INSTRUCTION & MAINTENANCE MANUAL

TECHTROL MAGNETIC FLOAT OPERATED

PIVOTED LEVEL SWITCH “FPS”

Introduction :
It is an economical, maintenance free and reliable device used for high, low or intermediate point level switching. It is
ideal for tanks with inaccessible tops or bottoms and where insertion depths of top mounted models are exceeded.

Construction and Operation (Fig. 1) :

Compact and rugged construction consisting of a free moving pivoted float assembly and a switch enclosure in
nonmagnetic material to achieve undisturbed magnetic flux. It employs dual magnets, one carried by the float arm,
other by the contact carriers housed in switch enclosure. A change in liquid level brings the like poles of dual magnets
opposite to each other and resulting repulsion force ensures a changeover of contacts with snap action. The magnetic
transmission is glandless, leaving no scope for leakages from vessel into switch housing. These switches are
manufactured in various materials, enclosures and special features to suit broad range of media / applications. They are
designed to provide high repeatability and to minimise effects of shock, vibration and pressure.

Fig. 1: Construction 01) TERMINAL CAP

02) GASKET
03) CONDUIT CONNECTION
TANK 04) EARTHING SCREW
13 12 11 10 09 08 07 06 14 05 02 01
05) SWITCH HOUSING
06) BOLTS
07) PROCESS CONNECTION
08) STOPPER
09) BRACKET
04 03 10) PIVOT PIN
LIQUID 11) TRIM
12) FLOAT LOCK NUT
13) FLOAT
14) SWITCH CHASSIS

Pre-Installation Procedure :
Select continuity range on multimeter and connect its probes to P and NO Contact of level switch.
Move the float manually upwards from its 'Normal Condition' to 'Alarm Condition' and ensure that 'NO' contacts
become 'NC' by observing continuity on the multimeter.
Repeat Select continuity range on multimeter and connect its probes to P and NC contacts of level switch.
Move the float manually upwards from its 'Normal Condition' to 'Alarm condition' and ensure that 'NC' contacts
become 'NO' by observing continuity on the multimeter.
 Installation : (Fig.2)
Mounted internally or externally through a chamber. External mounting is resorted to, where space is a limiting factor or
mechanical devices like stirrers operate within the tank. Besides, in applications like boilers, reaction kettles etc. with
external mounting, isolating is possible for regular servicing. The switch is normally side-mounted, however for
application like slurry, top installation is preferred. The switch can be wired directly ''to make or break electrical circuits”
of burners, heaters, motor-pumps, alarms and other such electrically operated devices.
1. Ensure that ID of mounting nozzle is greater than float diameter.
2. Select a suitable location on tank where vibrations if any are minimum.
3. Ensure that process connection of Level Switch match with those on tank.
4. Ensure counter connections provided on tank are vertical and in plumb line.
5. Ensure that C=C distance of external cage match with those on tank.
6. Ensure that in case of externally mounted version, provide separate isolation valve on tank for safety & removal
of Level Switch for repairs / maintenance.
7. Provide suitable gasket between the flanges before bolting, to ensure zero leakage through joints.
8. Ensure mounting nozzle length & inside diameter must be sized correctly to allow for switch actuation at desired level.

Fig. 2 : Installation

Adequate gasket
should be provided
Id of
TANK 100 Nuts, Bolt & Washer 100 Mounting
Nozzle

Tank
Process Connection Flange
Nozzle
Counter Connection

NOTE:- Distance 100 mm max. considered nozzle pipe schedule will be max. 40. If more contact factory.

Termination : (Fig. 3)
Before actually turning ON the power supply make sure that all the Fig. 3 : TERMINATION
wiring is done correctly.
Precautions:
1. Ensure that supply voltage and current rating is as per its rated
capacity. Excessive oltage / current will permanently damage the NC NC NC
switch contacts. NO NO NO
P P P
2. Ensure that the switch is duly earthed.
3. Ensure use of proper cable for wiring, which should match the
current rating of connected load.
4. Ensure terminal contacts are not loose. 1 C/O OUTPUT 2 C/O OUTPUT
5. Ensure that enclosure is always covered with its terminal along
with gasket provided for it, to protect if from dust and weather. POTENTIAL FREE MICRO
6. Ensure that Level Switch should not be used for Liquids containing SWITCH CONTACTS
iron particles or other strongly magnetic material
7. Ensure when mounting switch in the side of tank, arrow on the CONTACT RATING 5A @ 230VAC
switch enclosure must be pointing downward.
 In situ Test Device - T :
It is supplied as an accessory to Magnetic Switch (FPS) to facilitate
mechanical testing of electrical circuit. As such operations are
checked without carrying out the emptying / filling cycle.

Test device

Switch flange
Float

Trim

Tank Inside

Maintenance :
Switches must be cleaned frequently if the Liquid has high viscosity or contain floating material.
Ensure that terminal connections are not loose.
Ensure that contacts of switch mechanism are not pitted / oxidized due to sparking.
Be sure the switch enclosure cover is always in place on the enclosure.
Disconnect device from the supply ckt. before opening to prevent ignition of hazardous atmosphere.

Trouble shooting :

Problem Cause Solution

1. Switch is not operating a. Float trim movement jammed. Loosen the pivot pin.

b. Switch burnt due to load more than Change switch.

its rating.

c. Micro switch contacts oxidised / Clean contacts.

pitted due to sparking.

d. Float may be damaged / Change float.

Punctured.

e. Wiring connection is loose. Tighten connection.

f. Wire connection not proper. Wire properly as specified.

g. Liquid Sp. gravity is lesser than that Replace float to match

specified while ordering. Sp. gravity.

Non-valid Guarantee Claims : Abnormal usage, mishandling, breakage, disaster, incorrect installation and usage
beyond limits of specified operating conditions / electrical parameters.

PUNE TECHTROL PVT LTD

S-18, MIDC, Bhosari, Pune - 411026. India
+91-20-66342900, 27121052
+91-20-66342998
[email protected]
www.punetechtrol.com
MAN/FPS/Rev 02/02-09