madison company product catalog

© Copyright Madison Company – 7/10

SINGLE-POINT LEVEL SENSORS & SWITCHES LL-1 TO LL-43• Stainless Steel Single-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-2 to LL-3• Plastic Single-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-4 to LL-5• Brass Single-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-6• Metric Single-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-7 to LL-8• Data Sheet/Product Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-9 to LL-10• Combination Level & Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-11 to LL-12• HVAC Condensate Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-13 to LL-14• Harsh Environment Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-15 to LL-16• Harsh Environment & High-Purity PTFE Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-17 to LL-18• Heavy-Duty Side-Mounted “Tank Commander” Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-19 to LL-20 • Heavy-Duty Industrial Side-Mounted “Big Dipper” Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-21 to LL-22 • Subminiature Liquid Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-23 to LL-24• Leak Detection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-25 to LL-26• Bilge & Bottle Switches for Bilges and External Tank Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-27 to LL-28• Adjustable Height Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-29 to LL-30• Interstitial Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-31 to LL-32• Drum Level Indication Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-33 to LL-34• Refrigerant Recovery Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-35 to LL-36• Side-Mounted Switches with Male Spade Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-37 to LL-38• Tilt Float Switch for Open Vessels, Sumps & Ponds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-39 to LL-40• Stainless Steel Side-Mounted “Side Kick” Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-41 to LL-42• Single-Point Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-43

• Data Sheet/Product Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-45 to LL-46• Stainless Steel Multi-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-47• Plastic Multi-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-48• Brass Multi-Point Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-49• Multi-Point Switch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-50• Full-Size Multi-Point Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-51• Miniature Multi-Point Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LL-52

• Field-Repairable Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-2 to CL-6• 1-inch, 5mm & 10mm Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-2 to CL-8• 1-inch Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-9• 5mm & 10mm Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-10• Continuous Level Sensors with Integrated Programmable Display & Alarm . . . . . . . . . . . . . . . . . CL-3, CL-11 to CL-12

• Probe for Food Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD-1 to CD-2• Switches & Switch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD-3 to CD-4• Conductivity Switch Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD-5

• Hydrostatic Pressure Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-1 to PS-2• Hydrostatic Pressure Level Sensors for Turbulent Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-3 to PS-4• Pressure Sensor with Integrated Programmable Display & Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-5 to PS-6• Differential Pressure Transmitter with Integrated Programmable Display & Alarm . . . . . . . . . . . . . . . . . . . PS-7 to PS-8• Pressure Sensor Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-9 to PS-10

• Optical Switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OP-1• Optical Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OP-2 to OP-4• Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OP-5 to OP-6• Optical Switch Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OP-7

TABLE OF CONTENTS

LL

MULTI-POINT LEVEL SENSORS & SWITCHES LL-45 TO LL-52

CONTINUOUS LEVEL INDICATORS CL-1 TO CL-12

CONDUCTIVITY LEVEL SWITCHES CD-1 TO CD-5

PRESSURE LEVEL SENSORS PS-1 TO PS-10

OPTICAL LEVEL DETECTION SWITCHES OP-1 TO OP-7

LL

CL

CD

PS

OP

FL

NC

TM

PR

AC

RF

© Copyright Madison Company – 6/10

FLOATS FL-1 TO FL-4

NON-CONTACT LEVEL SENSORS NC-1 TO NC-28

TEMPERATURE SENSORS TM-1 TO TM-20

PROXIMITY SENSORS PR-1 TO PR-3

ACCESSORIES AC-1 TO AC-10

TECHNICAL DATA & REFERENCE MATERIAL RF-1 TO RF-33

FL

NC

TM

PR

AC

RF

Madison Company • (203) 488-4477 • (800) 466-5383 • Fax (203) 481-5036 • [email protected] • www.madisonco.comMadison Europe • +31 (0) 548 659 034 • Fax +31 (0) 548 659 010 • E-mail: [email protected]

LL

LL

CL

CD

PS

OP

• Ultra-Low-Level Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FL-1 to FL-2• Standard Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FL-3 to FL-4

• U Series Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-2 to NC-3• Madisonic™ Short-Range Ultrasonic Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-5 to NC-6• U4466 Series Programmable Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-7 to NC-8• U4467 Series Loop-Powered Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-9 to NC-10• U4468 Series Web-Enabled Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-11 to NC-12• Standard Ultrasonic Sensors Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-13 to NC-14• Madison-Omni® Ultrasonic Sensors with Integrated Programmable Display & Alarm . . . . . . . . . . . . . . . NC-15 to NC-16• U3M Mini Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-17 to NC-18• R Series Radar Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-4• Standard Radar Sensors Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-19 to NC-20• Sanitary “Smart” Radar Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-21 to NC-22• Non-Contact Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NC-23 to NC-24

• Standard Part Numbers/Ordering Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-2 to TM-6 • Indicators & Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-7• Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-8• Type K, J & T Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-2, TM-9 to TM-10• RTDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-5, TM-11 to TM-12• Temperature Sensor Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-8, TM-13 to TM-14• RTDs with Integrated Programmable Display & Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-15 to TM-16• Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-17 to TM-18• Bimetal Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-19 to TM-20• Temperature Sensor Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-21 to TM-22

• Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-1 to PR-2• Proximity Sensor Specification Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-3

• ESM & EZM Series Process Controllers, Indicators & Timers/Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-1 to AC-2• R1 General-Purpose Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-3 to AC-4• R2-120 & R2-220 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-5 to AC-6• PD765 Trident Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-7 to AC-8• ED Series Loop Powered Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-9 to AC-10

Liquid Level Switches• Material Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-1• General Product Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-2• Float Switch Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-3• Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-4 to RF-6• Switch Fittings & Stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-7• Multi-Point Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-8• Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-9 to RF-14

Non-Contact Sensors• Ultrasonic Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-15 to RF-16• Radar Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-17 to RF-19• Mounting Information & Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-20 to RF-21• Installation Guidelines & Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-22• Operation & Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-23 to RF-24• Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-25 to RF-26

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-27 to RF-30

Thermocouple Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF-31 to RF-33

Please visit www.MadisonCo.com for Installation Manuals and additional product reference information.

Madison Company's comprehensive line of level sensors includessingle- and multi-point level switches, continuous level andconductivity sensors, non-contact sensors and more. The wideselection of materials offers reliable and durable level sensors for all liquid environments, as well as a full range of other applicationconditions. Madison engineers can incorporate temperature sensorsinto level sensor designs, offering combination sensing and costsavings for many applications.

• Hermetically sealed reed switches

• Various models operate at temperatures ranging up to 300˚C

• Units available to withstand pressures up to 500 PSI

• Electronic controllers, relays and converters can be provided

Liquid Level Switchesand Sensors

© Copyright Madison Company – 5/08 LL-1

Madison Company(203) 488-4477 • (800) 466-5383 • Fax (203) 481-5036 • E-mail: [email protected]

Madison EuropePhone + 31 (0) 548 659 034 • Fax + 31 (0) 548 659 010 • E-mail: [email protected]

www.madisonco.com

LL

Full-Size Switches

Madison Company • (203) 488-4477 • (800) 466-5383 • Fax (203) 481-5036 • [email protected] • www.madisonco.com

With SLOSH

SHIELD #

MS5000

MS4400

MS8010

MS8020

FITTING

1/8" NPT

1/8" NPT

1/8" NPT

1/8" NPT

FLOAT

SG

0.70

0.45

0.80

0.80

MAX

PSIG

300

150

100

100

MAX TEMP

(CELSIUS)

200°

105°

105°

105°

STEM

MATL

316SS

316SS

316SS

316SS

FLOAT

MATL

316SS

Buna-N

PP†

PP†

DWG

NO.

5

6

6a

6

NOMINAL

VA

30

30

30

30

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C,D

A,B,C

A,B,C

A,B,C,D

Miniature Switches

With SLOSH

SHIELD #

–

–

–

–

MS5010

–

FLOAT

SG

0.60

0.60

0.60

0.70

0.70

0.50

MAX

PSIG

300

300

300

100

300

50

MAX TEMP

(CELSIUS)

200°

200°

200°

200°

200°

150°

STEM

MATL

316SS

316SS

316SS

316SS

316SS

316SS

FLOAT

MATL

316SS

316SS

316SS

316SS

316SS

304SS

DWG

NO.

11

13

12

14

15

42

NOMINAL

VA

30

30

30

30

30

30

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24”

22 AWG Halar Cable

APPROVALS

A,B,C,D,E

A,B,C,D,E

A,B,C,D,E,I

A,C

A,B,C,D

C

FLOAT

SG

0.60

0.60

0.60

0.60

0.60

0.60

0.55

MAX

PSIG

50

50

50

50

50

50

300

MAX TEMP

(CELSIUS)

200°

200°

200°

200°

200°

200°

250°

STEM

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

FLOAT

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

DWG

NO.

16

17

18

16

16

16

14

NOMINAL

VA

30

30

30

30

30

30

60

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

18 AWG TFE 24"

OUTER

THREAD

1/2-13 Bulkhead

1/2 NPT

1/8 NPT

1/2-13 Bulkhead

1/2 NPT

1/8 NPT

5/8-11 Thread

APPROVALS

C

C

C

C

C

C

C

Side-Mounted Switches

MODEL

M5000

M4400

M8010

M8020

MODEL

M5900 b

M5910 b

M5920 b

M5970

M5010

M4214

MODEL

M3827-1

M3827-2

M3827-3

M3827-1NO

M3827-2NO

M3827-3NO

M4249

MODEL

NO.

M5600***

M5600-SPDT

M5601

M5917

M4600

M4600-SPDT

M4601

M8600

M8600-SPDT

M8601

M5600-PR

MSB5600

M3842

With SLOSH

SHIELD #

MS5600

MS5600-SPDT

MS5601

MS5917

MS4600

MS4600-SPDT

MS4601

MS8600

MS8600-SPDT

MS8601

MS5600-PR

–

–

DWG

NO.

1

1

1

1

2

2

2

2

2

2

3

4

4

FLOAT

MATL

316SS

316SS

316SS

316SS

Buna-N

Buna-N

Buna-N

PP†

PP†

PP†

316SS

316SS

316SS

STEM

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

MAX TEMP

(CELSIUS)

200°

200°

200°

250°

105°

105°

105°

105°

105°

105°

200°

110°

90°

MAX

PSIG

200

200

200

200

150

150

150

100

100

100

500

85

30

FLOAT

SG

0.55

0.55

0.55

0.55

0.45

0.45

0.45

0.75

0.75

0.75

0.70

0.55

0.64

NOMINAL

VA

60

25a

100

60

60

25a

100

60

25a

100

100

60

25a

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

18 ga. UL/CSA appr.

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

Teflon Cable 6 ft.

18 AWG Neoprene Cable 10 ft.

FITTING

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

–

–

APPROVALS

A,B,C,D,E,I

A,B,C,D,I

A,B,C,D

A,B,C,D

A,B,C

A,B,C

A,B,C

A,B,C,D

A,B,C,D

A,B,C,D

C,D,I

C, I

C

**

**

**

M Series Stainless Steel Liquid Level Switches

All specifications are subject to change without notice.

PP=Polypropylene † Also available in Polysulfone (consult factory) # Approval “D” does not apply to units with Slosh Shieldsa SPDT switch operation b Available with extended stem length, see drawing No. 19. Consult factory for appropriate model number.** Refer to Approvals pages in Reference Section. Individual product explosion-proof (E) approvals vary. Consult factory for current product listings.*** Also available with a Thermocouple or RTD

LL-2 © Copyright Madison Company – 4/09

**

LL

3/8-24 THD

2.96"(75.1)

1"(25.4)

1.13"(28.7) max.

1.61"(40.8)

BulkheadMounting

0.34”(8.6)min.

0.75” (19.1) HEX

3.19” (81.0) max.

1.06” (26.9) max.

25˚ max.

(1.80”)

(0.93”)

SS Washer

1/2-13 HEX Nut

1/2-13 UNC Thread

Gasket24 ± 1

4.60" max.(116.8)

1/2-14 NPT

1/2-14 NPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)

APPROXIMATEACTUATION LEVEL

4.60" max.(116.8)

1/2-14 NPT

1-11.5 NPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)


4.60" max.(116.8)

1/4-18 NPT

1/2-14 NPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)


DWGNo. 15

DWG No. 13

DWG No. 12

DWG No. 11

5.12" (130.05)

6.25" (158.75) max.

3.50"(88.90)

1/2-13THD

1/2" NPT

1/8" NPT

5.77" (146.56)~

5.77" (146.56)~

5

DWGNo. 16

DWGNo. 17

DWG No. 18

DWGNo. 14

1/4" NPT

2.13" (54.1) dia. max.

3.38"(85.8)

2"(50.8)

2.63"(66.8)

1.50" (38.1) dia. max. (Polypro.)1.25" (31.75) dia. max. (Buna-N)

1/4" NPT

3.38"(85.8)

2"(50.8)

2.63"(66.8)

1/4" NPT

2.05" (52.0) dia. max.

2.63"(66.8)

3.38"(85.8)

Mounting bytwo 0.281"(7.1) dia.

holes

2.50"(63.5)

1.75"(44.4)

3.89"(98.8)

Actuationlevel 1.37"(34.7)

DWGNo. 1

1/8" NPT

2.25"(57.1)

1.19"(30.2)

1.63"(41.4)

1.13"(28.7)max.

1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

DWGNo. 3

DWGNo. 2

DWGNo. 4

DWGNo. 6

DWGNo. 5

2" dia. max.(50.8 mm)

1/2" NPTINNER THREAD

1/2" NPTOUTER THREAD

“X”SEE TABLE

FOR LENGTH

“Y”SEE TABLE

FOR LENGTH

STEMLENGTH

(0.10")

(1.22" max.)

(1.15" max.)

FITTING

APPROXIMATE ACTUATION LEVEL

1.50" dia. max.(38.1 mm)

1.90" dia. max.(48.2 mm)

1.90" dia. max.(48.2 mm)

2.38" dia. max.(60.4 mm)

Cutaway Showing Slosh Shield Operation Cutaway Showing Slosh Shield Operation

CutawayShowing Slosh ShieldOperation

DWG No. 19

4.63” (117.6) max.

1.30” (33.0) max.

0.40” (10.2)approx.operationpoint

1.50”(33.6)max.

“H” Grommet

30˚ max.

WasherHex Nut

72 ± 2

5/8-11 UNCThreads,

1.25” (31.8) long

0.94”(23.9)Hex

0.50” (12.7)Flats

ø 2.05”(52.1) max.

DWG No. 42

Vertical Switches





3/8-24 THD

2.96"(75.1)

1"(25.4)

1.61"(40.8)

BulkheadMounting

1"(25.4)

DWGNo. 6a


Cutaway Showing Slosh Shield Operation Cutaway Showing Slosh Shield Operation

STEM LENGTH “X” DIMENSION REF. “Y” DIMENSION MAX.STANDARD 0.81” 4.60”4-INCH 2.59” 6.42”6-INCH 4.61” 8.42”8-INCH 6.61” 10.42”

LL

Full-Size Switches

Miniature Switches

MODEL

NO.

M8800

M8800-SPDT

M8801

M8800-PR

M7800a

M7800-SPDTa

M7801a

M8060-PR

MSB7800a

MSB8800

With SLOSH

SHIELD #

MS8800

MS8800-SPDT

MS8801

MS8800-PR

MS7800a

MS7800-SPDTa

MS7801 a

MS8060-PR

–

–

DWG

NO.

28

28

28

28

28

28

28

28

29

29

FLOAT

MATL

PP†

PP†

PP†

PP†

Buna-N†

Buna-N†

Buna-N†

PP†

Buna-N†

PP†

STEM

MATL

PP†

PP†

PP†

PP†

PBT†

PBT†

PBT†

CPVC†

PBT†

PP†

MAX TEMP

(CELSIUS)

105°

105°

105°

105°

105°

105°

105°

105°

105°

105°

MAX

PSIG

100

100

100

100

150

150

150

100

150

100

FLOAT

SG

0.75

0.75

0.75

0.75

0.45

0.45

0.45

0.75

0.45

0.75

NOMINAL

VA

60

25b

100

100

60

25b

100

100

60

60

LEAD

WIRES

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. MTW 24"

Nylon Cable 6 ft.

PP Cable 6 ft.

FITTING

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

–

–

APPROVALS

A,B,C,D,I

A,B,C,D

A,B,C,D

C,D

A,B,C

A,B,C

A,B,C

C

C

C

DWG

NO.

30

30

30

30

FLOAT

MATL

PP†

Buna-N†

Buna-N†

Kynar†

STEM

MATL

PP†

PP†

PBT†

Kynar†

MAX TEMP

(CELSIUS)

105°

105°

105°

105°

MAX

PSIG

100

150

150

15

FLOAT

SG

0.80

0.45

0.45

0.85

NOMINAL

VA

30

30

30

30

LEAD

WIRES

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

FITTING

1/8" NPT

1/8" NPT

1/8" NPT

1/8" NPT

APPROVALS

A,B,C,D

A,B,C

A,B,C

A,B,C,D

MODEL

M8000***

M4008

M7000a

M9000

With SLOSH

SHIELD #

MS8000

MS4008

MS7000a

MS9000

Side-Mounted SwitchesMODEL

NO.

M8700

M8725

M8740

M8750

M8790

M8790-14/4184

M7700a

M7725a

M7740a

M7750a

M7790a

M9700

With SLOSH

SHIELD #

M8705

MS8725

–

M8755

–

–

M7705 a

MS7725 a

–

M7755 a

–

M9705

DWG

NO.

32

33

34

35

36

36a

32

33

34

35

36

32

FLOAT

MATL

PP†

PP†

PP†

PP†

PP†

PP†

PBT†

PBT†

PBT†

PBT†

PBT†

Kynar†

STEM

MATL

PP†

PP†

PP†

PP†

PP†

PP†

PBT†

PBT†

PBT†

PBT†

PBT†

Kynar†

MAX TEMP

(CELSIUS)

105°

105°

105°

105°

105°

105°

130°

130°

130°

130°

130°

105°

MAX

PSIG

100

100

100

100

100

100

100

100

100

100

100

100

FLOAT

SG

0.60

0.60

0.60

0.60

0.60

0.60

0.70

0.70

0.70

0.70

0.70

0.93

NOMINAL

VA

30

30

30

30

30

30

30

30

30

30

30

30

LEAD

WIRES

22 ga. MTW 24"

1/4" Spade Terminals

22 ga. Teflon 24"

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. Teflon 24"

1/4" Spade Terminals

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C,D

A,B,C,D

A,B,C ,D

A,B,C,D

A,B,C,D

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C,D

**

**

**

M Series Plastic Liquid Level Switches


All specifications are subject to change without notice.LL-4 © Copyright Madison Company – 6/08

PP=Polypropylene † Also available in Polysulfone (consult factory) # Approval “D” does not apply to units with Slosh Shields.a Not for use in hot water at temperatures above 65oC b SPDT switch operation** Refer to Approvals pages in Reference Section *** Also available with a Thermocouple or RTD

LL

† Also available in Polysulfone (consult factory) PP=Polypropylene ** Refer to Approvals pages in Reference Section

Subminiature SwitchesMAX TEMP

(CELSIUS)

105°

105°

105°

105°

105°

105°

105°

105°

105°

FLOAT

SG

0.70

0.70

0.70

0.70

0.85

0.70

0.70

0.70

0.70

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

24 ga. Teflon 24"

24 ga. Teflon 24"

With TEMP.

SENSOR

–

–

–

–

–

Type J

Type K

–

–


1/4" NPT

3.38"(85.8)

2"(50.8)

2.63"(66.8)

DWG No. 28

2" dia. max.(50.8 mm)

Cutaway Showing Slosh Shield Operation

1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

DWG No. 30

1.50" dia. max.(38.1 mm)



holes

2.50"(63.5)

1.75"(44.4)

3.89"(98.8)


DWG No. 29

1.85"(47)

1.25"(31.7)

.58"(14.7)

"O"Ring

3/8-16 THD

.63"(16.0)

DWG No. 31a

1/2" NPT 2.75" (69.8) max.

DWG No. 32

2.75" (69.8) max.1/2" NPT

DWG No. 33

4.30" (109.2)

3.31" (84.0) 7/8-14 THD

3/4-16 THD

DWG No. 34

2.75" (69.8) max.1/2" NPT

DWG No. 35

4.02" (102.1)

2.84" (72.1)5/8-11 THD

DWG No. 36

24.0 ± 1.0Wire Leads: 22 AWG MTW

Washer

Compression Gasket

ø.88” (22.4) Requires ø.91 mounting hole

5/8-11 UNC Nut

3.31” (84.1) max.

0.63” (16.0) min.

0.56” (14.2) min.

0.60” (15.2) min.

DWG No. 36a

2.84" (73.1 mm) max.

1" NPT


**




DWG No. 31b

1.68"(42.6)

1.25"(31.7)

.58"(14.7)

.63"(16.0)

1/8" NPT

DWG No. 31c

"O" Ring

1.85"(47)

1.24"(31.5)

24” ± 1.0”22 AWG TEFLONLEADS

Hex Nut3/8-16 UNC 2B9/16 acrossFlats

"O" Ring

.44"(11.2)

MØ.78"(19.8)


STEM

MATL

PP†

PP†

PP†

PP†

PP†

PP†

PP†

316SS

316SS

1/8" NPT

2 x 24” LEAD WIRES24 AWG TEFLONINSULATED

APPROX.ACTIVATIONLEVEL

7/16 HEX

.75"(19.1)

.27"(6.9) 1.44"

(36.6)

ø.78"(19.8)

DWG No. 39a

3/8 x 24 THREAD.75” (19.1) LONG



.56” HEX(14.2)

.50"(12.7) .95"

(24.1)

MOUNTING NUT(SUPPLIED)

ø.78"(19.8)

1.70"(43.2)

DWG No. 39b

With SLOSH

SHIELD

M3326

M3326-NO

M3326-NPT

M3326-NPT-NO

M3326-SM

MT3920-1

MT3920-2

M4035

M4035-B

DWG

NO.

31a

31a

31b

31b

31c

31a

31a

39a

39b

FLOAT

MATL

PP†

PP†

PP†

PP†

PP†

PP†

PP†

PP†

PP†

MAX

PSIG

50

50

50

50

50

50

50

100

100

NOMINAL

VA

15

15

15

15

15

15

15

15

15

FITTING

3/8-16

3/8-16

1/8" NPT

1/8" NPT

3/8-16

3/8-16

3/8-16

1/8" NPT

3/8-24

APPROVALS

A,B,C

A,B,C

C

C

A,C

A,B,C

A,B,C

C

C

LL

3/8-24 THD

2.96"(75.1)

1"(25.4) max.

1.61"(40.8)

BulkheadMounting

Full-Size Switches

With SLOSH

SHIELD

MS4500

MS5040

MS8040

FITTING

1/8" NPT

1/8" NPT

1/8" NPT

FLOAT

SG

0.45

0.70

0.80

MAX

PSIG

150

300

100

MAX TEMP

(CELSIUS)

105°

200°

105°

STEM

MATL

Brass

Brass

Brass

FLOAT

MATL

Buna-N

316SS

PP†

DWG

NO.

22

22

22

NOMINAL

VA

30

30

30

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C

A,B,C

A,B,C

Miniature Switches

With SLOSH

SHIELD

MS4010

FLOAT

SG

0.45

MAX

PSIG

100

MAX TEMP

(CELSIUS)

105°

STEM

MATL

Brass

FLOAT

MATL

Buna-N

DWG

NO.

23

NOMINAL

VA

30

LEAD

WIRES

22 ga. Teflon 24"

APPROVALS

A,B,C


MODEL

M4500

M5040

M8040

MODEL

M4010

MODEL

NO.

M4300

M4300-SPDT

M4301

M5400

M5400-SPDT

M5401

M8400

M8400-SPDT

M8401

With SLOSH

SHIELD

MS4300

MS4300-SPDT

MS4301

MS5400

MS5400-SPDT

MS5401

MS8400

MS8400-SPDT

MS8401

DWG

NO.

21

21

21

21

21

21

21

21

21

FLOAT

MATL

Buna-N

Buna-N

Buna-N

316SS

316SS

316SS

PP†

PP†

PP†

STEM

MATL

Brass

Brass

Brass

Brass

Brass

Brass

Brass

Brass

Brass

MAX TEMP

(CELSIUS)

105°

105°

105°

200°

200°

200°

105°

105°

105°

MAX

PSIG

150

150

150

200

200

200

100

100

100

FLOAT

SG

0.45

0.45

0.45

0.55

0.55

0.55

0.75

0.75

0.75

NOMINAL

VA

60

25*

100

60

25*

100

60

25*

100

LEAD

WIRES

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. MTW 24"

22 ga. Teflon 24"

22 ga. MTW 24"

FITTING

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

APPROVALS

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C

A,B,C


1/4" NPT

3.38"(85.8)

2"(50.8)

2.63"(66.8)

DWG No. 21

2" dia. max.(50.8 mm)


1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

DWG No. 22

1.50" dia. max.(38.1 mm)


DWG No. 23


1.50" dia. max.(38.1 mm)

**

**

**

M Series Brass Liquid Level Switches

* SPDT switch operation PP=Polypropylene † Also available in Polysulfone (consult factory) ** Refer to Approvals pages in Reference Section



LL

M Series Metric Sizes Liquid Level Switches


© Copyright Madison Company – 10/10 LL-7All specifications are subject to change without notice.

Full-Size SwitchesMODEL

NO.

M3842

M5000-E

M5600-E

MSB5600

MSB7800

MSB8800

With SLOSH

SHIELD

M3782

DWG

NO.

40

4

5

1

4

29

29

FLOAT

MATL

Buna-N*

316SS

316SS

316SS

316SS

Buna-N

PP†

STEM

MATL

Brass

316SS

316SS

316SS

316SS

PBT

PP

MAX TEMP

(CELSIUS)

105°

90°

200°

200°

110°

105°

105°

MAX

PRESSURE

3.4 BAR

2 BAR

20 BAR

13 BAR

5.8 BAR

10 BAR

6 BAR

FLOAT

SG

0.45

0.64

0.70

0.55

0.55

0.45

0.75

NOMINAL

VA

30

25

30

60

60

60

60

LEAD

WIRES

22 ga. PVC cable 6m

18 AWG Neoprene cable 3m

22 ga. Teflon 500mm

22 ga. Teflon 500mm

Teflon cable 1.8m

Nylon cable 1.8m

PP cable 1.8m

FITTING

G 1/8 A

G 1/4 A

APPROVALS

C

C

A,B,C,D

A,B,C,D

C, I

C

C

* Slosh Shield is PBT PP=Polypropylene † Also available in Polysulfone (consult factory) # Consult factory for specific size** Refer to Approvals pages in Reference Section. Individual product explosion-proof (E) approvals vary. Consult factory for current product listings.

Side-Mounted SwitchesWith SLOSH

SHIELD FITTING

Bulkhead #

Bulkhead #

Bulkhead #

Bulkhead

Available Mountings and OptionsM5900: 1-11.5 NPT x 1/2-14 NPT M5910-E: Fittings/Flanges: 1/2-14 BSPT x 1/4-19 BSPT M5920-E: 1/2-14 BSPT x 1/2-14 BSPT M5970: 1/2-13 Bulkhead

Subminiature SwitchesMODEL

NO.

M3326

M3326-NO

With SLOSH

SHIELD

DWG

NO.

31a

31a

FLOAT

MATL

PP†

PP†

STEM

MATL

PP

PP

MAX TEMP

(CELSIUS)

105°

105°

MAX

PRESSURE

3 BAR

3 BAR

FLOAT

SG

0.70

0.70

NOMINAL

VA

15

15

LEAD

WIRES

22 ga. Teflon 500mm

22 ga. Teflon 500mm

FITTING

3/8-16

3/8-16

APPROVALS

A,B,C

A,B,C

Miniature SwitchesMODEL

NO.

M7000B

M8000B

M8010

With SLOSH

SHIELD

MS8000B

DWG

NO.

30

30

6a

FLOAT

MATL

Buna-N

PP†

PP†

STEM

MATL

PBT

PP

316SS

MAX TEMP

(CELSIUS)

105°

105°

105°

MAX

PRESSURE

10 BAR

6 BAR

6 BAR

FLOAT

SG

0.45

0.80

0.80

NOMINAL

VA

30

30

30

LEAD

WIRES

22 ga. Teflon 500mm

22 ga. MTW 500mm

22 ga. Teflon 500mm

FITTING

Bulkhead

Bulkhead

Bulkhead

APPROVALS

A,B,C

A,B,C,D

C

Multi-Level SwitchesMODEL

NO.

M5002-E

M5602-E

With SLOSH

SHIELD

DWG

NO.

7

7

FLOAT

MATL

316SS

316SS

STEM

MATL

316SS

316SS

MAX TEMP

(CELSIUS)

200°

200°

MAX

PRESSURE

20 BAR

13 BAR

FLOAT

SG

0.70

0.55

NOMINAL

VA

30

60

LEAD

WIRES

22 ga. Teflon 500mm

22 ga. Teflon 500mm

FITTING APPROVALS

A,B,C,D

A,B,C,D

Available Mountings and OptionsM5002-E Fittings/Flanges: Outside Mount Flange or pipe plug; Inside mount (specify thread size) or bulkheadM5602-E Fittings/Flanges: Outside Mount Flange or pipe plug; Inside mount (specify thread size) or bulkhead

**

**

**

**

**

DWG

NO.

16

–

–

11

13

12

14

42

34

35

34

36

36a

36

41

23

MODEL

NO.

M3827-1

M3827-1NO

M4003

M5900

M5910-E

M5920-E

M5970

M4214

M8740

M8750

M7740

M8790

M8790-14/4184

M7790

M3769

M4010

FLOAT

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

304SS

PP†

PP†

PBT

PP†

PP†

PBT

PP†

Buna-N

STEM

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

PP†

PP†

PBT

PP†

PP†

PBT

PVC

Brass

MAX TEMP

(CELSIUS)

200°

200°

200°

200°

200°

200°

200°

150°

105°

105°

150°

105°

105°

150°

105°

105°

MAX

PRESSURE

3 BAR

3 BAR

20 BAR

20 BAR

20 BAR

20 BAR

6 BAR

3.45 BAR

6 BAR

6 BAR

6 BAR

6 BAR

6 BAR

6 BAR

1 BAR

6 BAR

FLOAT

SG

0.60

0.60

0.60

0.60

0.60

0.60

0.70

0.50

0.60

0.60

0.70

0.60

0.60

0.70

0.45

NOMINAL

VA

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

LEAD

WIRES

22 ga. Teflon 600mm

23 ga. Teflon 600mm

22 ga. PVC 2m

22 ga. Teflon 600mm

22 ga. Teflon 500mm

22 ga. Teflon 500mm

22 ga. Teflon 600mm

22 AWG Halar Cable

22 ga. Teflon 600mm

22 ga. MTW 600mm

22 ga. Teflon 600mm

22 ga. MTW 600mm

22 ga. MTW 600mm

22 ga. Teflon 600mm

22 ga. Halar Cbl. 3m

22 ga. Teflon 600mm

APPROVALS

C

C

C

A,B,C,D,E

A,B,C,D,E

A,B,C,D,E,I

A,C

C

A,B,C,D

A,B,C,D

A,B,C

A,B,C,D

A,B,C

A,B,C

C

A,B,C

LL

M Series Metric Sizes Liquid Level Switches



G 1/4 A

2.13" (54.1) dia. max.

3.38"(85.8)

2"(50.8)

2.63"(66.8)

DWGNo. 1

2.38" dia. max.(60.4 mm)



holes

2.50"(63.5)

1.75"(44.4)

3.89"(98.8)


DWGNo. 4

G 1/8 A

2.25"(57.1)

1.19"(30.2)

1.63"(41.4)

1.13"(28.7)max.

DWGNo. 5

1.90" dia. max.(48.2 mm)


3/8-24 THD

2.96"(75.1)

1"(25.4)

1.61"(40.8)

BulkheadMounting

1"(25.4) DWG

No. 6a

DWG No. 7

4.60" max.(116.8)

1/2 BSPT

1/2 BSPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)


4.60" max.(116.8)

1/2-14 NPT

1-11.5 NPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)


4.60" max.(116.8)

1/4 BSPT

1/2 BSPT

WIRE LEADS

0.81" min.(20.6)

1.22" max.(31.0)

1.15" max.(29.2)

FITTINGCENTERLINE

.10"(2.5)


DWG No. 13

DWG No. 12

DWG No. 11

0.34”(8.6)min.

0.75” (19.1) HEX

3.19” (81.0) max.

1.06” (26.9) max.

25˚ max.

(1.80”)

(0.93”)

SS Washer

1/2-13 HEX Nut

1/2-13 UNC Thread

Gasket24 ± 1

5.12" (130.05)

6.25" (158.75) max.

3.50"(88.90)

1/2-13THD

1/2" NPT

1/8" NPT

5.77" (146.56)~

5.77" (146.56)~

5

DWGNo. 16

DWGNo. 14


holes

2.50"(63.5)

1.75"(44.4)

3.89"(98.8)


DWGNo. 29

1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

DWG No. 301.50" dia. max.

(38.1 mm)


1.85"(47)

1.25"(31.7)

.58"(14.7)

"O"Ring

3/8-16 THD

.63"(16.0)

DWG No. 31a4.30" (109.2)

3.31" (84.0) 7/8-14 THD

3/4-16 THD

DWG No. 34

2.75" (69.8) max.1/2" NPT

DWG No. 35

4.02" (102.1)

2.84" (72.1)5/8-11 THD

DWG No. 36

3/8-24 THD

2.96"(75.1)

1"(25.4) max.

1.61"(40.8)

BulkheadMounting

DWGNo. 23


1.50" dia. max.(38.1 mm)

Wire Leads

4.06"(103.1)

ø1.44"(36.6)

DWG No. 40

3.00"(76.2)

1.50"(38.1)

0.375" (9.53)

10' Cable Leads

Switch Housing

Float

Pivot Pin

Attach String Here to Pull Through Tank

.75" REF (19.1)

DWG No. 41

2.13" dia. max.(54.1)

24.0 ± 1.0Wire Leads: 22 AWG MTW

Washer

Compression Gasket

ø.88” (22.4) Requires ø.91 mounting hole

5/8-11 UNC Nut

3.31” (84.1) max.

0.63” (16.0) min.

0.56” (14.2) min.

0.60” (15.2) min.

DWG No. 36a

4.63” (117.6) max.

1.30” (33.0) max.

0.40” (10.2)approx.operationpoint

1.50”(33.6)max.

“H” Grommet

30˚ max.

WasherHex Nut

72 ± 2

5/8-11 UNCThreads,

1.25” (31.8) long

0.94”(23.9)Hex

0.50” (12.7)Flats

ø 2.05”(52.1) max.

DWG No. 42

LL

M SeriesSingle-Point Liquid Level Switches

Engineered single-level switches

Madison Company offers a complete line of Standard andConfigured (slightly modified Standard designs) models.These products continue to meet the needs ofapplications in many markets, at competitive prices. Inaddition, Madison Company offers the capability to designspecific liquid level switches for OEM applications thatrequire unique considerations in materials, configurationsand system interfacing.

Engineered designs incorporate over 50 years ofexperience in liquid level switch applications in a varietyof environments and installation configurations. Highreliability of the magnetic reed switch technology assuresrepeatability at an economical price. Our designexperience and flexible manufacturing techniques alsooffer customers many value-added design and assemblyoptions to reduce their product cost.

Features

• Single-point • Magnetic reed switch technology

• High reliability • Wide selection of available materials

• Three basic sizes: full, miniature and subminiature

• Direct interface to controllers available



Each style switch is equipped with a means to identify which type of operation to which the switch is set.

Vertical: NO/NC operation is indicated by the position of the witness mark (stainless steel models) or magnets

(plastic models). NO is indicated by circle up (stainless steel) or magnets down plastic); NC is indicated by circledown (stainless steel) or magnets up (plastic).

Horizontal: NO/NC operation is indicated by the direction of the arrow on the hex. NO is indicated by arrow up;

NC is indicated by arrow down. An ohmmeter or continuity meter can be used to verify the switch setting andoperation. Simply connect the meter to the leads and, with the float hanging down away from the fitting, measure theswitch. If the meter reads a short, then the switch is normally closed and will open on rise.

All switches are shipped in the Normally Closed (NC) position, unless otherwise specified. To change the contactoperation, simply remove the retaining ring and float and reverse the float on the stem. The only exception to this isthe subminiature switch (M3326/M3326-NO), for which operation must be specified when ordered, since the float isnot reversible on this switch.

LL

Material Selection Guide

Sensor solutions for today and the future™

Madison Company 800-466-5383 www.madisonco.com27 Business Park Drive, Branford, CT 06405 • 203-488-4477 • Fax: 203-481-5036 • E-mail: [email protected] Europe – Phone: + 31 (0) 548 659 034 • Fax: + 31 (0) 548 659 010 • E-mail: [email protected]



The first consideration is the type of liquid, temperature and pressure to which the switch will be subjected. Madisonmanufactures liquid level switches in various styles, in avariety of materials, to cover a broad range of conditions.Following are some basic recommendations for selectingthe proper liquid level switch material for your application.

Material

316 Stainless Steel

PolypropylenePolysulfone

Brass & Buna-NPBT & Buna-N

KynarPTFE

Application

For high-temperature (to 300˚C), high-pressure (to 300 PSIG) andcorrosive conditions. Commonly used in food processing, medical,heating and cooling equipment.

