Tuffy
®
II
Liquid Level Controls
with Electric Switches
Installation and Operating Manual
Side
Mounted
Float Level
Switch
Read this Manual Before Installing
This manual provides information on the Tuffy II Float
Level Switch. It is important that all instructions are read
carefully and followed in sequence. Detailed installation
and wiring 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 component’s 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.
WARNING!
Explosion hazard. Do not connect or discon-
nect equipment unless power has been switched off or the
area is known to be non-hazardous.
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 Trademark, Copyright, and Limitations
Magnetrol & Magnetrol logotype, and Tuffy are registered
trademarks of Magnetrol International, Incorporated.
Copyright © 2010 Magnetrol International, Incorporated.
All rights reserved.
Performance specifications are effective with date of issue
and are subject to change without notice. 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 compa-
ny. Magnetrol is committed to providing full customer sat-
isfaction both in quality products and quality service.
Magnetrol’s 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.
44-607 Tuffy II Liquid Level Switch
Tuffy
®
II Liquid Level Controls
with Electric Switches
Table of Contents
1.0 Installation
1.1 Unpacking.............................................................4
1.2 Before You Begin ...................................................4
1.2.1 Site Preparation ..........................................4
1.2.2 Equipment and Tools..................................4
1.3 Mounting ..............................................................5
1.3.1 Mounting an NPT Tuffy II.........................5
1.3.2 Mounting a Flanged Tuffy II ......................5
1.3.3 Mounting External Cage Tuffy II................5
1.4 Wiring...................................................................7
1.5 Adjustable Differential...........................................8
1.6 Interface ................................................................9
2.0 Reference Information
2.1 Description ...........................................................9
2.2 Theory of Operation...............................................10
2.3 Troubleshooting...................................................10
2.3.1 External Causes.........................................10
2.3.2 Tuffy II Causes .........................................10
2.4 Preventive Maintenance.......................................12
2.4.1 What to Do ..............................................12
2.4.2 What to Avoid ..........................................13
2.4.3 Switch Mechanism Replacement...............13
2.5 Agency Approvals ................................................14
2.6 Parts ....................................................................14
2.6.1 Replacement Parts.....................................14
2.6.2 Recommended Spare Parts........................14
2.7 Specifications.......................................................15
2.7.1 Functional ................................................15
2.7.2 Performance..............................................15
2.7.3 Switch Temperature Ratings......................16
2.7.4 Physical.....................................................19
2.8 Model Numbers ..................................................21
2.8.1 Standard Narrow Differential Models .......22
2.8.2 Chamber Model Number .........................23
2.8.3 Interface Models .......................................24
2.8.4 Adjustable Wide Differential Models ........26
44-607 Tuffy II Liquid Level Switch
1.0
Installation
This section provides detailed procedures for properly
installing the Tuffy II Liquid Level Switch.
Caution:
If equipment is used in a manner not specified by
manufacturer, protection provided by equipment may be
impaired.
1.1
Unpacking
Unpack the instrument carefully. Inspect all units for damage.
Report any concealed damage to the carrier within 24 hours.
Ensure all components have been removed from the packing
material. Check all the contents against the packing slip and
report any discrepancies to the factory. Check the nameplate
model number to ensure that it agrees with the packing slip
and purchase order. Record the serial and model numbers
for future reference when ordering parts.
Model Number
Serial Number
1.2
Tuffy
II
Maximum Nozzle Lengths
(distance from face of mounting flange
to end of 3" sch 80 nozzle or the tip of
the mounting threads to the end of 2"
nozzle with ID same as 2" NPT)
T31 or T35
with NPT connection
T31, T32, T33, T34 or T35
with flanged connection
T3B
T3C
Figure 1
Maximum nozzle length
Before You Begin
1. Ensure that the length and inside diameter of the mounting
nozzle are sized correctly for the Tuffy II model and the
required actuation levels. Maximum nozzle lengths for each
model are specified in
Figure 1
.
2. Ensure that the mounting nozzle or coupling is within 3°
of horizontal. If mounting the Tuffy in an external cage,
ensure that the cage is mounted within 3° of horizontal
and that the top/bottom piping is within 3° of vertical in
all directions.
3. Ensure that the area is free of metallic particles which might
be attracted to the magnet holder/counterbalance and inter-
fere with the function of the Tuffy II.
1.2.1 Site Preparation
3.29"
3.35"
5.80"
4.35"
1.2.2 Equipment and Tools
No special equipment or tools are required to install
the Tuffy Liquid Level Switch. The following items are
recommended:
• Wrenches, flange gaskets and flange bolting appropriate for
process connection(s).
• Pipe wrench
• Level
• Flat head screwdriver
4
44-607 Tuffy II Liquid Level Switch
1.3
Mounting
The Tuffy II Liquid Level Switch is available with a 2" NPT
mounting bushing, a variety of flange mountings and
external cages for mounting outside of the vessel.
Caution:
This instrument is intended for use in Installation Category II,
Pollution Degree 2.
1.3.1 Mounting an NPT Tuffy
II
Conduit Entry
(down)
Figure 2
NPT Mounting Orientation
1. Apply either Teflon
®
tape or appropriate lubricant 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 conduit entry points
down.
See Figure 2.
Caution:
The Tuffy II must be installed with the conduit connection
pointing downward to ensure correct switching action.
1.3.2 Mounting a Flanged Tuffy
II
1. Have proper flange bolting and gasket on hand.
2. Cut and remove plastic shipping straps.
Conduit Entry
(down)
Figure 3
Flanged Mounting Orientation
3. Carefully align Tuffy flange raised face (cladding) with the
face of the vessel mounting flange. Slide the flange on the
control to the vessel mounting flange and align bolt holes.
Ensure that the conduit entry is pointing down.
See Figure 3.
4. Ensure that the flange gasket is seated properly. Install
flange bolts and nuts.
5. Tighten alternating flange bolts in a star pattern.
Caution:
The Tuffy II must be installed with the conduit connection
pointing downward to ensure correct switching action.
Pressure
Vessel
Shut–off
Valve
Safety
Check
Valve
1.3.3 Mounting External Cage Tuffy
II
C
L
C
L
C
L
C
L
NPT
Conduit
Connection
Drain Valve
Shut–off
Valve
Switch
Actuation
Level
A typical Tuffy external cage installation is shown in
Figure 4
.
1. Install cage so that trappings are within 3° of 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 Tuffy cage.
Figure 4
External Cage Mounting
44-607 Tuffy II Liquid Level Switch
5
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