts
Terminal connections
SPDT HS switch
with silver or gold contacts
050100 150 200 250 300 350
0
20
40
60
-20
-40
-40
Process Temperature (°C)
Ambient Temperature (°C)
Allowable operating range
Aluminium housing with silver switch contacts
with silver/gold contacts HS
050100 150 200 250 300 350
0
20
40
60
-20
-40
-40
Process Temperature (°C)
Ambient Temperature (°C)
Allowable operating range
Cast iron housing with gold switch contacts
050100 150 200 250 300 350
0
20
40
60
-20
-40
-40
Process Temperature (°C)
Ambient Temperature (°C)
Allowable operating range
Aluminium housing with gold switch contacts
050100 150 200 250 300 350
0
20
40
60
-20
-40
-40
Process Temperature (°C)
Ambient Temperature (°C)

4
TROUBLESHOOTING
Symptom Cause of malfunction / Action
Failure of the controlled equipment Check external causes first:
eg. pump does not start, - blown fuses
signal lamps fail to operate etc... - tripped reset button
- open power switch.
- controlled equipment fails.
- defective wiring to level switch.
Check wiring as per wiring diagrams on page 3
Check actuating arm and magnet assembly
1. Remove switch mechanism
2. Check for wiring interference or binding of actuating arm. The switch and
magnet must move throughout its entire range of motion without interference.
3. Replace the switch mechanism in case of binding.
Check float assembly
1. Remove the unit from service
2. Clean the mechanism if required
3. Tilt the float, when the unit is limited by its motion:
check differential setting (for T3C units only) – see above
4. Replace the unit in case cleaning and/or resetting did not solve the problem.
Float magnet
Switch magnet
Non-magnetic float
holder (pressure
boundary)
Magnet/Switch action
For T31-T35 / T3B / T3D and T3E units
CALIBRATION
Properly selected TUFFY units do not need any field calibration.
For T3C: field adjustable differential units
The Adjustable Differential Tuffy II, model T3C, may be set in the field for one of a variety of level differentials. By specific place-
ment of the stops in the holes of the adjustment plate, the level differential may be changed.
D
C
B
A
E
J
F
G
K
L
H
To determine the differential
Example: T3C-C unit with stop holes Band G
1. Select the rising level of the upper stop:
example: upper stop = hole B: +85 mm
2. Select the falling level of the lower stop:
example: lower stop = hole G: -205 mm
3. Substract levels:
rising level / upper stop - falling level / lower
stop:
example: +85 mm - (-205 mm) = +290 mm
Example 2:T3C-8 unit: with stop holes Dand B:
+183 mm - (+115 mm) = 68 mm
Impossible stop hole combinations due to the diameter of the stem (of the float):
Stop holes in mm (divide by 25,4 to obtain inches)
Upper stops middle Lower stops
Partnumber Level BCD KLAE FGH J
T3C-4XXX-XXX Rising +47 +90 +124 +39 +104 +4 -37 n/a n/a -42 n/a
Falling +80 n/a n/a +84 n/a [phone] +4 -62
T3C-8XXX-XXX Rising +63 +131 +183 +51 +153 -3 -67 n/a n/a -75 n/a
Falling +115 n/a n/a +122 n/a [phone]
T3C-CXXX-XXX Rising +85 +183 +259 +67 [phone] n/a n/a -115 n/a
Falling +160 n/a n/a +170 n/a 66 -43 -128 -205 -11 -106
Aand B
Aand E
Aand H
Aand K
Band C
Band K
Cand D
Cand K
Cand L
Dand LEand F
Eand H
Fand H
Fand J
Fand G
Jand G