For acidic conditions, such as found in electroplating and metalcleaning. Another choice for lower-temperature (to 105˚C) foodprocessing applications (Madison Company uses only polypropylenethat is FDA-approved for food contact). Also a good choice forgeneral-purpose applications in commercial or consumer appliancesand equipment. Available in white and other colors.

The selection for petroleum-based liquids, such as lubricating oils,gasoline and diesel fuels. Widely used in storage tanks of vehicles,generators, transmissions and hydraulic systems. Other uses are inlubrication, recovery, refining and fuel processing equipment. Please note: PBT is not suitable for use in temperatures above 130˚C.

Chemical- and solvent-resistant properties make this material aproblem solver for many applications. Its high-purity nature is idealfor food handling and sensitive laboratory or test equipment.

Once a suitable material has been selected, the type of switch and configuration are the nextconsiderations. Madison Company stocks a full line of standard products that can meet therequirements of many applications. For specific designs, Madison can custom-build, to order,switches with an infinite number of variations and options. Please utilize our M & MT Series single-level specification sheet which, when completed, will allow our engineering department tobetter meet your needs.

COMPONENT

See Approvals pages in Reference Section

LL

MT SeriesCombinationLevel/Temperature Sensors

Features

• Full size range of level switches available

• Broad selection of materials

• Dual-condition monitoring

• Standard or custom designs

• Electronic interfaces available

• Selected models carry industry-specific approvals (UL, NSF, CE)

• All technologies highly reliable



Switches shown above arerepresentative of our combination

level/temperature sensor capabilities.(Models MT3920-1, MT5600-1

and MT8000-1)

Madison Company offers many of its liquid level switchproducts with temperature sensing capabilities. Theincorporation of either thermocouples, RTD sensors,thermistors or bimetal switches can offer the user theability to determine level and temperature in the vesseland save the cost of having dual mounting considerations.Linked with Madison’s cable assemblies and controllers,combination sensors can provide a readout of theenvironmental conditions, as well as the capability to turnassociated equipment on and off.

The temperature limitations are dependent on thematerials selected for the level switch itself. As anexample, the subminiature Model MT3920-1 is apolypropylene level switch with a Type J thermocouple.The thermocouple temperature range is -40˚C to 250˚C (-40˚F to 482˚F), while the polypropylene is rated to105˚C (221˚F). Another example is a single-point 316stainless steel liquid level switch engineered for use in a300˚C (572˚F) environment. Other considerations thatMadison Company makes are the position of the sensors,time response and signal conditioning. Time responsetesting on selected MT configurations has shown a typicalresponse time to be 20 to 25 seconds.

LL




MT Series Specifications


Nearly all of Madison’s Single-Point, Multi-Point and Continuous Level Switches and Sensors areavailable as MT Series Combination Level/Temperature Sensors. Consult factory for details.

* SPDT reed switch operation NC Creep-action bimetal switch, open on rise NO Creep-action bimetal switch, close on rise† Also available in Polysulfone (consult factory) PP=Polypropylene** Refer to Approvals pages in Reference Section

Note regarding Bimetal switches: Snap action and creep action may be available in other temperature ranges. Complete our Specification WorkSheet with your specific application requirements and submit it for a quote.

Standard Stainless Steel MT Series SwitchesDWG

NO.

5

1

1

1

1

1

1

1

MAX TEMP

(CELSIUS)

200°

200°

200°

200°

200°

200°

200°

200°

MAX

PSIG

300

200

200

200

200

200

200

200

FLOAT

SG

0.70

0.55

0.55

0.55

0.55

0.55

0.55

0.55

NOMINAL

VA

30

60

60

60

25*

25*

60

60

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

FITTING

1/8" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

1/4" NPT

APPROVALS

C,D

A,C,D

A,C,D

A,C,D

A,C,D

A,C,D

A,C,D

A,C,D

MODEL

MT5000-HT-J

MT5600

MT5600-1

MT5600-2

MT5600-3*

MT5600-4*

MT5600-5-85C

MT5600-5-85C-NO

With TEMP.

SENSOR

Type J

Type J

Type K

100 ohm RTD

Type J

Type K

BimetalNC

BimetalNO

**FLOAT

MATL.

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

STEM

MATL.

316SS

316SS

316SS

316SS

316SS

316SS

316SS

316SS

Standard Plastic MT Series SwitchesDWG

NO.

31a

31a

30

30

30

30

MAX TEMP

(CELSIUS)

105°

105°

105°

105°

105°

105°

MAX

PSIG

50

50

100

100

100

100

FLOAT

SG

0.70

0.70

0.80

0.80

0.80

0.80

NOMINAL

VA

15

15

30

30

30

15

LEAD

WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. MTW 24"

22 ga. MTW 24"

FITTING

3/8-16

3/8-16

1/8" NPT

1/8" NPT

1/8" NPT

1/8" NPT

APPROVALS

A,C

A,C

A,C,D

A,C,D

A,C,D

C,D

MODEL

MT3920-1

MT3920-2

MT8000

MT8000-1

MT8000-2

MT8000-4-66C

With TEMP.

SENSOR

Type J

Type K

Type J

Type K

100 ohm RTD

BimetalNO

**FLOAT

MATL.

PP†

PP†

PP†

PP†

PP†

PP†

STEM

MATL.

PP†

PP†

PP†

PP†

PP†

PP†

1/4" NPT

2.13" (54.1) dia. max.

3.38"(85.8)

2"(50.8)

2.63"(66.8)

DWG No. 1

1/8" NPT

2.25"(57.1)

1.19"(30.2)

1.63"(41.4)

1.13"(28.7)max.

DWG No. 5

1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

DWG No. 30

1.85"(47)

1.25"(31.7)

.58"(14.7)

"O"Ring

3/8-16 THD

.63"(16.0)

DWG No. 31a

LL

M SeriesHVAC SeriesCondensate Level Switches

Features

• Highly reliable

• Affordable off-the-shelf design

• Easy installation

• Custom features available



Madison Company offers a standard family ofwater-activated level switches designed forcondensate return systems in HVAC and HVACRsystems. These condensate level float switchescan be used for the return of hot condensate in aboiler system, in an air conditioning condensateline, or to give a signal to a pump or compressorcontrol when water is detected in the drain pan.

The M8000-C float switch is designed for either apress fit into a standard 3/4” schedule 40 PVC pipetee allowing for future clean out, or glued in placeusing standard PVC pipe cement. This verticallymounted switch will provide an excellent levelsignal at up to a 30° angle and incorporates a venthole for line air to escape.

The M8000, also a vertically mounted switch,requires a mounting hole to accommodate a 1/8”NPT fitting. The M8700-C is a horizontally mountedfloat switch for use where side mounting ispreferred, such as in the side of a pan or reservoir.

These switches can also be used in compressed air condensate drain lines that are normally found on intercoolers, after coolers, dryers, drip legs and receiver tanks. They are cost-effectivesolutions when compared to electric solenoidvalve methods.

M8000

M8000-C

M8700-C

LL

Specifications





* With vent hole plugged

INSTALLATION NOTE: As with any condensate line, contamination from water content and debris could inhibit proper floatoperation. Occasional cleaning can be accomplished by wiping with a soft cloth. Flush line with bleach and a descaling solution if water conditions require such treatment.

HVAC Series

Material

Maximum Pressure

Maximum Temperature

Float Specific Gravity

Fitting

Lead Wires

Nominal VA

Approvals

M8700-C

Polypropylene

100 PSIG

105˚C (221˚F)

0.60

1/2” NPT or 3/4” NPT

22 ga. MTW 24”

30

UL, CSA, CE, NSF

M8000

Polypropylene

100 PSIG

105˚C (221˚F)

0.80

1/8” NPT

22 ga. MTW 24”

30

UL, CSA, CE, NSF

M8000-C

Polypropylene/PVC

50 PSIG*

60˚C (140˚F)

0.85

3/4” PVC Pipe

22 ga. MTW 24”

30

UL, CSA, CE

1.99"(50.5)

1.55"(39.4)

ø1.058"(26.9)

ø.875"(22.2)

1.125 1.25"OPERATION POINT

24.0 1.0"

.063"(609.6)

(1.6)

(28.6)

M8000 M8000-C

M8700-C

1/8" NPT

2.25"(57.1)

1.63"(41.4)

1"(25.4)

1"(25.4)

1/2" NPT 2.75" (69.9) max.3/4" NPTLL

M SeriesLevel Switchesfor Harsh Environments

Features

• Magnetic reed switch technology

• High reliability under harsh conditions

• Can incorporate both point level indication and temperature measurement

• Available in single-point and multi-point designs

• Continuous level in standard resolutions of 1”, 5mm or 10mm



Madison Company offers many of its liquid level switch products with high-temperaturecapabilities. A list of available models is on thereverse side. In addition, engineered designs tomeet specific application needs can be provided.Such designs will deal with harsh environmentssuch as high temperature and pressure and ensure material compatibility.

Using highly reliable magnetic float switchtechnology, units capable of reliable operation attemperatures as high as 300˚C (572˚F) andpressures of up to 1500 PSI (103 BAR) have beendesigned. Such harsh-environment switches canincorporate Madison’s temperature sensors, offeringthe combination of both point level indication andtemperature measurement within the same levelswitch design. This can eliminate costs for multiplemountings during assembly, while providing dual-condition monitoring. Level indication can be single-point, multi-point or continuous level, in one of threestandard resolutions.

Lead wires with overbraiding or shielding andvarious terminations can be designed for extremeconditions, as well as easy interfacing to conditionmonitoring devices.

A selection of engineered level switches

LL

Level Switches for Harsh Environments





Engineered designs available to meet application-specific needs. Please consult factory.

StandardModels

M5600M5600-SPDTM5601M5600-PRM5000M5900M5910M5920M5970M5010M3827-1M3827-2M3827-3M3827-1NOM3827-2NOM3827-3NOM5400M5400-SPDTM5401M5040M5602M5002M5402M5042M5600-EM5000-EM5910-EM5920-EM5602-EM5002-EM5917M3627

withSlosh Shield

MS5600MS5600-SPDTMS5601MS5600-PRMS5000

MS5010

MS5400MS5400-SPDTMS5401MS5040

MS5917

Max.Temp.

200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C200˚C250˚C250˚C

Max.Pressure

200 PSIG200 PSIG200 PSIG500 PSIG300 PSIG300 PSIG300 PSIG300 PSIG100 PSIG300 PSIG50 PSIG50 PSIG50 PSIG50 PSIG50 PSIG50 PSIG200 PSIG200 PSIG200 PSIG300 PSIG200 PSIG300 PSIG200 PSIG300 PSIG13 BAR20 BAR20 BAR20 BAR13 BAR20 BAR

200 PSIG300 PSIG

FloatSG

0.550.550.550.700.700.600.600.600.700.700.600.600.600.600.600.600.550.550.550.700.550.700.550.700.550.700.600.600.550.700.550.70

Fitting

1/4” NPT1/4” NPT1/4” NPT1/4” NPT1/8” NPT1” NPT X 1/2” NPT1/2” NPT X 1/4” NPT1/2” NPT X 1/2” NPT1/2-13 Bulkhead3/8-24 Bulkhead1/2-13 Bulkhead1/2” NPT1/8” NPT1/2-13 Bulkhead1/2” NPT1/8” NPT1/4” NPT1/4” NPT1/4” NPT1/8” NPT

G 1/4 AG 1/8 A1/2-14 BSPT X 1/4-19 BSPT1/2-14 BSPT X 1/2-14 BSPT

1/4” NPT1/8” NPT

LL

M SeriesSwitches for Harsh Environments& High-Purity Applications

Features

• All PTFE wetted surfaces

• Chemically inert

• Low particulate generation

• High purity reduces contamination

• Standard and engineered liquid level designs available



Madison Company has a complete line of level switches thatoffer all wetted polytetrafluoroethylene (PTFE) materials.PTFE is a chemically inert material that offers exceptionalperformance when aggressive solvents such as alcohols,esters and ketones, or other corrosive acids and bases, oils,steam and most chemicals, are present in your application.

These M Series switches are ideal for medical,pharmaceutical and food or beverage applications wherehigh-purity contact is essential. Other applications withstringent requirements, such as electronic componentmanufacturing, sterilization systems and those systemsrequiring biosafety performance standards of the liquid levelswitch, will find this Madison material capability suitable.

PTFE’s characteristics are ideal for withstanding extremeoperating temperatures, strenuous chemical environmentsand those applications where highly abrasive-resistantperformance is required.

The switch’s float is designed with an advanced chemicallymodified PTFE. While retaining the exceptional chemicalproperties of the conventional PTFE, superior thermal andmechanical properties have been introduced. This modifiedPTFE has also allowed some designs to be offered withoutthe spring assist that is found in many heavier float designs.

With the highly reliable reed switch technology and thePTFE wetted material, these liquid level switches offerdependability over a long service life.

Representative PTFE switches

LL





Material Approvals – CE, FDA Regulation 21 CFR 177.1550, USP Class 6

Standard Models

M9200

M9200-E

M9200-NO

M9200-NO-E

M9500

M9500-E

M9202-XXXX

M9502-XXXX

MaximumTemperature

150˚C (302˚F)

150˚C (302˚F)

150˚C (302˚F)

150˚C (302˚F)

150˚C (302˚F)

150˚C (302˚F)

MaximumPressure*

25 PSIG

25 PSIG

25 PSIG

25 PSIG

40 PSIG

40 PSIG

Fitting

1/8-27 NPT

G 1/8 A

1/8-27 NPT

G 1/8 A

1/4-18 NPT

G 1/4 A

SwitchRating

60-Watt SPST

60-Watt SPST

60-Watt SPST

60-Watt SPST

60-Watt SPST

60-Watt SPST

Float SG

0.69

0.69

0.69

0.69

0.63

0.63

NO – Normally Open; SPST – Single Pole Single Throw

Multi-point switch with M9200 characteristics

Multi-point switch with M9500 characteristics

* Maximum pressure at 21˚C

Lead wires are PTFE jacketed unless otherwise specified.

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M Series“Tank Commander” Heavy-DutySide-Mounted Level Switch

Features

• Rugged design

• Field serviceable

• Allows for direct switching



Madison Company’s M4065 side-mountedliquid level switch has both a rugged designand sufficient electrical switch power toeliminate the need for separate relays inyour current.

As with all Madison side-mount designs, theM4065 “Tank Commander” is intended formounting through a tank’s side wall utilizinga 1-1/2” NPT through hole.

The switch’s electrical ratings (refer to backside of sheet) allow for direct switchingcontrol of a pump’s on/off action. Thiseliminates the need for intermediate relays,along with their associated costs.

The M4065 basic design allows for fielddisassembly and cleaning when used inliquids containing contaminants or causingresidual build-up. This can extend theswitch’s serviceable life with plannedmaintenance.

M4065 heavy-duty side-mounted liquid level switch

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M4065 Specifications





Electrical – 20 A @ 125, 250 or 480 VAC10 A @ 125 VAC inductive1 HP @ 125 VAC2 HP @ 250 VAC1/2 A @ 125 VDC1/4 A @ 250 VDC

In-rush current is good for 75 A @ 120-480 VAC and varying currents at DC voltages.

Max. Operating Pressure – 100 PSIG (6.89 bar)

Max. Operating Temperature – 125˚C (257˚F)

Wetted Materials – 304 Stainless Steel, standard

Float Specific Gravity – 0.6

Mounting Box Enclosure – PVC with Viton sealing gasket

Wiring Diagram

NO

NC

Com

Switch type: SPDT Micro switch, screw terminals

4.13”(104.9)

3.13” (79.5)

2.56”(65.0)

1.56”(39.6)

4.75” (120.7)1.13” (28.7)0.69” (17.5)

5.5” (139.7)

1-1/2-11.5 NPT

1.65”(41.9)

LOWEST FLOAT POSITIONSCALE 3/4

HIGHEST FLOAT POSITIONSCALE 3/4

1.66”(42.1)

5.00”(127.0)

2.00”(50.8)

4.50” (114.3)

2.25” (57.2)

LL

M Series“Big Dipper” Heavy-DutyIndustrial Side-Mounted Switch

Features

• Easy mounting to vessel side wall

• Easy control circuit wiring

• Rugged design

• Suitable for high-contamination applications with field cleaning of float by user

• High reliability



Madison Company’s M4190 family of side-mountedliquid level switches features a robust design forheavy industrial tank applications.

Their corrosion-resistant construction, inconjunction with standard SPDT switch operation,provides for simplified wiring of control circuits. The M4190’s standard end thread is a 1/2” NPTstub for easy connection to common junction boxesor conduit.

The base model M4190 features 304 stainless steelconstruction, including the float. The M4190-BUoffers a Buna-N float for hydrocarbon liquids, andthe M4190-HP offers a float rated for 900 PSIoperational performance.

The standard configuration can be modified toaddress specific application requirements. ConsultMadison Company for such needs.

M4190

M4190-BU

M4190-HP

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* Due to the M4190-HP’s float diameter (2”), if access to the inside of the vessel is not available you must use a suitable bushing oradapter for a mounting hole larger than 2”.

“Big Dipper”

Wetted Materials:FloatStemOther

Operating Temperature

Operating Pressure

Switch Rating

Float Specific Gravity

Lead Wires

Mounting

M4190-HP

304SS304SS

Teflon® & Ceramic

150˚C (302˚F)

900 PSI

0.5

*

M4190

304SS304SS

Teflon® & Ceramic

150˚C (302˚F)

150 PSI

~ 0.5

1-11.5 NPT

M4190-BU

Buna-N304SS

Teflon® & Ceramic

105˚C (221˚F)

100 PSI

0.4

1-11.5 NPT

All Models: SPDT, 100 VA; 120 VAC max.

All Models: 22 AWG Teflon® jacket, 24” length standard

VE

4.

5.81” (147.6) max.

ø 1.00”(25.4)

1-11.5 NPTmounting threads

1-3/8 HEX

1/2” NPTconduit connection

22 AWG Teflon-insulated lead wires,24” long

3.45” (87.6)

VE

4.

4.43” (112.5) max.

ø 0.92”(23.4)

VE

4.

3.98” (101.1) max.

ø 2.04”(51.8)

Demountable float

4

M4190

M4190-BU

M4190-HP

M4190 Wiring Diagram

VE

4.

1.70”(43.2)

ø 1.00”(25.4)

4.06” (103.1) max.

B

M4190-SMVertical Mount

VE

BLACK – COMMON

ORANGE – N.O.

RED – N.C.

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M SeriesSubminiature Liquid Level Switches

Features

• Subminiature size

• Single or dual point indication

• Vertical or horizontal mounting

• Level and temperature sensing in one device



Madison Company’s line of subminiature liquidlevel switches offers a full range of vertical and horizontal mount configurations in single-point switch designs. In addition, there is a multi-level subminiature switch design offering two switch points within the same subminiaturedesign envelope.

As with all Madison Company liquid level switch products, the reliability and low cost of our reed switch technology provides for excellentservice life.

Our standard subminiature models (see back sideof this sheet) are also available as combinationsensors designed to provide point level indicationand temperature indication in one unit. Thetemperature sensor can be a thermocouple type K, J or T or platinum thin film RTDs.

Madison’s engineering department can design aswitch specific to your application. We havemounted this micro-miniature switch tosubassembly configurations for labor savings andenhanced product quality.

Above: Standardsubminiature liquidlevel switches

Right: Side-by-sidesize comparison withMadison’s miniatureswitches

LL

Representative Sizes





Standard Subminiature Models

M3326

M3326-NO

M3326-NPT

M3326-NPT-NO

MT3920-1*

MT3920-2**

M4035

M4035-B

M3326-SM

FloatMaterial

PP

PP

PP

PP

PP

PP

PP

PP

PP

StemMaterial

PP

PP

PP

PP

PP

PP

316SS

316SS

PP

Max.Temp.

105˚C

105˚C

105˚C

105˚C

105˚C

105˚C

105˚C

105˚C

105˚C

Max.PSIG

50

50

50

50

100

100

100

100

50

FloatSG

0.70

0.70

0.70

0.70

0.70

0.70

0.70

0.70

0.85

NominalVA

15

15

15

15

15

15

15

15

15

Lead Wires

22 AWG, Teflon®, 24”









Fitting

3/8-16

3/8-16

1/8” NPT

1/8” NPT

3/8-16

3/8-16

1/8” NPT

3/8-24

3/8-16

* with Type J Thermocouple; ** with Type K Thermocouple

1.85"(47)

1.25"(31.7)

.58"(14.7)

"O"Ring

3/8-16 THD

.63"(16.0)

1.68"(42.6)

1.25"(31.7)

.58"(14.7)

.63"(16.0)

1/8" NPT

3/8 x 24 THREAD.75” (19.1) LONG



.56” HEX(14.2)

.50"(12.7) .95"

(24.1)

MOUNTING NUT(SUPPLIED)

ø.78"(19.8)

1.70"(43.2)

M3326, M3920 M3326-NPT M4035-B

Consult factory for approvals for each model. For design or material modifications, you can complete aproduct specification worksheet found in this catalog and on our website, or contact one of our salesrepresentives with your specific requirements. Alternative materials or colors may require a a minimumorder quantity.

Teflon® is a registered trademark of E.I. du Pont de Nemours and Company.

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M SeriesSuspendible/SubmersibleLeak Detection Switch

Features

• Affordable

• Easy installation; compact size

• Highly reliable; long service life

• No calibration required

• Suitable for water and hydrocarbons



Madison Company offers a standard model M3782liquid level switch that can be fully submerged with 20’ of 22 AWG HALAR® jacketed 2-conductorwire. This model is weighted for suspension in non-magnetic tanks and can be used in conjunctionwith a still pipe. Its materials are suitable for water,hydrocarbons and certain chemicals. ContactMadison Company to check on material compatibility.

This low-cost switch is ideally suited for sumps,dispenser pans, monitoring wells and double-walltanks where monitoring for leaks is required. Thedepth of the vertical mount can be easily adjusted bycutting the cable length as required.

This standard model can also be customized to meetyour specific application needs. Simply complete the M Series Specification Worksheet and send it toMadison Company for a quotation.

M3782

HALAR® is a registered trademark of Ausimont USA, Inc.

LL

Specifications





MaterialsStem and Extension – Brass

Float – Buna-N

Slosh Shield – PBT (optional 316SS slosh shield also available)

Cable – 20’ 22 AWG, HALAR jacketed 2-conductor cable with watertight connector

OperationNormally Closed (NC), open on liquid rising

Options– Wire lengths– Wetted materials

Wire Leads

4.06"(103.1)

ø1.44"(36.6)

M3782Current and Voltage Ratings

Current Amps(Resistive)

0.140.280.070.28

Voltage

240 AC120 AC120 DC

24 DC

LL

M SeriesBilge/Bottle & Submersible Switches

Features

• Available with anodized or electropolish finish for harsh environments

• Universal design for bilge or bottle switch applications

• Reliable reed switch technology

• Multiple submersible switch models are also available as standard products(see reverse side)



Madison Company offers its newest universaldesign for bilge and external tank applications.The M4182 Series is a standard liquid level switchproduct available in four housing materialconfigurations. These Bilge/Bottle models allow forin-field replacement of the float switch, helping toensure minimal down time in applications wherethey are used. The same highly reliable liquid levelswitch technology used in other MadisonCompany reed switch products is also used in the M4182.

This design supplements the M4147 bracket-mounted liquid level switch and the othersubmersible switches referenced on the back sideof this sheet, which have been long-standingsolutions for bilge and sump applications. TheM4182 family of designs can also be bracketmounted and encloses the float for purposes ofminimizing the effect of turbulence and possiblecontamination of the float’s performance.

Madison Company can also provide application-specific designs for external tank and bilgeapplications.

M4182 Bottle Switch for bilge and external tank applications, available in

stainless steel (left) and aluminum (right)

LL






Specific Gravity – Float: 0.70

Max. Pressure – M4182-SS: 300 PSIGM4182-AL: 150 PSIG

Max. Temperature – M4182-SS: 200˚C (392˚F)M4182-AL: 105˚C (221˚F)

Switch Operation – SPST, normally closed

Electrical – 70 VA; 240 VAC resistive load

Other Submersible Switches

M4182-SS

M4182-SS-EP

M4182-AL

M4182-AL-A

HousingMaterial

316SS

316SS

6061 Aluminum

6061 Aluminum

FloatMaterial

316SS

316SS

Polypropylene

Polypropylene

Finish

Natural

Electropolish

Natural

Anodized (Clear)

FLOAT

MATL.

316SS

Buna-N

PP

Buna-N

316SS

MAX. TEMP.

(CELSIUS)

110˚

105˚

105˚

93˚

100˚

NOMINAL

VA

60

60

60

60

60

MAX.

PSIG

85

150

100

85

30

FLOAT

SG

0.55

0.45

0.75

0.45

0.64

MODEL

MSB5600

MSB7800

MSB8800

M3200

M3842

HOUSING

MATL.

316SS

PBT

PP

316SS

316SS

MSB5600MSB7800

M3200M3842

MSB8800

ø 2.38”(60.5)

Field-replaceable switch

1.71”(43.4)

4.3”(109.2)

2.0”(50.8)

3/4” NPTfluid connections

7.2”(182.9)

1.24”(31.5)

24” LeadWires

1/2” NPTfemale conduitconnection

Approx.actuation point

With optional mountingbracket kit

(stainless steel)

For 1/2” bolt(top & bottom)

3.75” (95.3)

5.38”(136.7)

ø 2

Includes self-test feature

Field replacement liquid level switch for the M4182-SS and M4182-SS-EP is the M5002-7801; for the M4182-AL andM4182-AL-A, it is the M5002-7802. Consult factory for availability and prices.

LL

M SeriesAdjustable Switch Height Feature

Features

• Common level switches allow end user to adjust switch depth or height

• Bracket designs can provide for easy mounting to tanks

• Can overcome uneven tank stands to allow for accurate low level indication

• User can change operation from normally closed to normally open

• Engineered configurations available



M4302-7807-x and M5602-7808-x adjustable-height liquid level switches

Madision Company’s engineered designs can provide a liquidlevel switch for tank applications with slight changes in thelevel at which the switch signal is needed, to accommodatemultiple tank designs or conditions.

In the M4302-7807 and M5602-7808 base models, downwardswitch height adjustment by the end user can be as much as2”, and an upward adjustment could be from 9” to 69”. Thiswould allow a series of tanks to use the same level switchconfiguration and provide easier field adjustments for low levelindication. Multi-level indications can also be provided.

The adjustment is done by loosening the compression fittingon the top of the 2’’-11.5 NPT pipe plug and moving the entirestem up or down as needed in the application. The M4302-7807-x series is manufactured with nylon ferrules in thecompression fitting. The M5602-7808-x series is supplied withTeflon ferrules in the compression fitting. These types offerrules allow the end user to adjust the length multiple times.The retaining rings are not to be moved, unless the operationneeds to be changed from normally closed to normally open.

The picture inset at right shows twoapproaches where bracket designscan also be used to provide heightadjustability in addition to multipleactivation points in a single tank.

Several standard MadisonCompany designs utilizing full-sizefloats are listed on the reverse sideof this page. Miniature-size stemsand/or floats can be engineered,which would additionally allow forMadison’s Ultra-Low-Level float options to be utilized.

LL

M4302-7807 Specifications (representative standard designs)





Wetted Materials – Stem and Fittings: BrassFloat: Buna-N Grip Rings: Beryllium Copper

Operation – Normally closed, opens on rising level. User can reverse operation.

Max. Temperature – 105˚C (221˚F)

Max. Pressure – 150 PSIG


Electrical Rating of Switch – 60 Watt, SPST

Mounting – 2”-11.5 NPT Pipe Plug

M4302-7807-1M4302-7807-2M4302-7807-3M4302-7807-4M4302-7807-5M4302-7807-6

TotalLength

12” (30.5cm)

24” (61.0)

36” (91.4)

48” (121.9)

60” (152.4)

72” (182.9)

Adjustable Switch LevelDown

2” (50.8mm)

2” (50.8)

2” (50.8)

2” (50.8)

2” (50.8)

2” (50.8)

Up

9” (22.9cm)

21” (53.3)

33” (83.8)

45” (114.3)

57” (144.8)

69” (175.3)

Level 1(± 0.125”)

10.5” (26.7cm)

22.5” (57.2)

34.5” (87.6)

46.5” (118.1)

58.5” (148.6)

70.5” (179.1)

M5602-7808 Specifications (representative standard designs)Wetted Materials – 316 Stainless Steel

Operation – Normally closed, opens on rising level. User can reverse operation.

Max. Temperature – 200˚C (392˚F)

Max. Pressure – 200 PSIG


Electrical Rating of Switch – 60 Watt, SPST

Mounting – 2”-11.5 NPT Pipe Plug

M5602-7808-1M5602-7808-2M5602-7808-3M5602-7808-4M5602-7808-5M5602-7808-6

TotalLength

12” (30.5cm)

24” (61.0)

36” (91.4)

48” (121.9)

60” (152.4)

72” (182.9)

Adjustable Switch LevelDown

2” (50.8mm)

2” (50.8)

2” (50.8)

2” (50.8)

2” (50.8)

2” (50.8)

Up

9” (22.9cm)

21” (53.3)

33” (83.8)

45” (114.3)

57” (144.8)

69” (175.3)

72” ± 2”(1828.8 ± 50.8)

2.0” (50.8),adjustable

1/2-14 NPTconduit connection

Compression fittingwith nylon ferrulesfor adjustability

2-11.5 NPTpipe plug

Level 1

Total Length

2.10” max.(53.3)

ø 2.13” max.(54.1)

72” ± 2”(1828.8 ± 50.8)

2.0” (50.8),adjustable

1/2-14 NPTconduit connection

Compression fittingwith nylon ferrulesfor adjustability

2-11.5 NPTpipe plug

Level 1

Total Length

2” max. (50.8)

ø 1.25” max.(31.8)

Level 1(± 0.125”)

10.5” (26.7cm)

22.5” (57.2)

34.5” (87.6)

46.5” (118.1)

58.5” (148.6)

70.5” (179.1)

LL

M SeriesInterstitial Switch

Features

• Thin profile

• Wide range of electrical voltages

• Full choice of alarms or control systems




M3769

Madison Company’s Interstitial Switch is a thinprofile device designed for double-wall tanks and pipes. The 3/8” high switch is ideal forunderground tanks and piping where the double-wall construction needs to be monitored forproduct release from the inner tank. It can alsobe used to signal the presence of liquid leaks oroverflows in any containment area by connectingto a suitable alarm indicator. The avoidance ofpotential cleanup costs through early detection of leaks is well worth the cost of this unit.

The M3769 Interstitial Switch is constructed of a Valox 420 housing and foamedpolypropylene float with a stainless steel pivotpin. The standard M3769 model comes with 10’ of Halar-jacketed cable.

Shown in Open Position

Cable toCustomerController

Double-WalledPipe or Tank

M3769

Typical Installation

LL

Specifications





Materials –

Body – Valox 420

Float – Foamed polypropylene

Cable – 10’, two conductorsHalar jacketed

Temperature – 105˚C (221˚F), maximum

Pressure – 50 PSIG, maximum

Switch Rating – 30 Watt, SPST

Operation – Normally Closed (NC), open on liquid rising

Approvals – UL, CE

3.00"(76.2)

1.50"(38.1)

0.375" (9.53)

10' Cable Leads

Switch Housing

Float

Pivot Pin

Attach String Here to Pull Through Tank

.75" REF (19.1)

Current and Voltage Ratings –

M3769

Current Amps(Resistive)

0.140.280.070.28

Voltage

240 AC120 AC120 DC

24 DC

LL

M SeriesDrum Level Indication

Features

• Multiple drum level choices

• Easy mating to standard drum bungs

• Remote alarm and power abilities

• Choice of contact or non-contact level indication

• Choice of high and/or low level indication and alarm



Madison Company offers several level indicationproducts designed specifically for standard 20-, 30-and 55-gallon drums. These level indicators will fit-updirectly with standard 3/4” NPT bungs.

This family of standard level indicators comes in low-level, high-level and multi-level designs, for both low-and high-level indication. The basic level switchesrequire a power source. When configured with analarm, battery power is on-board.

Optional alarms are available in either a fixed-mount(to the level switch) or a remote-mount design. Thisoption provides both the level switch and the alarmwith battery power for ease of use in remote siteswhere a power source is not readily available.

For those drum applications requiring a non-contactlevel device, the Madison U3M Mini Ultrasonic Sensoris the way to go. This sensor also mounts directly intoa 3/4” NPT bung and requires a power source. Thesensor is calibrated by the user using an on-boardpush button. The U3M is available in twoconfigurations: one that is designed for infrequentremoval and the other with a connector lead-wiretermination for quick disconnect and removal from thedrum head. These sensors are configured withRS485 communications for PC networks.

Above: Madisonoffers severalstandard and

non-contact sensorsfor drum levelindication

Left: Mini UltrasonicSensor mounted to

drum head

LL

Specifications





M4168-X (4168-1 without alarm)Wetted Materials:

Stem and Fittings – BrassFloats – Buna-NGrip Rings – Beryllium Copper

Maximum Temperature: 105˚C (221˚F)Maximum Pressure: 150 PSIGFloat Specific Gravity: ~ 0.5Reed Switch Rating: 30-Watt SPSTLead Wires: 2 or 4 conductor, 22 AWG,

Halar-jacketed; 72” length (±2”)

M4169-X (M4169-1 without alarm)Wetted Materials:

Stem, Fittings and Floats — 316SSGrip Rings — PH-15-7 Mo SS

Maximum Temperature: 150˚C (302˚F)Maximum Pressure: 250 PSIGFloat Specific Gravity: 0.73 (±0.02)Reed Switch Rating: 30-Watt SPSTLead Wires: 2 or 4 conductor, 22 AWG,

Halar-jacketed; 72” length (±2”)

U3M-XWetted Materials: PVCMaximum Temperature: 60˚C (140˚F)Maximum Pressure: 30 PSIGLead Wires: 6 conductor, 24 AWG,

shielded, PVC-jacketed; 60” length (±2”)Electrical: 12-30 VDC, 0.07 A max. @ 24 VDC

Liquid-tightfitting, typical

M

32” ± 0.125”(812.8 ± 3.2)

31” ± 0.125”(787.4 ± 3.2)

actuation point

1” ± 0.125”(25.4 ± 3.2)

actuation point

3/4-14 NPT,typical

31” ± 0.125”(787.4 ± 3.2)

actuation point

32” ± 0.125”(812.8 ± 3.2)

72” ± 2”(1828.8 ± 50.8),

typical

1.25” (31.8)max.

ø .90” (22.9)max.

2” ± 0.125”(50.8 ± 3.2)

1” ± 0.125”(25.4 ± 3.2)

actuation point

Liquid-tightfitting, typical

32” ± 0.125”(812.8 ± 3.2)

31” ± 0.125”(787.4 ± 3.2)

actuation point

1” ± 0.125”(25.4 ± 3.2)

actuation point

3/4-14 NPT,typical

31” ± 0.125”(787.4 ± 3.2)

actuation point

32” ± 0.125”(812.8 ± 3.2)

72” ± 2”(1828.8 ± 50.8),

typical

1.59” (40.4)max.

ø .90” (22.9)max.

2” ± 0.125”(50.8 ± 3.2)

1” ± 0.125”(25.4 ± 3.2)

actuation point

Electrical Data for M4168-1 & M4169-1

Watts

30303030

Voltage

240 VAC120 VAC120 VDC24 VDC

Amps(Resistive)

0.140.280.070.28

Alarms• Fixed mount to level switch 4168-X

or 4169-X• LED alarm standard• Audible alarm option (to replace LED or

in conjunction with an LED alarm)• All alarms are battery powered

Fixed-Mount Models

M4168-1-FMM4168-2-FMM4168-3-FMM4169-1-FMM4169-2-FMM4169-3-FM

Remote-Mount Models

M4168-1-RMM4168-2-RMM4168-3-RMM4169-1-RMM4169-2-RMM4169-3-RM

Alarm Level

HighLow

High & LowHighLow

High & Low

Alarm Level

HighLow

High & LowHighLow

High & Low

Electrical Connectorsor Lead Wires?

NoYesNoYesNoYesNoYes

Non-Contact Models

U3M-148-3/4U3M-148-3/4-18P154U3M-148C485-3/4U3M-148C485-3/4-18P154U3M-148C485R-3/4U3M-148C485R-3/4-18P154U3M-148R-3/4U3M-148R-3/4-18P154

RS485Communications?

NoNoYesYesYesYesNoNo

Relay?

NoNoNoNoYesYesYesYes

Operation (Dry Conditions)

NONC

NO/NCNONC

NO/NC

Operation (Dry Conditions)

NONC

NO/NCNONC

NO/NC

ø4.0"(ø101.6)

STANDARD CABLE OPTIONAL CABLE

1" NPT

4.1"(104.1) 3.125"

(79.4)1.95"(49.5)

ø1.125"(ø28.6)U3M-X

M4169-3

M4169-2 M4169-1

M4168-3 M4168-2

M4168-1

Standard Models

Note: The remote distance from top of drum to alarm box is 72”.

LL

M SeriesSingle-Level RefrigerantRecovery Switch

Features

• Highly reliable

• Float options and custom designs available

• UL, CSA and CE approved



M5042

Madison Company’s M5042 and M8042 models are 80% shut-off switches for all standard 30- and 50-pound D.O.T. approved recovery tanks. They are designed specifically to meet EPA directives foroverfill protection of refrigerant recovery tanks.

