sensilevel level switches installation and maintenance ... · sensilevel level switches...

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3.751.5275.204 Issue 3 - 2000 © Copyright 1994 SENSILEVEL Level Switches Installation and Maintenance Instructions Basic operating principle FLOAT CONTROLS The float is mechanically connected to a rod fitted with a stainless steel attraction sleeve (3) at the upper end, which is contained and guided inside the enclosing tube (5). This is made of austenitic or stainless steel, or of a similar non-magnetic material. The float chamber and the enclosing tube form a single, perfectly sealed system with an operating principle that does not employ bellows, flexible diaphragms or packing gland. A mechanism is mounted on the outside of the non-magnetic enclosing tube which, in the example shown below, is fitted with an electric switch (4) of the mercury type. The mercury bulb rotates freely around the pivot (7) and is rigidly connected to a lever fitted with a permanent magnet (1). The switching mechanism can also be a micro- switch or a pneumatic switch valve operating with the same principle. In rising level conditions, the magnetic field (2) attracts the upper end of the attraction sleeve which, overcoming the force exerted by the bias spring (6), attracts the magnet; in falling level conditions, the attraction sleeve (3) moves out of the magnetic field, and thus the working position of the switch is reversed. By varying the amount of the clearence between the stops on the magnetic attraction sleeve on the float rod, the level differential is modified within certain limits. DISPLACER CONTROLS (buoyancy) A weight (displacer) heavier than the liquid, is suspended from a suspension cable, the upper end of which is supported by a depressed spring. The spring is connected to the attraction sleeve (3) by a rod that slides in the non-magnetic enclosing tube (5). When the liquid level rises and contacts the displacer, a buoyancy force is produced wich causes the effective weight of the displacer to change in turn causing the spring to seek a new balance position accordingly moving the attraction sleeve into the field of the magnet, thus actuating the switch. The use of one or more displacers, and the possibility of positioning them freely along the suspension cable, makes it possible to control single or multiple levels with wide excursion and differentials. A futher advantege allows for adaptation to high pressure applications since displacers have substantially heavier wall thickness than floats and in many cases are made out of solid material. Spring Displacer Suspension Cable Level differential Rising level Falling level Displacer control principle Level differential Float Rising level Falling level Float control principle The PED Directive 97/23/EC is repealed and replaced by the new PED Directive 2014/68/EU with effect from 19 July 2016. The ATEX Directive 94/9/EC is repealed and replaced by the new ATEX Directive 2014/34/EU with effect from 20 April 2016.

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Page 1: SENSILEVEL Level Switches Installation and Maintenance ... · SENSILEVEL Level Switches Installation and Maintenance Instructions ... Flow Esempi di esecuzioni ... Use correct torque

3.751.5275.204 Issue 3 - 2000

© Copyright 1994

SENSILEVEL Level SwitchesInstallation and Maintenance Instructions

Basic operating principleFLOAT CONTROLSThe float is mechanically connected to a rod fittedwith a stainless steel attraction sleeve (3) at theupper end, which is contained and guided inside theenclosing tube (5). This is made of austenitic orstainless steel, or of a similar non-magnetic material.The float chamber and the enclosing tube form asingle, perfectly sealed system with an operatingprinciple that does not employ bellows, flexiblediaphragms or packing gland. A mechanism ismounted on the outside of the non-magneticenclosing tube which, in the example shown below,is fitted with an electric switch (4) of the mercurytype. The mercury bulb rotates freely around thepivot (7) and is rigidly connected to a lever fitted witha permanent magnet (1).The switching mechanism can also be a micro-switch or a pneumatic switch valve operatingwith the same principle.In rising level conditions, the magnetic field (2) attractsthe upper end of the attraction sleeve which,overcoming the force exerted by the bias spring (6),attracts the magnet; in falling level conditions, theattraction sleeve (3) moves out of the magnetic field,and thus the working position of the switch is reversed.By varying the amount of the clearence between thestops on the magnetic attraction sleeve on the floatrod, the level differential is modified within certain limits.

