Magnetrol Tuffy 039-6000-100 User manual

Side
Mounted
Float Level
Switch
Tuffy®
Liquid Level Controls
with Pneumatic witch
Installation and Operating Manual

Tuffy Liquid Level Control with Pneumatic Switch
Read this Ma ual Before I stalli g
This manual provides in ormation on the Tu y Liquid
Level Control with Pneumatic Switch. It is important that
all instructions are read care ully and ollowed in sequence.
Detailed installation and wiring instructions are included in
this manual.
Co ve tio s Used i this Ma ual
Certain conventions are used in this manual to convey
speci ic types o in ormation. General technical material,
support data, and sa ety in ormation are presented in
narrative orm. The ollowing styles are used or notes,
cautions, and warnings.
Notes
Notes contain in ormation that augments or clari ies an
operating step. Notes do not normally contain actions.
They ollow the procedural steps to which they re er.
Cautio s
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 unsa e practices or the
need or special protective equipment or speci ic
materials. In this manual, a caution box indicates a
potentially hazardous situation which, i not avoided,
may result in minor or moderate injury.
War i gs
Warnings identi y potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, i not avoided,
could result in serious injury or death.
Safety Messages
Follow all standard industry procedures or servicing elec-
trical equipment when working with or around high
voltage. Always shut o the power supply be ore touching
any components.
WARNING! Explosion hazard. Do not connect or dis-
connect equipment unless power has been switched o or
the area is known to be non-hazardous.
Notice of Trademark, Copyright, a d Limitatio s
Tu y is a registered trademark o Magnetrol International,
Incorporated. Tu y Liquid Level Switch is a tradename o
Magnetrol International, Incorporated.
© 2010 Magnetrol International, Incorporated.
All rights reserved.
Magnetrol reserves the right to make changes to the
product described in this manual at any time without
notice. Magnetrol makes no warranty with respect to the
accuracy o the in ormation in this manual.
Warra ty
All Magnetrol mechanical level and low controls are war-
ranted ree o de ects in materials or workmanship or ive
ull years rom the date o original actory shipment.
I returned within the warranty period; and, upon actory
inspection o the control, the cause o 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 or misapplication, labor
claims, direct or consequential damage or expense arising
rom the installation or use o equipment. There are no
other warranties expressed or implied, except special
written warranties covering some Magnetrol products.
Quality Assura ce
The quality assurance system in place at Magnetrol guar-
antees the highest level o quality throughout the compa-
ny. Magnetrol is committed to providing ull customer sat-
is action both in quality products and quality service.
Magnetrol’s quality assurance system is
registered to ISO 9001 a irming its
commitment to known international
quality standards providing the
strongest assurance o product/service
quality available.

3
Tuffy Liquid Level Control with Pneumatic Switch
1.0 Installation
This section provides detailed procedures or properly
installing the Tu y Liquid Level Control.
Caution: If equipment is used in a manner not specified by
manufacturer, protection provided by equipment
may be impaired.
1.1 Unpackin
Unpack the instrument care ully. Inspect all units or dam-
age. Report any concealed damage to the carrier within 24
hours. Check the contents o the packing slip and report
any discrepancies to Magnetrol. Check the nameplate model
number to be sure it agrees with the packing slip and pur-
chase order. Check and record the serial number or uture
re erence when ordering parts.
Model umber
Serial umber
1.2 Before You Be in
1.2.1 ite Preparation
1. Ensure that the length and inside diameter o the mounting
nozzle are sized correctly to allow or switch actuation at
design levels. Re er to Figure 1.
2. Ensure that the mounting nozzle or coupling is within 3°
o horizontal. I mounting the Tu y in an external cage,
ensure that the cage is mounted within 3° o horizontal
and that the top/bottom piping is within 3° o vertical in all
directions.
3. Ensure that the area is ree o metallic particles which might
be attracted to the magnet holder/counterbalance and inter-
ere with the unction o the Tu y.
1.2.2 Equipment and Tools
No special equipment or tools are required to install the
Tu y Liquid Level Switch. The ollowing items are recom-
mended:
• Wrenches, lange gaskets and lange bolting appropriate or
process connection(s).
• Pipe wrench
• Level
Figure 1
1/4" NPT
inlet (A)
1/4" NPT
outlet (C) 3.00" maximum
nozzle length
1/4" NPT
inlet (B)
Float must
clear inner
tank wall
Wrench flats
Serial number tag