Madison Company can provide customized switchdesigns to meet specific customer needs, includingmultiple floats, actuation points or termination styles.The Madison M and MT Series Specification Sheetshould be used to define custom requirements.

Models M5042 and M8042 (model M8042 not shown)have wetted materials that are compatible with allcommercially available refrigerants. Their PSIG rating is 300, which is standard for 30- and 50-pound D.O.T.refrigerant tanks.

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Specifications





Materials

Body and Float – M5042 – Yellow Brass stem and fitting; 316 Stainless Steel float M8042 – Yellow Brass stem and fitting; Teflon® float

Operating SpecificationsTemperature – 150˚C (302˚F) max.

Pressure – 300 PSIG, max.

Specific Gravity – 0.70 (M5042), 0.50 (M8042)

Switch Operation – SPDT normally closed (dry state)

Electrical Rating – 60 VA resistive; 120/240 VAC, 5-30 VDC

Mounting – Vertically mounted with 3/4” NPT; fitting hex is 1-1/16”

Connector OptionsM5042-134-3 = 3-pin connector, Brad Harrison 70303 Series or equivalent

M5042-134-4 = 4-pin connector, AMP (TYCO) CPC connector #20606-1 or equivalent

M8042-134-3 = 3-pin connector, Brad Harrison 70303 Series or equivalent

M8042-134-4 = 4-pin connector, AMP (TYCO) CPC connector #20606-1 or equivalent

NOTE:There are no user-serviceable components, and the location of the float retaining rings must not be changed. If service or repair is required, call for a return authorization.

3.31"(84.1)

5.31"(134.9)

7.28" max.(184.9)

3/4" NPT

SWITCH ACTUATIONPOINT

ø.88"(22.4)

3.31"(84.1)

4.75"(120.7)

6.66" max.(169.2)

3/4" NPT

SWITCH ACTUATIONPOINT

M5042

M8042

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M SeriesSide-Mounted Switch with Spade Connector

Features

• Integral male spade connectors

• Simplified electrical and mechanical installation

• Compact size

• Improved field maintainability

• Choice of materials for various liquid applications

• Available with wire leads



M8725 Polypropylene material (top) M7725 PBT material (bottom)

Madison Company offers a standard liquid levelside-mounted switch that has a 1/4” male spadeconnector for simplified electrical installation. Themounting is a 1/2” NPT thread for a vessel wallthrough hole. Both design features provide foreasy field maintenance.

The M7725 is constructed of PBT (PolybutyleneTerephthalate) with an operating temperature upto 130˚C for most hydrocarbon liquids. PBTshould not be used in water over 65˚C. TheM8725 is all polypropylene, for general-purposeapplications and those involving highly acidicliquids. Its operating temperature should notexceed 105˚C.

The M8750 and M8755 (not shown) are similar to the M8725 but come with 24” 22 ga. MTW wire leads. All models are UL, CSA, CE and NSF approved.

Madison Company also offers designs engineeredspecifically for unique application needs.

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Specifications





MaterialsBody and Float – M7725* – PBT (Polybutylene Terephthalate)

M8725 – Polypropylene

Operating SpecificationsTemperature – M7725* – 130˚C (266˚F) max.

M8725 – 105˚C (221˚F) max.

Pressure – 100 PSIG, max.

Specific Gravity – M7725* – 0.70M8725 – 0.60

Switch Operation – Normally Open (NO), close on liquid risingNormally Closed (NC), open on liquid rising

2.75" (69.85) max.

1/2" NPT

.29"(7.37)

2 x .25" x .03"(6.35 x 0.76)Male QC tabs

1" Hex.

.56" (14.22) min.

.60" (15.24) min.

.621" (15.77)

MAX

PSIG

100

100

FLOAT

SG

0.60

0.70

SWITCH

OPERATION

NO or NC

NO or NC

NOMINAL

VA

30

30

THREADS

1/2” NPT

1/2” NPT

MODEL

M8725

M7725*

MAX TEMP

(CELSIUS)

105˚

130˚

* Not for use in water over 65˚C

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M SeriesTilt Float Switch

Features

• Low cost


• Versatile in application

• Custom lead lengths available



Madison Company’s Tilt Float Switch is aninexpensive, efficient and highly reliable leveldetector for open vessels, sumps and ponds.

The molded rubber float has an integral threeconductor cable and operates on a micro-switchdevice that is located inside the float on an anti-vibration mount.

The rubber float is constructed of ethylenepropylene diene (EPDM), a synthetic rubber withrigid and durable characteristics for long servicelife and resistance to heat, oxidation, ozone andaging due to weather. As a non-polar elastomer,EPDM has good electrical resistivity, as well asresistance to polar solvents such as water, acids,alkalies, phosphate esters and many ketones and alcohols.

The basic operating principle is that as the fluidlevel rises the float will rise, causing the micro-switch to tilt and generate a signal that can beused to start or stop a pump, open or close avalve or actuate indicator alarms as required.

Float travel is approximately ± 45˚ arc from itsnominal position.

M4189 Tilt Float Switch

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Specifications





Contact Rating – 16(8)A 250V ~ 16(4)A 380V; Form C (SPDT)

Max. Temperature – 70˚ C (158˚F)

Standard Cable Length – 6.5’ (2 m); Additional lengths available. Lengths above 2 meters will have asplice in the length. Additional cable will be neoprene jacketed, andadhesive-lined polyolefin shrink tube will be used to insulate the splice.Non-spliced lengths can be special ordered upon request.

Max. Submerged Depth – 65’ (20 m)

Max. Working Pressure – 1 bar

Circuit Breaking Capacity – Directly 1KW with 250V

Wetted Materials – Float: EPDM rubber Cable: PVC jacket Weight: Polypropylene sealed housing

Specific Gravity – Stem & Float: 2.16 g/cm3

– Operational in specific gravity from 0.9 to 1.3

Mounting & InstallationThere are no specific installation concerns. However, the lead cable should be supported in anenclosed tank. Additionally, in an open tank, sump, or pond, it is advantageous to clip the lead cable tothe side, especially if excessive turbulence is experienced (a nylon cable-tie is included).

To alleviate the effects of rapid switching conditions if such turbulence is expected, it is recommendedthat a maintaining circuit be used to both safeguard the micro-switch and cut out any chatter from thestarters of associated equipment, such as pumps.

An optional stabilizing weight and rubber “O” ring are included with the M4189 Tilt Float Switch. Thismay be installed at any point on the lead cable.

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M SeriesStainless Steel “Side Kick”Side-Mounted Switch

Features

• Ideal for heavy-bodied liquids or fluids containing metal particles

• Compact installed height of 3-1/2” from switch to float

• Reed switch will not come in contact with the liquid

• All stainless steel construction

• Float is attached to an extended pivot arm



M3827-2

The M3827 is a traditional style reed switch in a new design. This all stainless steel side-mounted switch is engineered such that themagnetically-actuated reed switch will notcome in contact with the fluid being monitored.The float is attached to an extended pivot armthat, when moved, triggers the switch function.

This design makes the M3827 ideal for use in heavy-bodied liquids or in fluids containingmetal particles that would otherwise beattracted to a conventional style float. Thislevel switch has a compact installed height of 3-1/2” from switch to float and is availableNormally Open (NO) or Normally Closed (NC).The M3827 is offered in a choice of threemounting styles: 1/8” NPT, 1/2” NPT and 1/2-13 bulkhead.

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Specifications





Normally Open

MaterialsBody – Stainless Steel

Float – Stainless Steel

Gasket – Silicone*

Operating SpecificationsTemperature – 200˚C (392˚F), maximum

Pressure – 50 PSIG, maximum

Specific Gravity – 0.60

Switch – 30 VA, SPST

Operation – Normally Open (NO), close on liquid risingNormally Closed (NC), open on liquid rising

5.12" (130.05)

6.25" (158.75) max.

3.50"(88.90)

1/2-13THD

1/2" NPT

1/8" NPT

5.77" (146.56)~

5.77" (146.56)~

5

5.25" (133.35) max.

2.79"(70.87)

3.79"(96.27)

Normally Closed

MAX.

PSIG

50

50

50

50

50

50

FLOAT

SG

0.60

0.60

0.60

0.60

0.60

0.60

SWITCH

OPERATION

NC

NC

NC

NO

NO

NO

NOMINAL

VA

30

30

30

30

30

30

THREADS

1/2-13 Bulkhead

1/2" NPT

1/8" NPT

1/2-13 Bulkhead

1/2" NPT

1/8" NPT

MODEL

M3827-1*

M3827-2

M3827-3

M3827-1NO*

M3827-2NO

M3827-3NO

MAX. TEMP.

(CELSIUS)

200˚

200˚

200˚

200˚

200˚

200˚

* Silicone gasket supplied on M3827-1 and M3827-1NO

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Sensor Type: Thermocouple Thin-Film RTD Bimetal ThermistorType K 100 Ohm Snap ActionType J 1000 Ohm Creep ActionType T

Temperature Range:

Actuation Point (Open/close on rise at temp.): Other Considerations:

Madison Company can engineer single-point liquid level switches to meet your application needs. Pleaseprovide the information requested below so that our Engineering Department can determine the appropriateswitch design for your application.

Madison Company27 Business Park Dr., Branford, CT 06405800-466-5383 • 203-488-4477 • Fax: 203-481-5036www.madisonco.com • E-mail: [email protected]

ENVIRONMEN

TELEC

TRICAL

PHYS

ICAL

PROJECT

NOTES

DES

IGN

Customer: Contact Name:

Address:

Phone No.: Fax No.: E-mail:

Application Description:

Fluid: Tank Materials:

Temp. Range: Max. Pressure:

Misc. Conditions (vibration, food contact, hazardous location, turbulence, solids, approvals [i.e. UL, NSF] etc.):

Current: Voltage:

What type of device is being controlled:

4-20 mA Transmitter: o Yes o No

Controller required (refer to Accessory section for model):

Port Type: Inside/Outside Mount:

Lead Length: Cable/Flying Leads:

Connector/Terminations:

Misc:

TEMPE

RAT

URE

Unit Volume (monthly):

Packaging/Labeling:

Pricing Target:

Stocking/Shipping Requirements:

Design Completion Date:

First Delivery Date:


M & MT Series Specification SheetSingle-Point Liquid Level Switch (with temperature option)


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M SeriesMulti-Point Liquid Level Switches

Features

• Multi-point

• Customer-designed

• Magnetic reed switch technology

• High reliability

• Wide selection of available materials

• Three basic sizes: full, miniature and subminiature

• Direct interface to controllers available



A selection of engineered multi-level switches

Madison Company offers a complete lineof Standard and Configured (slightlymodified Standard designs) models. These products continue to meet theneeds of applications in many markets, at competitive prices. In addition, Madison Company offers the capability to design specific liquid level switches for OEM applications that require unique considerations in materials,configurations and system interfacing.

Engineered designs incorporate over 50 years of experience in liquid level switchapplications in a variety of environmentsand installation configurations. Highreliability of the magnetic reed switchtechnology assures repeatability at aneconomical price. Our design experienceand flexible manufacturing techniques alsooffer customers many value-added designand assembly options to reduce theirproduct cost.

LL






The first consideration is the type of liquid, temperature and pressure to which the switch will be subjected. Madisonmanufactures liquid level switches in various styles, in avariety of materials, to cover a broad range of conditions.Following are some basic recommendations for selectingthe proper liquid level switch material for your application.

Material

316 Stainless Steel

PolypropylenePolysulfone

Brass & Buna-NPBT & Buna-N

KynarPTFE

CPVC

Application

For high-temperature (to 300˚C), high-pressure (to 300 PSIG) andcorrosive conditions. Commonly used in food processing, medical,heating and cooling equipment.

For acidic conditions, such as found in electroplating and metalcleaning. Another choice for lower-temperature (to 105˚C) foodprocessing applications (Madison Company uses only polypropylenethat is FDA-approved for food contact). Also a good choice forgeneral-purpose applications in commercial or consumer appliancesand equipment. Available in white and other colors.

The selection for petroleum-based liquids, such as lubricating oils,gasoline and diesel fuels. Widely used in storage tanks of vehicles,generators, transmissions and hydraulic systems. Other uses are inlubrication, recovery, refining and fuel processing equipment. Please note: PBT is not suitable for use in temperatures above 130˚C.

Chemical- and solvent-resistant properties make this material aproblem solver for many applications. Its high-purity nature is idealfor food handling and sensitive laboratory or test equipment.

Good for water, acids, bases and oil products. Not suitable for use intemperatures above 90˚C.

Once a suitable material has been selected, the type of switch and configuration are the nextconsiderations. Madison Company stocks a full line of standard products that can meet therequirements of many applications. For specific designs, Madison can custom build, to order,switches with an infinite number of variations and options. Please utilize our multi-levelspecification sheet which, when completed, will allow our engineering department to better meet your needs.

COMPONENT

See Approvals pages in Reference Section

LL

Multi-point switches are available in many materials and configurationsand can contain as many float actuation points as the application andswitch design may allow (normally up to five). These rugged units canbe mounted within any vessel, utilizing the mounting options shownabove, or customized to the specific application. The actuation pointsare defined by the customer and can be engineered to address offsetlocations within the vessel, allowing for the bypass of obstructions orsaddle type tanks. For turbulent conditions, slosh shields, as well aselectronic interface components and accessories, can be provided.Temperature sensors can also be incorporated into these models.

MODEL

M5602-XXXX

M5605

M4602-XXXX

M8602-XXXX

M5002-XXXX

M4402-XXXX

M8002-XXXX

DWG

NO.

7

7

8

8

9

10

10

FLOAT

MATL

316SS

316SS

Buna-N

PP†

316SS

Buna-N

PP†

STEM

MATL

316SS

316SS

316SS

316SS

316SS

316SS

316SS

MAX TEMP

(CELSIUS)

200°

200°

105°

105°

200°

105°

105°

MAX

PSIG

200

200

150

100

300

150

100

FLOAT

SG

0.55

0.55

0.45

0.75

0.70

0.45

0.80

NOMINAL

VA

60

60

60

60

30

30

30

LEAD WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C,D,E,I

C

A,B,C

A,B,C,D

A,B,C,D,I

A,B,C

A,B,C,D

PIPE PLUG

2"

–

2", 1-1/2"

2", 1-1/2"

2", 1-1/2", 1-1/4"

2", 1-1/2", 1-1/4"

2", 1-1/2", 1-1/4"

FLANGE

SPECIFY SIZE

–

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

MOUNTINGS – NPT

Most Common Mountings and Options*

2.13" dia. max.(54.1)

1" dia. max.(24.4)

1.13" dia. max.(28.7)

1.50" dia. max.(38.1)

DWGNo. 7

Multi-Point Switches

Multi-Point Switch KitThis kit provides the user with the opportunity to optimize their own multi-point switch and fabricate it in the field fromthe kit components. The kit is furnished with two floats and a 2” pipe plug. Maximum stem length is 36” (914.4mm). Please contactfactory for additional components. See Multi-Point Switch Kits page for full specifications.

**



† Also available in Polysulfone (consult factory). PP=Polypropylene ** Refer to Approvals pages in Reference Section. Individual product explosion-proof (E) approvals vary. Consult factory for current product listings.

MODEL

M5602-XXXX

M5605

M4602-XXXX

M8602-XXXX

M5002-XXXX

M4402-XXXX

M8002-XXXX

MALE THREAD

3/8", 1/2"

1/2"

3/8", 1/2"

3/8", 1/2"

1/8", 1/4", 3/8", 1/2"

1/8", 1/4", 3/8", 1/2"

1/8", 1/4", 3/8", 1/2"

BULKHEAD

1/2-13, 3/4-10

–

1/2-13, 3/4-10

1/2-13, 3/4-10

3/8, 3/4-10

3/8, 3/4-10

3/8, 3/4-10

SPST 100 W

OPTION

YES

NO

YES

YES

NO

NO

NO

SPDT 25 W

OPTION

YES

NO

YES

YES

NO

NO

NO

DWGNo. 8

DWGNo. 9

DWGNo. 10



LL

* An expanded list of U.S. fittings and European BSPP and BSPT fittings is available in our e-catalog at www.madisonco.com.




Multi-point switches are available in configurations containing up tosix different levels, providing maximum flex i bil i ty for each user. Theserugged units can be mounted within any vessel, utilizing either malepipe threads, pipe plugs, flanges or bulk head fittings. The length ofeach switch, as well as the location of each of the floats, may bees tab lished by the designer. For difficult in stal la tions, stems can bebent to bypass obstructions within the vessel. Slosh shields are alsoavailable for turbulent conditions. Temperature sensors can beincorporated into these models.

1" dia. max.(24.4)

1.50" dia. max.(38.1)

DWGNo. 38

DWGNo. 37

MODEL

M8802-XXXX

M8080-XXXX

M8085

M6602-XXXX

DWG

NO.

37

38

38

37

FLOAT

MATL

PP†

PP†

PP†

PP

STEM

MATL

PP†

PP†

PP†

CPVC

MAX TEMP

(CELSIUS)

105˚

105˚

105˚

90˚

MAX

PSIG

100

25

100

100

FLOAT

SG

0.75

0.80

0.80

0.75

NOMINAL

VA

60

30

30

60

LEAD WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C,I

A,B,C,D,I

C

A,B,C

MODEL

M8802-XXXX

M8080-XXXX

M8085

M6602-XXXX

MALE THREAD

1/2"

1/8", 1/4", 1/2"

1/4"

1/2", 3/4", 1"

PIPE PLUG

2", 1-1/2"

2", 1-1/2", 1-1/4"

–

1-1/2", 2", 2-1/2"

FLANGE

SPECIFY SIZE

SPECIFY SIZE

–

2", 3"

BULKHEAD

1/2-13

1/2-13

–

–

MOUNTINGS – NPT SPST 100 W

OPTION

YES

NO

NO

YES

SPDT 25 W

OPTION

YES

NO

NO

YES



**

† Also available in Polysulfone (consult factory). PP=Polypropylene ** Refer to Approvals pages in Reference Section

Multi-Point Switch KitThis kit provides the user with the opportunity to optimize their own multi-point switch and fabricate it in the field fromthe kit components. The kit is furnished with two floats and a 2” pipe plug. Maximum stem length is 36” (914.4mm). Please contactfactory for additional components. See Multi-Point Switch Kits page for full specifications.

LL


Multi-point switches are available in configurations containing up to sixdifferent levels, providing maximum flex i bil i ty for each user. These ruggedunits can be mounted within any vessel, utilizing either male pipe threads,pipe plugs, flanges or bulk head fittings. The length of each switch, as wellas the location of each of the floats, may be es tab lished by the designer.For difficult in stal la tions, stems can be bent to bypass obstructions withinthe vessel. Slosh shields are also available for turbulent conditions.Temperature sensors can be incorporated into these models.

MODEL

M4302-XXXX

M4502-XXXX

M5042-XXXX

M5402-XXXX

M8042-XXXX

M8402-XXXX

DWG

NO.

25

27

26

24

27

25

FLOAT

MATL

Buna-N

Buna-N

316SS

316SS

PP

PP

STEM

MATL

Brass

Brass

Brass

Brass

Brass

Brass

MAX TEMP

(CELSIUS)

105°

105°

200°

200°

105°

105°

MAX

PSIG

150

150

300

200

100

100

FLOAT

SG

0.45

0.45

0.70

0.55

0.80

0.75

NOMINAL

VA

60

30

30

60

30

60

LEAD WIRES

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

22 ga. Teflon 24"

APPROVALS

A,B,C,I

A,B,C,I

A,B,C

A,B,C

A,B,C

A,B,C

MODEL

M4302-XXXX

M4502-XXXX

M5042-XXXX

M5402-XXXX

M8042-XXXX

M8402-XXXX

MALE THREAD

1/2"

1/8", 1/4", 1/2"

1/8", 1/4", 1/2"

1/2"

1/8", 1/4", 1/2"

1/2"

PIPE PLUG

2", 1-1/2"

2", 1-1/2", 1-1/4"

2", 1-1/2", 1-1/4"

2"

2", 1-1/2", 1-1/4"

2", 1-1/2"

FLANGE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

SPECIFY SIZE

BULKHEAD

1/2-13

3/8

3/8

1/2-13

3/8

1/2-13

MOUNTINGS – NPT SPST 100 W

OPTION

YES

NO

NO

YES

NO

YES

SPDT 25 W

OPTION

YES

NO

NO

YES

NO

YES



**

2.13" dia. max.(54.1)

1" dia. max.(24.4)

1.13" dia. max.(28.7)1.50" dia. max.

(38.1)

DWGNo. 24

DWGNo. 27

DWGNo. 26

DWGNo. 25



PP=Polypropylene ** Refer to Approvals pages in Reference Section

Multi-Point Switch KitThis kit provides the user with the opportunity to optimize their own multi-point switch and fabricate it in the field from the kit components. The kit is furnished with two floats and a 2” pipe plug. Maximum stem length is 36” (914.4mm). Please contactfactory for additional components. See Multi-Point Switch Kits page for full specifications.


M Series Brass Liquid Level Switches

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Stainless Steel



These easy-to-use, Do-It-Yourself Kits provide the user with the opportunity to optimize their own multi-pointswitches and fabricate them in the field from the kit components. The standard ML-XXXX kits are furnishedwith two floats and a 2” pipe plug. Maximum stem length is 36” (914.4mm). Users who require a 3rd or 4th

level can purchase adder kits as follows:

ML-XXXX-LVL3 to add a 3rd level to the ML-XXXX kitML-XXXX-LVL4 to add a 4th level to the ML-XXXX-LVL3 kitML-XXXX-LVL3&4 to add a 3rd and 4th level to the ML-XXXX kit

Kits are also available with Bent Stem (ML-XXXX-BENT). Bend angle is 90˚.

* Must be ordered in conjunction with ML-XXXX** Must be ordered in conjunction with ML-XXXX-LVL3

All kits are UL and CE approved. For full assembly guidelines and a sample configuration, please visit www.madisonco.com.

Plastic

Brass


M Series Multi-Point Switch Kits

LL

MODELFLOATMATL

STEMMATL

MAX TEMP(CELSIUS)

MAXPSIG

FLOATSG

NOMINALVA

ML-5555 316SS 316SS 200˚ 200 0.55 60

ML-5555-LVL3*

316SS 316SS 200˚ 200 0.55 60

ML-5555-LVL4**

316SS 316SS 200˚ 200 0.55 60

ML-5555-LVL3&4*

316SS 316SS 200˚ 200 0.55 60

ML-5555-BENT

316SS316SS

(90˚ Bend)200˚ 200 0.55 60

MODELFLOATMATL

STEMMATL

MAX TEMP(CELSIUS)

MAXPSIG

FLOATSG

NOMINALVA

ML-8888 PP PP 105˚ 100 0.75 60

ML-8888-LVL3*

PP PP 105˚ 100 0.75 60

ML-8888-LVL4**

PP PP 105˚ 100 0.75 60

ML-8888-LVL3&4*

PP PP 105˚ 100 0.75 60

ML-8888-BENT

PPPP

(90˚ Bend)105˚ 100 0.75 60

MODELFLOATMATL

STEMMATL

MAX TEMP(CELSIUS)

MAXPSIG

FLOATSG

NOMINALVA

ML-4444 Buna-N Brass 105˚ 150 0.45 60

ML-4444-LVL3*

Buna-N Brass 105˚ 150 0.45 60

ML-4444-LVL4**

Buna-N Brass 105˚ 150 0.45 60

ML-4444-LVL3&4*

Buna-N Brass 105˚ 150 0.45 60

ML-4444-BENT

Buna-NBrass

(90˚ Bend)105˚ 150 0.45 60

PP=Polypropylene

INSTRUCTIONSComplete Process Conditions (Table 1). Select float design, stemmaterial and watt rating (Table 2). Select mounting configuration(Table 3). Provide required dimensions and switch operation(Table 4). Mail or fax with purchase order to Madison Company.

All measurements in parentheses are in millimeters.

TABLE 1 PROCESS CONDITIONS

MAX. TEMP. MIN. TEMP.

MAX. PRESSURE SPECIFIC GRAVITY

FLUID

SPECIAL COND.

QUANTITY WIRE LENGTH24" (609.6mm) standard

TEMPERATURE SENSOR OPTION:

THERMOCOUPLE: TYPE J TYPE K TYPE T

THIN-FILM RTD: 100 OHM 1000 OHM

BIMETAL: CREEP ACTION SNAP ACTION THERMISTOR

TEMPERATURE RANGE

OTHER CONSIDERATIONS

CONTROLLER NEEDED?

TABLE 2

TABLE 3 MOUNTING CONFIGURATIONSMALE THREAD MALE PIPE PLUG FLANGE

BULKHEAD FITTING

1/8" NPT

1/4" NPT

3/8" NPT

1/2" NPT

3/4" NPT

2"

1-1/2"

1-1/4"

BULKHEAD

SPECIFY SIZE:

TABLE 4 LENGTH & OPERATING POINTAdditional levels are available. Please consult factory.

SPDT SLOSHSHIELD

L1

L2

L3*

L4

L5

L (Total) =

LENGTHSREQUIRED

LH =LH

L5

L (Total)

L1

SWITCHOPER.NO/NC

L4L2

L3

L4

L5

Refer to Switch Set-Up Criteria (Table 5)in order to determine lengths required.

*M5602

M5402

M8802

M8602

M8402

M6602

M4602

M4302

Full-Size FloatsSPST 60 WATTS SPDT 25 WATTSSPST 100 WATTS

STAINLESS STEEL

POLYPROPYLENE

BUNA-N

2"(50.8)

2.13" (53.9)

2"(50.8)

1.5" (38.1)

2"(50.8)

1.25" (31.75)

*Rated for hazardous locations.

For switches with bent stems,specify horizontal distance (LH).

Please specify lengths and switch operation inchart below, always starting with thebottom switch (L5).

FLOAT DESIGNAVAILABLE

STEM MATERIALSMODEL NO.

STAINLESS STEEL

BRASS

POLYPROPYLENE

POLYSULFONE

STAINLESS STEEL

BRASS

CPVC

STAINLESS STEEL

BRASS

For M5602, M5402, M8602, M8402, M4602, M4302L (Total) = L5 + 1-1/2" (38.1mm) Min.Distance from mounting fitting to first switch = 1-1/4" (31.7mm) Min.Minimum distance between floats: 2-1/2" (63.5mm)Minimum LH = 2-1/2" (63.5mm)

For M8802, M6602L (Total) = L5 + 2" (50.8mm) Min.Distance from mounting fitting to first switch = 1-3/4" (44.4mm) Min.Minimum distance between floats: 3" (76.2mm)

State your current ________ and voltage ________ requirements.

TABLE 5 SWITCH SET-UP CRITERIA

Max. Max.Model Temp. PSIG

M5602* 200˚C 200M5402 200˚C 200M4302 105˚C 150M4602 105˚C 150M6602 90˚C 100M8802* 105˚C 100M8602 105˚C 100M8402 105˚C 100

InstallationNC Operation:

SS Floats: Witness mark(round circle) down.

Plastic Floats: Magnets up.

NO Operation:SS Floats: Witness mark (round circle) up.Plastic Floats: Magnets down.

Above ratings are for resistive loads only.For inductive loads, maximum life will beachieved if appropriate arc suppressionis used.

Typical Current& Voltage Ratings

Watts

100

60

25

Voltage

240 AC120 AC120 DC24 DC

240 AC120 AC120 DC24 DC

240 AC120 AC120 DC24 DC

Current Amps

0.41.00.41.0

0.40.50.20.5

–0.28

–0.28

* NSF approved for use in food equipment.

* 4 levels maximum on model M8802

Madison Company • (203) 488-4477 • Fax (203) 481-5036 • E-mail: [email protected] • www.madisonco.com © Copyright Madison Co. – 6/08 LL-51

M Series Specification SheetFull-Size Multi-Point Liquid Level Switches

LL

INSTRUCTIONSComplete Process Conditions (Table 1). Select float design, stemmaterial and watt rating (Table 2). Select mounting configuration (Table 3). Provide required dimensions and switch operation (Table 4). Mail or fax with purchase order to Madison Company.

All measurements in parentheses are in millimeters.

TABLE 2

TABLE 3 MOUNTING CONFIGURATIONSMALE THREAD MALE PIPE PLUG FLANGE

BULKHEAD FITTING

1/8" NPT

1/4" NPT

3/8" NPT

1/2" NPT

3/4" NPT

2"

1-1/2"

1-1/4"

BULKHEAD

SPECIFY SIZE:

TABLE 4 LENGTH & OPERATING POINTAdditional levels are available. Please consult factory.

SLOSHSHIELD

L1

L2

L3*

L4

L (Total) =

LENGTHSREQUIRED

LH =LH

L4

L1

SWITCHOPER.NO/NC

L3L2

L3*

L4

L (Total)

Refer to Switch Set-Up Criteria (Table 5) in order to determinelengths required.

For switches with bent stems,specify horizontal distance (LH).

Please specify lengths and switch operation inchart below, always starting with thebottom switch (L4).

FLOAT DESIGNAVAILABLE

STEM MATERIALSMODEL NO.

For M5002, M5042, M8080, M8002, M8042, M4402, M4502

L (Total) = L4 + 1" (25.4mm) Min.

Distance from mounting fitting to first switch = 3/4" (19.05mm) Min.

Minimum distance between floats: 1-1/2" (38.1mm) / 1-3/4" (44.5mm) for M8080

Minimum LH = 1-1/2" (38.1mm) / NA for M8080

State your current ________ and voltage ________ requirements.

TABLE 5 SWITCH SET-UP CRITERIA

Max. Max.Model Temp. PSIG

M5002* 200°C 300M5042 200°C 300M4502 105°C 150M4402 105°C 150M8002* 105°C 100M8042 105°C 100M8080* 105°C 25

Installation

NC Operation:SS Floats: Witness mark (round circle) down.Plastic Floats: Magnets up.

NO Operation:SS Floats: Witness mark (round circle) up.Plastic Floats: Magnets down.

Above ratings are for resistive loads only.For inductive loads, maximum life will beachieved if appropriate arc suppressionis used.

Typical Current& Voltage Ratings

Watts

30

Voltage

240 AC120 AC120 DC24 DC

Current Amps

0.140.280.070.28

* NSF approved for use in food equipment.

* 3 levels maximum on model M8080

M5002

M5042

M8080

M8002

M8042

M4402

M4502

STAINLESS STEEL

BRASS

POLYPROPYLENE

POLYSULFONE

STAINLESS STEEL

BRASS

STAINLESS STEEL

BRASS

Miniature-Size Floats SPST 30 WATTS

STAINLESS STEEL

POLYPROPYLENE

BUNA-N

1.19"(30.2)

1.13" (28.7)

1"(25.4)

1" (25.4)

1"(25.4)

1" (25.4)

Madison Company • (203) 488-4477 • Fax (203) 481-5036 • E-mail: [email protected] • www.madisonco.comLL-52 © Copyright Madison Co. – 1/08

TABLE 1 PROCESS CONDITIONS

MAX. TEMP. MIN. TEMP.

MAX. PRESSURE SPECIFIC GRAVITY

FLUID

SPECIAL COND.

QUANTITY WIRE LENGTH24" (609.6mm) standard

TEMPERATURE SENSOR OPTION:

THERMOCOUPLE: TYPE J TYPE K TYPE T

THIN-FILM RTD: 100 OHM 1000 OHM

BIMETAL: CREEP ACTION SNAP ACTION THERMISTOR

TEMPERATURE RANGE

OTHER CONSIDERATIONS

CONTROLLER NEEDED?

M Series Specification SheetMiniature Multi-Point Liquid Level Switches

LL

© Copyright Madison Company – 4/09 CL-1

Model C3957 withStainless Steel Float

Madison Company offers a full line of standardmodels of continuous liquid level indicators withsensing ranges up to 96”. On the reverse side ofthis sheet, you will find a representative list of thesestandard models.

Our engineering staff can also provide customdesigns that are application specific to meetmaterial compatibility, length, resolution andmounting requirements. Use our C SeriesSpecification Sheet to define your requirements.

Our resolution options of 5mm, 10mm and 1”combine the accuracy and reliability of reed switchtechnology with a level indication interface that canmatch your need for continuous level monitoring atan affordable price.

Our 1” resolution model (C3975-XXXX) is offeredwith a field-repairable sensor strip. This allows forpermanent mounting of the level switch assemblywhile permitting in-field replacement of the flexiblesensor strip via a simple screw-in assembly. This isvery desirable where limited overhead space orpermanent tank closure are a consideration. This isoffered with a standard linear output or applicationspecific output.

• Continuous level indication

• Controllers available

• Various material choices, lengths andmounting configurations

• Wide selection of U.S. and European BSPP and BSPT fittings

• Configure online through our Product Configuratorand receive an instant quotation

Model C3975 withreplaceable flexible

sensor strip

ContinuousLevel Indicators



www.madisonco.com

CL

* Replacement Sensing Strips(For Models C3975-XXXX)

Continuous Level Transducers



PP = Polypropylene SS = Stainless Steel** All models are CE approved; refer to Approvals page in the Reference section for more information.† A wide selection of U.S. and European BSPP and BSPT fittings is available for all of these items.

CL-2 © Copyright Madison Company – 4/09

MODEL

080-003976-1000

080-003976-1004

080-003976-1003

080-003976-1007

080-003976-1006

SENSING LENGTH

16"

24"

32"

42"

48"

C Series Continuous Level Transducers

MODEL** RESOLUTIONFLOATMATL.

STEMMATL.

MAX.TEMP.(CELCIUS)

MAX.PSIG

FLOATSG

SENSINGLENGTH FITTING† OUTPUT

C3946-1002 10mm PP 316SS 85˚C 100 0.75 16" 2" Pipe Plug 4-20 mA





C3946-1000 10mm Buna-N 316SS 85˚C 150 0.45 40" 2" Pipe Plug 4-20 mA



C3946-1010 10mm Buna-N 316SS 85˚C 150 0.45 62" 1-1/2" Pipe Plug 4-20 mA

C3946-1011 10mm 316SS 316SS 85˚C 200 0.55 30" 2" Pipe Plug 4-20 mA




C3957-1007 5mm Buna-N 316SS 85˚C 150 0.45 36" 1/2" NPT 4-20 mA


C3957-1004 5mm 316SS 316SS 85˚C 200 0.55 48" 2" Pipe Plug 1-5 Volt


C3957-1006 5mm 316SS 316SS 105˚C 200 0.55 8" 1/2" NPT Resistive

C3975-1000* 1" PP 316SS 85˚C 100 0.75 16" 1-1/2" Pipe Plug 4-20 mA

C3975-1004* 1" PP 316SS 105˚C 100 0.75 24" 2" Pipe Plug 220 Ohms/inch




CL

In addition to the standard part numbers listed above, these Continuous Level Indicators can be custom configuredusing our online Product Configurator.

Visit www.madisonco.com for details.

Madison-Omni® Continuous Level Sensors



PP = Polypropylene SS = Stainless Steel


C Series Continuous Level Transducers

MODEL RESOLUTION / TYPEFLOATMATL.

STEMMATL.

MAX.TEMP.(CELCIUS)

MAX.PSIG

FLOATSG

SENSINGLENGTH FITTING

C4048-1000 5mm vertical PP 316SS 70˚C 100 0.75 12" 2" Pipe Plug

C4048-1000S 5mm swan PP 316SS 70˚C 100 0.75 12" 2" Pipe Plug























C4047-1000 1" vertical PP 316SS 70˚C 100 0.75 12" 2" Pipe Plug

C4047-1000S 1" swan PP 316SS 70˚C 100 0.75 12" 2" Pipe Plug











CL

C SeriesField-RepairableContinuous Level Switches

Features

• Field-repairable, watertight removable core

• Stainless steel or brass stem

• 3” minimum required above tank level

• Temperature sensing available

• Alarm and various output signals available



C3945 & C3975ContinuousLevel Switches

When your application calls for a sealed tank, or the installation does not lend itself to easy removal,Madison Company’s C3945 and C3975 field-repairablecontinuous level switches should be considered.

The entire stem and face mount can be permanentlysealed to the vessel. Should replacement of the reed switches become necessary, unscrewing the top mount and removing the entire switch assembly can be accomplished without compromising the vessel’s interior environment.

The ability to easily remove the C3945 and C3975 from a sealed tank allows most repairs to be completed on-site.When compared to conventional liquid level switches, thisfield-repairable continuous level switch eliminates the need for tank depressurization and reduces the chance ofenvironmental contamination.

Removal and replacement offlexible sensor strip can beeasily accomplished on-site

CL

Specifications





Options

Resolution – 1”

Resistive Value – 220 ohms with 220 ohms per inch linear, standard

– 240-33 or 0-90 ohms also available

– Application-specific ohms per inch, engineered

Max Power – 1/8 Watt

Lengths – 12” to 96”Standard lengths: 16”, 24”, 32”, 36”, 42”, 48”Shorter and longer, engineered-specific

Materials – Stainless Steel or Brass stem and fitting,Polypropylene and Buna-N floats

Temperature Range – -40˚C to 105˚C (-40˚F to 221˚F)

Output – 220 ohms to 5.2 K ohms, standardApplication-specific ohms, engineered

Float Diameter – Buna-N: 1-1/4”; Polypropylene: 1-1/2”

Approval – All models carry CE approval. Model C3975 is also ABS approved. Other approvals areavailable, please consult factory.