5
REPLACEMENT PARTS
PREVENTIVE MAINTENANCE
Periodic inspections are a necessary means to keep your level control in good working order. This control is a safety device
that protects the valuable equipment it serves. A systematic program of preventive maintenance should be implemented when
the control is placed into service. If the following instructions are observed, your control will provide reliable protection of your
equipment for many years.
What to do
1. Keep control clean.
Be sure the switch housing is always in place. This cover
is designed to keep dust and dirt from interfering with the
switch mechanism operation. In addition it protects
against damaging moisture and acts as a safety feature
by keeping bare wires and terminals from being exposed.
Should the housing cover become damaged or mis-
placed, obtain a replacement immediately.
2. Inspect switch mechanisms, terminals and connections
monthly.
Tuffy T3 level switches may sometimes be exposed to
excessive heat or moisture. Under such conditions insu-
lation on electrical wires may become brittle, eventually
breaking or peeling away. The resulting bare wires can
cause short circuits. Check wiring carefully and replace
at first sign of brittle insulation.
Vibration may sometimes cause terminal screws to
loosen. Check all terminal connections to ensure that
screws are tight. Check wiring carefully and repair or
replace if necessary.
Note: It is recommended that spare switches, housing
covers and o-rings be kept on hand at all times.
3. Inspect entire Tuffy T3 unit periodically.
A periodic cleaning of the float and counterweight
assembly will ensure continued free movement of the
mechanism.
What to avoid
1. NEVER leave the switch housing cover off of the control
longer than is 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,
ensure that it is removed before placing the control into
service.
3. NEVER attempt to make adjustments to or replace
switches without reading instructions carefully. When in
doubt, consult the factory or your local representative.
4. NEVER use in systems containing iron particles. The
magnet in the float assembly can attract the particles and
become jammed.
5. NEVER put insulation over the switch housing.
N° Discription Part number
Right hand* Left hand*
SPDT silver contacts 37-4814-001 not applicable
DPDT silver contacts 37-4814-001 37-4814-002
1Switch SPDT gold contacts 37-4814-003 not applicable
only DPDT gold contacts 37-4814-003 37-4814-004
HS SPDT silver contacts 37-9101-001 37-9101-001
HS SPDT gold contacts 37-9102-001 37-9102-001
SPDT silver contacts
DPDT silver contacts
2Switch SPDT gold contacts Consult factory
mechanisms DPDT gold contacts
HS SPDT silver contacts
HS SPDT gold contacts
3Housing cover Aluminium 04-9197-005
Cast Iron 04-9197-002
4Cover o-ring 12-2201-240
* Position of the switch is determined by looking at the terminal block with the cable entry pointing downward.
➀
➂➃
➁ (includes ➀)

6
SPECIFICATIONS
Description Specification
Switch ratings Up to 10 A @ 240 V AC
Up to 6.0 A @ 24 V DC
Signal output Single SPDT or single DPDT contacts
Switch types Dry contact with silver or gold plated contacts
Hermetically sealed for corrosive environment
Approvals ATEX II 1/2G EEx d II C T6, explosion proof (Zone 0)
ATEX II 1G EEx ia II C T6, intrinsically safe
NEMA 4X/7/9, Class 1, Div 1, Groups B, C & D
Cable entries 3/4" NPT and M20 x 1,5
PHYSICAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
Description Specification
Measured variable Liquid level
Physical range Narrow differential: 13 mm (0.5")
Adjustable differential: up to 464 mm (18.26")
Interface Service Differential: 44 mm (1.72")
Interface: min S.G. difference between both liquids: 0,1
Process temperature From -55 °C (-65 °F) up to 400 °C (750 °F) depending switch/housing selection
Process pressure Standard models: up to 50 bar abs. (720 psi)
High pressure models: up to 150 bar abs. (2160 psi)
Wetted parts 316/316L (1.4401/1.4404) or Hastelloy C (2.4819)
Flange materials Carbon steel
316/316L (1.4401/1.4404) or Carbon steel with 316/316L (1.4401/1.4404) cladding
Hastelloy C (2.4819) or Carbon steel with Hastelloy C (2.4819) cladding
Housing materials Cast aluminium or cast iron