DISPLACER CONTROLS (buoyancy)A weight (displacer) heavier than the liquid, issuspended from a suspension cable, the upperend of which is supported by a depressed spring.The spring is connected to the attraction sleeve(3) by a rod that slides in the non-magneticenclosing tube (5).When the liquid level rises and contacts thedisplacer, a buoyancy force is produced wichcauses the effective weight of the displacer tochange in turn causing the spring to seek a newbalance position accordingly moving the attractionsleeve into the field of the magnet, thus actuatingthe switch.The use of one or more displacers, and thepossibility of positioning them freely along thesuspension cable, makes it possible to controlsingle or multiple levels with wide excursion anddifferentials.A futher advantege allows for adaptation to highpressure applications since displacers havesubstantially heavier wall thickness than floats andin many cases are made out of solid material.

Spring

DisplacerSuspensionCable Level differential

Rising level Falling level

Displacer control principle

Level differential

Float

Rising level Falling level

Float control principle

The PED Directive 97/23/EC is repealed and replaced by the new PED Directive 2014/68/EU with effect from 19 July 2016.

The ATEX Directive 94/9/EC is repealed and replaced by the new ATEX Directive 2014/34/EU with effect from 20 April 2016.

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ATTENZIONELavorare in sicurezza con apparecchiature

in ghisa e vaporeWorking safely with cast iron products on steamInformazioni di sicurezza supplementari - Additional Informations for safety

Lavorare in sicurezza con prodotti in ghisa per linee vaporeI prodotti di ghisa sono comunemente presenti in molti sistemi a vapore. Se installati correttamente, in accordo alle migliori pratiche ingegneristiche, sono dispositivi totalmente sicuri. Tuttavia la ghisa, a causa delle sue proprietà meccaniche, è meno malleabile di altri materiali come la ghisa sferoidale o l’acciaio al carbonio. Di seguito sono indicate le migliori pratiche ingegneristiche necessarie per evitare i colpi d'ariete e garantire condizioni di lavoro sicure sui sistemi a vapore.

Movimentazione in sicurezzaLa ghisa è un materiale fragile: in caso di caduta accidentale il prodotto in ghisa non è più utilizzabile. Per informazioni più dettagliate consultare il manuale d'istruzioni del prodotto.Rimuovere la targhetta prima di effettuare la messa in servizio.

Working safely with cast iron products on steamCast iron products are commonly found on steam and condensate systems. If installed correctly using good steam engineering practices, it is perfectly safe.

However, because of its mechanical properties, it is less forgiving compared to other materials such as SG iron or carbon steel.The following are the good engineering prac-tices required to prevent waterhammer and ensure safe working conditions on a steam system.

Safe HandlingCast Iron is a brittle material. If the product is dropped during installation and there is any risk of damage the product should not be used unless it is fully inspected and pressure tested by the manufacturer. Please remove label before commissioning

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VaporeSteam

Flusso Flow

Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:Steam Mains - Do's and Dont's:

Flusso Flow

Prevenzione dai colpi d’ariete - Prevention of water hammerScarico condensa nelle linee vapore - Steam trapping on steam mains:

Intervalli di 30÷50 m. intervals

Pendenza - Gradient 1:100VaporeSteam

Gruppo di scaricoTrap set

Condensa - Condasate

Pendenza - Gradient 1:100

Gruppo di scaricoTrap set

Gruppo di scaricoTrap set

Condensa - CondasateCondensa - Condasate

VaporeSteam

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Prevenzione delle sollecitazioni di trazionePrevention of tensile stressingEvitare il disallineamento delle tubazioni - Pipe misalignment:

Installazione dei prodotti o loro rimontaggio post-manutenzione:Installing products or re-assembling after maintenance:

Evitare l’eccessivo serraggio.Utilizzare le coppie di serraggio

raccomandate.Do not over tighten.

Use correct torque figures.

Per garantire l’uniformità del carico e dell'allineamento, i bulloni delle flange devono essere serrati in modo

graduale e in sequenza, come indicato in figura.Flange bolts should be gradually tightened across

diameters to ensure even load and alignment.

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Dilatazioni termiche - Thermal expansion:Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.Examples showing the use of expansion bellows. It is highly recommended that expert advise is sought from the bellows manufacturer.