1.92”(48.8)

ø1.25”(31.8)

Buna-NFloat

1.85”(47.0)

ø1.5”(38.1)

PolypropyleneFloat

2.10”(53.3)

ø2.05”(52.1)

StainlessSteel Float

Inside Mount Outside Mount ANSI Flange

Fitting Options: Representative samples at right

• 3/4”, 1” or 1-1/2” NPT inside mount

• 1-1/2” or 2” NPT outside mount*

• 2”, 3” or 4” ANSI flange

• Other mounting options available

• 4-20 mA output – 2-wire• 1-5 VDC output – 3-wire• Additional alarm levels• Temperature sensing• Replacement sensor assembly• Elbow extension for fitting available• Controller

*1-1/2” NPT outside mount not available with stainless float

SensingRange

L Total

0.25” (7.1)Deadband*

2.63” (66.8)Deadband*

CL

C SeriesContinuous Level Transducer

Features

• Flexibility for varied fluid environments

• Suitable for any tank application

• Provides precise, uninterrupted readout with 5mm or 10mm resolution

• Various output signals available (4-20 mA, 1-5 DC, resistive, etc.)

• Ideal for: – Remote sensing in tanks with restricted or limited access– Precise liquid level monitoring in a series of tanks in

mixing operations– Central monitoring of liquid level in remote multiple tanks– Any tank application where the exact liquid level has to be

known at any time



Model C3957 withStainless Steel Float

Madison’s continuous level transducers aredesigned for vertical mounting in a tank. Reedswitches are evenly spaced over the operationrange to achieve the desired resolution. A singlemagnet-containing float travels the length of thesensing range. The reed switches aremagnetically actuated as the float moves with theliquid level. DC power is applied to the switch,and the output signal can then be routed toprogrammable controllers, microprocessors orother readout devices.

Model C3946 is a 10mm resolution continuouslevel float switch with a stainless steel or brassstem and available with either a polypropylene,Buna-N or stainless steel float.

Model C3957 is a 5mm resolution continuouslevel float switch with a stainless steel or brassstem and is available with either a stainless steel,polypropylene or Buna-N float.

Both models are suitable for petroleum-basedliquid applications, in addition to many otherliquids with low- to mid-range viscosity.

Model C3946 withBuna-N Float

Model C3946 withPolypropylene

Float

CL

Specifications





Inside Mount Outside Mount ANSI Flange

Fitting Options: Representative samples at right

• 1/2”, 3/4”, 1” or 1-1/2” NPT inside mount

• 1-1/2” or 2” NPT outside mount*

• 2”, 3” or 4” ANSI flange

• Other mounting options available

• Temperature Sensing

• High/Low Set Point Alarms

Resolution – 5 or 10mm

Signal Output – 1/10 Watt resistive, 100 ohms per 5mm3-wire: 10-30 VDC, 1-5 V output2-wire: 10-30 VDC, 4-20 mA output

Wiring Details – 2-wire: Red - positiveBlack - negative

3-wire: Red - positiveBlack - negativeWhite - signal out

Switch Materials – 316 SS or brass stem and

Buna-N float (float dia. 1.25”) orStainless float (float dia. 2.05”) orPolypropylene float (FDA approved) (float dia. 1.5”) Note: all stem diameters are 0.5” OD

Sensing Length – 6” to 96”Standard lengths: 16”, 24”, 32”, 36”, 42”, 48”Note: overall switch length will be longer, to allow float travel over the sensing range

Operating Temp. – -40˚C to 105˚C (-40˚F to 221˚F), Resistive output– -40˚C to 85˚C (-40˚F to 185˚F),

4-20 mA, 1-5 V output

Approval – All models carry CE approval. Model C3975 is also ABS approved. Other approvals areavailable, please consult factory.

.75” (19.1)Deadband

L Total

SensingRange

1.88” (47.8)Deadband

Buna-NFloat

PolypropyleneFloat



Options

1.92”(48.8)

ø1.25”(31.8)

1.85”(47.0)

ø1.5”(38.1)

2.10”(53.3)

ø2.05”(52.1)

CL

Sensing Range: ___________________________________

Signal Output: 3-wire, 1-5 VDC

2-wire, 4-20 mA

Resistive

Controller (specify type): ____________________________

Madison Company can engineer field-repairable continuous level transducers to meet your application needs.Please provide the information requested below so that our Engineering Department can determine theappropriate design for your application.

PART

#M

ATER

IALS

TOTA

L LE

NG

TH

NO

TES


Address:


Madison Part Number:

C3945 Non-Linear C3975 Linear

MO

UN

TIN

G

Stem and fitting are Stainless Steel or Brass. Stem dia. is 0.5”.Stem: Stainless Steel BrassCollar is stainless steel. Float is Buna-N or polypropylene.Float: Buna-N Polypropylene

REQ

UIR

EMEN

TS

Sensing Range: _________________

Plus Top Deadband: 0.25” (C3975) or 1” (C3945)

Plus Bottom Deadband: 2.63” (C3975) or 1” (C3945)

Equals L Total: _________________



* DEADBAND: EXTRA STEMLENGTH TO ALLOW FORPROPER FLOAT TRAVELOVER SENSING RANGE

LTOTAL

LTOTAL

LTOTAL

Pipe Plug:Outside Mount

1-1/2” 2”

Flange: Outside Mount

2” 3” 4”

NPT: Inside Mount

3/4” 1”

1-1/2”

Other mountingconfiguration(please describe below)

Buna-NFloat

PolypropyleneFloat


1.92”(48.8)

ø1.25”(31.8)

1.85”(47.0)

ø1.5”(38.1)

ø2.05”(52.1)

2.10”(53.3)

SensingRange

L Total

0.25” (7.1)Deadband*

2.63” (66.8)Deadband*

OPT

ION

S

Temperature sensor (Type) _________________

High/low set point alarms


C Series Specification SheetField-Repairable 1” Continuous Level Transducer

CL

Sensing Range (6” to 96” standard): _____________________

Resolution: 5mm (C3957) 10mm (C3946)

Signal Output: 3-wire – 1-5 VDC

2-wire – 4-20 mA

2-wire (resistive) – 1/10 W rating,100 ohms per 5mm of indication

Controller (specify type): ______________________________

Madison Company can engineer continuous level transducers to meet your application needs. Pleaseprovide the information requested below so that our Engineering Department can determine the appropriatedesign for your application.

MAT

ERIA

LSTO

TAL

LEN

GTH

NO

TES


Address:


OPT

ION

S

Stem: 316 Stainless Steel BrassStem diameter is 0.5”.

Float: Polypropylene Stainless Steel* Buna-N


REQ

UIR

EMEN

TS

L Total: _________________


C Series Specification Sheet5 and 10 mm Continuous Level Transducers

* DEADBAND: EXTRA STEMLENGTH TO ALLOW FORPROPER FLOAT TRAVELOVER SENSING RANGE

Madison Company27 Business Park Dr., Branford, CT 06405800-466-5383 • 203-488-4477 • Fax: 203-481-5036www.madisonco.com • E-mail: [email protected] © Copyright Madison Company – 10/05

Temperature sensor (Type) _________________

High/low set point alarms

Buna-NFloat

PolypropyleneFloat


MO

UN

TIN

G

Pipe Plug:Outside Mount

1-1/2” 2”

Flange: Outside Mount

2” 3” 4”

NPT: Inside Mount

1/2” 3/4”

1” 1-1/2”

Other mountingconfiguration(please describe below)

1.92”(48.8)

ø1.25”(31.8)

1.85”(47.0)

ø1.5”(38.1)

ø2.05”(52.1)

2.10”(53.3)

1.88” (47.8)Deadband

SensingRange

L Total

.75” (19.1)Deadband

LTOTAL

LTOTAL

LTOTAL

CL

C SeriesMadison-Omni® Sensors

Features

• Two switching points (e.g. high and low alarms)

• Hysteresis selectable in magnitudeand direction

• 4-20 mA analog output

• Graphical LCD display (increasedtemperature range, illuminated, unitsin the display, includes super-brightsignaling LED)

• Programming ring; lock in customsettings by inverting or removing ring

• Dialog messages in the display

• Stainless steel housing

• Mineral glass (tempered, scratch- andbreak-proof) for covering the display

• M 12x1 connector system

• System mounting to all Madisonprimary C-Series sensors

• Compact dimensions

• IP 67

Madison Company • (203) 488-4477 • (800) 466-5383 • Fax (203) 481-5036 • [email protected] • www.madisonco.comMadison Europe • Phone: + 31 (0) 548 659 034 • Fax: + 31 (0) 548 659 010 • [email protected]


Madison Company introduces a self-contained, compact alarmdisplay as an integral part of its continuous liquid level switch family.The Madison-Omni is a user-programmable device that has a simpleand secure set of options for level indication, unit of measure andseveral other variables. The LCD display is easy to read, and aseparate red LED light is a visual alarm when the programmedparameters are outside the set ranges. The program ring can beremoved or left on the unit in a reverse manner to secure the settings.

Switch point indications can be set directly on site using Madison-Omni Sensors for upper and lower set point values. Using the display,these settings can also be programmed without the Madison-Omniinstalled in the tank. The current values at the measuring point arealways visible and all the important parameters can be called up atthe point of measurement, saving time during installation, setup andtroubleshooting. The analog current signal can be evaluated over longdistances and the momentary value made available remotely.Madison-Omni Sensors are configured to your specifications and areready for use without any programming. If you need to changeparameters, use the programming ring directly on the sensor withoutany additional tools.

CL

Specifications




Supply Voltage – 18-30 VDC

Power Consumption – 0.5 Watts

Measurement Range – Varies according to specific model

Accuracy – 1% of full scale

Reproducibility – 0.1% of full scale

Dynamic Response – Measurement cycle: 32 ms; Display cycle: 0.5 s

Operating Temperature – -20˚C to 70˚C (-4˚F to 158˚F)

Storage Temperature – -20˚C to 80˚C (-4˚F to 176˚F)

Signal Output – 4-20 mA, 2-10 V through 500 Ohm termination resistance

Switching Points S1 & S2 – PNP or NPN selectable; 300 mA load in sum, maximum; programmable asminimum or maximum value; short-circuit and reverse-polarity proof

Hysteresis – Adjustable; position of hysteresis depends on minimum or maximum

Display – Graphical LCD display, extended temperature range -20˚C to 70˚C; 32x16 pixels; back-lit; showsvalue and units; LED signaling lamp with simultaneous message in display

Connection – At locking plug M 12x1, 5-pole*

Protection Class – IP67

Material – Varies according to specific model

Mounting – Varies according to specific model

Approval –


M12 x 1

2.09" (53)

≈ 1.

10" (

28)

ø1.3

8" (3

5)

ø1.7

7" (4

5)

CL

Wherever Madison Company’s C-Series continuous level switches have been used, a direct replacementwith the Madison-Omni switch can be made. Give us the previously used part number and we will provideyou with a new Madison-Omni part number.

Where the Madison C-Series switch with a separate display was used, with minimal effort you can now usethe Madison-Omni as a combined sensor with integrated display.

Applications

* Madison-Omni® Sensor Accessories (sold separately)029-P00001 – Shielded cable; 2m length with straight plug029-P00002 – Shielded cable; 5m length with straight plug029-P00003 – Shielded cable; 10m length with straight plug

029-P00004 – Shielded cable; 2m length with 90˚ angled plug029-P00005 – Shielded cable; 5m length with 90˚ angled plug029-P00006 – Shielded cable; 10m length with 90˚ angled plug

M SeriesSingle-Point Probe ConductivitySensor for Food Applications

Features

• Small size

• Low cost

• Sensitivity-adjustable controller

• No moving parts

• Safe operation

• Made entirely of food-grade materials

• Can be used for multiple level indication


© Copyright Madison Company – 2/05 CD-1

M3850

The M3850 is a small, low-cost sensor designed forfood applications in metal-walled tanks or vessels.Installation is simple, and they can be wired in phaseso that multiple level points can be detected. Allmaterials are food-grade, and the contours of theinsulator shell meet NSF requirements for cleaning.

While a conductivity switch and a float-type switchperform the same functions, the advantage of nomoving parts is that the conductivity switch can beused in several environments that would cause afloat to stick or to not operate at all. The probe ismounted with an insulator shell for sensing in suchliquids. With no moving parts, switch operation of theM3850 is not interrupted.

Only an extremely small amount of current isnecessary for the unit to perform. As with anydevice, a properly installed and grounded systemposes no electrical hazard.

Madison supplies a basic controller with the M3850that will satisfy a broad range of applications.Because conductivity varies widely among liquids,the controller is adjustable for sensitivity in differentliquids. Consult factory for details on a specific liquid.

CD

Specifications



CD-2 © Copyright Madison Company – 5/08


01.00"(25.4)

0.75"(19.05)

0.59"(14.99)

1.63"(41.4)

0.84"(21.3)

ConductivityProbe

NutWasher

Tank Wall

Insulator

Chamfer45° x 0.080" (2.03)

Upper Probe

Lower Probe

CommonProbe

1

4 NC

3 NO

7

2

Switched Contacts

120 VAC Input

5 6 8

• 120 VAC is connected between pins 2 and 7

• Wire the Common Probe to pin 5• Wire the Lower Probe to pin 6• Wire the Upper Probe to pin 8

Pins 1-3 and 1-4 are isolated switchcontacts to switch power to a valve or pump.

For single level control, connect probe to pin 8 and use pin 5 as the return.

R2 Conductivity Configuration

M3850

105˚C (221˚F)

30

Bulkhead 1/2-13

Model No.

Max. Temp.

Max. PSIG

Available Mounting

R2

3 max., High, Low, Common

12 VAC

Adj. to 100,000 Ohms

120 VAC 50/60 Hz

5 Amps res. @ 240 VAC, form SPDT

Socket mount; socket is DINrail-mountable

Model No.

Sensing Inputs

Sensing Voltage

Sensing Resistance

Input

Output

Mounting

M3850

R2

Sensing Head

Controller

(1-3 or 1-4)

5A @ 220 VAC10A @120 VAC10A @ 30 VDC

Output Contact Rating

PUMP

INPUTPOWER

R2

8 7

643

12

LOW LEVEL

HIGH LEVEL

COMMON

M3850 (X3)

5

NOTE: DRAWING FOR PUMP UP OPERATION.TO CHANGE TO PUMP DOWN, WIRE PUMPTO TERMINAL 3 ON CONTROLLER INSTEADOF TERMINAL 4.

Three M3850 units in phase

CD

M SeriesConductivity Switch

Features

• Sensitivity-adjustable controller

• No moving parts

• Safe operation

• Controls up to two levels with controller

• NPT fitting (bulkhead or flange-type fitting available)

• One to three electrodes, depending on tankmaterial and number of functions required

• Electrodes are 1/8” diameter 316 Stainless Steel; all wetted materials are food-grade

• Standard 24” electrode can be cut by end user toshorter length; two 24” extensions can be added fora maximum recommended length of 72”



M3784

Madison Company’s conductivity switch is the current choice forheavy-bodied or semisolid liquids.

Madison supplies a basic controller with the M3784 that will satisfy abroad range of applications. Because the conductivity varies widelyamong liquids, the controller is adjustable for sensitivity in differentliquids. Consult factory for details on specific liquids.

While a conductivity switch and a float-type switch provide the samefunctions, the advantage of no moving parts is that the conductivityswitch can be used in several environments that would cause a floatto stick or to not operate at all. These would include semisolid liquidslike food industry and industrial slurries or heavy-bodied liquids likewastewater. With no moving parts, switch operation of the M3784 isnot interrupted.

Only an extremely small amount of current is necessary for the unit toperform. As with any device, a properly installed and grounded systemposes no electrical hazard.

Model No.

M3784-12M3784-110M3784-220

M3784-2

Voltage

12 AC110 AC220 AC

no controller

For installation instructions,please visit

www.madisonco.com

CD

Specifications



CD-4 © Copyright Madison Company – 5/08


Sensing Head

Electrodes

Materials

Mounting

Pressure

Temperature

Other

24” length, standard72” length, maximum (with two extensions)May be cut to custom length

316 Stainless Steel electrodesPolypropylene all food-grade materials

1” NPT, standardBulkhead or snap-in flange optional

30 PSIG, maximum

100˚C, maximum (212˚F)

Integral junction box with IP68 (NEMA 6)protection 10’ cable for attaching sensinghead to controller

Controller

Model No.

Sensing Inputs

Sensing Voltage

Sensing Resistance

Input

Output

Mounting

R2-120 (Refer to Accessories sectionfor more information)

3 maximum (High, Low, Common)

12 VAC

Adjustable to 100,000 Ohms

120 VAC 50/60 Hz

Contact rating 5 Amps resistive @ 240 VAC, form SPDT

Socket mount, socket is DIN rail-mountable

Options– Electrode extensions, two each, 24” length, with coupling nuts and electrode spreader– Single electrode fitting with 24” electrode

Upper Probe

Lower Probe

CommonProbe

1

4 NC

3 NO

7

2

Switched Contacts

120 VAC Input

5 6 8

• 120 VAC is connected between pins 2 and 7

• Wire the Common Probe to pin 5• Wire the Lower Probe to pin 6• Wire the Upper Probe to pin 8

Pins 1-3 and 1-4 are isolated switchcontacts to switch power to a valve or pump.

For single level control, connect probe to pin 8 and use pin 5 as the return.

R2 Conductivity Configuration

R2

(1-3 or 1-4)

5A @ 220 VAC10A @120 VAC10A @ 30 VDC

Output Contact Rating

Conductivity Switch KitM3784-110MK

CD

Madison Company can engineer custom-designed conductivity switches to meet your application needs.Please provide the information requested below so that our Engineering Department can determine theappropriate design for your application.


Address:



M Series Specification SheetCustom-Designed Conductivity Switches



Male Thread: 1/4” NPT – One probe max. (plastic only)

3/8” NPT – One probe max. (plastic or metal)

1/2” NPT – Two probe max. (plastic or metal)

3/4” NPT – Three probe max. (plastic or metal)

1” NPT – Four probe max. (plastic or metal)

Flange: Specify size: (plastic or metal)

PRO

CESS

ING

CO

ND

ITIO

NS

CON

NEC

TIO

NS

Maximum Temperature:

Minimum Temperature:

Maximum Pressure:

Fluid:

Special Conditions:

Quantity:

Controller (specify type):

ADD

ITIO

NAL

REQ

UIR

EMEN

TS

MO

UN

TIN

G C

ON

FIG

UR

ATIO

NS

Standard insulated stainless steel screw lock terminal

Wire length: Gauge:

Cable (specify):

Other (specify):

LEN

GTH

S

Required Lengths (refer to diagram at right):

L1

L2

L3

L4

L1

L2

L3

L4

Please use the space below to list any additional requirements, such

as junction box, etc.

CD

PR SeriesHydrostatic Pressure Level Sensors

Submersiblehydrostaticpressure sensors;tube filter shownat left (P/N 099-00088,sold separately)

The MAD4500 and MAD4510 submersible pressure sensorsare approved to UL/cUL913 (CSA 157) Class I Div 1,Groups C and D for use in intrinsically safe areas with an approved barrier. For pressure ranges from 0-2.5 PSIGto 0-100 PSIG that require a wide range of mediacompatibility, the submersible series is an excellent solutionfor level monitoring in both indoor and outdoor applications.

With their rugged construction and materials, these pressure sensors offer a wide range of compatibility. Typicalapplications include: ground water level depth measurement;earthen and concrete dams; liquid tanks; gasoline and dieselfuel tanks; irrigation; and waste water canals.

Madison’s hydrostatic line of liquid leve l sensors utilizes aunique diaphragm technology and solid state design thatprovides high accuracy, reliability and versatility in variousvessel configurations with liquid specific gravity pressure up to 100 PSIG. Should these standard models not matchyour application, our PR Series Specification Worksheet can be completed and submitted for engineering evaluationand quotation.

Features

• High-strength stainless steel construction

• One-piece construction – no internal O-ring

• Wide operating temperature range

• Ranges up to 100 PSI with 4-20 mA or 0-5 V output; tank depths of 3’ to 250’

• Unparalleled price and performance

• Rugged design is suitable for harsh environments

• Compatible with a wide range of liquids

• EMI/RFI protection

• Easy to install


© Copyright Madison Company – 6/09 PS-1

PS

MAD4500 & MAD4510 Specifications



PS-2 © Copyright Madison Company – 9/09

Output 4-20 mA 1-5 VDCExcitation 10-28 VDC 10-28 VDC

Output Impedance > 10k Ohms < 100 Ohms, nominal

Current Consumption 20 mA, typical < 10 mA

Bandwidth (-3 dB) DC to 250 Hz DC to 1 kHz

Output Noise N/A < 2 mV RMS

Zero Offset < ±1% of FS < ±1% of FS

Span Tolerance < ±2% of FS < ±1.5% of FS

Output Load 0-800 Ohms @ 10-28 VDC 10k Ohms, min.

Reverse Polarity Protection Yes Yes

Jacketed cable,customer specified length,0.25” max. dia.

Nose cone(optional)

0.88” (22.4)

4.78” (121.4)

Jacketed cable,customer specified length,0.25” max. dia.

Nose cone(optional)

1.00” (25.4)

5.62” (142.7)

M

MAD4500 MAD4510

MAD4510 L 00005 P 4 X 1 000

Series Type

Configuration InterfaceL = Cone

Pressure RangeInsert pressure range from chart

Pressure UnitH= Inches H20P = PSI

Outputs3 = 1-5 VDC4 = 4-20 mA

ElectricalX = Optional Length (see Options below)

Wetted Materials1 = 316L, 304, Nickel Plated Brass, Hytrel

Options: Cable Lengths:003 = 100 Ft. (30.5m) Special Order050 = 150 Ft. (45.7m) Special Order065 = 50 Ft. (15.2m) Standard Length074 = 25 Ft. (7.6m) Standard Length

Note: Sensors are vented to atmosphere through surface end of cables.In high-humidity areas, a Hydrophobic Filter for the end of the vent tube (P/N 099-P00088) is recommended.


Intrinsically safe installations require approved barriers. Refer to the PR Seriesarea of the Reference section on www.madisonco.com for further details.

Performance @ 25˚C (77˚F):Accuracy* – < ± 0.25% BFSLStability (1 year) – ±0.25% FS, typicalOver-Range Protection – 2X Rated PressureBurst Pressure – 5X or 1,250 PSI (whichever is less)Pressure Cycles – > 50 Million* Accuracy includes non-linearity, hysteresis & non-repeatability

Environmental:Operating Temperature – -40˚F to 185˚F (-40˚C to 85˚C)Storage Temperature – -40˚F to 212˚F (-40˚C to 100˚C)Compensated Range – 30˚F to 130˚F (0˚C to 55˚C)TC Zero – < ±1.5% of FSTC Span – < ±1.5% of FSShock – 100G, 11 msec, 1/2 sineVibration – 10G peak, 20 to 2000 HzEMI/RFI Protection – YesRating – IP-68Cable Length (recommended max.) – 1-5 V < 35’; 4-20 mA, 500’

Electrical:PS

Pressure Ranges:MAD4500

Gage PSIG BAR Pressure Range Code

0-100 6.89 00100

0-50 3.45 00050

0-30 2.07 00030

0-20 1.38 00020

MAD4510

Gage PSIG BAR Pressure Range Code

0-15 1.03 00015

0-10 0.69 00010

0-7.5 0.52 00208**

0-5 0.35 00005

0-2.5 0.17 00069

0-1† 0.068 00001

Typical ranges. All ranges between 0-15 PSI and 0-100 PSI are available. Please consult factory.** Must be ordered in inches of H2O.† Only available with 1-5 VDC output.

PR SeriesHydrostatic Pressure LevelSensors for Turbulent Tanks

MAD4520-x hydrostatic pressure level sensorfor turbulent tanks

The MAD4520 Flush Submersible Series is thelatest addition to Madison’s line of hydrostaticpressure level sensors. It is designed formonitoring viscous material and/or turbulentconditions within a vessel. This cost-effectivesensor is approved to UL/cUL913 Class 1Division 1 IS, Groups C and D, with anapproved barrier. There are four pressureranges available, and the cage design allowsfor proper media flow while keeping the sensorat the bottom of the vessel or well.

The 316L and PVDF construction will withstandthe toughest environments. The MAD4520 isideal for sewage lift stations, food tanks andviscous media applications. Other typical usesinclude: grease and lubrication tanks; drillingmud pits; vegetable and animal oil tanks; andstorm and industrial holding tanks.

Features

• Compatible with a wide range of chemicals

• Suitable for waste, salt, brackish or fresh water systems and a wide range of chemicals

• EMI/RFI protection

• Reverse polarity protection

• Compact, non-clogging design



PS

MAD4520 Specifications





Performance @ 25˚C (77˚F):Accuracy* – < ±0.25% BFSLStability (1 year) – ±0.25% of FS, typicalOver-Range Protection – 2X rated pressureBurst Pressure – 5X or 1,250 PSI (whichever is less)Pressure Cycles – > 50 Million* Accuracy includes non-linearity, hysteresis and non-repeatability

Environmental:Operating Temperature – -40˚F to 185˚F (-40˚C to 85˚C)Storage Temperature – -40˚F to 212˚F (-40˚C to 100˚C)Temperature Compensated Range – 30˚F to 130˚F (0˚C to 55˚C)TC Zero – < ±1.5% of FSTC Span – < ±1.5% of FSShock – 100G, 11 msec, 1/2 sineVibration – 10G peak, 20 to 2000 HzEMI/RFI Protection – YesRating – IP-68Wetted Materials – Kynar and 316L stainless steelCable – PVDF jacketed

Electrical:Output – 4-20 mAExcitation – 10-28 VDCOutput Impedence – > 10k OhmsCurrent Consumption – 20 mA, typicalBandwidth – (-3 dB): DC to 250 HzZero Offset – < ±1% of FSSpan Tolerance – ±2% of FSOutput Load – 0-800 Ohms @ 10-28 VDCReverse Polarity Protection – YesLightning and Surge Protection – Yes

Approvals:UL and cUL913 listed, Class 1 Div 1 IS, Groups C and D with approved barrier

Pressure Ranges:0-150-100-7.5**0-5** Must be ordered in inches of H2O.Note: All ranges between 0-100 PSI are available. Please consult factory for specific needs.

Intrinsically safe installations require approvedbarriers. Refer to the PR Series area of the Reference section onwww.madisonco.com for further details.

Jacketed cable,customer-specified length,0.25” max. OD

Ø 1.00”(25.4)

Ø 3.00”(76.2)

5.54”(140.7)

2.25”(57.2)

† Wiring: 24 AWG, 4-conductorKynar (PVDF-jacketed) cable withdrain wire and breather tube;Standard lengths: 25’, 50’ and 75’

†

PS

PR SeriesMadison-Omni® Pressure Sensors

Madison-Omni-P and Omni-P1pressure sensors with integrated

programmable display

The Madison-Omni-P and Omni-P1 pressure sensormodels offer the same standard Madison-Omniprogrammable display as found on our level, ultrasonic andtemperature Madison-Omni switch models.

These pressure sensors consist of a primary sensor and the integrated signal processing electronics. Theprimary sensor is available in two different technologiesand ranges.

The Omni-P features a stainless steel diaphragm that transmits pressure data via an oil-filled cavity onto a mono-silicone substrate, utilizing anaccommodated piezo-resistive measuring bridge andthin-film poly-silicone technology. With a flush membrane,this sensor is suitable for applications with sticky fluid(such as glue components) or other critical liquids.

The Omni-P1 features an economical monolithic ceramicmeasuring cell with an accommodated resistive bridgeand thick-film technology. The integrated signalprocessing microcontroller evaluates the signal andoperates an analog output beside the display. Since thecomplete upper part of the housing can be rotated, thecable connection can be easily aligned as needed.

Features

• Analog output, two switching outputs

• Clear, easy-to-read backlit LCD display

• Changeable display units

• Designed for industrial applications



PS

Madison-Omni-P & Omni-P1 Specifications





Madison-Omni-P Madison-Omni-P1

Relative PressureRanges

Range Overload Range Burst

PSIG BAR PSIG BAR PSIG BAR PSIG BAR

0-14.50-36.30-87.0

0-145.00-362.60-870.2

0-1450.40-3626.00-5801.5

0-10-2.50-6

0-100-250-60

0-1000-2500-400

58.0145.0348.1580.2

1450.43480.95801.58702.38702.3

4102440100240400600600

0-14.50-29.00-72.50-87.00-290.10-725.20-1450.40-2900.8*0-5801.5*

0-10-20-50-100-200-500-1000-200*0-400*

58.087.0217.6580.2870.22175.64061.15801.515229.0

46

154060

150280400

1050

Options – Additional measurement ranges – Absolute pressure metering (low limit 10 mbar abs.)

* For gas applications, by request only

Accuracy ±1% v. FS, above 60˚C 0.02% / ˚C ±1% FS; 0.05% / ˚C below 0˚C and above 60˚C

Reproductability ±0.5% FS ±0.1% FS

Dynamic Measurement and output cycle 32 ms; display cycle 0.5 sec.

Operating Temp. -4˚F to 158˚F (-20˚C to 70˚C); 248˚F (120˚C) max. with swan neck

Storage Temp. -4˚F to 176˚F (-20˚C to 80˚C)

Supply Voltage 18-30 VDC

Power Consumption < 1 W

Analog Output 4(0)-20mA, 2(0)-10 V via resistor of 500 Ohm to GND (impedance of receiver > 100 kOhm)

Switching Outputs (S1 and S2)

PNP or NPN (push-pull), programmable as minimum- or maximum-switchMax. 300 mA output current (sum of both outputs), short-circuit proof, polarity safe

Hysteresis Adjustable, direction dependent on setting min. or max.

Display Graphical LCD display with extended temperature range -4˚F to 158˚F (-20˚C to 70˚C), 32x16 pixels, backlitLED-indicator flashing with additional message on display

Connection Process connection is only available with parallel threads (not NPT) and at locking plugs M12x1, 5 pole

Protection Class IP67

Materials – Media Contact Stainless steel 1.4301 Stainless steel 1.4571, ceramic Al2O3, Viton

Materials – Electronic Housing

Stainless steel 1.4305 (housing), hardened mineral glass, POM (programming ring), cobalt-samarium (magnet)

ø1.

77”

(45)

2.76” (70)

ø1.

38”

(35

)

0.55” (14)

G1/2A

SW 2727 AF

Locking plugs M12x1, 5-pole (accessory)*

5.51” (140)

An optional swan neck betweenthe electronic head and thesensor offers easy adjustmentand readout. This optionadditionally ensures the thermaldecoupling of both units.

18 to 30 VDC

4(0)-20 mA

OmniSensor

white

brown

gray

black

bluez

z

Z = load

1

2

3

4

5

z

or NPNExample: PNP

0 V

S1

S2

Terminal Assignment

Before carrying out the electrical installation,make sure that the supply voltage correspondsto the data provided. The switching outputs canbe connected as NPN or PNP without anyhardware or software settings (push-pull driver).A shielded cable (< 30m) and supply lines (< 10m) are recommended.

PS



PR SeriesMadison-Omni® Differential Pressure Transmitter

Madison-Omni-DP1 differentialpressure transmitter with integrated

programmable display

The Madison-Omni-DP1 is a differential pressuretransmitter that incorporates a programmable display. Thisis the same display that is featured on our Madison-Omnicontinuous level switches, ultrasonic sensors andtemperature sensors.

The Madison-Omni-DP1 has two separate ceramic sensorsembedded in a thick-film technology. The bridge signals aretemperature compensated. These PSIG measurements arecompaired and processed as a differential pressure outputsignal. The wetted materials are stainless steel, Al2O3

ceramic and Viton O-rings, making this model suitable formost liquid applications.

Features

• Suitable for use in most liquid applications

• Can also be used for high differential pressures

• High-quality materials offer high chemical resistance

• Display head can be turned for alignment after installation

• Analog output, frequency output, switching outputs

• Clear, easy-to-read backlit LCD display

• Changeable display units

• Designed for industrial applications

• Small and compact

• Quick and easy installation



PS

Relative Pressure Operating Ranges / Overload Limits / Burst Pressure:

Differential Pressure Range: Customer-specified (min.: 10% of operating range; max.: operating range)Accuracy – ± 1% FSDOperating Temperature – 32˚F to 158˚F (0˚C to 70˚C); 185˚F (85˚C) max. with swan neckStorage Temperature – -4˚F to 176˚F (-20˚C to 80˚C)Supply Voltage – 18-30 VDCPower Consumption – < 1 WSwitching Values (S1 and S2) – PNP or NPN selectable; 300 mA load in sum max.; programmable as min.

or max. value; short-circuit proof; reverse-polarity proofHysteresis – Adjustable; position of hysteresis depends on min. or max.Display – Graphical back-lit LCD display with extended temperature range (-4˚F to 158˚F / -20˚C to 70˚C);

32x16 pixels; shows value and units; LED signaling lamp with simultaneous message in displayConnection – At locking plug M12x1, 5-pole*Protection Class – IP67Materials: Medium Contact – Stainless steel 1.4571, Viton, Ceramic Al2O3

Materials: Electronic Housing – Stainless steel 1.4305 (housing); tempered mineral glass (glass); cobalt samarium (magnet); POM (ring)

Madison-Omni-DP1 Specifications





ø1.77” (45)

3.98

” (1

01)

2.09

” (5

3)

0.79

” (2

0)

Locking plugs M12x1, 5-pole (accessory)*

G 1

/80.83”

(21)

1.97” (50)

1.97

” (5

0)

5.51” (140)

An optional swan neck betweenthe electronic head and thesensor offers easy adjustmentand readout. This optionadditionally ensures the thermaldecoupling of both units.

18 to 30 VDC

4(0)-20 mA

OmniSensor

white

brown

gray

black

bluez

z

Z = load

1

2

3

4

5

z

or NPNExample: PNP

0 V

S1

S2

Terminal Assignment

The switch points are changing to PNP or NPN,depending on your interface, automatically.

Range Overload Burst

PSIG BAR PSIG BAR PSIG BAR

0-14.50-29.00-72.50-87.00-290.10-725.20-1450.40-2900.8

0-10-20-50-100-200-500-1000-200

43.587.0

217.6435.1870.2

2175.62900.84061.1

36

153060

150200400

58.0116.0290.1580.21015.32610.75076.38702.3

48204070180350600

PS

* Madison-Omni® Sensor Accessories (sold separately)029-P00001 – Shielded cable; 2m length with straight plug029-P00002 – Shielded cable; 5m length with straight plug029-P00003 – Shielded cable; 10m length with straight plug029-P00004 – Shielded cable; 2m length with 90˚ angled plug029-P00005 – Shielded cable; 5m length with 90˚ angled plug029-P00006 – Shielded cable; 10m length with 90˚ angled plug

Madison Company can engineer hydrostatic pressure sensor designs for liquid level applications. To request this, your specific requirements must be defined below to help us determine both the technical andeconomic requirements for your application.


ENVI

RO

NM

ENT

ELEC

TRIC

AL

DES

IGN


Address:


Application: Indoor Outdoor Mobile Hazardous Location Other:

Feet to PSI: (1 ft. of water = 12” H2O = 0.4335 PSI; multiply 0.4335 by the span to be measured within your vessel)

PSI Range: 0-100 0-50 0-30 0-20 0-15 0-10 0-7.5 0-5 0-2.5 Other:

Pressure Fitting: 1/4” NPT Male 1/8” NPT Male 1/2” NPT Male 1/4” NPT Female 1/8” NPT Female

7/16-20 UNF Male 7/16-20 UNF Female 9/16-18 UNF Male 1/4” BSP Male

F250C Female Autoclave

Pressure Range: Type: PSIG PSIS Bar Inches H2O kg/cm2

Vibration / Shock: Low High Humidity: Low High Accuracy:

Media:

Ambient Temperature – MIN: MAX: Media Temperature – MIN: MAX:

Submersible Transducer? Yes – Cable Length: Type: Jacket: Hytrel Kynar Other:

Turbulent Media? Yes No If yes, added weight required for stability:

Wetted Material: 17/4 PH 316 SS 304SS Inconel 718 Titanium Hastaloy Plated Brass

Other:

Agency Approvals (i.e. UL, NSF):

Output: 0-50 mV 0.5-4.5 VDC 1-5 VDC 4-20 mA 1-6 V 0-5 V, 3-wire 0-5 V, 4-wire

1-6 kHz Other:

Supply Voltage: 5 VDC 10 VDC 10-30 VDC

Electrical Connection: Cable, 2 ft Cable, 4 ft Cable, 6 ft Cable, 10 ft Bendix 6 pin

2 ft with conduit 4 ft with conduit 6 ft with conduit 10 ft with conduit

2 ft 18 AWE wires 4 ft 18 AWE wires 2 meter AWE wires

Packard Metripack 150 Other:


PR Series Specification SheetLevel Pressure Sensor


Continuedon Back

PS

PRO

JECT

NO

TES

Unit Volume (annual; minimum qty. may apply): Prototype Quantity Required:

Packaging/Labeling:

Pricing Target:



PR Series Specification SheetLevel Pressure Sensor




PS

Madison Company offers an extensive line of standard optical single-point liquid level detectionswitches for use in non-coating liquids.

These compact optical switches incorporate a phototransistor that provides a digital outputindicating the presence or absence of liquid. The sensor tip houses the phototransistor in a formthat provides highly reliable and repeatable performance in compact designs.

Housings are offered in both metal and plastic with various mounting configurations. When youchoose from the extensive list of our standard part numbers, Madison can provide you with a verycost-effective solution to those level indication applications where high reliability, ease ofinstallation and maintenance-free performance are desired.

