Magnetrol Tuffy User manual

TUFFY®

Liquid Level Controls

with Pneumatic Switches

INSTRUCTION MANUAL AND PARTS LIST

DESCRIPTION

Tuffy liquid level switches are designed for horizontal mount-

ing in a tank or vessel through threaded or ﬂanged pipe con-

nections. Standard models are equipped with a three-

port/two-position valve, actuated by a magnetically actuated

pivoted cam mechanism. This instruction manual covers

Tuffy level controls which have pneumatic switches. For

Tuffy controls with electric switches, please consult Bulletin

BE 44-605.

OPERATING PRINCIPLE

Figures 1 and 2 illustrate the simple Magnetrol operating

principle. Switching action is obtained through the use of a

magnet attached to a ﬂoat and a switching mechanism.

These two basic component assemblies are separated by a

non-magnetic, pressure tight barrier.

APPLICATIONS

Tuffy is recommended as a high or low alarm switch for

clean liquid applications only.

(For Tuffy controls with electric switches, consult bulletin BE 44-605)

OPERATING CYCLE

At a “low operating level” of liquid in a tank or vessel (refer

to Figure 1), the ﬂoat moves the magnet upward and into

the ﬁeld of 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 from air inlet A to air out-

let C. As liquid level rises, for “High Operating Level” indi-

cation (refer to Figure 2), the ﬂoat moves the magnet down-

ward until the switch mechanism magnet reverses position,

allowing the valve plunger to move so that air is allowed to

pass from air inlet B to air outlet C.

For direct acting low level operation, air inlet A is closed off

when liquid level increases. Conversely, for direct acting

high level operation, air inlet B is closed off when liquid level

recedes.

For reverse acting operation, air inlet A is used for high level

and air inlet B is used for low level. The air inlet that is not in use

should be plugged to prevent foreign materials from entering.

UNPACKING

Unpack the instrument carefully. Inspect all units for dam-

age. Report any concealed damage to carrier within 24

hours. Check the contents of the packing slip and purchase

order. Check and record the serial number for future refer-

ence when ordering parts.

MODEL IDENTIFICATION

Air inlet B

(no air ﬂow)

Air inlet A

Valve body Air outlet C Pivot arm

Falling level

Float

Pivot

Magnets

Magnet

pivot Tuffy body

(non-magnetic)

Spring

Valve

plunger

Figure 1: Low level operation – direct acting

Air inlet B

Air inlet A

(no air ﬂow)

Valve body Air outlet C Pivot arm

Rising level

Float

Pivot

Magnets

Magnet

pivot Tuffy body

(non-magnetic)

Spring

Valve

plunger

Figure 2: High level operation – direct acting

SPECIFIC GRAVITY

PNEUMATIC SWITCH

0 0,6 minimum

4 0,4 minimum

0 00 09 1 03 6

INSTALLATION

EXTERNAL CAGE INSTALLATION

MOUNTING

1. Before assembling Tuffy in a tank or vessel, check

threaded or ﬂanged mounting nozzle for the following:

a. Nozzle length and inside diameter must be sized

correctly to allow for switch actuation at design

levels. Refer to Figure 3.

b. Nozzle must be checked for horizontal alignment.

2. Tuffy mounting does not differ for high level or low level

operation. For proper operation, the serial number tag

must be on top. Depending on whether direct or indi-

rect action is required, air inlet A or air inlet B are used

for supply air input. Air outlet C is always used for out-

put. Table 1 summarizes the pneumatic valve action

that takes place based on the inlets used.

3. Inlet air should be ﬁltered with a 5 micron or ﬁner ﬁlter.

This will extend the life of the valve mechanism.

4. Connect the inlet air line to the 1⁄4" NPT connection for

either air inlet A or air inlet B, depending on the valve

action desired (refer to Table 1). Inlet air pressure

should be between 0–13.8 bar (0–200 PSIG). Refer to

Figure 3 for location of air inlets.

5. Connect outlet air line to the 1⁄4" NPT connection on

the bottom of the valve. This air outlet is designated

with a “C”. Refer to Figure 3 for location.

6. If 3-way function is used, attach the exhaust air line to

the appropriate 1⁄4" NPT connection based on valve

action described in Table 1.

Table 1

N.O.—Direct Acting: Air supply on switch condition.

N.C.—Reverse Acting: Air cut-off on switch condition.

Float 2-Way 2-Way 3-Way 3-Way

Position Port N.O. N.C. N.O. N.C. Diverter Selector

(direct) (reverse) (direct) (reverse)

Down A Inlet Plug Inlet Exhaust Outlet Outlet

(Low)

Up B Plug Inlet Exhaust Inlet Outlet Inlet

(High)

— C Outlet Outlet Outlet Outlet Inlet Outlet

Float must clear

inner tank wall

Serial No.

Tag

1/4" NPT

inlet (B)

1/4" NPT

inlet (A)

1/4" NPT

outlet (C)

Wrench ﬂats

Figure 3

Shutt-off

Valve

Pressure

Vessel

Switch

Actuation

Level

Shutt-off

Valve

Drain Valve

Safety

Check

Valve

1/4" NPT

inlet (B)

1/4" NPT

inlet (A)

1/4" NPT

outlet (C)

Figure 4

Figure 4 shows a typical piping installation of a Tuffy Exter-

nal Cage Assembly. Switch actuates within 19 mm (0.75")

above the cage-Tuffy centerline for rising level and within

19 mm (0.75") below the centerline on falling level.

The external cage must be installed so that the tappings

are vertical. Installation should be checked with a spirit

level on top and/or sides of the cage.