GuideGuides

Distanza breveShort distance

Punto di fissaggioFixing point

Movimento assialeAxial movement

Distanza media Mediumdistance

Tiranti limitatoriLimit rods

Piccolo movimento

lateraleSmall lateral

movement

Piccolo movimento lateraleSmall lateralmovement

Ampio movimento

lateraleLarge lateral

movement

Ampio movimento lateraleLarge lateralmovement

GuideGuides

GuideGuides

GuideGuides

Punto di fissaggioFixing point

Tiranti limitatoriLimit rods

Movimento assialeAxial movement

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3.751.5275.204 Issue 32

9. Protective clothingConsider whether any protective clothing isrequired, to protect against the hazards of, forexample, chemicals, high/low temperature, noise,falling objects, dangers to eyes/face.

10. Permits to workAll works must be carried out or be supervisedby a suitable competent person.Where a formal permit to work system is inforce it must be complied with. Where there isno such system, it is recommended that aresponsible person knows what work is goingon and where necessary arrange to have anassistant whose primary responsibi-lity is safety. Post warning notices if necessary.

11. Electrical workBefore starting work study the wiring diagram andwiring instructions and note any specialrequirements. Consider particularly:mains supply voltage and phase, local mainsisolation, fuse requirements, earthing, specialcables, cable entries/cable glands, electricalscreening.

12. CommissioningAfter installation or maintenance ensure that thesystem is fully functioning. Carry out tests on anyalarms or protective devices.

13. DisposalUnwanted equipment should be disposed of in asafe manner.

IMPORTANTSAFETY INFORMATION:PLEASE READ CAREFULLY

Hazards to be considered when installing/using/maintaining

1. AccessEnsure safe access and if necessary a safeworking platform before attempting to work onthe product.Arrange suitable lifting gear if required.

2. LightingEnsure adequate lighting, particularly wheredetailed or intricate work is required e.g.electrical wiring.

3. Hazardous liquids or gases in the pipelineConsider what is in the pipeline or what mayhave been in the pipeline at some previoustime.Consider: flammable materials, substanceshazardaous to health, extremes of tempe-rature.

4. Hazardous environment around the productConsider, explosion risk areas, lack of oxygen(e.g. tanks, pits) dangerous gases, extremesof temperature, hot surfaces, fire hazard (e.g.during welding), excessive noise, movingmachinery.

5. The systemConsider the effect on the complete system ofthe work proposed. Will any proposed action(e.g. closing isolating valves, electricalisolation) put any other part of the system orany other workers at risk? Dangers might in-clude isolation of vents or protective devicesor the rendering ineffective of controls oralarms. Ensure isolation valves are turned onand off in a gradual way to avoid systemshocks.

6. Pressure systemsEnsure that any pressure is isolated andsafety vented to atmospheric pressure.Consider double isolation (double block andbleed) and the locking and/or labelling of val-ve shut. Do not assume the system is de-pressurized even when the pressure gaugeindicates zero.

7. TemperatureAllow time for temperature to normalise afterisolation to avoid the danger of burns.

8. Tools and consumablesBefore starting work ensure that you havesuitable tools and/or consumables available. Useonly genuine Spirax Sarco replacement parts.

Note: The products supplied by Spirax Sarcoare classified as components and are notgenerally affected by the Machinery Directive89/392/EEC.

14. Returning productsCustomers and stockists are remindedthat under EC Health, Safety andEnvironmental Law, when returningproducts to Spirax Sarco they mustprovide information on any hazards andthe precautions to be taken due tocontamination residues or mechanicaldamage which may present a health,safety and environmental risk.This information must be provided inwriting including Health and Safety datasheets relating to any substancesidentified as hazardous.

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3.751.5275.204 Issue 3 3

1 - INSTALLATIONMounting the deviceMount the instrument on the equipment by meansof the appropriate connections (threaded orflanged) so that the housing of the switchmechanism is turned upwards and its axis isvertical (a maximum deviation of 3° is admissible).The process connection tubes to instruments fittedwith external chamber must be rectilinear and full-flow. The length of the tubes must be kept to aminimum to ensure proper circulation of the liquid.Suitable support systems are to be used so as toavoid undesirable forces on the chamber and re-lative attachments. The level controls with externalchamber operating with liquids which tend to leavedeposits must have union tees or cross fittings inorder to allow periodical cleaning of the tubes. Adrain valve (preferably with rectilinear flow) will al-so be useful when cleaning the float chamber andprocess connection tubes. All the on-off valvesmust be full-flow and completely open duringoperation in order to avoid irregular or incorrecttriggering of the level control device. Leave a spaceof at least 200 mm free above the housing in orderto enable it to be removed.