4Tuffy Liquid Level Control with Pneumatic Switch
1.3 Mountin
The pneumatic Tu y Liquid Level Switch is available with a
2" NPT mounting bushing, a variety o lange mountings
and external cages or mounting outside o the vessel.
1.3.1 Mounting an NPT Tuffy
1. Apply either Te lon®tape or Petrolatum to the mounting
threads to prevent galling.
2. Engage the 2" NPT by hand to avoid damaging threads.
3. Using a pipe wrench, rotate the unit clockwise until threads
are tight in mounting. Ensure that the serial number plate is
on top. See Figure 1.
Caution: The pneumatic Tuffy must be installed with the serial
number plate on top to ensure correct switching action.
1.3.2 Mounting a Tuffy with Flange
1. Have proper lange bolting and gasket on hand.
2. Care ully align mounting lange with the vessel mounting
lange.
3. Ensure that the lange gasket is seated properly. Install
lange bolts and nuts.
4. Tighten alternating lange bolts in a star pattern.
5. Install Tu y into 2" NPT o mounting lange as described
in Section 1.3.1 above.
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 control is to equal-
ize pressure across the device very slowly.
1.3.3 Mounting External Cage Tuffy
A typical Tu y external cage installation is shown in Figure 2.
1. Install cage so that tappings are within 3° o vertical in all
directions. Check installation with a level.
2. Mount cage as close to vessel as possible, to provide more
accurate level in cage. Long pipe runs may result in cooler,
denser liquid than that in the vessel and cause inaccurate
level in the Tu y cage.
3. Use pipe o su icient size and strength to support the
control. I necessary, provide a hanger or stand to help
support the weight o the cage.
4. All piping should be straight and ree o low spots or pockets.
Lower liquid line should drain toward vessel and upper line
toward Tu y cage.
5. Shut-o valves are recommended or installation between
the vessel and the cage assembly.
6. Once external cage is mounted, install pneumatic Tu y into
cage per Section 1.3.1 or 1.3.2.
C
L
Pressure
vessel
Shut–off
valve
Safety
check
valve
Shut–off
valve
Drain valve
Switch
actuation
level
1/4" NPT
inlet (A)
1/4" NPT
outlet (C)
1/4" NPT
inlet (B)
Figure 2

5
Tuffy Liquid Level Control with Pneumatic Switch
1.4 Airline Connections
1. Inlet air should be iltered with a 5 micron or iner ilter.
This will extend the li e o the valve mechanism.
2. Connect the inlet air line to the 1⁄4" NPT connection or
either air inlet A or air inlet B, depending on the valve
action desired (re er to Figure 3). Inlet air pressure should
be between 0–200 psig. Re er to Figure 1 or location o air
inlets.
3. Connect outlet air line to the 1⁄4" NPT connection on the
bottom o the valve. This air outlet is designated with a
“C”. Re er to Figure 1 or location.
4. I 3-way unction is used, attach the exhaust air line to the
appropriate 1⁄4" NPT connection based on valve action
described in Figure 3.
2.0 Reference Information
2.1 Description
Tu y liquid level switches are designed or horizontal
mounting in a tank or vessel through threaded or langed
pipe connections. Standard models are equipped with a
three-port/two-position valve actuated by a magnetically
actuated pivoted cam mechanism. This instruction manual
covers Tu y level controls which have pneumatic switches.
For Tu y controls with electric switches, please consult
Bulletin 44-607.
2.2 Theory of Operation
At a “low operating level” o liquid in a tank or vessel (re er
to Figure 4), the loat moves the magnet upward and into
the ield o the switch mechanism magnet. As a result, the
magnets repel causing the pivot arm and valve plunger to
move so that air is allowed to pass rom air inlet A to air
outlet C. As liquid level rises, the loat moves the magnet
downward until the switch mechanism magnet reverses
position, allowing the valve plunger to move so that air is
allowed to pass rom air inlet B to air outlet C (re er to
Figure 5).
For direct acting low level operation, air inlet A is closed o
when liquid level increases. Conversely, or high level opera-
tion, air inlet B is closed o when liquid level recedes.
For reverse acting operation, air inlet A is used or high level
and air inlet B is used or low level. Plug the air inlet that is
not in use to prevent oreign materials rom entering.
Figure 3
.O.—Direct acting: Air supply on switch condition.
.C.—Reverse acting: Air cut-off on switch condition.
2-Way 2-Way 3-Way 3-Way
Port N.O. N.C. N.O. N.C. Diverter elector
(direct) (reverse) (direct) (reverse)
AInlet Plug Inlet Exhaust Outlet Outlet
B Plug Inlet Exhaust Inlet Outlet Inlet
C Outlet Outlet Outlet Outlet Inlet Outlet
Float
Tuffy body
(Non-magnetic)
Magnet
Pivot
Falling level
Air inlet (B)
(no air flow)
Air inlet (A)
Air outlet (C) Pivot arm
Magnet
pivot
Spring
Valve
plunger
Valve body
Float
Pivot
Rising level
Tuffy body
(Non-magnetic)
Air inlet (B)
Air inlet (A)
(no air flow)
Air outlet (C)
Spring
Valve
plunger
Valve body
Magnets
Pivot arm
Magnet
pivot
Figure 4
Low Level Operation—Direct Acting
Figure 5
High Level Operation—Direct Acting