At the end of this product section, you will find the O Series Specification Sheet. This sheet can beused to define your unique optical switch requirements and application needs. By sending this toMadison Company, a custom-engineered design may be quoted.

• Accurate, repeatable switching point detection with no moving parts

• Can be mounted with limited space required

• Easy to install

• Reverse polarity, over voltage, short circuit and transient protected

Optical Liquid LevelDetection Switches

© Copyright Madison Company – 5/08 OP-1



www.madisonco.com

OP

Standard Optical Switches


All specifications are subject to change without notice.OP-2 © Copyright Madison Company – 4/07

O Series Optical Liquid Level Switches

MODELDWG.NO. OPERATION MODE MOUNTING

HOUSINGMATL.

OPERATINGTEMPERATURE

SUPPLYVOLTAGE TERMINATION TYPE

Standard LLE Series Optical Switches

OPT4290-1 O-1 Digital output; high in air From outside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 250mm




OPT4292-1 O-3 Digital output; high in air From inside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 250mm




OPT4294-1 O-5 Digital output; high in air From outside Brass a -25˚C to 80˚C 5 to 12 VDC Lead wires, 250mm

Standard High-Reliability POS Series Optical Switches†

OPT4295-1 O-6 NPN N.O.; high in air From outside SS -25˚C to 100˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4295-2 O-6 NPN N.C.; low in air From outside SS -25˚C to 100˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4295-3 O-6 PNP N.O.; low in air From outside SS -25˚C to 100˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4295-4 O-6 PNP N.C.; high in air From outside SS -25˚C to 100˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4296-1 O-7 NPN N.O.; high in air From outside SS -25˚C to 100˚C* 12 to 28 VDC M12 Connector

OPT4296-2 O-7 NPN N.C.; low in air From outside SS -25˚C to 100˚C* 12 to 28 VDC M12 Connector

OPT4296-3 O-7 PNP N.O.; low in air From outside SS -25˚C to 100˚C* 12 to 28 VDC M12 Connector

OPT4296-4 O-7 PNP N.C.; high in air From outside SS -25˚C to 100˚C* 12 to 28 VDC M12 Connector

OPT4297-1 O-8 NPN N.O.; high in air From outside SS -25˚C to 140˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4297-2 O-8 NPN N.C.; low in air From outside SS -25˚C to 140˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4297-3 O-8 PNP N.O.; low in air From outside SS -25˚C to 140˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4297-4 O-8 PNP N.C.; high in air From outside SS -25˚C to 140˚C* 12 to 28 VDC Cable PUR 3x0.25mm sq; 2m long

OPT4298-1 O-9 NPN N.O.; high in air From outside SS -25˚C to 140˚C* 12 to 28 VDC M12 Connector

OPT4298-2 O-9 NPN N.C.; low in air From outside SS -25˚C to 140˚C* 12 to 28 VDC M12 Connector

OPT4298-3 O-9 PNP N.O.; low in air From outside SS -25˚C to 140˚C* 12 to 28 VDC M12 Connector

OPT4298-4 O-9 PNP N.C.; high in air From outside SS -25˚C to 140˚C* 12 to 28 VDC M12 Connector

Standard High-Performance LLHP Series Optical Switches

OPT4299-1 O-10 NPN N.O.; high in air From outside PSU -25˚C to 80˚C 10 to 40 VDC Lead wires, 200mm

OPT4299-2 O-10 NPN N.C.; low in air From outside PSU -25˚C to 80˚C 10 to 40 VDC Lead wires, 200mm

OPT4299-3 O-10 PNP N.O.; low in air From outside PSU -25˚C to 80˚C 10 to 40 VDC Lead wires, 200mm

OPT4299-4 O-10 PNP N.C.; high in air From outside PSU -25˚C to 80˚C 10 to 40 VDC Lead wires, 200mm

OPT4300-1 O-11 Digital output; high in air From outside SS -25˚C to 80˚C 5 to 12 VDC Lead wires, 150mm


OPT4300-3 O-11 Push-pull; high in air From outside SS -25˚C to 80˚C 10 to 40 VDC Cable, 1m


OPT4300-5 O-11 Digital output; high in air From outside Brass -25˚C to 80˚C 5 to 12 VDC Lead wires, 150mm


OPT4300-7 O-11 Push-pull; high in air From outside Brass -25˚C to 80˚C 10 to 40 VDC Cable, 1m










Repeatability of all LLE, POS and LLHP Series Optical Switches is ±1mm. Hysteresis is 1mm (dependent on liquid). PSU = PolysulfoneAll LLE, POS and LLHP Series Optical Switches have reverse polarity protection. SS = Stainless Steel† POS Series is *not* available with NPT threads. POS Series Switches are CE approved.* Sensing tip only a Nickel-plated brass

OP

© Copyright Madison Company – 7/10 OP-3All specifications are subject to change without notice.


Standard Optical Switches (continued)

MODELDWG.NO. OPERATION MODE MOUNTING

HOUSINGMATL.

OPERATINGTEMPERATURE

SUPPLYVOLTAGE TERMINATION TYPE

Standard LLN Series Optical Switches

OPT4301-1 O-12 NPN N.O.; high in air From outside SS -40˚C to 125˚C 10 to 40 VDC M12 Connector, 3-pin

OPT4301-2 O-12 NPN N.C.; low in air From outside SS -40˚C to 125˚C 10 to 40 VDC M12 Connector, 3-pin

Standard LLC Series Optical Switches

OPT4303-3* O-14 Digital output; high in air From inside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm

OPT4303-5* O-14 Digital output; low in air From inside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm

OPT4305-3* O-16 Digital output; high in air From outside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm

OPT4305-5* O-16 Digital output; low in air From outside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm

OPT4305-9* O-16 Digital output; high in air From outside PSU -25˚C to 80˚C 24 VDC Lead wires, 200mm

OPT4305-11* O-16 Digital output; low in air From outside PSU -25˚C to 80˚C 24 VDC Lead wires, 200mm

OPT4306-3* O-17 Digital output; high in air From outside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm

OPT4306-5* O-17 Digital output; low in air From outside PSU -25˚C to 80˚C 5 to 12 VDC Lead wires, 200mm


Repeatability of all LLN and LLC Series Optical Switches is ±1mm. Hysteresis is 1mm (dependent on liquid). PSU = PolysulfoneAll LLN Series Optical Switches have reverse polarity protection. They are *not* available with NPT threads. SS = Stainless Steel* Model has reverse polarity protection

OP


All specifications are subject to change without notice. OP-4 © Copyright Madison Company – 10/06


0.49”(12.4)

0.19”(4.7)

6.1” - 8.1”(155 - 205)

0.40”(10.3)

0.61”(15.5)

M12x1

R.14(3.5)

DOME

0.75”(19.0)HEX

0.75”(19.0)HEX

R.14(3.5)

CAPERUZA

M12x1

0.76”(19.4)

0.49”(12.4)

0.19”(4.7)

0.89”(22.5)

6.1” - 8.1”(155 - 205)

0.75”(19.0)HEX

0.69”(17.5)

R.14(3.5)

DOME

M12x1

6.1” - 8.1”(155 - 205)

0.41”(10.3)

0.51”(13.0)

0.57”(14.4)

LLE Series

DWG No. O-2

ø.48”(12.2)

R.14(3.5)

DOME

0.63”(16.1)

0.51”(13.0)

0.42”(10.7)

0.35”(8.9)

6.1” - 8.1”(155 - 205)

ø.39”+.004-.000

10.0+.1- 0( )

6.1” - 8.1”(155 - 205)

0.94”(24.0)HEX

1.81” MAX(46.0)

R.14(3.5)

DOME

1/2 BSPT

2.30”(58.5)

1.36”(34.5)

0.65”(16.5)

0.17”(4.2)

DWG No. O-4

DWG No. O-3

0.94”(24.0)HEX

R.22(5.5)

DOMEG 1/2

3.07” MAX(78.0)

2.64”(67.0)

1.77”(45.0)

76.8” - 80.7”(1950 - 2050)

LED

0.94”(24.0)HEX

R.22(5.5)

CAPERUZA

G 1/2

LED

M12x1CONECTORELÉCTRICO

3.07” MAX(78.0)

2.64”(67.0)

1.77”(45.0)

0.94”(24.0)HEX

R.22(5.5)

DOME

G 1/2

LED

5.43” MAX(138.0)

5.04”(128.0)

4.17”(106.0)

76.8” - 80.7”(1950 - 2050)

DWG No. O-6

DWG No. O-7

DWG No. O-8

0.94”(24.0)HEX

R.22(5.5)

DOME

G 1/2

5.43” MAX(138.0)

5.04”(128.0)

4.17”(106.0)

LED

M12x1ELECTRICALCONNECTOR

DWG No. O-9

POS Series

0.75”(19.0)HEX

R.16(4.0)

DOME

M12x1

1.17”(29.7)

0.90”(22.8)

0.59”(15.0)

1.33”(33.7)

6.9” - 8.9”(175 - 225)

DWG No. O-10

0.94”(24.0)HEX

R.16(4.0)

DOME

3/8 BSPor 1/2” NPT

2.27”(57.6)

2.11”(53.5)

1.50”(38.0)

0.12”(3.0)

5.0” - 7.0”(127 - 177.8)

DWG No. O-11

0.94”(24.0)HEX

R.14(3.5)

DOME3/8 BSP

3.54” MAX(90.0)

3.39”(86.0)

2.56”(65.0)

1.77”(45.0)

1.22”(31.0)

0.35”(9.0)

M12x1ELECTRICALCONNECTOR

DWG No. O-12

LLN Series

DWG No. O-1

DWG No. O-5

LLHP Series

ø.40”(10.2)

R.16(4.0)

DOME

M8x1

0.89”(22.7)

0.74”(18.7)

0.66”(16.7)

6.9” - 8.9”(175 - 225)

DWGNo. O-13

ø.47”(12.0)

R.16(4.0)

DOME

M10x1

0.89”(22.7)

0.74”(18.7)

0.66”(16.7)

6.9” - 8.9”(175 - 225) DWG

No. O-14

ø.47”(12.0)

R.12(3.1)

DOME10mmPRESS FIT

0.74”(18.7)

0.58”(14.7)

0.50”(12.7)

6.9” - 8.9”(175 - 225) DWG

No. O-15

0.75”(19.0)HEX

R.16(4.0)

DOME

M12x1

1.33”(33.7)

1.17”(29.7)

0.90”(22.8)

0.59”(15.0)

6.9” - 8.9”(175 - 225)

0.75”(19.0)HEX

0.92”(23.4)

0.76”(19.4)

0.49”(12.5)

0.19”(4.7)

R.16(4.0)

DOME

M12x1

6.9” - 8.9”(175 - 225)

DWGNo. O-17

LLC Series

DWGNo. O-16

OP

O SeriesOptical Liquid Level Switches

Madison’s optical liquid level switches are ideal foruse in non-coating materials

Madison Company offers an extensive lineof standard optical point level detectionswitches for use in non-coating liquids.

These compact optical switchesincorporate a phototransistor thatprovides a digital output indicating the presence or absence of liquid. Thesensor tip houses the phototransistor.The refractive index is changed whencovered by liquid, thus indicating the level.

There are several wetted materials andoperating ranges to choose from withinMadison’s optical switch series, includinghigh-temperature performance options.

As with all Madison products, engineeredconfigurations for your uniquerequirements can be quoted.

Features

• Compact size

• Solid-state technology with digital output

• Robust design

• Wire and supply current options available

• Digital (TTL output)

• Various voltage outputs available

• 4-wire option offers sensitivity adjustment



OP

Optical Switch Series



OP-6 © Copyright Madison Company – 5/08


LLE SeriesBasic range of polysulfone optical sensors ideal for commercial and industrial applications:

• -40˚F to 257˚F (-40˚C to 125˚C)• Solid-state technology, micro-processor compatible• Reverse polarity, over voltage, short circuit and transient protected

POS SeriesHigh-performance, high-reliability sensors ideal for high or low temperatures and suitable for aggressive environments, with a wide variety of optional terminations:

• Shock resistant• Chemical resistant• Optional high switching currents• -13˚F to 284˚F (-25˚C to 140˚C)• Additional power sinking• Stainless steel housing• CE approved

LLN SeriesDesigned for harsh environments with extremes in temperature, pressure, vibration and shock. Sealed to meet IP67 in a stainless steel housing:

• Phototransistor trigger• Digital output, solid-state technology• Output: TTL 200 mA, sinking• Fast response

LLHP SeriesUtilizes the basic LLE or LLC series sensor with enhanced electronic capability to switch at higherpower or operate at higher temperatures:

• Polysulfone or metal housing• Optoschmitt trigger with digital output, compatible with TTL/CMOS

LLC SeriesA low-cost family of sensors offering high reliability. Ideal for medical, appliance and commercial applications:

• Compact size• Voltage output• Pre-wired

OP

Madison Company can engineer single-point optical switch designs for liquid level applications. To requestthis, your specific specifications must to be defined below to help us determine both the technical andeconomic requirements for your application.


ENVI

RO

NM

ENT

ELEC

TRIC

ALPR

OJE

CTN

OTE

S

DES

IGN


Address:



Fluid: Shock: Pressure:

Temp. Range: Vibration:

Humidity Range: Immersion:

Misc. Conditions (vibration, food contact, hazardous location, turbulence, solids, approvals [i.e. UL, NSF] etc.):

Sensor Inputs: Supply Voltage: Current Consumption:

Input Protection: Trigger Signal:

Sensor Outputs: Signal Type: Voltage Swing:

Output Current: Connecting Load:

Termination Type:

Other Electrical Considerations:

Unit Volume (annual):

Packaging/Labeling:

Pricing Target:




O Series Specification SheetOptical Liquid Level Switch


OP

M SeriesUltra-Low-Level Switch Designs

Features

• Lowest reed switch liquid level indication available

• Requires 0.19” to 0.31” of liquid to become buoyant

• Efficient use of tank capacity

• Can provide early alarm


© Copyright Madison Company – 4/07 FL-1

When very low liquid levels (0.19” to 0.31”) need to be monitored, a reed switch device can be used. Madison Company’s array of ultra-low-level floats are offered in several standard levelswitch designs.

The liquid level switch configuration can featureplastic or metal stems for the ultra-low-level floatsto ride on. In the case of multi-level switches, thelow level indication can be as much as 0.57” lowerthan a typical barrel float design.

Ultra-low-level floats are available in Kynar forhigh-purity applications, PBT or Buna-N forhydrocarbon liquids and FDA-approvedpolypropylene for food applications and general-purpose liquids.

With this unique ultra-low-level monitoring ability,these switches make more efficient use of high-cost liquids, and an early indication of liquidpresence can be attained.

Madison’s Ultra-Low-Level Switches areavailable in Kynar,PBT, Buna-N,Polypropylene andPolysulfone and canmonitor liquid levelsas low as 0.19”.

FL

Standard Ultra-Low-Level Switch Floats



FL-2 © Copyright Madison Company – 5/08


Kynar (Model Number: 200-M04176-K)

Maximum Temperature: 105˚CMaximum Pressure: 25 PSIGFloat Specific Gravity: 0.69Can be used on Madison Company Liquid Level Switches: M9000 and M9002-xxxx*

* Only available for bottom level of Multi-Point Switches M9002-xxxx

PBT (Model Number: 200-M04176-PBT)

Maximum Temperature: 105˚CMaximum Pressure: 25 PSIGFloat Specific Gravity: 0.55Can be used on Madison Liquid Level Switches: M4008, M4400, M4402-xxxx*, M4500, M4502-xxxx* and M7000

* Only available for bottom level of Multi-Point Switches M4402-xxxx and M4502-xxxx

Buna-N (Model Numbers: 200-M03544-NC or 200-M03544-NO)

Maximum Temperature: 105˚CMaximum Pressure: 25 PSIGFloat Specific Gravity: 0.44Can be used on Madison Liquid Level Switches: M4008, M4400, M4402-xxxx*, M4500, M4502-xxxx* and M7000


Polypropylene (Model Number: 200-M04176-PP)

Maximum Temperature: 105˚CMaximum Pressure: 25 PSIGFloat Specific Gravity: 0.42Can be used on Madison Liquid Level Switches: M8000, M8020, M8040, M8080-xxxx, M8002-xxxx* and M8042-xxxx*


Polysulfone (Model Number: 200-M04176-PS)

Maximum Temperature: 105˚CMaximum Pressure: 25 PSIGFloat Specific Gravity: 0.53Can be used on Madison Liquid Level Switches: M8000, M8020, M8040, M8042-xxxx* and M8080-xxxx** Only available for bottom level of Multi-Point Switch M8042-xxxx and M8080-xxxx

Standard Ultra-Low-Level Float Dimensions:Diameter: 1.875” max. Height: 1.156” for any Miniature Stem

FL


© Copyright Madison Company – 3/08 FL-3All specifications are subject to change without notice.

Standard FloatsAll measurements in parentheses are in millimeters.

Stainless Steel

1.50" (38.1) O.D. max.

2"(50.8)

0.59" I.D.(14.99)

2.13" (54.1) O.D. max.

2"(50.8)

0.595" I.D.(15.11)

0.555" (14.10) I.D.

1.31"(33.27)

1.54" O.D.(39.1) max. 2.05" (52.1) O.D. max.

0.555" I.D.(14.1)

Buna-N

1.25" (31.75) O.D. max.

2"(50.8)

0.59" I.D.(14.99)

Stainless Steel

1.59"(40.39)

0.90"(22.86) O.D. max.

0.35" I.D.(8.89)

1.19"(30.2)

1.13"(28.7) O.D. max.

0.35" I.D.(8.89)

Polypropylene

Polypropylene

1"(25.4) O.D. max.

1"(25.4)

0.37" I.D.(9.4)

Buna-N Kynar

1"(25.4) O.D. max.

1"(25.4)

0.34" I.D.(8.64)

1"(25.4) O.D. max.

1"(25.4)

0.37" I.D.(9.4)

3.5" (88.9) O.D. max.

0.555" I.D.(14.1)

200-M03645 200-M03196 200-P00011 200-M03656

200-P00002 200-P00004 200-M03592

200-M03890 200-P00055

200-P00001 200-P00030 200-M04378-K

1.87"(47.5) O.D. max.

1.82"(46.23)

0.62" I.D.(15.75)

0.376" I.D.(9.55)

1.18"(29.97)

O.D. max.200-P00015

Max.Temp. 150˚CMax. PSIG 120Float SG 0.61 ±.02

Max.Temp. 200˚CMax. PSIG 200Float SG 0.55











1"(25.4) O.D. max.

1"(25.4)

0.37" I.D.(9.4)

200-M04378-P


Full-Size Floats

Miniature-Size Floats


FL


All specifications are subject to change without notice.FL-4 © Copyright Madison Company – 1/08

Standard FloatsAll measurements in parentheses are in millimeters.

For special applications, such as detecting water in a petroleum product, three full-size Buna-Ninterface floats with different specific gravities are available. For detection of dissimilar fluids that arenot petroleum-based, specially weighted full-size interface floats are available in polypropylene orstainless steel.

Typical application: separation of oil and water

Buna-NPolypropylene

For ultra-low-level detection, special floats which will actuate in as little as 0.19” of liquid are availableto fit various single-point and multi-point switch configurations. In the case of multi-level switches, thelow-level indication can be as much as 0.57” lower than a typical barrel float design. Ultra-low-levelfloats are available in Kynar for high-purity applications, PBT or Buna-N for hydrocarbon liquids andFDA-approved polypropylene for food applications and general-purpose liquids. With this unique ultra-low-level monitoring ability, these switches make more efficient use of high-cost liquids, and an earlyindication of liquid presence can be attained. Typical applications include sump pumps and drain pans.Please see the Ultra Low-Level Switch Designs sheet (page FL-1) in this catalog for more standardmodels and Madison level switch compatibility.

1.50" (38.1) O.D. max.

2"(50.8)

0.59" I.D.(14.99)

200-M03745 200-M03641-1200-M03641-2200-M03641-3

2.05" (52.1) O.D. max.

0.555" I.D.(14.1)

200-P00090

Stainless Steel

Ultra-Low-Level Floats

Interface Floats


Max.Temp. 105˚CMax. PSIG 150Float SG

-1 0.95-2 0.87 - 0.90 (.885 ±.015)-3 0.915 ±.01


1.25" (31.75) O.D. max.

2"(50.8)

0.59" I.D.(14.99)

Kynar200-M04176-K

PBT200-M04176-PBT

Buna-N200-M03544-NC200-M03544-NO

Polypropylene200-M04176-PP

Polysulfone200-M04176-PS

FL

Madison Company's expanding line of non-contact level sensors utilize both ultrasonic and radartechnologies. The U and R Series models are available in both standard and engineeredconfigurations, making them cost-effective solutions to your specific application needs. Theseproducts can provide accurate single-point or continuous level measurement for a full range ofliquids and solids. Madison’s non-contact sensors are temperature compensated, with a self-cleaning sensor face and on-board push-button calibration. Most models come withcommunication and programming capabilities to aid in self-adjusting to application conditions.

Some of these non-contact products are approved for use in hazardous locations. The U4468series of ultrasonic sensors is web enabled for remote monitoring of tanks and other vesselsthrough secure communications over the Internet.

For user-programmable settings and on-board display with alarm, the Madison-Omni® ultrasonicsensor is the compact and secure solution for continuous level measurement.

Non-ContactLevel Sensors

© Copyright Madison Company – 6/10 NC-1



www.madisonco.com

NC

U4468

U3M

U4359

U4466

Madison-Omni®

U2

U3

R3

** Refer to Approvals pages in Reference Section

Maximum operating temperature for PVC-94V0 is 60°C. Optional materials for higher temperatures are available.


All specifications are subject to change without notice.NC-2 © Copyright Madison Company – 6/10

U and R Series Non-Contact Level Sensors

U Series Ultrasonic Sensors

MODEL

U3-70

U3-70C2

U3-70C4

U2-70

U2-80

U2-81

U2-148

(INCHES)

0.130

0.130

0.130

0.130

0.088

0.070

0.040

(MM)

3.4

3.4

3.4

3.4

2.2

1.8

0.98

RESOLUTIONMOUNTING

3.0/2.0" NPT

3.0/2.0" NPT

3.0/2.0" NPT

2.0" NPT

2.0" NPT

1.5" NPT

1.0" NPT

OPERATINGFREQUENCY

70 KHz

70 KHz

70 KHz

70 KHz

80 KHz

81 KHz

148 KHz

BEAMANGLE

12˚

12˚

12˚

12˚

12˚

12˚

12˚

VOLTS

24 DC

24 DC

24 DC

Loop PwrLoop PwrLoop PwrLoop Pwr

**APPROVALS

C,H

C,H

C,H

COMM.PORT

RS232

RS485

HOUSING MATL.STD. (OPTIONAL)

Aluminum (PVC-94V0)

Aluminum (PVC-94V0)

Aluminum (PVC-94V0)

PVC-94V0 (Aluminum)

PVC-94V0 (Aluminum)

PVC-94V0 (Aluminum)

PVC-94V0 (Aluminum)

DWGNO.

NC-4

NC-4

NC-4

NC-7

NC-7

NC-7

NC-7

(M)

0.2-9.1

0.2-9.1

0.2-9.1

0.2-9.1

0.2-6.1

0.2-4.9

0.1-2.7

RANGE


U Series Mini Ultrasonic Sensors

MODEL

U3M-148C485

U3M-148C485R

U3M-148S15C485

U3M-148S15C485R

(INCHES)

0.040

0.040

0.040

0.040

(MM)

0.98

0.98

0.98

0.98

RESOLUTIONMOUNTING

1" NPT

1" NPT

1" NPT

1" NPT

OPERATINGFREQUENCY

148 KHz

148 KHz

148 KHz

148 KHz

BEAMANGLE

12˚

12˚

12˚

12˚

VOLTS

24 DC

24 DC

24 DC

24 DC

** APPROVALSCOMM.PORT

RS485

RS485

RS485

RS485

HOUSING MATL.

PVC-94V0

PVC-94V0

PVC-94V0

PVC-94V0

DWGNO.

NC-9

NC-9

NC-9

NC-9

(FEET)

0.33-6

0.33-6

0.33-6

0.33-6

RANGE(M)

0.10-1.8

0.10-1.8

0.10-1.8

0.10-1.8


U Series Madison-Omni® Sensors

MODEL

UM4270-1

UM4270-4

UM4270-3

UM4270-6

(INCHES)

0.12

0.20

0.12

0.20

(MM)

3.0

5.0

3.0

5.0

RESOLUTIONMOUNTING

Flange

Flange

Flange

Flange

OPERATINGFREQUENCY

180 KHz

130 KHz

180 KHz

130 KHz

BEAMANGLE

8˚

8˚

8˚

8˚

VOLTS

18-30 DC

18-30 DC

18-30 DC

18-30 DC

** APPROVALS

C

C

C

C

HOUSING MATL.

SS

SS

SS

SS

DWGNO.

NC-15

NC-15

NC-15

NC-15

(FEET)

4.92

8.20

4.92

8.20

RANGE(M)

1.5

2.5

1.5

2.5

U Series Madison-Omni Sensor AccessoriesK5 PU-02SG – Ready-made cable; 5-pole, 2m length, molded-on straight plugK5 PU-05SG – Ready made cable; 5-pole, 5m length, molded-on straight plugK5 PU-10SG – Ready-made cable; 5-pole, 10m length, molded-on straight plugK5 PU-02SW – Ready-made cable; 5-pole, 2m length, molded-on 90˚ angled plugK5 PU-05SW – Ready-made cable; 5-pole, 5m length, molded-on 90˚ angled plugK5 PU-10SW – Ready-made cable; 5-pole, 10m length, molded-on 90˚ angled plugKB05 PU-W – For user-constructed cable; 5-pole, 90˚ angled plugKB05 PU-G – For user-constructed cable; 5-pole, straight plug

NC

(FEET)

0.8-30

0.8-30

0.8-30

0.8-30

0.7-20

0.6-16

0.4-9


© Copyright Madison Company – 6/10 NC-3All specifications are subject to change without notice.


NC

ø3.95"(ø100.3)

COVER TOOLACCESS HOLE

1/2" NPT CONDUIT ENTRY

USE PVC CONDUIT ONLY

4.75"(120.7)

øB

C A

DWGNo. NC-7

ø4.0"(ø100.3)

COVER TOOLACCESS HOLE

6.2"(157.5)

8.9"(226.1)

2.7"(68.6)

1/2" NPT CONDUIT ENTRY

USE PVC CONDUIT ONLY

3" NPT

ø3.0"(ø76.2)

DWGNo. NC-4

Ultrasonic Sensors

ø4.0"(ø101.6)

STANDARD CABLEOPTIONAL CABLE

1" NPT

4.1"(104.1) 3.125"

(79.4)1.95"(49.5)

ø1.125"(ø28.6)

DWGNo. NC-9

Mini Ultrasonic Sensors

MODEL

U2-70

U2-80

U2-81

U2-148

A

2.25" (57.2)

2.25" (57.2)

2.10" (53.3)

2.00" (50.8)

B

1.80" (45.7)

1.80" (45.7)

1.50" (38.1)

1.10" (27.9)

C

2.0" NPT

2.0" NPT

1.5" NPT

1.0" NPT

DWGNo. NC-15

Shown with optionalswan neck sensor head

Madison-Omni® Ultrasonic Sensors

MODEL

UM4270-1

UM4270-2

UM4270-3

UM4270-4

UM4270-5

UM4270-6

LENGTH

3.98" (101)

3.98" (101)

3.98" (101)

5.55" (141)

5.55" (141)

5.55" (141)

FIXED-MOUNTSENSOR HEAD

3 x ø.177” (4.5) THRU

ø2.165” (55.0)BOLT CIRCLE

ø2.756” (70.0)MOUNTING

FLANGE

SWAN NECKSENSOR HEAD

M12x1 5-POLELOCKING PLUG

LENGTH

ø1.378” (35.0)

0.591” (15.0)

M12x1 5-POLELOCKING PLUG

SET SCREW FORADJUSTING POSITIONOF SENSOR


All specifications are subject to change without notice. NC-4 © Copyright Madison Company – 6/10


R Series Radar Sensors

MODEL

R3-50C232

R3-50C485

R3-100C232

R3-100C485

(INCHES)0.22

0.22

0.44

0.44

RESOLUTION(MM)5.7

5.7

11.0

11.0

MOUNTING

2.0" NPT

2.0" NPT

2.0" NPT

2.0" NPT

OPERATINGFREQUENCY

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

BEAMANGLE

20˚

20˚

20˚

20˚

VOLTS

24 DC

24 DC

24 DC

24 DC

**APPROVALS

J

J

J

J

COMM.PORT

RS232

RS485

RS232

RS485


Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

DWGNO.

NC-10

NC-10

NC-10

NC-10

(FT)50

50

100

100

(M)15.2

15.2

30.5

30.5

RANGE


All the above models are available with AC or DC power and in sanitary (food-grade) designs. Please contact the factory for further information.

NC

R Series Explosion-Proof Radar Sensors

** Refer to Approvals pages in Reference Section PP = Polypropylene Teflon® is a registered trademark of E.I. du Pont de Nemours and Company.

MODEL

R3-50C232-EXP

R3-50C485-EXP

R3-50C232-EXP-T

R3-50C482-EXP-T

R3-100C232-EXP

R3-100C485-EXP

R3-100C232-EXP-T

R3-100C485-EXP-T

VOLTS

24 DC

24 DC

24 DC

24 DC

24 DC

24 DC

24 DC

24 DC

DWGNO.

NC-11

NC-11

NC-11

NC-11

NC-11

NC-11

NC-11

NC-11


Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

Aluminum (316 SS)

ANTENNAMATL.

PP

PP

Teflon®

Teflon®

PP

PP

Teflon®

Teflon®

COMM.PORT

RS232

RS485

RS232

RS485

RS232

RS485

RS232

RS485

(FT)

50

50

50

50

100

100

100

100

(M)

15.2

15.2

15.2

15.2

30.5

30.5

30.5

30.5

(INCHES)

0.22

0.22

0.22

0.22

0.44

0.44

0.44

0.44

(MM)

5.7

5.7

5.7

5.7

11.0

11.0

11.0

11.0

MOUNTING

2" NPT

2" NPT

2" NPT

2" NPT

2" NPT

2" NPT

2" NPT

2" NPT

OPERATINGFREQUENCY

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

6.3 GHz

BEAMANGLE

20˚

20˚

20˚

20˚

20˚

20˚

20˚

20˚

**APPROVALS

J,K

J,K

J,K

J,K

J,K

J,K

J,K

J,K

RESOLUTIONRANGE

4"(101.6)

ACCESS HOLECOVER TOOL

1/2" NPTCONDUITENTRY

ANTENNA

2" NPT

SANITARYANTENNA

2" NPT

7.3"(186.5)

10.2"(259.1) 9.4"

(238.8)

1.5"Ø(38.1)

1.5"Ø(38.1)

2.125"(54.0)

DWGNo. NC-10

ACCESS HOLECOVER TOOL

1/2" NPTCONDUITENTRY

2-11.5NPT

6.6"(168.4)

10.3"(260.4)

ø1.5(38.1)

OPTIONALSANITARY

MOUNTANTENNA

ø 3.97(100.84)

1.3"(33.6)

DWGNo. NC-11

(Explosion-Proof)



U SeriesMadisonic™ U4359 Short-RangeUltrasonic Level Sensor

The Madisonic™U4359 ultrasonicsensor is ideal forcontinuous levelmeasurement in small tanks.

Madison Company has designed and developed theMadisonic™ ultrasonic sensor for small-tank continuouslevel measurement. With its range of 4” to 70” (0.1m to1.78m), it is ideal for small tanks, day tanks and drums in aprocess environment.

With its accuracy of ± 0.25% of full span with temperaturecompensation at atmospheric pressure, the Madisonic is areliable sensor for the continuous monitoring of critical

liquids and some solids. A 10-degree beam angle and supply voltage of 12 to 28 VDC, coupled with ease of use and 3/4-inch NPT mounting, allow thesensor to accomodate many applications withoutfurther alterations.

The Madisonic’s attractive polycarbonate housing is very rigid and is NEMA 4X (IP65) rated. A simplegreen/red LED indicates the ultrasonic operation, and the 4-20 mA and 0-5 volt industry-standardoutputs may be used individually or at the same time. Madison Company can also offer interfacing

process controllers or indicators, which will directly connectto the Madisonic.

• Compact size

• Competitively priced

• Easy installation and operation

• LED for operation display indication

• Fixed calibration

• Nema 4X (IP65)

• FM (pending)

• Temperature compensated

• Day tanks and drums in process lines

• Small tanks for industrial liquids and certain solids

• Food and beverage

Features

Applications

NC

U4359 Specifications



NC-6 © Copyright Madison Company – 6/08


Electrical:Supply Voltage – 12 to 28 VDCOutput – 4-20 mA or 0 to 5 VDC linear

Operational:Accuracy – ± 0.25% of full span @ 22˚C (72˚F)Resolution – .040” (min.)Beam Angle – 10˚Loss of Echo – 2 mA ± 10%Calibration – Fixed Display – LEDDead Band – 4” (10.1cm)Range of Operation – 4” to 70” (0.1m to 1.78m)

Environmental:Temperature Range of Operation – -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 1 barHousing – PolycarbonateIngress Protection – NEMA 4X (IP65)Sensor – Closed-face, PVDFWetted Materials – PVDF

Mechanical:Cable Leads – 6’, 4 conductor, 24 AWG with PVC jacketMounting – 3/4” NPTApprovals – FM (pending)

Controllers, Displays, Relays and Annunciators:ESM series – Controllers, indicators and timersPD series – Programmable 4 or 8 channel controllers, multiple relays and set points,

RS232, RS422/RS485 communications and explosion-proof models availableNC



U SeriesU4466 Ultrasonic Sensor

The U4466 is a self-containedultrasonic sensor.

Madison Company’s U4466 Series is an ultrasonic sensormodel designed for non-contact level, presence/absence,volume, proximity and distance measurements. This self-contained sensor is supplied with hassle-free set-upsoftware and user-selectable options that allow for a varietyof easy application interface considerations.

These microprocessor-based sensors are enhanced withinternal temperature compensation, wave action(turbulence) compensation, agitator blanking and humiditycompensation, among other user-defined settings.

The sensor adjustments and calibration can be made bythe user via a Windows™ computer and the RST modulewith its software. This computer interface may beconnected using either USB or RS-232 connections.

• Range from 4” to 79” (102 to 2007mm)

• Housing – Polycarbonate blend with 1”, 2” NPT or 2” sanitary 3A flange; wetted material is PVDF

• Programmability – Utility program supplied on CD, requires MS Windows; 5 real-time sensorstatus parameters to choose from (distance, analog output, temperature, communicationstatus and signal strength)

• Approvals – NEMA 4X, (pending), IP65

• Works with liquids and solids

• Easy to install and set up

• Virtually maintenance free

Features

NC

Applications

The U44xx series of ultrasonic sensors provide a non-contact method of detecting level,presence/absence, volume, proximity and distance measurements. With this versatility, these ultrasonic sensors are ideal for a variety of applications. Some examples are:

• Car wash vehicle position and spray arm locations• Vessel level of liquid or solid media• River, stream or irrigation canal flow and level• Waste water effluent gate for discharge rate monitoring• Process control applications for liquids

US

U4466 Series Specifications





Electrical:Operating Voltage – 12 to 28 VDCProgramming Voltage – for RST module: 15 to 28 VDCOutput – 4-20 mA; or 4-20 mA with (2) NPN outputs; or 0-2.5 V / 0-5 VTotal Current Draw – 75 mA @ 24 VDCMaximum Power Rating – 2.5 W

Operational:Accuracy – ±0.25% of detectable range with no temperature gradient Resolution – 0.1” (2.5mm)Beam Angle – 9˚ at full signal strength and sensitivity settingFrequency – 143 kHzTemperature Compensation – Yes, internalCalibration – Factory settings, user-programmableRange – 4” to 79” (102mm to 2007mm)Response Time – User-programmable, 20 ms minimumSampling Rate – User-programmable, 1 to 22 Hz

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 30 psi maximum (2 BAR)Installation Category – Class 1, Div. II, Groups A, B, C & D (pending)Approvals – NEMA 4X, (pending), IP65

Mechanical:Cable – Flying leads (pigtails) or micro connector (Phoenix) standardsComputer Interface – USB for RST-3001 or RS-232 for RST-2001AEnclosure – Polycarbonate/PET blend; Transducer is PVDF-faced ceramicMounting – 1” NPT; or 2” NPT; or 2” sanitary feral standards

Optional Features:Over-molded extension cables (shielded), 4-conductor or 5-conductor, with straight or right-angled Phoenix connector, in 2mm or 5mm lengths (see page 12-13 of our installationmanual for details)

NC

IRU-xxx5-M1 Brown +24VDC2 White NPN 13 Blue Ground

4 Black mA+5 Grey NPN 2

Sample Connector

(US

Madison Company’s U4467 Series is a microprocessor-basedultrasonic sensor that offers non-contact continuous levelmeasurement in a low-powered sensor suitable for hazardouslocations (when used with approved barrier). This sensor is listedby CSA for Class 1, Division I, Groups C & D and Class 1, Zone0, A Ex ia II B hazardous areas.

Featuring a ceramic transducer designed with a rugged Kynarhousing, the U4467 Series is ideal for harsh enviroments andoffers a high degree of chemical compatibility over a wide rangeof materials.

