bleed type valve for liquid level switches series j pneumatic switch mechanism installation and operating manual
read this manual before installing this manual provides information on the series j pneumatic switch mechanism. it is important that all instructions are read carefully and followed in sequence. detailed installation and hook-up instructions are included in 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 installations category ii, pollution degree 2. if equipment is used in a manner not specified by the manufacturer, protection provided by equipment may be impaired. notice of copyright, and limitations copyright ? 2009 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 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. 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 guar- antees the highest level of quality throughout the company. magnetrol is committed to providing full cus- tomer satisfaction 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. 42-685 series j pneumatic switch mechanism
1.0 description the series j pneumatic switch is a single airline, bleed type valve with a magnetically actuated flapper. the move- ment of the magnet assembly causes the switch to change state, either moving the flapper away from the nozzle allow- ing the pressure in the line to vent or moving the flapper against the nozzle causing pressure to build up in the line. 2.0 principle of operation figure 1 shows the attraction sleeve and magnet in the posi- tion when the liquid level is such that the attraction sleeve is below the field of the magnet. in this position, the flapper has been drawn away from the nozzle by the fall-out spring; and, air flows faster through the nozzle than it can be sup- plied through the restriction. the air pressure to the control valve then drops to zero. figure 2 shows the attraction sleeve when it is within the field of the magnet. when a change in the liquid level moves the attraction sleeve into the field of the magnet, it causes the magnet to pull in against the enclosing tube. in this position, the flapper is held against the nozzle, thus shutting off the bleed of air. the air pressure to the control valve builds up to supply pressure. the switch is reversible with two simple adjustments described on page 4. note: clean, dry, regulated air should be used with the pneumatic switch. 3 42-685 series j pneumatic switch mechanism r d attraction sleeve non-magnetic enclosing tube air s upply bleed restriction falling level magnet (swing out position) r everse link position for opp osite action t o control valve nozzle flapper r d attraction sleeve non-magnetic enclosing tube air s upply bleed restriction rising level magnet (swing in position) reverse link position for opp osite action t o control valve nozzle flapper 31>;/ ==;+-=398 <6//?/ ,/69@ 03/6. 90 7+18/= 31>;/
==;+-=398 <6//?/ 38 03/6. 90 7+18/=
3.0 reversing pilot action all series j pneumatic switch mechanisms are shipped from the factory set-up for direct action; closed at high level. they can be field modified for the reverse (open) position by following the steps below: 1. first remove the upper shoulder screw from the actuator link and move it from the direct (d) position to the reverse (r); refer to figure 3. 2. loosen the screw that positions the spring bracket and move it from the direct (d) position to the reverse (r) position; refer to figure 4. 3. fasten screw securely. the switch is now setup for reverse action. 4 42-685 series j pneumatic switch mechanism figure 4 fall out spring reverse position enclosing tube direct position air line adapter spring bracket reverse position upper shoulder screw actuator link air line adapter enclosing tube direct position figure 3
5 42-685 series j pneumatic switch mechanism figure 5 fall-out stop base locking screw air line adapter enclosing tube frame screw enclosing tube nut magnet figure 6 1 M 16 " allen wrench flapper air line adapter enclosing tube flapper adjustment screw strainer o-ring nozzle 4.0 locating air line connection the air line connection may be rotated a full 360 for your convenience in connecting the instrument air supply. to rotate the switch and base assembly: 1. loosen both the locking screw above the enclosing tube nut and the frame screw. refer to figure 5. 2. rotate the entire base to the desired position. 3. tighten both the locking screw and the frame screw. 4.0.1 remove complete mechanism 1. disconnect air line from air line adapter. 2. loosen both the locking screw above the enclosing tube nut, and the frame screw approximately 3 to 4 turns. refer to figure 5. 3. lift the entire base and switch assembly straight up and off the enclosing tube. 5.0 preventive maintenance 5.0.1 nozzle cleaning to clean the nozzle, follow the steps below: 1. unscrew and remove the adapter. refer to figure 6. 2. the o-ring and strainer will now fall out when the switch is tipped. 3. unscrew the flapper adjustment screw with a 1 M 16 " allen wrench. this will prevent damage to the flapper when performing step 4. 4. insert a 1 M 16 " diameter wire into the nozzle from the air line connection side. refer to figure 7. the wire may be moved back and forth to clean the opening of any accumulated matter. 5. reassemble the o-ring, strainer, and air line adapter; insert into nozzle. refer to figure 6. 6. securely tighten the air line adapter. 7. readjust the flapper to its original position; refer to section 5.02 nozzle flapper readjustment on page 6.