Controls should be mounted as close to the vessel as pos-

sible. This will result in a more responsive and accurate

level change in the cage. Liquid in a long pipeline may be

cooler and more dense than liquid in a vessel causing lower

level indication in the control than actual level in the vessel.

Use pipe of sufﬁcient strength to support the control. If nec-

essary, 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 will drain towards the ves-

sel and upper vapor line will drain toward the control. Shut-

off valves are recommended for installation between the

vessel and the cage assembly. If a 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 pip-

ing should be insulated. Such boiling in the chamber will

cause false level indicators. In this case, DO NOT insulate

the switch mechanism housing.

PREVENTIVE MAINTENANCE

TROUBLESHOOTING

SPECIFICATIONS

WHAT TO AVOID

1. Use only the 2" wrench ﬂats to install or remove the

unit. Refer to Figure 3. Use of any other surface could

change the calibration. The valve body is calibrated at

the factory and locked in place.

Periodic inspections are a necessary means to keep your Magnetrol level control in good working order. This control is a safety

device to protect the valuable equipment it serves. A systematic program of preventive maintenance should be implemented

when the control is placed into service. Based on utilizing a preventative maintenance program and observing the following sec-

tion on “what to avoid”, your Tuffy will provide reliable protection of your capital equipment for many years.

2. NEVER attempt to make adjustments without reading

the instructions carefully. When in doubt, consult the

factory or your local representative.

3. NEVER use in systems which have excess iron parti-

cles in the solution. The magnet at the counterweight

end of the ﬂoat can attract the particles which could

cause the ﬂoat rod to jam.

FAILURE TO SHUT OFF OR TURN ON INLET AIR

1. Check ﬂoat for full range of travel; clicking of mecha-

nism should be heard.

2. If the complete Tuffy mechanism operates properly

when removed from 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. If the ﬂoat is determined to be ﬁlled with liquid or is

collapsed, the entire level switch must be replaced. Do

not attempt to repair the ﬂoat.

4. The factory calibration setting should not require any

adjustment in the ﬁeld. Check to see that the unit is

installed properly with the serial number tag posi-

tioned on the top of the unit. If the unit is still not oper-

ating correctly, please contact the factory.

NOTE: When in doubt about the condition or performance

of a control, please contact the factory for assistance.

Description Speciﬁcation

Max. design pressure 0,6 SG: 103 bar @ 040°C (1500 PSIG @ 100°F)

0,4 SG: 34 bar @ 040°C (1500 PSIG @ 100°F)

Max. process temperature -40°C to 200°C (-40°F to 400°F)

Pneumatic switch supply pressure Vacuum - max 13.8 bar (200 PSIG)

Max. leakage rate 14.16 l/h (0.5 SCFH)

Max. air ﬂow 2.55 m3/h (1.5 SCFM)

Speciﬁc gravity 0.6 minimum or 0.4 minimum

Materials of construction 316/316 SS wetted components including ANSI B 31.3/NACE

Housing 316/316 L SST

Cage (optional) Carbon steel or 316/316L stainless steel

Cage rating 103 bar @ 260°C (1500 PSIG @ 500°F)

Square ﬂange (optional) rating 017 bar @ 204°C (0250 PSIG @ 400°F)

MECHANICAL SPECIFICATIONS

DIMENSIONAL SPECIFICATIONS in mm (inches)

329 (12.94)

76 (3) max.

nozzle length

2" NPT

1/4" NPT

outlet (C)

1/4" NPT

inlet (B)

1/4" NPT

inlet (A)

Switch Actuates

Rising Level

Falling Level

Switch Actuates

64 (2.5) Ø

(0.75)

95 (3.75)

ﬂoat

minimum

clearance

226 (8.91) [Sp. Gr. 0.4 Min.]

Float Size = 51 (2) Ø x 130 (5.12) Long

202 (7.96) [Sp. Gr. 0.6 Min.]

Float Size = 51 (2) Ø x 116 (4.57) Long

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 trans-

portation 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, cred-

it 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 4. Desired Action

2. Description of Material 5. Reason for Return

3. Serial Number 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.

BELGIUM Heikensstraat 6, 9240 Zele

Tel. (052) 45.11.11 Fax (052) 45.09.93

DEUTSCHLAND Schloßstraße 76, D-51429 Bergisch Gladbach-Bensberg

Tel. (02204) 9536-0 Fax (02204) 9536-53

FRANCE 11, Rue A. Einstein, Espace Descartes, 77420 Champs-sur-Marne

adresse postale: 77436 Marne-la-Vallée Cédex 2

Tel. (0) 164.68.58.28 Fax (0) 164.68.58.27

ITALIA Via Arese 12, I-20159 Milano

Tel. (02) 607.22.98 (R.A.) Fax (02) 668.66.52

UNITED Unit 1 Regent Business Centre

KINGDOM Jubilee Road Burgess Hill West Sussex RH 15 9TL

Tel. (01444) 871313 Fax (01444) 871317

INDIA B4/115 Safdurjung Enclave, New Delhi 110 029

Tel. 91 (11) 6186211 Fax 91 (11) 6186418

BULLETIN N°: BE 44-606.3

EFFECTIVE: JANUARY 1998

UNDER RESERVE OF MODIFICATIONS SUPERSEDES: March 1991

REPLACEMENT PARTS

Optional accessories

For selection of cages and ﬂanges please refer to bulletin

BE 44-118.

The pneumatic Tuffy is designed for years of trouble free

use. Due to the nature of the valve design and the factory

calibration required for proper operation, no specific

replacement parts are offered.

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