2 - CONNECTING THE SWITCHESGeneral informationsCaution: power or compressed air to the controlmust be disconnected before removing the switchhousing.To access the switch mechanisms, remove thecover of the housing unscrewing the upper screwfor the standard housing (Fig. 1), or elseunscrewing, in an anticlockwise direction, the coveritself, after having loosened the locking screw forthe explosion-proof housing (Fig. 2). The base ofthe housing is fitted with a threaded connectionand may be rotated through 360°, loosening thescrew located in the lower part (with the exceptionof the type 4 explosion-proof housing which cannotbe rotated).

Fig. 3 - Wiring diagram of electrical switchmechanisms

A - Power connectionsBe certain that all wiring conforms to all localelectrical codes.Carry out the connections to the switchmechanisms, referring to the diagrams shown inFig. 3.The wires must be passed through the threadedconnection, then into the space between the baseand the plate below the switch mechanism, andfinally connected to the terminals, preferably bymeans of suitable lead-in wires. Cut the excesswires so that they do not interfere with the switchmechanism or with the housing. The passagethrough the threaded connection must then besealed so as not to jeopardise the degree ofprotection or safety of the housing. Theconnections to the switch mechanism can bemade without the need to remove it from itshousing. Bring the switch mechanism back to theposition preset in the factory, should it have beenmoved during installation. Check the couplingbetween base and cover, and ensure that theseal, if provided on the basis of the degree ofprotection required, is correctly mounted, beforeclosing the housing once again.

EXTERNAL CIRCUIT

SPDT MECHANISM

EXTERNALCIRCUIT

DPDT MECHANISM

Type 3 and 4 housing(explosion-proof)

Type 1 and 2 housing(general purpose)

Fig. 1 Fig. 2

Open

Locking screws

Close

Open Close

STATE OF THE CONTACTS AS FUNCTION OFTHE LEVEL

CLOSED OPENCONTACT CONTACT

Level increasing 2-3 and 5-6 1-2 and 4-5

Level decreasing 1-2 and 4-5 2-3 and 5-6

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3.751.5275.204 Issue 34

3 - DIFFERENTIAL AND SWITCHINGLEVELS

In order to fully understand the descriptions givenbelow, note the following definitions:- HIGH LEVEL: level of liquid at which the switch

mechanism is triggered when the level is rising.- LOW LEVEL: level of liquid at which the switch

mechanism is triggered when the level is falling.- DIFFERENTIAL: difference between high and

low level.The differential for the floating controls may be fieldadjusted by means of the relative nuts. Thedifferential and the switching points for displacercontrols with wide differential can be adjusted inthe field by moving the displacers upwards ordownwards on the suspension cable. For displacercontrols with fixed differential, however, only theactuation point can be adjusted in the field, bymoving the displacer upwards or downwards on thesuspension cable.

B - Pneumatic connectionsConnect the instrument to the pneumatic circuitwith reference to the diagrams shown at Fig. 4 inorder to obtain the function required from thepneumatic switch (three-way valve, two-way val-ve, selector, deviation).The tubes must be connected to the 1/4” NPTconnections located on the base of the housing,which are indicated by the letters A, B and C andare already connected inside the housing to thethree-way pneumatic switch.