6Tuffy Liquid Level Control with Pneumatic Switch
2.3 Preventive Maintenance
Periodic inspections are a necessary means to keep your
Magnetrol level control in good working order. This control
is a sa ety device to protect the valuable equipment it serves.
A systematic program o preventive maintenance should be
implemented when the control is placed into service. Based
on utilizing a preventative maintenance program and
observing the ollowing section on “what to avoid”, your
Tu y will provide reliable protection o your capital equip-
ment or many years.
WHAT TO AVOID
1. Use only the 2" wrench lats to install or remove the unit.
Re er to Figure 1. Use o any other sur ace could change the
calibration. The valve body is calibrated at the actory and
locked in place.
2. NEVER attempt to make adjustments without reading the
instructions care ully. When in doubt, consult the actory or
your local representative.
3. NEVER use in systems which have excess iron particles in
the solution. The magnet at the counterweight end o the
loat can attract the particles which could cause the loat rod
to jam.
2.4 Troubleshootin
I Tu y ails to shut o or turn on inlet air:
1. Check loat or ull range o travel; clicking o mechanism
should be heard.
2. I the complete Tu y mechanism operates properly when
removed rom service, check to be certain that liquid is
entering the storage tank or vessel. A valve may be closed
or a pipe line clogged.
3. I the loat is determined to be illed with liquid or is
collapsed, the entire level switch must be replaced. Do
not attempt to repair the loat.
4. The actory calibration setting should not require any
adjustment in the ield. Check to see that the unit is
installed properly with the serial number tag positioned
on the top o the unit. I the unit is still not operating
correctly, please contact the actory.
OTE: When in doubt about the condition or performance of a
control, please contact the factory for assistance.

7
Tuffy Liquid Level Control with Pneumatic Switch
2.6 Parts
2.6.1 Physical
Pneumatic switch models
3.75 (95)
Float
minimum
clearance
2" NPT
2.50 (64) Dia.
.75
(19)
C
L
3.00 (76) max.
Nozzle length
7.96 (202) [Sp. Gr. 0.6 min.]
Float size = 2.00 (51) Dia. x 4.57 (116) long
8.91 (226) [Sp. Gr. 0.4 min.]
Float size = 2.00 (51) Dia. x 5.12 (130) long
Switch actuates
Rising level
Falling level
Switch actuates
12.94 (329) [Sp. Gr. 0.4 Min]
12.00 (304) [Sp.Gr. 0.6 Min]
1/4" NPT
inlet (A)
1/4" NPT
outlet (C)
1/4" NPT
inlet (B)
Pressure: 0.6 SG 1500 psig at +300° F (103 bar at +149° C)
0.4 SG 500 psig at +300° F (34 bar at +149° C)
Process Temperature: -40° F to +300° F (-40° C to +149° C)
Ambient Temperature: Max. +100° F (+38° C) with maximum process temperature
Pneumatic Switch Supply Pressure: Vacuum to 200 psig (13.8 bar) maximum
Maximum Leakage Rate: 0.5 SCFH (0.015 SCMH @ 100 psig (6.9 bar))
Maximum Air Flow: 12.0 SCFH (0.34 SCMH @ 100 psig (6.9 bar))
Specific Gravity: 0.6 minimum or 0.4 minimum
Materials of Construction: 316/316L SS wetted components including ACE and ASME B31.3
Housing: 316 stainless steel
2.5 Specifications
2.5.1 Mechanical pecifications
039 6000 10
BA IC MODEL NUMBER
0 3 9 Tuffy Float Switch
WITCH ACTION
6 Pneumatic
HOU ING
0 316 Stainle teel with 1 /4" NPT airline connection
PECIFIC GRAVITY AND PRE URE RATING
0 0.60 minimum S.G., 1500 p i maximum pre ure
4 0.40 minimum S.G., 500 p i maximum pre ure
2.7 Model Numbers

Service Policy
Owners o Magnetrol may request the return o a control
or any part o a control or 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 i :
1. Returned within the warranty period; and
2. The actory inspection inds the cause o the claim to
be covered under the warranty.
I the trouble is the result o conditions beyond our con-
trol; or, is NOT covered by the warranty, there will be
charges or 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 be ore it is returned. I this
is desired, noti y the actory o both the model and serial
numbers o the control to be replaced. In such cases, cred-
it or the materials returned will be determined on the
basis o the applicability o our warranty.
No claims or misapplication, labor, direct or consequen-
tial damage will be allowed.
Low Voltage Directive
For use in Installations Category II, Pollution Degree 2.
I equipment is used in a manner not speci ied by the
manu acturer, protection provided by equipment may be
impaired.
Retur Material Procedure
So that we may e iciently process any materials that are
returned, it is essential that a “Return Material
Authorization” (RMA) number be obtained rom the ac-
tory, prior to the material's return. This is available
through Magnetrol’s local representative or by contacting
the actory. Please supply the ollowing in ormation:
1. Company Name
2. Description o Material
3. Serial Number
4. Reason or Return
5. Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, be ore it is
returned to the actory.
A Material Sa ety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the actory must be by prepaid
transportation.
All replacements will be shipped F.O.B. actory.
A URED QUALITY & ERVICE CO T LE
BULLETIN: 44-606.11
EFFECTIVE: May 2010
UPER EDE : May 2006
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax [phone] • www.magnetrol.com
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax [phone]
Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax [phone]
Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax [phone]
Copyright © 2010 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Performance specifications are effective with date of issue and are subject to change without notice.
Magnetrol & Magnetrol logotype are registered trademarks of Magnetrol International.
Teflon is a registered trademark of DuPont.