Factory settings allow you to power-up-and-use with the softwareprovided. An optional remote programmer (U4467-99) is alsoavailable, eliminating the otherwise required sensor-to-computerlink. Either way, there are a host of user-selected variables totailor the U4467 Series to your specific application. User settingscan be saved into a Word document and downloaded whenneeded, for example, to set up another sensor with identicalapplication parameters.



Madison’s U4467 Loop-PoweredUltrasonic Sensor, shown with optionalU4467-99 remote programmer

U SeriesLoop-Powered Ultrasonic Level Sensors

NC

Applications

This loop-powered 4-20 mA output ultrasonic sensor was specifically designed for measuring volume and flow of liquids. The U44xx series of ultrasonic sensors provide a non-contact method of detecting level,presence/ absence, volume, proximity and distance measurements. With this versatility, these ultrasonic sensorsare ideal for a variety of applications. Some examples are:


• Range from 1 to 25 feet (0.3 to 7.6m) in liquids, or 1 to 10 feet (0.3 to 3.0m) in solids

• Housing – PC/PBT with 2” NPT; wetted material is PVDF (Kynar®)

• Programmability – Fully programmable using an external programming module that acts as an interfacebetween the sensor and your personal computer. Utility program supplied on CD, requires MS Windows;5 real-time sensor status parameters to choose from (distance, analog output, temperature,communication status and signal strength)

• Approvals – Class I, Div 1, Groups C & D; Class I, Zone 0, AEx ia llB, T3; IS with approved barrier; IP65; (pending)

• Graphical representation for level, volume and flow applications

• Easy to install and set up

• Virtually maintenance free

Features

US

Electrical:Operating Voltage – 12 to 28 VDC, loop current 4-20 mAProgramming Voltage – 24 VDCOutput – 4-20 mA, loop-poweredTotal Current Draw – 4-20 mAMaximum Power Rating – 0.91 Watt

Operational:Accuracy – ±0.25% of detectable range with no temperature gradient Resolution – 0.1” (2.5mm)Beam Angle – 9˚ off-axisFrequency – 68 kHzTemperature Compensation – Yes, internalCalibration – Factory settings, user-programmable with U4467-99 or USB-to-computer,

software providedRange – 1 to 25 feet (0.3 to 7.6m) in liquids; 1 to 10 feet (0.3 to 3.0m) in solidsResponse Time – Dependent on output ranges, from 0.6 to 3 secondsSampling Rate – 2 seconds

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 30 psi maximum (2 BAR)Installation Category – Class 1, Div. 1, Groups C & D; Class 1, Zone 0, A Ex ia, T3Approvals – IP65, (pending), IS

Mechanical:Cable – 2-conductor shielded, with 6-foot length standardComputer Interface – USB through U4467-99 programmerEnclosure – Polycarbonate/PBT blend; Transducer is ceramic with PVDF housingMounting – 2” NPT

Optional Features:Remote Programmer (U4467-99)

Safety Barrier:Recommended Stahl part number 9001/51-280-091-141

U4467 Series Specifications





NC

o y

US



U SeriesWeb-Enabled Ultrasonic Sensors

Madison Company’s U4468 Series of Web-enabled ultrasonicsensors are ideal for monitoring both local and remote tanklocations. The non-contact measurements that can be obtainedfrom the U4468 Series are level, presence/absence, volume anddistance. Each individual sensor model is designed for a specificrange (span).

The Internet connection from any computer will provide access toa secure site – after you enter your sensor’s IP address set-up,measurements will begin to be logged in real time. You canprogram the website to send you an E-mail, text message orboth, as well as set two relays for pump control and/or alarm.

Sensor parameters and settings can be changed via the sensor’sinternal Web page and the unique IP address. This affordableremote tank monitoring set-up provides, essentially, maintenance-free service.U4468 Series Ultrasonic Sensors are

web enabled for monitoring both localand remote tank locations.

NC

• Detect ranges from 1 foot to 15 feet (model dependent)

• Housing – Polycarbonate blend with 2” or 3” NPT; wetted material is PVDF

• Programmability – Ethernet connections to World Wide Web to secure host server (ideal for remotemonitoring); AutoSence software for hassle-free set up

• Approvals – Class I, Div 2, Groups A B C & D; (pending)

• Works on liquids and solids

• Calculates level or volume of vessel’s contents

• Storage of readings to a secure, private database

• Remote monitoring and control and/or alarm features

Features

Applications

This loop-powered 4-20 mA output ultrasonic sensor was specifically designed for measuring volume and flow of liquids. The U44xx series of ultrasonic sensors provide a non-contact method of detecting level,presence/absence, volume, proximity and distance measurements. With this versatility, these ultrasonic sensorsare ideal for a variety of applications. Some examples are:


US

U4468 Specifications





Electrical:Operating Voltage – 48 VDC POE; Sensor is powered over Ethernet cable – requires POE

injector or switchOutput – Ethernet TCP/IP to internal Web page;

(2) isolated solid state relays (130 mA maximum)Total Current Draw – 40 mA @ 48 VDCMaximum Power Rating – 2.0 WElectrical Connection – RJ-45 port; terminal blocks for relay connections

Operational:Accuracy – ±0.25% of detectable range with no temperature gradient Resolution – 0.1” (2.5mm)Beam Angle – 9˚ off-axis at full signal strength and sensitivity settingsFrequency – U4468-1 and -3 are 69 kHz; U4468-2 is 43 kHz Temperature Compensation – Yes, internalCalibration – User-programmableRange – 1 to 25 feet (305mm to 7620mm) for U4468-1

1.5 to 40 feet (457mm to 12192mm) for U4468-24” to 180” (102mm to 4572mm) for U4468-3

Response Time – User-programmableSampling Rate – User-programmable, 1 to 12 Hz

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 30 psi maximum (2 BAR)Installation Category – Class 1, Div. II, Groups A, B, C & DApprovals – IP65, (pending), IS

Mechanical:Computer Interface – Windows XP or higherEnclosure – Polycarbonate/PBT blend; Transducer is ceramic with PVDF housingMounting – 2” NPT for U4468-1 and U4468-3; 3” NPT for U4468-2

Optional Features:7 ft. orange crossover (P/N 136282) 7 ft. blue cable (P/N 136284-0007)7 ft. red cable (P/N 136283-0007) 25 ft. blue cable (P/N 136284-0025)25 ft. red cable (P/N 136283-0025) POE power supply, 48V, 0.42 A & cable (P/N 136281-0001)

Safety Barrier:Recommended Stahl part number 9001/51-280-091-141

NC

Installation Category –IP65, (pending), IS

US

• Pulse ultrasonic technology

• Non-contact measurement

• Programmable

• Field/Bench calibration

• Push-button calibration

• Elimination ofunwanted echoes


• Water and wastewater

• Microprocessor-based reliability

• Temperature compensation

• Self-cleaning sensor face

• Non-volatile memory (batteries not required)

• Automatic adjustment of power andsensitivity to any environment

• Window Out of unwanted echoes

• Electrical and acoustical noise filters

• Chemicals and oils

• Various liquids, slurries and solids

Madison Company offers a complete line of Standardmodels of advanced ultrasonic level measurementsensors for liquids and solids. These products continueto meet demanding applications in many markets, atcompetitive prices.

In addition, Madison Company has the engineeringcapabilities to design these sensors for your specificnon-contact level measurement needs, providingunique considerations for materials to be measured,vessel configuration and system interfacing.

The microprocessor-based circuits provide atemperature-compensated signal for improvedaccuracy. All models have the ability to filter falseechoes produced by peripheral obstructions.

Continuous level measurement can be provided in a range of 0.16’ to 30’ (0.049m to 9.1m) with severalpower and programmability options. Point level can alsobe obtained using a PLC (Industrial ProgrammableController). Measurement of solids requires thecommuncations option; when selecting a standardmodel for these cases, cut the range of the unit in half.



Space-savingmodels areavailable withremote sensorsthat can beseparated fromhousings by upto 6 feet.

U SeriesUltrasonic Level Sensors

Features

Applications

NC

Electrical:Power Options – DC: 12 to 30 VDC, 0.07 Amps max. @ 24 VDC

R load = (Vs–6)/24 mAOutput – 4-20 mA or 20-4 mA, 6.1 uA resolution; 750 ohms (isolated

on 4-wire models only)Optional RS232 or RS485 communications port

Fuse – 0.125 Amps/250 V type 2AG

Operational:Accuracy – ±0.25% of max. target range (in air) Beam Angle – 6-12 degrees at -3 dB (model dependent)Loss of Echo Hold – 1 minute (programmable 1-4 min.), 22 mA or 2 mA current outputTemperature Compensation – Onboard the sensorCalibration – Push-button or optional programmableDiagnostics (Echo Profile) – Via optional programmable portDead Zone Range – Model dependent or engineered to minimum

Environmental:Operating Temperature Range: -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 1 BAR (15 PSIG max.)Approval – Entela, CE (in aluminum enclosure)

Mechanical:Conduit Entry – 1/2” NPT hole (PVC only)Enclosure – PVC-94V0, aluminumIngress Protection – NEMA 4X (IP65)Mounting Options – Swivel socket (cold-rolled steel); PVC flange with 3”-8 or 6”-8 NPT thread

Optional Features:Sanitary designsBSP thread typesVarious housing materials (may affect approval)High-temperature designsRemote displayBall coupler with 3” NPT thread for mounting and easy beam alignment

Approvals:Consult factory

Specifications





NC



U SeriesMadison-Omni® Sensors forShort-Range Measurement

The Madison-Omni®

integrated displaydesign is available for ultrasonic (non-contact) sensors

In addition to the Madison-Omni® configurations featured inMadison’s reed-switch-based continuous level devices, theMadison-Omni® design is available as an ultrasonic sensorfor short-range (8” - 48” or 12” - 90”) measurement.

There are four models and two standard ranges availablewith the integrated Madison-Omni® display. This universaldisplay is the same one utilized in reed-switch-based levelmeasurement. It offers user-programmable settings and, inaddition to the displayed values, features an LED alarm light.

This non-contact level measurement sensor can be used invarious liquids and solids. Level measurement can bedisplayed in inches or centimeters. As with all ultrasonicdevices, you should avoid turbulance or sloping surfaces onthe level to be measured.

• Range: 8” - 90”

• Ultrasonic level sensing with integrated user-programmable display

• Narrow 8˚ beam width

• Adjustable ranges and alarm set points (NPN or PNP)

• Scalable 4-20 mA output

• Several mounting options

Features NC

Specifications





Electrical:Supply Voltage – 18 to 30 VDCPower Consumption – < 3 WattsOutput – 4(0)-20 mA, 2(0)-10 V across; 500 Ohm resistor to 0 VSwitching Values (S1 and S2) – PNP or NPN selectable; 300 mA load sum max.;

programmable as min. or max. value; short circuit proof; reverse polarity proofHysteresis – Adjustable; position depends on min. or max. settingDisplay – Graphical LCD display; temperature range -20˚C to 70˚C (-4˚F to 158˚F);

32x16 pixels; back-lit LED signaling lamp Connection – M 12x1; 5-pole locking plug*

Operational:Accuracy – ±0.2% full scale Linearity Error – < 0.3% full scaleTemperature Error – 0.03% ˚COperating Temperature – 0˚C to 70˚C (32˚F to 158˚F)Operating Pressure – Ambient

Environmental:Approval – IP67, CE

Mechanical:Wetted Materials – PET 30% GV, epoxy resin, POMHousing Materials – Stainless steel, tempered glass, POM ringMounting – Flange mount with center hole 35.5mm and three fastening through holes for

screws or bolts

Options:Swan Neck – Optional swan neck between the electronics head and the primary sensor

provides complete freedom in the sensor alignment and reading direction. Additionallyprovides thermal decoupling between units. See catalog drawing #NC-15 for illustration.

Operating RangeDead Zone

Emergency-Off Contact

4.3’ (1.3m)7.5’ (2.3m)

0.66’ (0.2m)0.98’ (0.3m)

Type: 4.9’ (1.5m)8.2’ (2.5m)

8˚

Madison-Omni® Operation: Wiring Diagram: 18 to 30 VDC

4(0)-20 mA

OmniSensor

white

brown

gray

black

bluez

z

Z = load

1

2

3

4

5

z

or NPNExample: PNP

0 V

S1

S2

NC





U SeriesU3M “Mini Probe” Ultrasonic Level SensorsMadison Company’s “Mini Probe” is an addition to the fullrange of ultrasonic level sensors already offered. Its design iscompact, extending just over 2” in height above the tank ordrum surface, and it has an operating range of 4” to 6’(0.10m to 1.8m).

As with all of our standard Ultrasonic models, the U3M has aPVC housing that allows for an operating temperature rangeof -40˚C to 60˚C (-40˚F to 140˚F). This range can beincreased to 80˚C (176˚F) with an optional CPVC housing orincreased to 125˚C (257˚F) with an optional Kynar housing.

The U3M’s microprocessor-based circuits provide atemperature-compensated signal for improved accuracy andthe ability to filter false echoes produced by peripheralobstructions. On-board push buttons allow for calibrationwithout the need for software and computers. OptionalRS485 communications are available for computer interfacingand for networking up to 128 sensors. Relay models foralarm and/or on/off control by sensor can be provided.

For applications requiring a sanitary interface to the sensor, an optional 316L stainless steel transducer face withtri-clover clamp is also available.

• Pulse ultrasonic technology

• Non-contact measurement

• Programmable

• Push-button calibration

• Elimination ofunwanted echoes

• Microprocessor-based reliability


• Water and wastewater

• Temperature compensation

• Field or bench calibration

• Self-cleaning sensor face

• Non-volatile memory (batteries not required)

• Automatic adjustment of power andsensitivity to any environment

• Low profile

• Chemicals and oils

• Various liquids, slurries and solids

Features

Applications

U3M Ultrasonic “Mini Probe”

NC

Specifications






R load = (Vs–6)/24 mAOutput – 4-20 mA, 6.1 uA resolution

Relay: DPST, 5 Amps @ 230 VACOptional RS485 communications port (comes with free software)Note: If a converter is required, Madison recommends B & B Electronics Model 485SD9TB

Operational:Accuracy – ±0.25% of max. target range (in air) Beam Angle – 12 degrees at -3 dBLoss of Echo Hold – 1 minute (programmable 1-4 min.), 22 mA or 2 mA current outputTemperature Compensation – Onboard the sensorCalibration – Push-button or optional programmableDiagnostics (Echo Profile) – Via optional programmable portHigh-Level Alarm – 5 Amp relay has hysteresis and delay of 5% of the tank height;

changes at full tank calibration heightRange – 0.33’ to 6’ (0.10m to 1.8m)Resolution – 0.04” (0.98mm)Operating Frequency – 148 kHz

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Pressure – 1 BAR to 2 BARInstallation Category – Class 11Approval – CE

Mechanical:Cable – 24 AWG, 3 pair, 60” long (1.5m); Relay option requires 18 AWG, 3 conductorEnclosure – PVC-94V0Ingress Protection – NEMA 4X (IP65)Mounting Options – Swivel socket (cold-rolled steel); PVC flange with 3”-8 or 6”-8 NPT thread

Optional Features:U3M-148 Standard modelU3M-148C485 with communications portU3M-148-R with relay U3M-148C485-R with communications port and relayFor higher operating temperatures, request factory quote for a CPVC or Kynar housing.

NC

Madison Company offers a series of low-costradar sensors for continuous levelmeasurement. This product series offers alogical extension to the ultrasonic sensorseries, where application conditions are in need of non-contact liquid level measurement,and where ultrasonic level measurement is not acceptable.

As with all Madison products, this radartechnology can be designed for your specificlevel measurement needs, providing uniqueconsiderations for materials to be measured,vessel configuration and system interface.

These radar level sensors are ideal forreflective liquids that have a foaming surface or vapor conditions beyond ultrasonic wave capabilities.



R SeriesRadar Level Sensors

Features• Non-contact measurement

• Continuous level measurement

• Pulse radar measurement range 10” to 100’ (0.254m to 30m)

• Networkable, multi-sensor with available software

• Programmable and push-button calibration

• Various liquids and solids

Applications

NC


R load = (Vs–6)/24 mAOutput – 4-20 mA, 6.1 uA resolution; 750 ohms

Optional RS232 or RS485 communications port

Operational:Accuracy – ±0.25% of max. target range (in air)

Frequency – 5.8 GHz or 6.3 GHzLoss of Echo Hold – 30 seconds, 22 mA outputTransmitter Power – 50 uW averageCalibration – Programmable via communications portDiagnostics (Echo Profile) – Via programmable portAntenna – Dielectric rod

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Installation Category – Class IIApprovals – FCC Part 15 – low-power communication device

– CE – 5.8 GHz models

Mechanical:Conduit Entry – 1/2” NPT standardHousing – Aluminum or stainless steel 316L (optional)Ingress Protection – NEMA 4 (IP65)Decoupler – PolypropyleneMounting Options – Swivel socket (cold-rolled steel); PVC flange with 3”-8 NPT thread

Options:PTFE antenna or sanitary PTFE antenna1.5” or 2” NPT PTFE decoupler for high-temperature applicationsSanitary designsAntenna extension: 6” or 8”

Approvals:Consult factory

Specifications





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R SeriesSanitary “Smart” RadarLevel Measurement Sensors

Features• Programmable and push-button calibration

• Output: 4-20 mA/20-4 mA (isolated on 4-wire models only)

• PLC compatible (Modbus RTU)

• 3-wire operation


• Water

• Pharmaceutical

Applications

Standard sanitaryunit features

aluminum housing, polypropylene antenna and 2” tri-clamp

MODEL

R3-50S3-wire, DC

R3-100S3-wire, DC

RANGEIn Liquids

* to 50’(* to 15m)

* to 100’(* to 30m)

RESOLUTION

0.22”(5.7mm)

0.44”(11mm)

TRI-CLAMPFitting

2.0”

2.0”

* Minimum distance starts at the lower tip of the antenna.

NC

Electrical:Power – DC: 12 to 30 VDC, 0.07 Amps max. @ 24 VDC

R Load = (Vs–6)/24 mAOutput – 4-20 mA output, 6.1 uA resolution; 750 ohms

RS232 or RS485 communications port

Operational:Operation – Pulse radarAccuracy – ± 0.1% of maximum range in lab using 4-20 mA current output

± 0.25% of maximum range (typically in field)Frequency – 5.8 GHz or 6.3 GHzLoss of Echo Hold – 30 seconds, 22 mA output timeTransmitter Power – 50 uW averageCalibration – Programmable via communications port or push buttonDiagnostics (Echo Profile) – Via communications portAntenna Dielectric Rod – Polypropylene (standard), PTFE (optional)Decoupler – Polypropylene (standard), PTFE (optional)

Environmental:Operating Temperature Range – -40˚C to 60˚C (-40˚F to 140˚F)Installation Category – Class IIApprovals – FCC Part 15 – low-power communication device

Mechanical:Conduit Entry – 1/2” NPT standardEnclosure – Aluminum (standard) or stainless steel 316L (optional)Ingress Protection – NEMA 4 (IP65)Mounting Options – Swivel socket (galvanized steel); PVC flange with 3”-8 NPT thread

Process:Temperature – PTFE Rod: -40˚C to 204˚C (-40˚F to 400˚F) with tri-clampMaterial Dielectric – Class IIPressure – 1-10 BAR, 15-150 PSI

Approvals:CE approval on 5.8 GHz modelsConsult factory for others

Specifications





NC

Unit Volume (monthly): Packaging/Labeling:

Price Target:


Design Completion Date: First Delivery Date:

ENVIRONMEN

TELEC

TRICAL

PHYS

ICAL

NOTES

DES

IGN

Application description:

Material to be measured:

Vessel construction (wall material, shape, size):

Max. distance from top of vessel to lowest measurement point: Turbulence?

Level range – Min: Max: Normal: Liquid? Solid?

Ambient temperature range (inside the vessel) – Min: Max: Normal:

Material density: Units: Material dielectric constant:

Pressure – Min: Max: Normal: Units: Vented? Vacuum?

Washdown required? IP rating required: 3A?

Other considerations (vibration, food contact, hazardous location, turbulence, foams, solids, approvals, filling method, vapors/dust, etc.):

Installation: Indoors or Outdoors Intrinsically safe or Explosion proof

Output: 4-20 mA 20-4 mA 0-5 V 5-0 V PNP NPN N.O.N.C.

Communications: RS232 RS485 None Wireless Type required:

Power: 3-wire: 24 VDC 2-wire: Loop powered

Resolution: Accuracy: Repeatability:

Terminations:

Cable length:

Mounting considerations:

Antenna Material: Polypropylene (standard) PTFE

Sanitary design High temperature (above 140˚F)

PROJECT

See reverse side for Considerations for Sensor Applications

Madison Company can engineer the ultrasonic or radar sensor to meet your application needs. Please provide thefollowing information so that our engineering staff can determine the appropriate sensor design for your requirements.


Address:


U or R Series Specification Work SheetUltrasonic or Radar Sensor




NC

Considerations for Sensor Applicationsin a Typical Vessel, Container or Tank

Sensor Location?*

Mounting Style?Fill Location?

Wall Material/Surface Typeand Shape?

Distance?

TemperatureRange InsideVessel?

Material to Measure?Foam (Depth)?

Valve

Vapor? Y N

Dust? Y NType:

Condensation? Y N

Cavitation? Y N(Air Bubbles)

Turbulence? Y N

Foam? Y N

Obstructions?

* Note: Sensor must be installed on the top of the vessel. Please indicate hole location.




Tank Shape?

Shape of Tank Top?

Top of Tank:Open

Closed

Shape of Tank Bottom?

Power Required: 24 VDC (3-Wire) Loop Power (2-Wire)

Communications: RS232 RS485 Mod Bus Wireless required

Liquid Solid

Slurry

NC

Madison Company has been incorporating temperature sensors into its level switch products for

over 50 years. With this temperature sensor experience, a basic standard product line has been

established to complement our capability to design and manufacture application-specific sensors.

Madison’s temperature offerings include:

• Thermocouples

• RTDs (Resistance Temperature Detectors)

• Madison-Omni® RTDs with integrated user-programmable controls

• Bimetal Thermal Switches

• Indicators and Controllers

• Accessories for Temperature Sensors

Temperature Sensors,Controllers & Accessories

© Copyright Madison Company – 3/11 TM-1



www.madisonco.com

TM

Thermocouples


All specifications are subject to change without notice.TM-2 © Copyright Madison Company – 7/09

T Series Standard Temperature Sensors

MODEL CALIBRATION TYPEWIRE SIZE

(DIA.)

OVERALL LENGTH

(INCHES) (M)

T4271-J5 J 0.005” 12 0.3

T4271-J10 J 0.010” 12 0.3

T4271-J15 J 0.016” 12 0.3

T4271-J20 J 0.020” 12 0.3

T4271-J30 J 0.032” 12 0.3

T4271-K5 K 0.005” 12 0.3

T4271-K10 K 0.010” 12 0.3

T4271-K15 K 0.016” 12 0.3

T4271-K20 K 0.020” 12 0.3

T4271-K30 K 0.032” 12 0.3

T4271-T5 T 0.005” 12 0.3

T4271-T10 T 0.010” 12 0.3

T4271-T15 T 0.016” 12 0.3

T4271-T20 T 0.020” 12 0.3

T4271-T30 T 0.032” 12 0.3

MODELCALIBRATION

TYPESHEATHMATL.

SHEATH ODINSULATIONMATERIAL

JUNCTIONTYPE

WIRESIZE

OVERALL LENGTH

TERMINATIONTIP

STYLE(INCH) (MM) (INCH) (M)

T4269-J12NC25 J 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Strip lead Closed

T4269-J12MP25 J 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Mini plug Closed

T4269-J12CP25 J 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Full-size plug Closed

T4269-K12NC25 K 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Strip lead Closed

T4269-K12MP25 K 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Mini plug Closed

T4269-K12CP25 K 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Full-size plug Closed

T4269-T12NC25 T 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Strip lead Closed

T4269-T12MP25 T 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Mini plug Closed

T4269-T12CP25 T 316 SS 0.250 6.35 MgO Grounded 24 AWG 12 0.3 Full-size plug Closed



















Bare-wire thermocouples. Sold in packages of 10 pieces.

General-purpose thermocouples with fiberglass-insulated extensionleads and various termination styles.

TM

© Copyright Madison Company – 4/07 TM-3All specifications are subject to change without notice.


Thermocouples


MODELCALIB.TYPE

SHEATHMATL.

MAX.TEMP.


JUNCTIONTYPE

WIRESIZE

OVERALL LENGTHPROCESS

CONNECTIONTIP


T3966-1001 J 316 SS 200˚C 0.188 4.76 Epoxy Ungrounded 24 AWG 2 0.05 1/4” tube Closed






T3967-1001 K 316 SS 200˚C 0.188 4.76 Epoxy Ungrounded 24 AWG 2 0.05 1/4” tube Closed






T3964-1001 J 316 SS 200˚C 0.188 4.76 Epoxy Ungrounded 24 AWG 2 0.05 1/2” NPT Closed






T3965-1001 K 316 SS 200˚C 0.188 4.76 Epoxy Ungrounded 24 AWG 2 0.05 1/2” NPT Closed






MODELCALIBRATION

TYPESHEATHMATL.


JUNCTIONTYPE

CABLELENGTH

OVERALL LENGTH

TERMINATIONTIP


T4268-J12C J 316 SS 0.250 6.35 MgO Grounded 5' 12 0.30 Mini connector Closed



T4268-K12C K 316 SS 0.250 6.35 MgO Grounded 5' 12 0.30 Mini connector Closed



T4268-T12C T 316 SS 0.250 6.35 MgO Grounded 5' 12 0.30 Mini connector Closed



T4268-J12NC J 316 SS 0.250 6.35 MgO Grounded 10' 12 0.30 Stripped ends Closed



T4268-K12NC K 316 SS 0.250 6.35 MgO Grounded 10' 12 0.30 Stripped ends Closed



T4268-T12NC T 316 SS 0.250 6.35 MgO Grounded 10' 12 0.30 Stripped ends Closed



Thermocouples with reduced tip for improved response time. The probe comes with a nylon handle, cable strain reliefand extension cable. Overall length listed below refers to probe only.

General-purpose epoxy-insulated thermocouples.

TM


All specifications are subject to change without notice. TM-4 © Copyright Madison Company – 1/09


MODELCALIB.TYPE

SHEATHMATL.

MAX.TEMP.


JUNCTIONTYPE

WIRESIZE

OVERALL LENGTHTIP


T4267-J20TFEEC J N/A 200˚C N/A N/A PTFE jacket Enclosed 20 AWG 120 3.00 Epoxy coated

T4267-J24TFEEC J N/A 200˚C N/A N/A PTFE jacket Enclosed 24 AWG 120 3.00 Epoxy coated

T4267-K20TFEEC K N/A 200˚C N/A N/A PTFE jacket Enclosed 20 AWG 120 3.00 Epoxy coated

T4267-K24TFEEC K N/A 200˚C N/A N/A PTFE jacket Enclosed 24 AWG 120 3.00 Epoxy coated

T4267-T20TFEEC T N/A 200˚C N/A N/A PTFE jacket Enclosed 20 AWG 120 3.00 Epoxy coated

T4267-T24TFEEC T N/A 200˚C N/A N/A PTFE jacket Enclosed 24 AWG 120 3.00 Epoxy coated

T4267-J20TFEEJ J N/A 250˚C N/A N/A PTFE jacket Exposed 20 AWG 120 3.00 Bare

T4267-J24TFEEJ J N/A 250˚C N/A N/A PTFE jacket Exposed 24 AWG 120 3.00 Bare

T4267-K20TFEEJ K N/A 250˚C N/A N/A PTFE jacket Exposed 20 AWG 120 3.00 Bare

T4267-K24TFEEJ K N/A 250˚C N/A N/A PTFE jacket Exposed 24 AWG 120 3.00 Bare

T4267-T20TFEEJ T N/A 250˚C N/A N/A PTFE jacket Exposed 20 AWG 120 3.00 Bare

T4267-T24TFEEJ T N/A 250˚C N/A N/A PTFE jacket Exposed 24 AWG 120 3.00 Bare

T4267-J20FGEJ J N/A 500˚C N/A N/A Fiberglass jacket Exposed 20 AWG 120 3.00 Bare

T4267-J24FGEJ J N/A 500˚C N/A N/A Fiberglass jacket Exposed 24 AWG 120 3.00 Bare

T4267-K20FGEJ K N/A 500˚C N/A N/A Fiberglass jacket Exposed 20 AWG 120 3.00 Bare

T4267-K24FGEJ K N/A 500˚C N/A N/A Fiberglass jacket Exposed 24 AWG 120 3.00 Bare

T4267-T20FGEJ T N/A 400˚C N/A N/A Fiberglass jacket Exposed 20 AWG 120 3.00 Bare

T4267-T24FGEJ T N/A 400˚C N/A N/A Fiberglass jacket Exposed 24 AWG 120 3.00 Bare

T4267-J20HTEJ J N/A 700˚C N/A N/A Fiberglass jacket* Exposed 20 AWG 120 3.00 Bare

T4267-J24HTEJ J N/A 700˚C N/A N/A Fiberglass jacket* Exposed 24 AWG 120 3.00 Bare

T4267-K20HTEJ K N/A 700˚C N/A N/A Fiberglass jacket* Exposed 20 AWG 120 3.00 Bare

T4267-K24HTEJ K N/A 700˚C N/A N/A Fiberglass jacket* Exposed 24 AWG 120 3.00 Bare

T4267-J20PVCEC J N/A 90˚C N/A N/A PVC Jacket Exposed 20 AWG 120 3.00 Bare

T4267-K20PVCEC K N/A 90˚C N/A N/A PVC Jacket Exposed 20 AWG 120 3.00 Bare

T4267-T20PVCEC T N/A 90˚C N/A N/A PVC Jacket Exposed 20 AWG 120 3.00 Bare

T4267-J20PVCEJ J N/A 90˚C N/A N/A PVC Jacket Enclosed 20 AWG 120 3.00 Epoxy coated

T4267-K20PVCEJ K N/A 90˚C N/A N/A PVC Jacket Enclosed 20 AWG 120 3.00 Epoxy coated

T4267-T20PVCEJ T N/A 90˚C N/A N/A PVC Jacket Enclosed 20 AWG 120 3.00 Epoxy coated

Thermocouples

MODELCALIBRATION

TYPESHEATHMATL.


JUNCTIONTYPE

OVERALL LENGTH

TERMINATIONTIP


T4266-J12 J 316 SS 0.250 6.35 MgO Grounded 12 0.30 1” bare leads Closed

T4266-J21 J 316 SS 0.250 6.35 MgO Grounded 24 0.60 1” bare leads Closed

T4266-K12 K 316 SS 0.250 6.35 MgO Grounded 12 0.30 1” bare leads Closed

T4266-K21 K 316 SS 0.250 6.35 MgO Grounded 24 0.60 1” bare leads Closed

T4266-T12 T 316 SS 0.250 6.35 MgO Grounded 12 0.30 1” bare leads Closed

T4266-T21 T 316 SS 0.250 6.35 MgO Grounded 24 0.60 1” bare leads Closed

Sheathed thermocouples with MgO insulation, grounded junction. Sold in packages of 6 pieces.

MODELCALIBRATION

TYPESHEATHMATL.


JUNCTIONTYPE

OVERALL LENGTH

TERMINATIONTIP


T4274-JA* J 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

T4274-KA* K 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

T4274-TA* T 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

T4274-J1** J 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

T4274-K1** K 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

T4274-T1** T 316 SS 0.250 6.35 MgO Grounded 18 0.40 1” bare leads Closed

Industrial thermocouples with 1/2” NPT process connection and aluminum or cast iron J-box.

* Aluminum J-box ** Cast iron J-box

Thermocouples with mini plug termination.

* High-temperature fiberglass jacket.

TM



RTDs (Resistance Temperature Detectors)


MODELOHM

VALUEPROBE

MATERIALMAX.TEMP.

PROBE LENGTH PROBE DIAMETER

WIRES TERMINATION(INCH) (M) (INCH) (MM)

T4272-4A 100 316 SS 200˚C 4 0.10 0.250 6.4 3 Aluminum J-box




T4272-4N 100 316 SS 200˚C 4 0.10 0.250 6.4 3 Plastic J-box




Industrial 100 ohm RTD probes, rigid mount. Process connection is 1/2” NPT with 1/2” conduit connection.

MODELOHM

VALUEPROBE

MATERIALMAX.TEMP.

PROBE LENGTH PROBE DIAMETER

WIRES TERMINATION(INCH) (M) (INCH) (MM)

T4273-2-9 100 316 SS 200˚C 9 0.22 0.250 6.4 2 #8 spade terminals






RTD probes with 48” Teflon®-jacketed cables terminated with spade terminals.

MODELOHM

VALUEPROBE

MATERIALMAX.TEMP.

PROBE LENGTH PROBE OD

WIRES INSULATION TERMINATION(INCH) (M) (INCH) (MM)

T3969-1001 100 316 SS 200˚C 2 0.05 0.188 4.8 2, 22 AWG Teflon® Leads






T3968-1001 100 316 SS 200˚C 2 0.05 0.188 4.8 2, 22 AWG Teflon® 1/2” NPT






T4198 100 316 SS 200˚C 316 SS plug N/A N/A 3, 24 AWG Teflon® 2 x 1/16” NPT













RTD probe style is closed tip.

TM




Madison-Omni® RTDs

MODEL NECK STYLE

PROBE LENGTH TEMPERATURE RANGE

THREAD(INCH) (MM) (˚C) (˚F)

T4275-1 Vertical 1.96 50 0˚C to 100˚C 32˚F to 212˚F NPT 1/2 A

T4275-2 Swan 1.96 50 0˚C to 100˚C 32˚F to 212˚F NPT 1/2 A











T4275-13 Vertical 1.96 50 0˚C to 100˚C 32˚F to 212˚F G 1/2 A

T4275-14 Swan 1.96 50 0˚C to 100˚C 32˚F to 212˚F G 1/2 A











Madison-Omni® RTD Sensor Accessories029-P00001 – Shielded cable; 2m length with straight plug029-P00002 – Shielded cable; 5m length with straight plug029-P00003 – Shielded cable; 10m length with straight plug029-P00004 – Shielded cable; 2m length with 90˚ angled plug029-P00005 – Shielded cable; 5m length with 90˚ angled plug029-P00006 – Shielded cable; 10m length with 90˚ angled plug

User-programmable indicator that provides range indication and offers two alarm settings. The platinum RTD sensor with a 316 stainless steel sheath has an analog 4-20 mA outputsignal and a supply voltage of 10-30 VDC. The electrical connection has an M 12x1 thread; ifa mating connector is required, one of the accessory cables (listed below) should be ordered.The process connection is available with either a G 1/2 or a 1/2” NPT thread and meets IP67.

TM


Temperature Indicators and Controllers

Temperature Indicators


MODEL BASE UNIT PART NO.

SIZE (W x H) DISPLAY HEIGHT

DISPLAY DIGITS(INCH) (MM) (INCH) (MM)

ESM-4400 ESM-4400-12011/0000 1.89 x 1.89 48 x 48 0.39 10.0 4

ESM-4900 ESM-4900-12011/0000 3.78 x 1.89 96 x 48 0.80 20.3 4

ESM-7700 ESM-7700-12011/0000 2.83 x 2.83 72 x 72 0.55 14.0 4

ESM-9900 ESM-9900-12011/0000 3.78 x 3.78 96 x 96 0.55 14.0 4

Base indicator with NO contact, programmable to NC for reverse action. Display has fourprocess and four set points. Supply voltage is 100-240 VAC, 50/60 Hz. Features a universalinput for thermocouple, RTD (2- or 3-wire), analog 0-50 V, 0-5 V, 0-10 V or 4-20 mA. Alsoincludes a communications port for RS232 MODBUS.

Additional module chips are available (specify indication model): Output: Input:– Relay Output – Thermocouple– SSR Output (15-18 VDC / 50 mA) – RTD– Transistor Output (24 VDC / 100 mA)– Volt/Current Output (0/4-20 mA, 0-10 V)

Temperature Controllers

MODEL BASE UNIT PART NO.

SIZE (W x H) DISPLAY HEIGHT

DISPLAY DIGITS(INCH) (MM) (INCH) (MM)

ESM-4450 ESM-4450-12011/0000 1.89 x 1.89 48 x 48 0.39 10.0 4

ESM-7750 ESM-7750-12011/0000 2.83 x 2.83 72 x 72 0.55 14.0 4

ESM-9450 ESM-9450-12011/0000 1.89 x 3.78 48 x 96 0.39 10.0 4

ESM-9950 ESM-9950-12011/0000 3.78 x 3.78 96 x 96 0.55 14.0 4

Base controller with NO contact, programmable to NC for reverse action. Display has fourprocess and four set points (8mm height). Features a universal input for thermocouple, RTD(2- or 3-wire), analog 0-50 V, 0-5 V, 0-10 V or 4-20 mA, and can accept a second input modulechip. Communications port is RS232 MODBUS; an optional RS485 port can be requested.

Additional module chips are available (specify indication model): Output: Input:– Relay Output – Thermocouple– SSR Output (15-18 VDC / 50 mA) – RTD– Transistor Output (24 VDC / 100 mA)– Volt/Current Output (0/4-20 mA, 0-10 V)

Other wire gauges, insulation types and lengths are available. Contact factory for details.