EXTERNALCONNECTIONS

Fig. 4 - Diagram of the pneumatic switch

PNEUMATIC VALVE

STATE OF PORTS DEPENDING ON LEVEL(Intervention for low level)

CONNECTION 3-way N.O. 2-way N.C. 3-way N.O. 3-way N.C.A plugged inlet bleed inletB inlet plugged inlet bleedC outlet outlet outlet outlet

Adjusting the differential and switching pointsfor float controls (electric switches 1, 2 and 3)

The instrument is normally set in the factory to theminimum differential (there must be slightclearance between the pair of nuts which hold themagnetic piston). The range of the differential canbe increased, even once the instrument is installed,by lowering only the lower pair of nuts, thusachieving an increase upwards of the maximumswitching level. The differential can be regulatedwithin the following limits:- For the SENSILEVELS with only one switch

mechanism type 1, 2 and 3, the differential canbe increased up to a maximum of 50 mmbeyond the value set in the factory.

- For the SENSILEVELS with two switchmechanisms, the differential can be increasedup to a maximum of 25 mm beyond the valueset in the factory.

- For the SENSILEVELS with three switchmechanisms, the differential is fixed accordingto the minimum value set in the factory.

In order to change the original calibration of thedifferential, where possible, follow the proceduredescribed below carefully. The devices calibratedon request for interface control (point of separa-tion between two non-mixable liquids with differentmass density) are supplied with a fixed differential,therefore no regulation can be performed. All thegeneral suggestions do however apply.

A - Preliminary operations for modifying thedifferential

1 - Disconnect the electric connections at thehousing.

2 - Remove the enclosing tube as well as theentire housing by means of the hexagonal nut(41 mm) beneath the base. In this way themagnetic piston and the relative locking nutscan be reached directly (see Fig. 5).

3 - Remove the two upper nuts and the guidewasher after having noted the exact positionfrom the top of the threaded rod.

4 - Extract the magnetic piston from the threaded rod.5 - Note the exact position of the lower nuts from

the top of the threaded rod.

B - Modifying the differentialIn order to modify the setting, i.e. to change theswitching levels of the instrument, it is sufficient tochange the position of the nuts which attach themagnetic piston along the rod. Bear in mind that achange by 1 mm in the position of the nuts alongthe rod corresponds to the same change in theswitching level. Therefore in order to increase thedifferential, lower the pair of lower nuts by as manymillimetres as necessary for bringing the differentialfrom the value set in the factory to the required value.Warning: the distance between the two pairs ofnuts must never be smaller than the distance definedin the factory.

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3.751.5275.204 Issue 3 5

4 - REPLACING THE SWITCH

A - Electric switch1 -Remove the switch cables from the terminal block.

C - Restoring working conditionsAfter having set the new position of the nuts inrelation to the required differential, re-instate theworking conditions as follows:1 - Tighten the lower nut and lock nut.2 - Re-insert the magnetic piston.3 - Position the pair of upper nuts to the

dimension noted before dismantling andtighten them completely so as to avoidpossible loosening during operation.

4 - Reconnect the external connections at thehousing.

D - Adjusting the switching levelThis operation is performed by changing theposition of the switch mechanism. In the devicesfitted with one or two switches of types 1, 2 and3, it is possible to move the mechanism/s up to50 mm upwards when the device is fitted withonly one switch mechanism and up to 25 mmwhen it is fitted with two mechanisms. Thisoperation is required when the switching valuesare to be raised without modifying the processattachments. In order to move the mechanism,the fastening screw (Fig. 7) has to be loosenedin order to enable the switch to run freely alongthe enclosing tube. Then attach the mechanismin the new position. For the lower mechanismthe plate locking screw also has to be removed.

N.B. - When the switches are moved upwardsthe possibil ity of increasing thedifferential is reduced by the same valueof the movement made (e.g. if on aSENSILEVEL fitted with only one switchmechanism, the latter has been movedupwards by 20 mm, it is possible toincrease the differential by only 30 mminstead of 50 mm).

- After having modified the differentialand/or the switching level, check, bymoving the float by hand, that theswitch commutates properly.

Fig. 5

Threadedrod

Lock nuts factorycalibrated (smallclearance)

Lower nutsLowering this pair of nutsincreases the differential

Attraction sleeve

Pneumatic type

Fig. 6 - Electric and pneumatic type switches

Electric type

A B

C

C

E

D

BA

F

5 - REPLACING THE SWITCHMECHANISM

A - Electric switch mechanismDisconnect power, remove the cover of the housingand proceed as follows:1 - Disconnect the external connections of the

terminal board, noting the position of theindividual wires. Also note the position of themechanism on the enclosing tube.