7
DIMENSIONS in mm (inches)
T31 and T35: threaded narrow differential
T31, T33 and T35: flanged narrow differential
T32: flanged high pressure narrow differential
112
(4.39)
211
(8.29)
84
(3.29)
T31: 91 (3.59)
T35: 85 (3.33)
T31: 220 (8.66)
T35: 200 (7.86)
2" NPT
Cable entries: M20 x 1.5 or 3/4" NPT
112
(4.39)
211
(8.29)
85
(3.35)
T31/T33: 91 (3.59)
T35: 85 (3.33)
T31: 221 (8.72)
T33: 190 (7.50)
T35: 201 (7.92)
Cable entries: M20 x 1.5 or 3/4" NPT
112
(4.39)
211
(8.29)
204
(8.02)
85
(3.35)
85
(3.35)
Cable entries: M20 x 1.5 or 3/4" NPT
T3C: adjustable wide differential
112
(4.39)
209
(8.23)
Stem length (code 4): 95 (3.75)
Stem length (code 8): 190 (7.50)
Stem length (code C): 311 (12.25)
Stem length (code 4): 346 (13.62)
Stem length (code 8): 471 (18.54)
Stem length (code C): 629 (24.76)
Stem length (code 4): 327 (12.86)
Stem length (code 8): 422 (16.61)
Stem length (code C): 543 (21.36)
85
(3.35)
Cable entries: M20 x 1.5 or 3/4" NPT

8
T3B: interface
209
(8.23)
112
(4.39)
85
(3.35)
448
(17.62)
172
(6.78)
Cable entries: M20 x 1.5 or 3/4" NPT
DIMENSIONS in mm (inches)

9
MODEL IDENTIFICATION
T31 Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,4 / max 50 bar abs (720 psi)
T32Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 150 bar abs (2160 psi)
T33Tuffy with Hastelloy C (2.4819) float - min S.G. 0,65 / max 50 bar abs. (720 psi)
T35Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,6 / max 104 bar abs (1500 psi)
T3B Interface Tuffy with 316/316L (1.4401/1.4404) float - max 50 bar abs (720 psi)
T3C Adjustable diff. Tuffy with 316/316L (1.4401/1.4404) float - min S.G. 0,78 / max 50 bar abs (720 psi)
T 03 complete code for TUFFY®T3
PROCESS CONNECTION – ANSI Flanges
3A 3" 150 lbs RF ANSI Flange
3B 3" 300 lbs RF ANSI Flange
3C 3" 600 lbs RF ANSI Flange
3D 3" 900 lbs RF ANSI Flange
4A 4" 150 lbs RF ANSI Flange
4B 4" 300 lbs RF ANSI Flange
4C 4" 600 lbs RF ANSI Flange
4D 4" 900 lbs RF ANSI Flange
5A 5" 150 lbs RF ANSI Flange
5B 5" 300 lbs RF ANSI Flange
6A 6" 150 lbs RF ANSI Flange
6B 6" 300 lbs RF ANSI Flange
PROCESS CONNECTION – THREADED
2N 2" NPT connection
PROCESS CONNECTION – DIN Flanges
A1 DN 80, PN 16 DIN 2527 Form C flange
A2 DN 80, PN 25/40 DIN 2527 Form C flange
A3 DN 80, PN 64 DIN 2527 Form E flange
A4 DN 80, PN 100 DIN 2527 Form E flange
A5 DN 80, PN 160 DIN 2527 Form E flange
B1 DN 100, PN 16 DIN 2527 Form C flange
B2 DN 100, PN 25/40 DIN 2527 Form C flange
B3 DN 100, PN 64 DIN 2527 Form E flange
B4 DN 100, PN 100 DIN 2527 Form E flange
B5 DN 100, PN 160 DIN 2527 Form E flange
C1 DN 125, PN 16 DIN 2527 Form C flange
C2 DN 125, PN 25/40 DIN 2527 Form C flange
D1 DN 150, PN 16 DIN 2527 Form C flange
D2 DN 150, PN 25/40 DIN 2527 Form C flange
STEM EXTENSION LENGTH FOR T3C - DIMENSION "A"
495 mm (3.75") stem extension / 346 mm (13.62") differential
8190 mm (7.50") stem extension / 471 mm (18.54") differential
C311 mm (12.25") stem extension / 629 mm (24.76") differential
NARROW DIFFERENTIAL UNITS - T31, T32, T33 AND T35
OStandard level differential of 13 mm (0,5")
0,81 0,82 0,83 0,84 0,85 0,86 0,87 0,88 0,89 0,90 Specific Gravity
AB CDEFGHJK Code
0,91 0,92 0,93 0,94 0,95 0,96 0,97 0,98 0,99 1 Specific Gravity
LMNPRSTUVW Code
SPECIFIC GRAVITY OF LOWER LIQUID FOR T3B
SEE PAGE 10