TM



Temperature Sensor Accessories and Kits

Accessories

MODEL TYPE DESCRIPTION

Thermocouple Extension Wires011-P00003-J25 J 24 AWG, TFE-jacketed, 25’ long

011-P00004-K25 K 24 AWG, TFE-jacketed, 25’ long

011-P00008-T25 T 24 AWG, TFE-jacketed, 25’ long

Miniature Connectors018-P00173 J Plug style

018-P00174 K Plug style

018-P00175 T Plug style

018-P00189 J Jack style

018-P00190 K Jack style

018-P00191 T Jack style

Full-Size Connectors018-P00178 J Plug style

018-P00179 K Plug style

018-P00180 T Plug style

018-P00184 J Jack style

018-P00185 K Jack style

018-P00186 T Jack style

Temperature Kits

MODELTEMPERATURESENSOR TYPE INDICATOR CONTROLLER

TK-CB001 RTD 1000 ohm No Yes

TK-CB002 Thermocouple Type J No Yes

TK-CB003 Thermocouple Type K No Yes

TK-CD001 RTD 1000 ohm No Yes*

TK-CD002 Thermocouple Type J No Yes*

TK-CD003 Thermocouple Type K No Yes*

TK-DB001 RTD 1000 ohm Yes No

TK-DB002 Thermocouple Type J Yes No

TK-DB003 Thermocouple Type K Yes No

TK-DD001 RTD 1000 ohm Yes* No

TK-DD002 Thermocouple Type J Yes* No

TK-DD003 Thermocouple Type K Yes* No

* With bench-top enclosure and fused input power setup.

Madison Temperature Kits include a temperature sensor(RTD or choice of J or K Thermocouples) and either abasic temperature indicator or a full-featured controller. The kits contain all of the hardware that is necessary tomeasure temperature (Basic kits – TK-xBxxx) or measure temperature and control a process (Deluxe kits –TK-xDxxx). Each kit includes complete wiring instructionsand a stainless steel compression fitting to mount thetemperature sensor. Also included in each kit are MadisonCompany Application Notes to guide you through the set-up of the indicator or controller. Choose from Basic kits with a panel-mountedinstrument or Deluxe kits that have the instrument factory assembled into a bench-top enclosure. The Deluxe kits alsoinclude a fused power inlet and mating 120 VAC power cord.

TK-CB003

TK-DB003

TM

T SeriesType K, J & T Thermocouples

Madison Company’s T Series thermocouples aredesigned specifically for long life and reliability using well-established engineering techniques. They are intendedfor use in measuring environmental temperatures inindustrial applications from engines and ovens todishwashers and heaters. Madison Company’s engineersconsider all aspects of the application including vibration,mechanical and thermal shock, time response, hightemperature and other environmental extremes.

The T Series Type K, J and T have a typical constructionof grounded, ungrounded or exposed tips using stainlesssteel sheath material, standard lead lengths of 24” withcustomer-specified terminations. Tip configurations canbe general purpose, penetration, air surface or tapered.

Madison Company’s thermocouple assemblies areconstructed from a variety of materials that are selectedfor the performance capability required by the applicationfor which they are designed. In addition to materialselections, junction style will also be considered withregard to time response requirements.

All Madison thermocouple products are manufacturedunder our strict total quality management system in conformance with ISO 9001:2000. T Seriesthermocouples are available in custom configurations tomeet the unique requirements of individual applications.

Typical configurations of T-typethermocouples. Madison’sengineers will design a customprobe to your specifications.



Features

• Custom configuration to customer specifications

• Wide selection of thermocouple styles, sheath materials and insulation materials

• All thermocouple material is certified, traceable to N.I.S.T.

• Sheath coatings can be provided to enhance the thermocouple

TM

Junctions

Protecting Sheath

Three main styles of thermocouple junctions are available on T Seriesthermocouples:

• Closed tip – specified when a pressure seal or protection from the atmosphereis desired. Can be made with an isolated junction or grounded junction.

• Exposed junction – specified when IR radiation or contamination by-productsare not a factor, or where fast response to temperature change is desired.

• Shielded junction – used when it is necessary to reduce the effect of radiationon accuracy but still maintain a fast response time.

Insulation Materials

Typical Design Specifications

Terminations and Leads

Although maximum sensitivity is achieved with an exposed thermocouple, the majority of applicationsrequire that the thermocouple wires be protected from mechanical damage by a tube. Sheath materials canbe specified from a variety of metals, including various stainless steels, usually 300 series or alloys.

T Series terminations can be supplied with a wide variety of terminal, stud, junction box and connectorconfigurations. All terminations are manufactured from materials that eliminate undesired junctions. Leadwires can be designed with overbraid and other forms of protection.

Magnesium oxide (MgO) is the most commonly used insulation; however, other materials such asaluminum oxide (Al2O2) and boron nitride (BN) are available.

Refer to the Madison Company Temperature Sensor Specification Sheet.For interfacing controllers, refer to Madison's E Series products.Interconnect cable assemblies can also be supplied.

Isolated

ExposedShielded

Closed Tip

Grounded



TM-10 © Copyright Madison Company – 5/08


TM

T SeriesRTDs (Resistance Temperature Detectors)



Features

• Interchangeable without sensor-to-sensor recalibration

• Very small thermal mass for fast response time

• Air or liquid temperature sensing

• Proven reliability

• Long-term stability

Madison Company’s T Series ResistanceTemperature Detectors (RTDs) are selected for theirhigh accuracy. Used in a multitude of process, foodand HVAC applications, these general-purpose RTDsare offered with a choice of elements and insulatingmaterials, providing the user with a range of valuesand accuracies. Choices in lead wire, sheathmaterials and terminations are also available.

Madison’s thin-film platinum RTDs are available in100 Ohm or 1,000 Ohm versions and are suitable forapplications that require small envelope size andlinear output. The T Series RTDs respond rapidly totemperature changes with an accuracy of ±0.7˚C at20˚C. Dependent upon the application requirements,the outside sheath materials and insulation materialswill determine the sensor assembly’s response time.Termination and fit up options are directly related tothe application specifications of the customer.

The typical configurations are three wire output -40˚C to 125˚C (-40˚F to 257˚F).

Madison Company can also provide the interfacingtransmitters, interconnecting cable and controllers fora matched subsystem.

Typical platinum RTDs offered by Madison Company provide a change in resistance thatcorresponds to a temperaturechange.

TM

Typical Applications• HVAC – room, duct and refrigerant temperatures

• Process Control – temperature regulation

• Appliances – cooking and cleaning temperatures





Specifications

Thin-film platinum RTD

-40˚C to 125˚C (-40˚F to 257˚F)

±0.7˚C

100 or 1000 ohms

Customer defined, dependent on application


Sensor Type

Temperature Range

Temperature Accuracy

Resistance at 0˚C

Sheath Material

Termination and Leads

TM

T SeriesTemperature Sensor Kits



Features

• Choice of temperature sensor -1000 ohm RTD or Type J or K Thermocouple

• Choice of digital temperature indicator or full-featured process controller

• Stainless steel compression fitting for easy mounting of the sensor

• Complete wiring instruction and application notes

• Built-in front panel interface for easy indicator set-up

Madison Company has been incorporating temperature sensors into

its level switch products for over 50 years. As an extension of this

experience, these temperature kits provide the user with the

components that are required to either measure temperature or

measure temperature and control a process.

Temperature kits are available with your choice of sensor:

• 1000 ohm RTD

• Type J Thermocouple

• Type K Thermocouple

The Basic Temperature Kits provide the user with a basic set of

components that can be incorporated into a variety of applications

that require temperature measurement and/or process control. Both

the indicator and controller are designed for panel mounting using

supplied hardware.

Deluxe Temperature Kits are turn-key and feature an indicator or

controller assembled in a bench-top enclosure with all of the

electrical (AC power) wiring completed. All the user needs to do is

mount the sensor, connect it to the indicator or controller and plug in

the power cord.

Madison Temperature Kits include a temperature sensor (RTD or

choice of J or K Thermocouples) and either a basic temperature

indicator or a full-featured controller. The kits contain all of the

hardware that is necessary to measure temperature (Display kits

TK-Dxxxx) or measure temperature and control a process (Controller

kits TK-Cxxxx). Each kit includes complete wiring instructions and a

stainless steel compression fitting to mount the temperature sensor.

Also included in each kit are Madison Company Application Notes to

guide you through the setup of the indicator or controller.

TK-CB003

TK-CD003

Basic Indicator Kit

Deluxe Controller Kit

TM

Temperature Sensor Kits





MODEL TEMPERATURE SENSOR TYPE INDICATOR CONTROLLER

TK-CB001 RTD 1000 ohm Yes Yes

TK-CB002 Thermocouple Type J Yes Yes

TK-CB003 Thermocouple Type K Yes Yes

TK-DB001 RTD 1000 ohm Yes No

TK-DB002 Thermocouple Type J Yes No

TK-DB003 Thermocouple Type K Yes No

MODEL TEMPERATURE SENSOR TYPE INDICATOR CONTROLLER

TK-CD001 RTD 1000 ohm Yes Yes

TK-CD002 Thermocouple Type J Yes Yes

TK-CD003 Thermocouple Type K Yes Yes

TK-DD001 RTD 1000 ohm Yes No

TK-DD002 Thermocouple Type J Yes No

TK-DD003 Thermocouple Type K Yes No

Basic Temperature Indicator & Process Controller Kits Panel-Mounted Instruments

Deluxe Temperature Indicator & Process Controller Kits Bench-Top Enclosure Instruments

Process Indicator Features:• Large 4-digit display – digits are 0.80” (20.3mm) high• Plug-in output module design• On-board sensor power supply• Universal process input (TC, RTD, VDC, mA)

Process & Temperature Controller Features:• 4 digits process and 4 digits set display• Universal process input (TC, RTD, VDC, mA)• Dual- or multi-point calibration for V and mA inputs• Programmable ON/OFF and PID control forms

Both of these units feature standard relay output. Additional input and output modules are availableto meet your requirements.

TM

T SeriesMadison-Omni®RTD Temperature Sensors



Features

• Provides the accuracy of RTD sensors with the easy-to-use convenience ofthe user-programmable Madison-Omni® display interface

• Compact design

• Adjustable limits and alarm points with LED alarm light

• 4-20 mA output

In addition to being offered with our continuous levelsensing products (reed switch or ultrasonic), theMadison-Omni® integrated display/control unit can beprovided with a platinum RTD (resistance temperaturedetector) temperature sensor tip. Featuring the sameuser-programmable interface utilized throughout theMadison-Omni® family, the RTD can be set for twoalarm points and offers a uniform readout for severalsensor monitoring options.

There are 12 standard configurations available for thisMadison-Omni® temperature sensor, all usingplatinum RTD technology. The temperature range ismodel dependent.Madison-Omni ® RTD

temperature sensor with integrated display/control

TM





SpecificationsElectrical:

Supply Voltage – 10-30 VDC ±10% Maximum Load – 700 Watts @ 24 V (100 Watts @ 10 V, 1K @ 30 V, linear to the

operation voltage)Output – 4-20 mAPlug Connection – M 12x1*Cable Length Options (sold separately) –

5-pole shielded cable with 90˚ angled connector in 2m, 5m or 10m lengths5-pole shielded cable with straight connector in 2m, 5m or 10m lengths

Mechanical:Sheath Material – 316 stainless steel Thread – 1/2” NPT

Operational:

Standard Models

T4275-1T4275-2T4275-3T4275-4T4275-5T4275-6T4275-7T4275-8T4275-9T4275-10T4275-11T4275-12T4275-13T4275-14T4275-15T4275-16T4275-17T4275-18T4275-19T4275-20T4275-21T4275-22T4275-23T4275-24

Neck Style

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

VerticalSwanSwan

Probe Length

1.96” (50mm)1.96” (50mm)1.96” (50mm)3.93” (100mm)3.93” (100mm)3.93” (100mm)5.90” (150mm)5.90” (150mm)5.90” (150mm)7.87” (200mm)7.87” (200mm)7.87” (200mm)1.96” (50mm)1.96” (50mm)1.96” (50mm)3.93” (100mm)3.93” (100mm)3.93” (100mm)5.90” (150mm)5.90” (150mm)5.90” (150mm)7.87” (200mm)7.87” (200mm)7.87” (200mm)

Thread

NPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 ANPT 1/2 A

G 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 AG 12 A

Temperature Range

0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 100˚C (32˚F to 212˚F)0˚C to 250˚C (32˚F to 482˚F)



TM

T SeriesThermistors (Thermally Sensitive Resistors)



Features

• Interchangeable without sensor-to-sensor recalibration

• Very small thermal mass for fast response time

• Air or liquid temperature sensing

• Proven reliability

• Long-term stability

Madison Company’s T Series Thermistors(THERMally sensitive resISTORS) are selected fortheir high accuracy. Used in a wide variety of process,food and HVAC applications, these general-purposeThermistors are offered with a choice of elements andinsulating materials, providing the user with a range ofvalues and accuracies. Choices in lead wires, sheathmaterials and terminations are also available.

Madison’s Thermistors are available in NegativeTemperature Coefficient (NTC) versions. NTCThermistors exhibit decreasing electrical resistancewith increases in environmental temperature andincreasing electrical resistance with decreasingtemperature.

The T Series Thermistors respond rapidly totemperature changes, with an accuracy of ±2˚C.Depending on the application requirements, theoutside sheath materials and insulation materials willdetermine the sensor assembly’s response time.Termination and fit up options are directly related tothe application specifications of the customer.

Typical Thermistors offered byMadison Company.

TM








Specifications

Thermistor

-80˚C to 150˚C (-112˚F to 302˚F)

±0.2˚C



Sensor Type

Temperature Range


Sheath Material


TM

T SeriesBimetal Thermal Switches



Madison Company offers a full range of thermal switches that can be designed as a stand-alonetemperature sensor or combined into liquid level switches. The thermal switches are preciselycalibrated devices that cover a broad temperature range. Configurations using snap-action bimetallicdisk, bimetal slow make/slow break, rod and tube and solid state construction are also available tooffer a broad array of temperature control solutions.

The bimetal contact movement is achieved using the different expansion rates of two metals fusedtogether. This is a creep action device, providing very-close-tolerance temperature sensing andhaving small differential. The set point range is 30˚C to 130˚C. All thermal switches are factory-calibrated to customer-defined set point range.

Features

• Bimetal construction

• Creep action (slow make/slow break switching) or snap action

• Low differential between opening/closing temperatures

• Various contact types and ratings are available, depending on application

• Available in open on rising temperature or close on rising temperature configuration

• Close on rising available from 30˚C to 130˚C (86˚F to 266˚F)

• Open on rising available from 30˚C to 125˚C (86˚F to 257˚F)

• Accuracy of ±5˚C (±9˚F)

• Rated life: 100,000 cycles, depending on application

• Repeatability of ±1˚C (±1.8˚F)

• Small size permits flexible and innovative product enhancementsTM








• Motors – overload protection

Specifications

Bimetal Thermal Switch

30˚C to 130˚C (86˚F to 266˚F)

±5˚C (±9˚F) – Special tolerances can be quoted



Quick make/quick break switching

In some cases, the differential between opening/closing temperatures can be specified from 2˚C to 40˚C (36˚F to 104˚F); most models have“zero” differential

Various ratings available, depending on application

Sensor Type

Temperature Range


Sheath Material


Snap Action

Temperature Differential

Contact Ratings

Madison Company offers two types of Bimetal Switches:

Creep ActionCreep action is when the switch element is designed to open slowly at the rated temperature. Many switches have atemperature differential between the opening and closing temperature. This type of action may be useful in anapplication where the switch is being used as a protection device for when the temperature of the process has rapidtransient changes. The creep action tends to “average” the changes and prevent nuisance operation of the switch.This is also important because most of the temperature switches listed for protection applications are listed for alimited number of cycles. This type of switch is intended for use as a protection device only.

Snap ActionThese switches are called snap action because they open very rapidly (“snap”) at the rated temperature. This type isusually best for thermostat applications. They typically have no (or very small) temperature differential betweenopening and closing. They will respond to relatively short-lived changes in temperature, which can make them cyclevery frequently in applications where the temperature changes often.

TM

Madison Company can engineer temperature sensors to meet your application needs. Please provide theinformation requested below so that our Engineering Department can determine the appropriate sensordesign for your application.


Address:



SENSO

R TYP

E

Temperature Switch: Open on rising Close on rising

@ degrees C or F Tolerance: (±%)

Snap action Creep action

Current capacity: Amps @ Volts AC or DC

RTD Sensor: 100 Ohm 1000 Ohm

Temperature range – High limit: Low limit: degrees F or C

Critical range of measurement:

Thermistors: Resistance Ohms @ 25 degrees C Tolerance (%)



Thermocouples: Type J Type K Type T



Accuracy – Standard limits: Special limits:

Junction type: Ungrounded Grounded Exposed

OUTP

UT

Output: Direct 4-20 mA 0-5 V Other

Interface requirements: Controller Digital thermometer Relay Other

PACK

AGIN

G

Media (type and concentration): Pressure:

Probe length: Diameter:

Mounting connection: Flange – Size: Weight:

Pipe thread – Size: Inside mount Outside mount

Bulkhead fitting – Size:

Adjustable fitting – Size:

Lead termination: Bare leads – Length:

Insulated ext. cable – Length: Type:

Connector – Type:

Junction box – Size: Type:

Other:

Environmental (special requirements, e.g. immersion):


T Series Specification SheetTemperature Sensor

Continuedon Back

TM


APPL

ICAT

ION DES

CRIPTION

DES

IGN

PROJE

CT


Packaging/Labeling:

Pricing Target:






T Series Specification SheetTemperature Sensor

St

TM

P SeriesProximity Sensors

Madison Company’s P Series proximity sensors use reedswitch-based technology, which offers reliability of up to 5 million cycles. Offered in both plastic and metalhousings, these proximity sensors are interchangeablewith existing sensors of similar characteristics or can bedesigned specifically for individual application needs.

These noncontact sensors are available with single poledouble throw switches (Form C), or Form A and B. Theyoffer a variety of ways to sense the relative position ofspecific machine elements requiring continuousmonitoring. Several different fabrication materials can beused. Materials are selected based on the applicationenvironment. The standard operating temperature rangeis from -40˚C to 125˚C (-40˚F to 257˚F).

Sensors can be ordered in sets containing the sensor, the actuator and hardware, or the components can beordered separately. These cost-effective sensors areoffered in standard designs and engineered designs withvarious actuation points.

DIRECTIONS OFUSE FOR PROPERACTUATION


© Copyright Madison Company – 2/05 PR-1

Typical standard product designsoffered from stock.

Features

• Fully potted switch and leads

• High cycle rate capabilities

• High-speed operation

• Compact for limited-spaceapplications

• No moving parts, for longer life

• Corrosion-resistant

• Wide selection of materials

• Engineered designs available

PR

Proximity Sensors

Specifications for Representative Standard Products

Contact Form

Maximum Voltage(based on switch selection)

Maximum Switching Amps

Watts (max.)

Contact Resistance

Breakdown Voltage

Operating Temperature

“Must Operate” Distance

“Must Release” Distance

Standard Actuator Size

Operating Time

Release Time

Leads (standard)(3 leads with color options)

P300 SeriesStainless Steel

A (SPDT)

300 V

.5 A

50 W

.1 Ohm maximum

600 VDC

-40˚C to 125˚C

.200”

.600”

.670” OD x .200” H

.6 msec

.05 msec

24”, 22 AWG Teflon®

P450 SeriesPVC

1C

120 VDC; 120 VAC

3 A

100 W

.5 Ohm maximum

250 VDC

0˚C to 60˚C

.200”

.700”

1.125” OD x .470” H

3 msec

3 msec


P400 SeriesStainless Steel

1C

120 VDC; 120 VAC

3 A

100 W

.5 Ohm maximum

250 VDC

-40˚C to 125˚C

.200”

.700”

1.125” OD x .470” H

3 msec

3 msec


WIRE LEADSSEE CHART FOR

LENGTH AND TYPE

4.030" (102.4)3.330" (84.6)

2.415"(61.3)0.188" (4.8)

4 PLACES

.210"(5.3)

1/2" NPT 1.105"(28.1)

.214"(5.4)

1" (25.4)square

1" (25.4)square


LENGTH AND TYPE

2.750"(69.9)

1.000"(25.4)

.750"(19.1)

1/2" NPT 5/8-18THREAD


LENGTH AND TYPE 1.575"(40.0)

HEX NUT5/16-18

THREAD

P450 Series P400 Series P300 Series

Wiring Chart

Common Black

NC Yellow

NO Green




PR-2 © Copyright Madison Company – 5/08

PR

Madison Company can engineer proximity sensors to meet your application needs. Please provide theinformation requested below so that our Engineering Department can determine the appropriate switchdesign for your application.

ENVI

RO

NM

ENT

ELEC

TRIC

ALPH

YSIC

ALPR

OJE

CTN

OTE

S

DES

IGN


Address:



Fluid:

Temp. Range: Max. Pressure:

Misc. Conditions (vibration, food contact, hazardous location, turbulence, solids, approvals [i.e. UL, NSF], etc.):

Contact Form (1A, 1B or 1C): Voltage:

Type of device being controlled:

Operating Time: Release Time: Switch Amps:

Misc.:

Operational Distance: Release Distance:

Lead Length: Lead Color:

Connector/Terminations:

Mounting:


Packaging/Labeling:

Pricing Target:






© Copyright Madison Company – 2/05 PR-3

P Series Specification SheetProximity Sensors

St

PR

E Series


© Copyright Madison Company – 7/06 AC-1

Features

• Input can be scaled for a linear readout; 4-20 mA input is reversible

• Base models are offered in industry-recognized sizes

• Module chips allow for many input configurations for the same base model

• Minimal down time

• Software is downloadable to text file for easy uploading, without having toprogram each individual unit

• Communication port standard; network port optional

Madison Company offers a full line of process controllers, indicatorsand timer/counters that mate to any of our liquid level switches,ultrasonic sensors, thermocouples or RTD temperature sensors.

This common family of interfacing devices offers both a base unitand modular chip that is inserted to provide flexibility when inputsignals vary from one sensor to another, plus a common base type.This is the most cost-effective way to maintain a factory-wide systemor multiple application needs.

ESM CONTROLLERS offer universal input capabilities with a 4-digitdisplay for both process and set points. The plug-in module chipdesign allows for the configuration of one or two input channels forthermocouples, 2- or 3-wire RTDs or analog 0-5 V, 0-50 V, 0-10 V or4-20 mA. This chip array allows for more than 150 possibleconfigurations from the same base controller. ESM Controllersfeature programmable ON/OFF, P, PI, PD and PID control forms andautomatic or manual operation within the base controller. There areheating, cooling and alarm functions and ramp, soak and assuredsoak settings. Standard RS232 with optional RS485 serialcommunication connection allows for PC interfacing or networking.

ESM INDICATORS are not designed to maintain (control) a process but can be used as high-limit alarm units by virtueof a programmable latch feature. Otherwise, these Indicators offer many of the features of the ESM Controllers. Theseindicators offer dual or multi-point calibration for Volt and mA inputs. There can be up to three output channels and twolevels of password protection. All Indicators offer the same module chip design.

EZM TIMER/COUNTERS have two 6-digit displays: red for the actual count and green for either of the two set points.They will accept input signals from NPN, PNP, Encoder or Dry Contact with reset, pause and channel A and channel Bcounter inputs. Programmable counter/totalizer counter, batch counter, timer, chronometer, frequency meter andtachometer functions are all offered within the same model. Programmable time range is from 0.01 second to 999.99hours, with programmable alarm functions. All Timer/Counters offer the same module chip design.

ESM and EZM Series Controllers

AC

ESM and EZM Series Specifications




AC-2 © Copyright Madison Company – 5/08

ESM Controller Family:• 4-digit process and 4-digit set point displays• Plug-in input and output module chips• Universal process input: Thermocouple, RTD, V, mA• Dual- and multi-point calibration for V and mA inputs• Programmable ON/OFF, P, PI, PD and PID control forms• Autotune and Selftune selection• Automatic or manual operation

Model**

ESM4450ESM7750ESM9450ESM9950

Size

1.89” x 1.89” (48 x 48mm)2.83” x 2.83” (72 x 72mm)1.89” x 3.78” (48 x 96mm)3.78” x 3.78” (96 x 96mm)

Base Part Number

ESM4450-12011/0000ESM7750-12011/0000ESM9450-12011/0000ESM9950-12011/0000

EZM ProgrammableTimer/Counter Family:

• Two 6-digit displays: one for actualcount, one for up to two set points

• Reset, pause and channel A and B inputs• Input signals from NPN, PNP, Encoder or Dry Contact• Programmable counter/totalizer counter, batch counter, timer,

chronometer, frequency meter and tachometer functions• Programmable time range from 0.01 sec. to 999.99 hours• Automatic and manual resets• Programmable alarm functions

• Counting functions are selectable: INC, DEC, INC/INC,INC/DEC or UP/DOWN; x1/x2/x4 with Encoder type of counting

• Coefficient and decimal point position to precisely scale input(eg. feet/min., gal./hr., etc.)

• Password protection• Standard RS232 or optional RS485 serial interface port• On-board sensor power supply

Model**

EZM4450EZM4950EZM7750EZM9950

Size

1.89” x 1.89” x 4.13” (48 x 48 x 105mm), 1/16 DIN1.89” x 3.78” x 2.99” (48 x 96 x 76mm), 1/8 DIN2.83” x 2.83” x 2.99” (72 x 72 x 76mm), 1/8 DIN3.78” x 3.78” x 2.99” (96 x 96 x 76mm), 1/4 DIN

Base Part Number

EZM4450-10010/0000EZM4950-10010/0000EZM7750-10010/0000EZM9950-10010/0000

Module Chips:Relay Output*SSR Output (15-18 VDC)Transistor OutputVolt / Current Out (0/4-20 mA, 0-10 V)

Digital Input (5-30 VDC)0/4-20 mA Current Input0-5 A AC Current InputThermocouple Input (Type J, K, T, R, S, B, E, N or C)RTD Input

**Base Size: 4xxx

EMO400EMO410EMO420EMO430

EMI400EMI410EMI420EMI430EMI440

7xxx



9xxx



* Relay Outputs: 3 A @ 250 VAC for EMO400;5 A @ 250 VAC for EMO700 and EMO900

** Base Size is Model Number Type

• Heating, cooling and alarm functions• Ramp, soak and assured soak settings• Standard RS232 or optional RS485 serial interface port

ESM Indicator Family:• Large 0.80” (20.3mm) high 4-digit display (on ESM4900)• Plug-in output module chips • Universal process input: Thermocouple, RTD, V, mA• Dual- and multi-point calibration for V and mA inputs• Cold dual- and multi-point calibration for V and mA inputs• Junction compensation• Adjustable input filtering, 0.0 to 900.0 seconds

Model**

ESM4400ESM4900ESM7700ESM9900

Size

1.57” x 1.89” (40 x 48mm)3.78” x 1.89” (96 x 48mm)2.83” x 2.83” (72 x 72mm)3.78” x 3.78” (96 x 96mm)

Base Part Number

ESM4400-12011/0000ESM4900-12011/0000ESM7700-12011/0000ESM9900-12011/0000

• Up to three outputs• Password protection at two levels• Standard RS232 or optional RS485 serial interface port

AC

R SeriesR1 General-Purpose Relay



Features

R1 General-Purpose Relay

Madison Company offers a full range of relays forcustom applications. Our engineers are available to review customers’ specifications and suggest the proper relay for their application.

This DPDT relay device provides electrical isolation for all Madison single-level and multi-levelswitches. Multi-level switches typically require one relay per level. Relay coils are available for110 VAC, 220 VAC or 12 VDC applications. Theisolated output contacts can be used to switch awide variety of voltages. The relay can be used forsolenoid valves, pumps and alarm applications thatdo not exceed the listed output contact ratings. The30 amp load rating can eliminate the need for apump motor starter in some applications.

Terminal Configuration (switch protection)

1. Apply the input power through the Float Switch and attach to terminals 1 and 0 as shown.

2. Connect one line of the switched power to pin 8. Connect the other power lead through the switched device and to the desired operationterminal (pin 6 or 7).

Switched Terminals

7 Normally Closed 3 Normally Closed6 Normally Open 2 Normally Open8 Common (6-7) 4 Common (2-3)

Output Contact Ratings

(8-6, 8-7 or 4-2, 4-3)30A @ 277 VAC20A @ 28 VDC

1 Hp @ 120 VAC3 Hp @ 240 VAC

• DPDT switching capability

• Control compressor loads to 3.5 tons,25.3 FLA, 110 LRA

• Extended life: > 300,000 operations @ 30A, 240 VAC (DC coil)> 100,000 operations @ 30A, 240 VAC (AC coil)

• Meets UL873, UL508 and VDE 8mmspacing requirements

• UL Class F construction; UL approved for 600 VAC switching

• Conforms to VDE 0435, 0631 & 0700

6

8

7

1

2

4

3

0

115 VAC

V+ -

Pump / Valve

AC

Specifications





Electrical: Contact Ratings – @ 25˚C (77˚F) with relay properly vented.

Maximum Load Ratings –Normally Open Contacts:

40A @ 277 VAC, resistive; 6K Ops. (Flange Mount);

30A @ 120/277 VAC, resistive; 10A @ 600 VAC, resistive;

1 Hp @ 120 VAC, 3 Hp @ 240 VAC;

1.5 Hp @ 480 VAC, 1.5 Hp @ 600 VAC;

110 LRA, 25.3 FLA @ 240 VAC with DC coil*;

60 LRA, 14 FLA @ 240 VAC with AC coil;

3A @ 240 VAC pilot duty; 20A @ 28 VDC; TV10 @ 120 VAC

VDE Rating (Flange Mount): 25A @ 400 VAC, 30K Ops.

Normally Closed Contacts:

3A @ 28 VDC or 277 VAC, 2A @ 480 VAC, 1A @ 600 VAC

VDE Rating: 3A @ 400 VAC, 30K Ops.

Minimum Load Ratings –Normally Open Contacts: 500 mA @ 12 VAC/VDC

Normally Closed Contacts: 100 mA @ 6 VAC/VDC

Expected Mechanical Life – 5 million operations

Expected Electrical Life – 100,000 operations at rated load

ARI 780-86 Endurance Test (section 6.6) – HVAC Definite

Purpose Contactor Standard

Normally Open Contacts:

Single Phase/Two Pole (Both poles together switching a single load)

100 LRA, 25.3 FLA, 200K operations (DC Coil)

Single Phase Per Pole (Single load per pole)

110 LRA, 18 FLA, 200K operations (DC Coil)

60 LRA, 14 FLA, 200K operations (AC Coil)

Initial Dielectric Strength: Between Contacts & Coil – 4,000 V rms, 50/60 Hz.

Between Open Contacts – 1,500 V rms, 50/60 Hz.

Between Poles – 2,000 V rms, 50/60 Hz.

Initial Insulation Resistance: Between Mutually Insulated Elements – 109 ohm min. @ 500 VDC

Coil: Voltage – 12 VDC, 120 VAC and 220 VAC

Nominal Power – AC Coil: 4.0 VA; DC Coil: 1.7 W

Coil Temp. Rise – 35˚C/W (95˚F/W)

Maximum Coil Temp. – 155˚C (311˚F)

Duty Cycle – Continuous

Operational: Must Operate Voltage –

AC Coil: 80% of nominal voltage or less

DC Coil: 75% of nominal voltage or less

Must Release Voltage – 10% of nominal voltage or more

Initial Operate Time** – 15 ms typical (25 ms max. w/ bounce)

Initial Release Time** – 10 ms typical (25 ms max. w/ bounce)

Maximum Operating Frequency – 14 operations per minute

Environmental: Temperature Range –

Storage: -55˚C to 155˚C (-67˚F to 311˚F)

Operating: AC Coil: -40˚C to 65˚C (-40˚F to 149˚F)

DC Coil: -40˚C to 85˚C (-40˚F to 185˚F)

Vibration – 0.065” (1.65mm) double amplitude for

10-55 Hz., functional

Shock, Operational – 10g for 11 ms, 1/2 sine wave pulse

with no contact opening > 100 ms

Mechanical: Termination – 0.25” (6.35mm) quick connects for coil

and contacts

Enclosure – Immersion cleanable, plastic

Weight – Approx. 3 oz. (86 g)

Conditions: All parametric, environmental and life tests are performed

according to EIA Standard RS-407-A at standard test

conditions (25˚C ambient, 20-50% RH, 29.5 ± 1” Hg.), unless

otherwise noted.

* FLA and LRA ratings are compatible with 3.5 ton

compressor applications

** Nominal voltage, no coil suppression, excluding bounce

AC

R SeriesR2 Controllers



Features

• Dual probe level detection

• Solid state circuitry, coated for moisture protection

• Factory-fixed or adjustable sense resistance

• UL and CSA approvals

• Electromechanical relay output for isolation and reliability

R2-120 Liquid Level Controller

The R2-type liquid level controllers provide high-level,low-level or bilevel control in a convenient octal plug-inpackage. Models are available for pump-up or pump-down operation. Transformer isolated AC voltage on theprobes prevents electrolytic plating. Less than 1/1000of an amp of current is used to sense the presence ofconductive liquid between the probes and common.Onboard sensitivity-adjustable units eliminate falsetripping caused by floating debris and foaming agents.Isolated electromechanical relay contacts can be directlyconnected to the control circuitry or control pumps andsolenoids. The R2-type controllers can be used at adistance of up to 500 feet from probes, and twisted pairor shielded cable is recommended.

Typical Controller Hookup to Switches

1. Set switches “Normally Open.”

2. Connect Upper switch to pins 5 and 8, Lower switch to pins 5 and 6.

3. Connect the switched voltage to terminal 1 (AC or DC Volts).

4. FOR PUMP-UP: Connect one end of the pump/valve to terminal 4 andthe other end to the switched voltage return.FOR PUMP-DOWN: Connect one end of the pump/valve to terminal 3and the other end to the switched voltage return.

5. Connect line voltage to terminals 2 and 7.

AC

Specifications





Control

Sensing Type

Voltage at Probe Terminals

Sensing Resistance

Sensing ResistanceTolerance

ON/OFF resistance

12 VAC nominal

Factory-fixed or adjustable to 100,000 ohms

Factory-fixed – ±10%; adjustable – guaranteed range

R2-24 – 24 VACR2-120 – 120 VACR2-220 – 220 VAC

±15% nominal

50/60 Hertz

Output

Type

Contact

Output Contact Ratings (1-3 or 1-4)

Socket Rating

Electromechanical relay

SPDT isolated

5A @ 220 VAC 10A @ 120 VAC 10A @ 30 VDC

10A @ 300 VAC

Transient Protection – Dielectric Breakdown: 1500 volts RMS minimum

Environmental – -20˚C to 60˚C Operating Temperature

Mechanical – Plug-in Mounting: DIN-type track mount/surface mount, 8-pin socket termination: Octal 8-pin plug

Mounting Connection – Two molded thru holes for mounting with #8 screws or bolts; can be DIN rail-mounted

Dimensions

Controller

Socket

Total Installed Height

1-3/4” x 2-3/8” x 2-3/4”

1-9/16” x 2” x 11/16”

3-11/16”

AC

Operating Voltage (Input)

Voltage

Tolerance

Frequency

PD SeriesPD765 Trident Meter



Features

• Current, voltage, thermocouple and RTD inputs

• Shallow depth case, 3.6” behind panel

• NEMA 4X, IP65 front

• Universal Power Supply: 85-265 VAC or 90-265 VDC

• Two-relay output

• Process and temperature

• High and low alarms

• Latching or non-latching relays

• Pump alternation control

• Time delay and fail-safe relays

• Maximum and minimum readings

• Easy four-button programming and setup with lockout capability

• Display: 4 digits (-1999 to 9999), 0.56” high

• Linear or square root function with low-flow cutoff

• Optional plastic, steel and stainless steel NEMA 4 and 4X boxes

Model PD765

The Madison Model PD765 Trident Meter is aUniversal Panel Meter that handles all of thecommon process display applications withsimplicity, reliability, accuracy and ease. It isfactory calibrated to accept process voltage andcurrent inputs, 100 ohm platinum RTDs and thefour most common thermocouples. Setup andprogramming are a jumper-free, single-switchsnap using a simple four-button programmingmethod or a computer. If there are multiplemeters to be programmed, the Trident’s copycapability allows one meter’s setup to beautomatically copied to another.