2 - Loosen the plate locking screw (only for thelower mechanism) and the fixing screw (seeFig. 7) and extract the switch mechanism fromthe enclosing tube.

3 - Replace the switch mechanism and re-assemble by following the process of points 2and 1 in reverse.

4 - Actuate by hand the magnet-holder arm,making sure that it moves freely and that theswitch is actuated properly.

2a - Mercury switch (see Fig. 6).Remove the drop of adhesive that secures themercury bulb to clip “B” and remove the switch.

2b - Microswitch.Loosen the fixing screws and remove the switch.

3 -Replace the old switch with the new one and re-assemble, proceeding in the reverse order fromposition 2a or 2b and then 1.

4 -Manually move the magnet carriage, makingsure that the switch functions correctly, i.e. opensand closes properly; if necessary adjusting it bymeans of screw “C” (see Figs. 6 and 7).

B - Pneumatic switch1 - Remove the valve pipes.2 - Remove fixing screws “D” (Fig. 6) and remove

the valve.3 - Replace the old valve with the new one and

re-assemble, by reversing points 2 and 1.4 - Manually move the magnet carriage, making

sure that the switch functions correctly, i.e.opens and closes properly; if necessaryadjusting it by means of screw “E” (see Fig. 6).

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3.751.5275.204 Issue 36

6 - PREVENTATIVE MAINTENANCE

Periodic inspection is necessary to ensure thecontrol is kept in good working order.We recommend that a systematic program ofPreventative Maintenance be implemented atinstallation. The following precautions are importantand will keep your control in top operating condition.

A - Keep the SENSILEVEL control cleanTo prevent the damaging action of damp and dust,do not leave the cover off longer than absolutelynecessary.There is no need to lubricate any component ofthe SENSILEVEL control.Bleed the float chamber at least once a day, toprevent the build-up of deposits and scale, whichwould prejudice the efficiency of the control.In models without an external chamber, keep thefloat free, and make sure that the displacers arefree of scale and deposits.Every six months, check the float chamber; this isextremely important in making certain that,notwithstanding the daily bleed, there are noresidues and scale inside the chamber. It is

advisable to inspect the float for corrosion. If itshows signs of corrosion, replace it immediately.

B - Check the switches monthlyDisconnect the power to the control and removethe switch housing.1 - Connections

Check that the connections to the switch(whether electric or pneumatic) are in order.

2a - Mercury switchesVisually check the condition of the mercurybulb; if the internal surface looks opaque, thisis a sign that it is probably cracked. Make surethat the mercury moves between the contactsproperly.

2b - MicroswitchesCheck the alignment between the adjustingscrew “C” and the microswitch actuating lever(Fig. 7).Make sure that the microswitch switchesproperly, by manually actuating the magnetcarriage.

2c - Pneumatic switchesCheck that the adjusting screw “C” and thevalve’s control switch “E” are aligned (Figs. 6and 7).Make sure that the valve switches properly,by manually actuating the magnet carriage.

Checks for ensuring that the switches operateproperly should be made also in the event ofpotentially damaging events such as, for example,short circuits, electrical discharges, or over-pressures.When the controls are exposed to excessive heat ordamp, the insulation of the wires will tend to dry andbecome fragile, thus provoking short circuits. Werecommend to replace any damaged cables or wiring.Vibration may loosen the screws of the terminal blocksand the terminals. Check that all screws are tightenedproperly.Do not lubricate the switch pins, as they have beendesigned to operate dry; oil would attract dust anddirt, which are detrimental to efficient operation.

7- TROUBLE SHOOTING

SENSILEVEL level controls are designed for longlife and trouble free operation.However, should you suspect a malfunction, thefollowing steps should be followed to diagnose theproblem.1 - Has the level control been installed properly?2 - Is the level control being operated within the

specified pressure, temperature and liquiddensity limits indicated on the nameplate of thecontrol?

3 - Are the electrical and pneumatic connectionsin good order? Is the power “ON”?