10
SWITCH MECHANISMS
SWITCH TYPE (see table below - "SWITCH MECHANISMS")
0SPDT with silver contacts
1DPDT with silver contacts
2SPDT with gold plated contacts
3DPDT with gold plated contacts
4Hermetically sealed, SPDT with silver contacts
6Hermetically sealed, SPDT with gold plated contacts
T 3 complete code for TUFFY®T3
DESIGN CODE AND FLANGE MATERIAL
Design codes
Standard ANSI/ NACE ANSI/ASME Flange material
ASME B31.3 B31.3 & NACE
123
➀4➀Carbon steel
AEJNCarbon steel w. 316/316L cladding
BFKP 316/316L (1.4401/1.4404) stainless steel
CGLRCarbon steel w. Hastelloy C cladding
DHMTHastelloy C (2.4819)
MODEL IDENTIFICATION
SEE PAGE 9
HOUSING MATERIALS AND CABLE ENTRY
Consult factory for proper partnumbers for FM/CSA approved units
1Cast aluminium, single 3/4" NPT cable entry, ATEX II 1/2G EEx d II C T6
2Cast iron, single 3/4" NPT cable entry, ATEX II 1/2G EEx d II C T6
3Cast aluminium, single M20 x 1,5 cable entry, ATEX II 1/2G EEx d II C T6
4Cast iron, single M20 x 1,5 cable entry, ATEX II 1/2G EEx d II C T6
MCast aluminium, single 3/4" NPT cable entry, ATEX II 1G EEx ia II C T6
NCast iron, single 3/4" NPT cable entry, ATEX II 1G EEx ia II C T6
PCast aluminium, single M20 x 1,5 cable entry, ATEX II 1G EEx ia II C T6
RCast iron, single M20 x 1,5 cable entry, ATEX II 1G EEx ia II C T6
All TUFFY®are available with a selection of switch modules that vary in switch rating (Amp) and max process temperature
allowance. The max temperature is dependent upon the housing material selected. Consult table below, before selecting the
proper module in the order number structure on pages 9 or 10.
Electric switch rating Process temperature range
V AC V DC @ 40 °C (100 °F) ambient temp.
Code Contacts and type 120 240 24 120 Cast Iron Cast Aluminium
0 SPDT with silver contacts 10.0 10.0 6.0 0.6 -40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F)
1 DPDT with silver contacts 10.0 10.0 6.0 0.6 -40 °C to +400 °C (-40 °F to +750 °F) -40 °C to +345 °C (-40 °F to +650 °F)
2 SPDT with gold plated contacts 0.1 - 0.1 - -40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F)
3 DPDT with gold plated contacts 0.1 - 0.1 - -40 °C to +190 °C (-40 °F to +375 °F) -40 °C to +160 °C (-40 °F to +325 °F)
4 HS SPDT with silver contacts 1.0 1.0 3.0 0.5 -55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F)
6 HS SPDT with gold plated contacts 0.5 0.5 0.5 0.5 -55 °C to +400 °C (-65 °F to +750 °F) -55 °C to +345 °C (-65 °F to +650 °F)
➀Not for all models

11

IMPORTANT
SERVICE POLICY
Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or
replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner) other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
and the parts required to rebuild or replace the equipment.
In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the
original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the
control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of
our warranty.
No claims for misapplication, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrol’s local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number and Ref Number
4. Desired Action
5. Reason for Return
6. Process details
All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments.
All replacements will be shipped FOB factory.
®
www.magnetrol.com
BENELUX Heikensstraat 6, 9240 Zele, België
Tel. [phone] • Fax. [phone] • E-Mail: [email protected]
DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath
Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected]
FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard
Tél. [phone] • Fax. [phone] • E-Mail: [email protected]
ITALIA Via Arese 12, I-20159 Milano
Tel. [phone] (R.A.) • Fax. [phone] • E-Mail: [email protected]
UNITED Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
KINGDOM Tel. [phone] • Fax [phone] • E-Mail: [email protected]
INDIA E-22, Anand Niketan, New Delhi - 110 021
Tel. [phone] • Fax [phone] • E-Mail: [email protected]
BULLETIN N°: BE 44-605.8
EFFECTIVE: JUNE 2005
SUPERSEDES: October 2000
UNDER RESERVE OF MODIFICATIONS