5.0.2 nozzle flapper readjustment 1. connect an air line to the adapter. 2. pressurize the air line. 3. adjust the flapper adjustment screw for the desired action: direct action a. hold the magnet against the enclosing tube. b. adjust the flapper adjustment screw with a 1 M 16 " allen wrench until the air flow stops, plus an extra one-eighth turn. reverse action a. hold the magnet against the fall out stop. refer to figure 5 on page 5. b. adjust the flapper adjustment screw with a 1 M 16 " allen wrench until the air flow stops. 4. manually actuate the switch under pressure to assure its correct actuation. the unit is now ready for service. 6 42-685 series j pneumatic switch mechanism figure 7 1 M 16 " diameter wire flapper enclosing tube floppy adjustment screw nozzle magnet (yellow or red dot) 6.0 replacement parts 6.1 j series pneumatic switch replacement parts for j series pneumatic switch mechanisms are available as an assembly only. when ordering an assem- bly, be certain to specify: 1. the model number of the level control in which the switch was installed, for example b75-1b20-jde. 2. the serial number of the level control in which the switch was installed. refer to nameplate attached to control 3. the part number of the replacement switch assembly, for example 89-7501-026. for models rated below 1480 psig. for models rated above 1480 psig. description part number red dot jdg, jgh 89-7501-027 jeg, jhh 89-7501-029 jfg, jjh 89-7501-031 yellow dot jde, jgf 89-7501-026 jee, jhf 89-7501-028 jfe, jjf 89-7501-030 yellow dot jke, jnf 89-7501-032 jle, jpf 89-7501-033 jme, jrf 89-7501-034
7 42-685 series j pneumatic switch mechanism 7.0 switch codes magnetrol level controls are identified by an alpha-numeric numbering system. the last digits describe the type of switch mechanism furnished. b75 1b20 switch mechanism and enclosure 6.2 switch housing replacement assembly standard carbon steel housing replacement assemblies are available. refer to figure 8. includes assembly hardware kit 89-6508-001. figure 8 carbon steel housing assembly example model number: description replacement kit part number gray cover blue cover standard housing cover short 4" (102 mm) 89-6523-002 89-6509-003 tall 6" (152 mm) 89-6523-001 89-6510-003 cover assembly hardware 89-6508-001 89-6508-001 note: maximum leakage rate is .5 scfh at maximum supply pressure. for models rated below 1480 psig. for models rated above 1480 psig. switch code maximum supply maximum process temp. orifice diameter in. (mm) cover height in. (mm) red dot yellow dot jdg jde jke 100 psig (6 bar) 400 f (204 c) .063 (1) 4 (101) jeg jee jle 60 psig (4 bar) 400 f (204 c) .094 (2) 4 (101) jfg jfe jme 60 psig (4 bar) 700 f (371 c) .055 (1) 4 (101) jgh jgf jnf 100 psig (6 bar) 400 f (204 c) .063 (1) 6 (152) jhh jhf jpf 60 psig (4 bar) 400 f (204 c) .094 (2) 6 (152) jjh jjf jrf 60 psig (4 bar) 700 f (371 c) .055 (1) 6 (152)
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 control; 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, credit for the materials returned will be determined on the basis of the applicability of our warranty. no claims for misapplication, labor, direct or consequential 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 material's 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 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 ? 2009 magnetrol international, incorporated. all rights reserved. printed in the usa. bulletin: 42-685.4 effective: february 2005 supersedes: april 1997
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