Fig. 7 - Switch mechanism

Fixing screw

Platelockingscrew

Type 1 SPDT Type 2 SPDT

Adjusting screw C

B - Pneumatic switch mechanismSwitch off the supply of compressed air, removethe cover of the housing and proceed as follows:1 - Disconnect the tubes from the valve and note the

position of the mechanism on the enclosing tube.2 - Loosen the screw for fastening the mechanism

(Fig. 6) and remove the latter from the enclosingtube.

3 - Replace the switch mechanism and re-assembleby following the instructions of points 2 and 1 inreverse.

4 - Actuate the magnet-holder arm by hand, makingsure that it moves freely and that the valve isactuated properly.

5 - Reconnect the tubes to the valve, ensuring thatthey do not interfere with the movement of themechanism nor with the housing.

5 - Reconnect the electric wires ensuring that theydo not interfere with the movement of themechanism nor with the housing.

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3.751.5275.204 Issue 3 7

4 - Are the voltage and current, that is, the servocontrol pressures, within the limits fixed for theswitches, as specified on the nameplate?

5 - Do the connections to the switch correspondwith both the instructions provided and thesystem’s general diagrams?

6 - Is the controlled equipment functional and wiredproperly?

7 - Is the switch mechanism fixed in the enclosingtube in the position set at the factory?

8 - Is the switch damaged?Check that the switch is not cracked and thatthere is no corrosion on the terminals, or onthe wire leads. If there is any physical damage,the switch must be replaced.

9 - Does the switch function when operatedmanually?Using a non-conductive tool, manually movethe magnet carriage, which must not offer anyresistance. This manual movement of thecarriage will cause the switch to actuate. Checkcontinuity of the contact with a suitableinstrument.a) Mercury switches: make certain that the

mercury bulb is correctly positioned in itsmounting clip.

b) Microswitches: make certain that theactuation lever of the microswitch is notbent, and that the adjusting screw is positio-ned in the centre of the lever.

c) If the magnet does not make a completestroke towards the enclosing tube in whichit is fitted:Remedy 1 - The pin seatings are too nar-

row and brake the oscillatingarm. Loosen one of the twopin seatings by about ¼ of aturn. Leave a little lateralclearance between the pinsand their seatings.

Remedy 2 - If the magnet binds on thewalls of the enclosing tube,adjust the pin seatings sothat the magnet is centred inthe tube. To achieve this, usea screwdriver to loosen the

pin seating where the magnetbinds against the enclosingtube. Tighten the pin seatingon the opposite side to acorresponding degree. Oneof the two seatings is hiddenby the mercury bulb; in orderto make the adjustment, thismust therefore be removedfrom the two fixing clips.

10 - Is the chamber of the level control free of dirtand scale?a) - Inspect the enclosing tube for dents on

the outside of the tube (the tube mustnot be bent).

b) - Inspect the inside part of the tube for cor-rosion, dirt or scale.

c) - Check that the attraction sleeve and stemare not corroded, bent, or affected byscale build-up.

d) - The lock nut settings of each level controlare factory calibrated individually. Makesure the lock nuts have not been loosen-ed and that their position is such as tomove the attraction sleeve in and out ofthe magnetic field following a change inthe liquid level.

e) - Make certain that the float has not beenpierced (i.e. it floats) and that it is free ofcorrosion.

f) - Inspect the interior of the chamber andprocess connection and make sure it isfree of dirt and scale.

11 - If the above inspections and checks do nottrace the fault, contact our local engineer orour Service Department, providing a comple-te description of functioning and the defectencountered. A diagram of the connectionsand the layout of the installation will berequired.

Contacting us, or ordering spare parts, alwaysindicate the Serial Number of the control. Thisnumber is printed on the nameplate fixed to thebase of the switch housing.

REPAIRSPlease contact our nearest Branch Office or Agent, or directly Spirax-Sarco S.r.l.Via Pasubio, 8 - Cernusco sul Naviglio (MI) - ITALY - Tel.: +39 02 92 11 95 11 - Fax: +39 02 924 03 21

LOSS OF GUARANTEETotal or partial disregard of above instructions involves loss of any right to guarantee.

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3.751.5275.204 2001.05

Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20054 Nova Milanese (MI) - Tel.: +39 0362 49 17.1 - Fax: +39 0362 49 17 307