AC

PD765 Available Options





4-20 mA Analog Output option

24 VDC @ 200 mA Transmitter Power option

RS-232, RS-422/485 Serial Communication options

Data Acquisition with MeterView® software

Meter Copy feature

Optional Plastic, Steel and Stainless Steel NEMA 4 and 4X Boxes

2.45"(62.2)

0.59"(15.0) 3.6"

(91.4)

3.2"(81.3)

1.76" (44.7)

2.50"(63.5)

4.68”(118.9)

3.61"(91.7)

Side View Top View

AC

ED SeriesLoop Powered Displays



Features

Model ED-001 Loop Powered Probe-Mount Display – Plastic Housing

Model ED-002 (not shown) –Metal Housing

For use with most Ultrasonic andRadar Sensor models

Model ED-003 Loop Powered Wall-Mount Display

For use with any Level Switch with a4-20 mA output, and with Ultrasonic orRadar Sensor models

• For use with tanks whose level isbeing monitored by a sensor witha 4-20 mA output

• Indicates the percentage full or empty

• Display can be changed to indicate100% at 4 mA or 20 mA by simplymoving an internal link

• Packaged in a compact NEMA 4X enclosure that can be wallmounted (ED-003) or probe mounted(ED-001 or ED-002)

AC

ED-003 Specifications





Display – 3 digit LCD 1/2” (12.7mm) high

Temperature – -40˚C to 60˚C (-40˚F to 140˚F)

Voltage Drop – 0.95V @ 20 mA

Accuracy – Reading ±0.5%

Humidity – 0-95% non-condensing

Range – 3.5 mA to 22 mA

Maximum Current – 150 mA

Display Range – Normal 100% @ 20 mA -3% to +112%0% @ 4 mA

Reverse 100% @ 4 mA -12% to +113%0% @ 20 mA

22 mA and Above – LOE (Loss of Echo)

Wall-Mounted Enclosure – NEMA 4X, IP65

LOOP POWERED DISPLAY

20

%

4

++

+ +

3.54"(89.9)

2.37"(60.2)

4.53"(115.1)

4.05"(102.9)

ø0.172" Typ. of4 Mtg. Holes

Front View

0.24"(6.1)

AC

The first consideration is the type of liquid, temperature and pressure to which the switch will be subjected. Madisonmanufactures liquid level switches in various styles, in a variety of materials, to cover a broad range of conditions.Following are some basic recommendations for selecting the proper liquid level switch material for your application.

Material

316 Stainless Steel

Polypropylene (PP)

Polysulfone (PSU)

Brass

Buna-N (Nitrile)

PBT(PolybutyleneTerephthalate)

Kynar

PTFE (Teflon®)

Application

For high-temperature (to 300˚C), high-pressure (to 300 PSIG) and corrosive conditions.Commonly used in food processing, medical, heating and cooling equipment.

For acidic conditions, such as found in electroplating and metal cleaning. Another choice forlower-temperature (to 105˚C) food processing applications (Madison Company uses onlypolypropylene that is FDA-approved for food contact). Also a good choice for general-purpose applications in commercial or consumer appliances and equipment.

A hydrolysis-resistant material for continuous use in hot water and steam, at temperaturesup to 148˚C. High chemical resistance to acidic and salty solutions and good resistance todetergents. Commonly used for analytical instrumentation, medical devices andsemiconductor process equipment components. Food-grade material available with FDA,NSF, 3A-Dairy and USP Class VI compliance, upon request.

The selection for petroleum-based liquids, such as lubricating oils, gasoline and diesel fuels.Widely used in storage tanks of vehicles, generators, transmissions and hydraulic systems.Other uses are in lubrication, recovery, refining and fuel processing equipment withtemperatures up to 130˚C.

Suitable for use with aromatic hydrocarbons, dilute acids and bases with a temperature rangeof -50˚C to 120˚C. Applications include fuel tanks, transmissions and hydraulic systems.

A strong and highly crystaline plastic featuring good dimensional stability. Generally serveswhere temperature resistance and permeability are not important. Ideal for applicationssuch as fuel and hydraulic systems with continuous service at 120˚C.Please note: PBT is not suitable for use in temperatures above 130°C.

Chemical- and solvent-resistant properties make this material a problem solver for manyapplications. Its high purity nature is ideal for food handling and sensitive laboratory or testequipment with temperatures up to 105˚C.

This material is ideal for acids, alkalis, oils and gasoline applications where temperaturesare up to 260˚C. Temperature-stable and chemical-resistant, with a very low coefficient of friction.

Environmental Considerations

Madison Company also manufactures selected switch models in a combination of materials that are available fromstock or in a custom, build-to-order configuration.

Once a suitable material has been selected, the type of switch and configuration of actuation points, fittings and wireterminations are the next considerations. Madison Company stocks a full line of standard products that can meet therequirements of many applications. For specific designs, Madison can custom build, to order, switches with an infinitenumber of variations and options.

Teflon® is a registered trademark of E.I. du Pont de Nemours and Company.



© Copyright Madison Company – 2/05 RF-1

RF

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General Product Guide

RF

Intensive agitation of liquid, boiling fluids and surging due tolarge inflows of liquid can all cause tur bu lence and erraticfloat switch operation. This problem can be eliminated by theuse of slosh shields with adequately-sized fluid and ventholes, as il lus trat ed here. Available for vertical, horizontal(side-mounted) and multi-level switches with full-size orminiature floats, these slosh shields can be sup plied in stain less steel, brass, polypropylene, PBT or Kynar.

Turbulence

Every Madison float switch has a float containing a magnet and a dry reed switch encapsulated within a stem. Thefloat travel in the liquid magnetically actuates the reed switch, providing an “on” or “off ” function.

NORMALLY CLOSEDNORMALLY OPEN

Operation (NO/NC)

Every Madison float switch contains a dry reed switch encapsulated within a stem. Reed switches are highly reliableand able to deliver more than 5 million switching cycles when operated at their rated electrical load. To ensure manyyears of operation, it is important to consider the electrical load conditions to which the switch will be subjected.

All reed switches are rated for resistive loads or steady state current. Devices such as motors, solenoids, coils, strobesor tungsten lights are capable of producing a capacitive or inductive electrical load. When power is applied or removed,these devices can produce a current spike that is four to ten times the steady state current. The resulting exposure tohigh current can burn the reed switch contacts or fuse the reeds together, causing a shortened switch life or failure.

We recommend that a circuit be used to protect a reed switch from current overload caused by a capacitive orinductive device. The commonly-used circuits shown below will allow the switch to function while preventing highcurrent from damaging the reed switch contacts.

–+

Ind. Load

DC Contact Protection/Load Drain

1N4004

Note: For AC loads, the diode can be replaced with a varistor.

–+

Ind. Load

Reed Protection

V

R

Is

Lamp Loads

Switch operation is determined while the switch is inthe dry position with the installation fitting up.

Normally Closed: Switch will open on the rise ofliquid and close on the fall of liquid.

Normally Open: Switch will close on the rise ofliquid and open on the fall of liquid.

Madison switches are supplied in the normallyclosed (NC) position, unless otherwise specified.

Reed Contact Protection

R = Current limiting resistor("R" should be selected to give "Is" less than the rated carrying current.)

L

Float Switch Technology



RF

Madison has extensive experience in the design and production of tank levelcontrols. Level switches with two or more floats are often used as part of a controlsystem for pumps and other filling devices. For single-phase devices, such assolenoids and pumps with fractional horsepower motors, a single relay circuit maybe incorporated in an enclosure for either filling or draining operations. For largerpumps, where three-phase operation is required, the same relay circuit can beused to control the three-phase contactor in the motor control circuit. ConsultMadison's fluid control engineers for assistance with these applications. Typicalcircuits for this type of control are illustrated here.

TopSwitch

BottomSwitch

Relay

Relay

Single Phase Pump Motoror 3-Phase Contactor Coil

or Solenoid Valve

B

BottomSwitch

TopSwitch

Relay

Relay

Single Phase Pump Motoror 3-Phase Contactor Coil

or Solenoid Valve

F

Electrical Considerations for Reed Switch Devices

For Pump-Up Applications

For Pump-Down Applications

Electrical current overload is a common cause of failure for liquid level switches utilizing reed switch technology. Reedswitches are rated for a steady-state current. Devices such as motors, solenoids or coils can produce capacitive orinductive electrical loads. When power is applied or removed from these devices, it can produce a current spike from 4 to 10 times the switch’s steady-state current. This spike in the current can arc across the contacts of the reed switch,causing the contacts to fuse together or stick. When this occurs, the switch may fail or appear unreliable. To preventthis type of failure, a circuit can be wired in conjunction with the switch to protect it from the current overload causedby capacitive or inductive devices. A resistor/capacitor network or varistor can be used for AC loads, and a diode canbe used for DC loads.

cable capacitance

R

load

load

load

diod

e

+

-

load

R

C

varistor (VDR)

Capacitive Load

Inductive Load

When trying to switch loads (capacitive orinductive) that exceed the maximum steady-state current rating of the reed switch (see UL Current & Voltage Rating Chart onfollowing page), Madison recommends the use of general-purpose/isolation relays orcontrollers to protect the switch from currentoverload. This will prevent the contact of thereed switch from fusing together, therebyincreasing the lifespan and reliability of theswitch. Madison offers the R1 general-purpose DPDT relay for switching simpleloads, as well as the R2 controller to performpump-up or pump-down control when usedwith at least two levels. Keep in mind that anyrelay or controller that you use should berated to handle your supply voltage and havea current rating greater than your maximumsupply current.

The life of the reed switch istypically 10 6 - 10 9 operations,dependent upon loadconditions. The special reedblade material is selected toensure a mechanical life of atleast 3 x 10 9 operations.

Contact Protection: Thespecified value of switchingcurrent and/or voltage mustnever be exceeded, even forvery short periods. It isstrongly recommended thatcontact protection be usedwhenever there are capacitiveor inductive loads (long leadsand relay loads). High inrushloads caused by filamentlamp switching orcapacitances may becompensated for by usingcurrent limiting resistors.These should limit the currentto that acceptable to the reedswitch.

Tank Level Control



Electrical Data

RF

Nominal VA

360

100

60

30

25

15

Amperes(resistive)at 240 VAC

1.50

0.40

0.40

0.14

–

–

Amperes(resistive)at 120 VAC

3.00

1.00

0.50

0.28

0.28

0.12

Amperes(resistive)at 120 VDC

0.75

0.40

0.20

0.07

–

100 VDC / 0.10


3.00

1.00

0.50

0.28

0.28

0.30


3.00

2.00

0.70

0.56

0.28

0.30

MadisonCalculation

UL Rating of Level Switch

Current & Voltage Rating of Liquid Level Switches

Above ratings are for resistive loads only.Maximum voltage ratings: SPST Switches – 240 VAC; SPDT Switches – 120 VAC

Please note: Nominal VA is Volts x Amps and is the term used for Apparent Power in AC circuits. It is simply the product ofvoltage and current, without taking into account the type of load (resistive or inductive). In this chart we use the Nominal VAwith resistive load in conjunction with the applied AC voltage to determine the current – we are stating currents with aresistive load. Watts and VA can be used interchangeably in the charts above.

We recommend that switches stay below these ratings for non-resistive loads.

Current and Voltage ratings are for resistive loads only. For inductive loads, maximum life will be achieved ifappropriate arc suppression is used.Maximum voltage ratings: SPST Switches — 240 VAC

SPDT Switches — 120 VAC

Each switch has a power rating in watts. These power ratings are for resistive loads that are at a steadystate and are calculated as Power (Watts) = Voltage (AC/DC) * Current (Amps-resistive load). Most deviceshave other things to consider, such as current or voltage spikes caused when powering up or shuttingdown. Common devices such as pumps, coils and light bulbs can create these types of spikes. For thesemore complex cases, one must remember to stay within the maximum current and voltage ratings of theswitch regardless of the power rating.

For example, our 30-watt standard switches have a maximum switching current of 1 Amp and a carryingcurrent of 2.5 Amps. If the switch is connected to a 12 V circuit that spikes to 2 Amps and runs at a steadystate of 1 Amp, the power spike exceeds the switch rating although the steady state running power is 12 Watts. Due to the heat and type of power dissipated during the spike, the contact may be damaged or even welded together, causing switch failure.

Custom designs have other elements to consider and even alternative ground paths that may affect thepower delivered to a switch. It is important to consult your engineering department before assuming thesystem's power requirements. Contact the factory for additional assistance.

Electrical Data



RF

Wire Color Guide

Wire Colors forStandard Switches

Wire Colors for Full-Size Multi-Point Switches with SPDT Switches

Note: Maximum of four levels with SPDT switchesWireColor

White

Black

Yellow

Brown

Red

Switch Materialor Model No.

Polypropylene

Stainless Steel,Brass/Buna-N, PBT

Kynar

M3326

M3326-NO

Number ofSwitches

1

2

3

4

Color Code(Top to Bottom)

C - Black, NO - Green, NC - Yellow

C - Blue, NO - White, NC - RedC - Black, NO - Green, NC - Yellow

C - Blue, NO - White, NC - RedC - Brown, NO - Orange, NC - VioletC - Black, NO - Green, NC - Yellow

C - Blue, NO - White, NC - RedC - Brown, NO - Orange, NC - VioletC - Grey, NO - Red/White, NC Yellow/WhiteC - Black, NO - Green, NC - Yellow

Note: Custom colors are available at customer request.

Wire Colors forFull-Size and Miniature

Multi-Level Switcheswith SPST Switches

Number of Switches

2

3

4

5

6

Color Code (Top to Bottom)

RedBlack

RedWhiteBlack

RedWhiteBlueBlack

RedWhiteBlue

GreenBlack

RedWhiteBlue

GreenYellowBlack



Electrical Data

RF

Pipe Plug Flange Male Thread Bulkhead

Madison multi-pointswitches are available withbulkhead, male thread,male pipe plug or flangemounting. These switchesmay be mounted with thestem at up to a 30° anglefrom the vertical position.

Obstructions in tanks anddifficult mountings oftenrequire bending the tube toallow proper installation.Madison's engineering staffcan design switches withoffset stems to solve manytypes of installation problems.All metal stems are availablewith offset configurations.

Typical Installation Fittings

Offset Stems

Switch Fittings and Stems



RF

Many Madison switches can be furnished inadjustable form, permitting installationpersonnel to set any desired level of switchactuation. A male pipe plug with integralcompression fitting is installed in the tank. Thetube containing the reed switch can then beadjusted to actuate at any desired level. Allmetal multi-point switches are available withthe adjustable feature.

Mounting Plug

Compression Fittingfor Adjusting Length

1/2" NPTConduit Connector

Adjustable Liquid Level Switches

Madison Company uses special floats, stems, fittings and construction techniques to produce levelswitches which will operate properly under conditions of severely high pressure. Two high pressureranges are available: HP (750 PSIG maximum) and VHP (1500 PSIG maximum).

The M5602 switch with 2” NPT pipe plug mounting is available for use under high-pressure conditions.

High-Pressure Applications

Multi-Point Switch Set Up Criteria

Special OptionsPlease consult factory concerning available options such as the following:

• TERMINATIONS • TEMPERATURE SENSORS • OTHER FITTINGS • ADJUSTABLE FITTINGS• OFFSET SWITCHES • JUNCTION BOXES • EXTRA CABLE LENGTHS • CABLE • FLOATS • PLASTIC COLORS

For M5002, M5042, M8080*, M8002, M8042, M4402, M4502

L (Total) = L4 + 1” (25.4mm) Min.

Distance from mounting fitting to first switch = 3/4” (19mm) Min.

Minimum distance between floats:1-1/2” (38.1mm) / 1-3/4” (44.4mm) for M8080

Minimum LH = 1-1/2” (38.1mm)

Not applicable for M8080*

* Note: 3 levels maximum on model M8080.

For M8802

L (Total) = L5 + 2” (50.8mm) Min.

Distance from mounting fitting to first switch = 1-3/4” (44.4mm) Min.

Minimum distance between floats: 3” (76.2mm)

For M5602, M5402, M8602, M8402, M4602, M4302

L (Total) = L5 + 1-1/2” (38.1mm) Min.

Distance from mounting fitting to firstswitch = 1-1/4” (31.7mm) Min.

Minimum distance between floats: 2-1/2” (63.5mm)

Minimum LH = 2-1/2” (63.5mm)




RF

Frequently-Asked Questions

1. How can I connect my float level switch to a pump or valve while protecting it from the highcurrent that these devices use?

In most applications, a relay is required to isolate the float switch from the device. The float switch will be connected in series with a relay input coil that typically draws less than 500 mA.When the switch is closed, the relay coil is activated and closes the output contacts. Thesecontacts turn on or off the high current required by the device.

1a. How can I control my pump to maintain a range of fluid in my application?

Madison offers several solutions to control fluid levels in custom applications. The most common isby using a Double Pole Double Throw (DPDT) relay combined with a custom two-level float switchor two independent Normally Open float switches placed at the levels to turn the pump on and off.

The diagrams shown on the fourth page of this Reference section illustrate typical circuits for these“pump-up” or “pump-down” applications.

Madison also stocks an R2 pump controller that can be used with float switches or conductivityprobes. Madison stocks relays and controllers to activate pumps, solenoid valves, motors andalarms. Our fluid control engineers are on-hand to assist you with these applications.

2. How can I tell if my switch is set for Normally Open (NO) or Normally Closed (NC) operation?How can I change from NO to NC (or vice versa)?

Each style switch is equipped with a means to identify the type of operation to which the switch is set.

Vertical: NO/NC operation is indicated by the position of the witness mark (stainless steel models)or magnets (plastic models). NO is indicated by circle up (stainless steel) or magnets down plastic); NC is indicated by circle down (stainless steel) or magnets up (plastic).

Horizontal: NO/NC operation is indicated by the direction of the arrow on the hex. NO is indicatedby arrow up; NC is indicated by arrow down. An ohmmeter or continuity meter can be used toverify the switch setting and operation. Simply connect the meter to the leads and, with the floathanging down away from the fitting, measure the switch. If the meter reads a short, then the switchis normally closed and will open on rise.

All switches are shipped in the Normally Closed (NC) position, unless otherwise specified. Tochange the contact operation, simply remove the retaining ring and float and reverse the float onthe stem. The only exception to this is the subminiature switch (M3326/M3326-NO), for whichoperation must be specified when ordered, since the float is not reversible on this switch.

Magnetic Float Level Sensors



RF


3. Is there a way to sense between two liquids?

Madison can furnish an Interface Float that, given two mediums, is designed to sink in onemedium and float in the other. A typical application would be one where oil and water accumulatein one tank, and sensing of only a fall in water level is required (oil level is not an issue). Since astandard float of any material will float in any liquid with a specific gravity higher than the specificgravity of the float, Madison would “weight” the float to a specific gravity of 0.95. Since the specificgravity of the oil is 0.8-0.9 and that of the water is 1.0, the float will sink in the oil and float in thewater. Both full-size Buna-N and polypropylene floats can be modified in this manner.

4. How do I make sure the switch I choose has the correct specific gravity?

One of the main considerations when choosing a switch is the specific gravity of the float. To makesure the float will function properly in the application, the specific gravity of the fluid must begreater than the float’s specific gravity at the maximum temperature range of the application. Forreference, below are specific gravities of some of our floats.

Full-size floats:Stainless steel — 0.55 SG, except M5600-PR float is 0.70 SGPolypropylene — 0.75 SGBuna-N — 0.45 SGKynar — 0.75 SG

Miniature floats: Stainless steel — 0.70 SGPolypropylene — 0.80 SG, except M3326 is 0.60 SGBuna-N — 0.45 SGKynar — 0.85 SG

Side-mounted floats:M5900 series (stainless steel) — 0.60 SGM5970 — 0.70 SGM5010 — 0.60 SGM4010 — 0.45 SGPolypropylene — 0.60 SGPBT — 0.75 SGKynar — 0.75 SG




RF


5. Which switch material is best suited for my liquid level application?

316 Stainless Steel: For high-temperature (to 300°C), high-pressure (to 300 PSIG) and corrosiveconditions. Commonly used in food processing, medical, heating and cooling equipment.

Polypropylene & Polysulfone: For acidic conditions, such as found in electroplating and metalcleaning. Another choice for lower-temperature (to 105°C) food processing applications (MadisonCompany uses only polypropylene that is FDA-approved for food contact). Also a good choice forgeneral-purpose applications in commercial or consumer appliances and equipment.

Brass & Buna-N, PBT & Buna-N: The selection for petroleum-based liquids, such as lubricatingoils, gasoline and diesel fuels. Widely used in storage tanks of vehicles, generators, transmissionsand hydraulic systems. Other uses are in lubrication, recovery, refining and fuel processingequipment. PBT is not suitable for use at temperatures above 130°C.

Kynar: Chemical- and solvent-resistant properties make this material a problem solver for many applications. Its high-purity nature is ideal for food handling and sensitive laboratory or test equipment.

6. Can I order directly from Madison, or should I go through a distributor?

Madison products can be ordered direct from the factory. Minimum order is $300. We acceptpayment by credit card (Visa, MasterCard and American Express) or COD. Please contactMadison to set up an account on open terms.

We also have a network of distributors located in various regions across the U.S. and Europe.Please visit www.madisonco.com.

7. How can I ensure that my switch’s performance will not be affected by turbulence?

Turbulence, which can be caused by a vibrating tank, intensive mixer agitation or surging of liquidduring tank filling, can result in premature failure of both the switch and the relay, due to chattering.A very low-cost, reliable solution to this problem is the use of a slosh shield. This device is equippedwith fluid and vent holes and surrounds the switch float to prevent erratic switch operation.

Madison stocks a complete selection of slosh shields for vertical and horizontal switches instainless steel, polypropylene, PBT, brass or Kynar.

8. Can I customize a standard switch?

Madison Company offers a full range of value-added options, including terminations andconnectors; extra-long or -short lead lengths; special cable or wire; shrink tubing for wireprotection; and special sealing materials, such as Viton or Buna-N gaskets and O-rings. We can also meet special requirements with our temperature switches, slosh shields and weather-proof or explosion-proof junction boxes.




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9. Which Madison switches are explosion-proof?

Our vertical M5600 series and our horizontal M5900 series are rated explosion-proof by UL andCSA for use in Hazardous Locations, Class I, Groups A, B, C, D; Class II, Groups E, F, G; Class I.These switches are also approved by DEMKO for use in potentially explosive atmospheresEEx d IIC T2 and carry the Ex mark.

10. Are liquid level switches affected by semi-solid particles or magnetic particles in the liquid?

Yes, standard float switches may be affected by these conditions because such particles cancause a float to stick or to not operate at all. Instead, we recommend using a conductivity switch,such as our multi-point model M3784 or single level model M3850. Because our conductivityswitches have no moving parts, operation of these switches is not interrupted. Furthermore, theM3827 side-mounted switch is engineered such that the magnetically actuated reed switch will notcome in contact with the fluid being monitored. The float is attached to an extended pivot arm that,when moved, triggers the switch function. This switch is ideal for use in heavy-bodied liquids or influids containing metal particles that would otherwise be attracted to a conventional style float.

11. What industry ratings do Madison’s switches have?

We have a continuing program to upgrade our list of UL and CSA approvals. Madison Company’sliquid level switches have general-purpose approval as recognized components granted by ULunder file number E54633 and CSA file number LR56150.

Some Madison switches are also NSF-certified for food applications.

In addition, we are self-certified for CE under the following directives:

EN60730-1 — Automatic Electric Controls for Household and Similar Use – Part 1: GeneralRequirements (1995)

EN60730-2 — Automatic Electric Controls for Household and Similar Use – Part 2: ParticularRequirements – Section 2-15: Automatic Electrical Water Level Sensing of the Float or Electrode-Sensor Type used in Boiler Applications (1996)

Low Voltage Directive (72/73/EEC)

Our M5600 and M5900 switches are certified explosion proof by DEMKONo. 99E.126064X EEx d IIC T2: Protected for use in potentially explosive atmospheres.




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12. What types of testing do Madison switches undergo?

Madison Company periodically life tests the reed switches used in its liquid level switches. This isdone to ensure that the reed switches, as obtained from our vendors, have not had a shift inoperating characteristics. The reed switches are tested, rather than the complete assembly,because they are the principal electrical component of the liquid level switch.

The testing is performed by cycling the switch, using a standard coil, one million times. The loadon the switch is an incandescent light bulb rated for the maximum wattage of the reed switch (i.e.,a 60-Watt bulb is used to test a reed switch rated at 60 Watts maximum).

A resistive load (light bulb) is used because it provides a uniform standard against whichcomparisons can be made. Inductive loads vary greatly from device to device, making comparativeanalysis very difficult.

The degree of deterioration of a reed switch after life cycle testing is measured by determining thechanges in contact resistance, pull-in force and drop-out force as compared to those samemeasurements made before testing commenced.

Madison Company has the capability of doing life-cycle testing of reed switches using specificelectrical loads, such as relays or solenoids supplied by our customers. Please contact the factoryfor more information.

13. What type of warranty does Madison offer on its sensors? What is the return policy?

Our sensors are warranted for one year from date of manufacture. We only accept returns that areauthorized by the factory. Please contact the Sales Department for a Return Authorization Number.

14. Does Madison offer special packaging and/or labeling?

Yes, we offer a variety of custom packaging — bar coding, special unit packs, etc. Please contactthe factory for more information.




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15. How does Madison keep such a large variety of sensors in stock?

In order to better serve our customers, we continually review our Lean Manufacturing techniquesand Kanban systems to meet demands. These systems eliminate both overstocks and stockoutsand allow us to maintain the proper level of inventory for both standard switches and custom fittings.

16. What kind of lead time can I expect once I order my switch? Is there a difference whenordering standard or custom switches?

Standard switches have a lead time of one to two weeks. Custom switches have a three-weeklead time.

17. Can I order a Madison switch with more than one level?

Yes, Madison offers multi-point switches in many configurations. Our full-size multi-point switchescan be set for up to six levels, and our miniature switches can be set for up to four levels. Theycan be mounted within any vessel, utilizing male pipe threads, pipe plugs, flanges or bulkheadfittings. The length of each switch, as well as the location of the floats, can be established by thedesigner. For those users who want to design and install their own systems, multi-point switch kitsare available in three different materials.




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Madison’s ultrasonic sensors rely on high-frequency soundwaves above the range of human hearing (over 20,000hertz) to measure level. Our ultrasonic sensors useultrasonic sound waves to sense the level of liquids, solids orpowders in airbased containers, tanks and vessels of allsizes and shapes.

Madison’s sensors can be bench- or field-calibrated throughcommunications with a PC or a push button on the sensor.This capability enables the user to define the span in thevessel and only trigger on objects within that window. Eachstandard model has its defined operating distance listed onthe catalog chart page. Custom models can be designed forspecific application needs based on the variables that can befound on the Madison Specification Work Sheet.

These ultrasonic sensors are not susceptible to error due tothe target material’s color, shape or composition (e.g.,transparent or opaque, liquid or solid). They are particularlygood for applications that must sense a non-metallic object inan environment where there is systematic, heavy wash down, liquid, dust, heavy spray, food, ink, or otherenvironmental hazards. Since sound energy is used for detection, the reflecting object does not have to bemetal, but can also be glass, plastic or even paper.

Stagnant, non-agitated liquids and solids consisting of large and hard particles are good reflectors and, therefore,good candidates for ultrasonic level measurement. Fluff, foam and loose dirt are poor reflectors, and dust, mistor humidity in the vapor space tend to absorb ultrasonic pulse. When these conditions are present, they aregenerally not measurable. As a rule of thumb, use 20% of the stated range of a Standard model to see if it will overcome these conditions. Where these characteristics are present, a Madison radar sensor might be appropriate.

Refer to the Product Data Sheet(s) for specific product operation characteristics, or contact a Madisonrepresentative for further information.

Ultrasonic Level Sensors



Architecture of an Ultrasonic Level Device

1/2” conduit for wiring

3” NPT thread

1” to 2” NPT on select models

Ultrasonic trandsucer vibrating face

Zero Distance (when communication with a computer is utilized)

Dead Zone / Minimum Range (no measurement in dead zone)

20 mA or 4 mA

Span

4 mA or 20 mA (target)

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Ultrasonic Level Sensors



Operation Principle of Ultrasonic Level Devices

An ultrasonic transducer matched to air is stimulated by a pulse transmitter, and it generates a pressure wavethat propagates to a target and then reflects (in similar fashion to a loudspeaker). The reflected wave is receivedby the same transducer, in the receiver mode, and is converted into an electrical signal (as a microphone would).The electrical signal is amplified and processed to find the reflected echo and then calculated to find the distanceto a specific target. Distances to a target are converted linearly to a 4-20 mA current and, optionally, informationabout level measurement is sent via RS232 or RS485 to a PC for processing such functions as diagnostics,programmble set-up and data logging.

PROCESSOR

PULSE RECEIVER

PULSE TRANSMITTER

4-20 mA output RS232/485

communications

Ultrasonic Transducer

Ultrasonic Sensor Still-Pipe Mounting Considerations

Still-Pipe: Use metal or plasticpipe with a smooth inside.

Make sure the transducernozzle does not make physicalcontact with the still-pipe.

Remove all sharp edges.

45˚

No end cut is required for pipes shorterthan 6”. The ID of the pipe must be greaterthan the OD of the transducer nozzle.

If pipe is longer than 6”, a 45˚ cut is required.

If pipe issubmerged inliquid, a vent holeis required.

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If a Madison ultrasonic sensor can’t measure the level of your liquid, ourradar sensors can. Madison’s radar sensors can detect the liquid levelunder a layer of airy foam.

Internal piping, deposits on the antenna, multiple reflections or reflections from the wall can all interfere with the proper operation of the radar sensor.

Madison’s radar sensors use improved microwave pulse technology totrack any target material from the tip of its antenna to the bottom of thetank. Their power, pulse widths and sensitivity depend on the distance of the target from the antenna and the dielectric constant of the reflecting material.

Madison’s radar sensors feature “echo marker” signal processing, makingthem among the most technologically advanced pulse radar systems onthe market. This technology will provide a reliable continuous pulseshape unaffected by environmental conditions such as:

The antenna is offered in Polypropylene or an optional high-resistance PTFE (Teflon®) that can help provideresistance to material buildup.

Simple mounting and push-button calibration make for a very easy installation. Calibration can be completed on thebench or in the field by following simple instructions. The sensor can be threaded directly into a 2” NPT metal orplastic flange. Unique application requirements can be described on the Madison Specification Work Sheet, which ourengineering department will use to produce a design that meets your needs.

Refer to the Product Data Sheet(s) for specific product operation characteristics, or contact a Madison representativefor further information.



Radar Level Sensors

Architecture of a Microwave Device

Rod Antenna

Aluminum Enclosurewith 1/2” conduit for wiring

1-1/2” and 2” NPT thread. For 1-1/2” NPT models, a thermal decoupler isavailable for use in high-temperature applications.

Zero Distance

Dead Zone / Minimum Range (no measurement in dead zone)

20 mA or 4 mA

Span

4 mA or 20 mA (target)

• Temperature• Pressure• Vapors

• Steam• Wind• Vacuums

• Methane• CO2

• Condensation

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Operation NoteTurning the low dielectric materials operation mode ON or OFF

The ON mode is recommended for materials with a dielectric constant lower than 4 and to eliminate multiplereflections in tanks.

1. To turn the low dielectric materials mode ON, push the calibration button and hold until the LED light flashes yellow,then red, and then turns off. Release the button. The blinking green LED light indicates that the low dielectricmaterials mode is ON.

2. To turn the low dielectric materials mode OFF, push the calibration button and hold until the LED light flashes yellow,then red, then turns off. Release the button. The constant green LED light indicates that the low dielectric materialsmode is OFF.

The low dielectric materials operation can also be turned ON or OFF with Madison’s software during PC communications, which is recommended.



Radar Level SensorsOperation Principle of Microwave Level Devices

The microwave rod antenna is stimulated by an electromagnetic pulse transmitter and sends very short pulses toa target. The pulses reflect from the target and then they are received back by the same antenna. The electricalsignal from the antenna is amplified and processed. The distance to an object is calculated and then convertedto 4-20 mA. Optionally, level information is also sent to a PC via RS232 or RS485 for diagnostic data logging andprogrammable set-up.

PROCESSOR

PULSE RECEIVER

PULSE TRANSMITTER

4-20 mA output

Microwave Antenna

RS232/485 communications

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FCC Information for UsersSensors have been tested and found to comply with the limits for Class A digital device, pursuant to Part15 of the FCC rules. These limits are designed to provide reasonable protection against harmfulinterference when the equipment is operating in a commercial environment. These sensors generate, use,and can radiate radio frequency energy and, if not installed and used in accordance with the instructions,may cause interference with radio communications. Operation of this equipment in a residential area islikely to cause interference that the user will be required to correct.

Radar features: Madison Company’s radar sensors are highly accurate, noiseless and self-adjustingpulse radar transmitters for distances up to 100’. The sensors adjust their microwave pulse amplitude andwidth to a target distance and target reflection properties. The receivers change their sensitivity with theamplitude of received echoes. In addition, the sensors analyze the shapes of the received echoes andeliminate the ones coming from tank walls, standpipes and other obstructions. These features allow thesensors to track any wanted target from the tips of their rod antennas to the bottom of the tank,regardless of the tank shape or environmental conditions. For very low dielectric constant materials (≈2),the radar sensor needs at least 2’ from the antenna tip to detect the material. Any buildup on the rodantennas does not deteriorate the performance of the radar sensors. The radar transmitters do not haveany mismatch between resonator and transceiver. This eliminates problems when a target is close to theantenna and gives optimal performance of the radar sensor’s very high efficiency. The Madison radarsensors also feature a low dielectric mode. In this mode, the Madison sensors will ignore echoes fromtank bottoms with material present, and they will increase their transmit energy and the sensitivity of theirreceivers until they detect echoes from the surfaces of the low dielectric materials. This mode will workwith dielectrics around 2 and higher.



Radar Level SensorsRadar Sensor Still-Pipe Mounting Considerations

If pipe issubmerged inliquid, a vent holeis required.

Remove all sharp edges.

45˚

No end cut is required for the following: End cut of 45˚ is required for pipes longer than 10.5”; the ID of the pipe must be greater than 6”.

Pipe ID

2.0”3.0”

4.0” and 5.0”6.0”

Max. Length

2.5”3.5”6.0”10.5”

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The best echo is obtained when the sensor diaphragm is parallel to the surfaceof the material being monitored. Make sure that the material does not encroachinto the dead zone (ultrasonic sensor).

A ball aimer with a 3” NPT thread is available for all ultrasonic models.

For ultrasonic model U3-25U, a 9” PVC flange is available.

Do not attempt to measure through thefilling curtain. Make sure that the materialor product does not encroach into thedead zone.

X X

X X

Fill

FillHole

FillHole

Dead Zone

Dead Zone

Avoid interference from the side ofthe tank or from obstructions insidethe vessel. Do not install the sensorat an angle.

The sensor must be installed on the top of the vessel and must be positioned to ensure that the sensor face hasan unobstructed line of sight to the “empty” level of the tank. (Ultrasonic Sensors will not operate in a vacuum.)

To calculate the minimum distance from the wall for sensor placement, use: Minimum Distance From Wall = Tangent (Beam Angle/2) (Tank Height)

Range



Mounting of Non-Contact Level Sensors

2/3

1/3

In tanks with dome tops, thesensor should not be installedin the center. Place it 2/3 ofthe way between the wall andthe center line.

In tanks with domed tops, aimthe sensor to point toward thedischarge hole.

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SphericalTanks

CylindricalTanks

Conical Tanksand Hoppers

Moving Parts(During Calibration)

TypicalApplicationsfor Ultrasonicand RadarSensors



Non-Contact Level Sensors

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Software

Standard Mounting

Mounting the sensor correctly is critical to its proper operation. Refer to instruction manual forwiring information.

Ultrasonic – The ultrasonic sensor can bemounted directly by threading it into a 2” NPTplastic or metal mounting flange with the sensorface below the flange and pointing down, withoutmaking contact with any surface.

Radar – The radar sensor can be mounted directlyby threading it into a 2” NPT metal mounting flangewith the antenna pointing down. The radar sensormust be installed in a metal flange. If a still-pipe isrequired, it must be metal as well.

Metal Still-Pipe Mounting

Pipe Diameter(Radar models*)

2.0”3.0”

4.0” and 5.0”6.0”

Maximum Length

2.5”3.5”6.0”10.5”

StandardMounting

(Radar shown)

Mountingwith MetalStill-Pipe(Ultrasonic

shown)

2” NPT

Still-Pipe

For any Madison ultrasonic orradar model ordered with oneof the optional communicationports, the interfacing software is provided. The softwareoperates on a basic PC that is

running Microsoft Windows 95™

or higher and has a serial port.Please refer to the standardcatalog chart pages or selectthis option when completing the Madison Specification Work Sheet.

Both ultrasonic and radar sensors can beinstalled utilizing a metal still-pipe. Plastic may also be used for ultrasonic.

* For metal still-pipes that have a small ID and that are longer than 4” in this table, use 6” or 8” antenna extensions that are equal toor longer than the still-pipe.

If your mounting material or configuration doesnot comply with these notes, please consultMadison Company for proper interface.

45°



Installation of Ultrasonic or Radar Sensors

For pipes longerthan 6”, use a 45˚termination.

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A pulse is emitted from the sensor’s transmitter. The pulse travels tothe surface being monitored and is reflected off the surface, back tothe sensor. The time of flight is divided by 2 and converted to anoutput signal directly proportional to the material level. In the case ofthe ultrasonic sensor, temperature is measured to compensate forthe speed variation of the ultrasonic pulse.

Span(Ultrasonic)Span

(Radar)

Material

Pulse

RadarSensor

UltrasonicSensor

Dead Zone (Ultrasonic)Dead Zone(Radar)



Operation of Non-Contact Level Sensors

4 mA or 20 mA at target

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Full Tank Calibration

Empty Tank Calibration

20 mA or 4 mA (750 ohm max.) outputset near target (full tank)

1. Calibration mode LED color green2. Push button

Hold until LED turns yellow (20 mA)or hold until LED turns red (4 mA)

3. Release button, observe, LED flashesto acknowledge

Note: When calibrating radar sensor, lowdielectric materials mode must be OFF.See reference page for instructions.

4 mA or 20 mAset far from target (empty tank)

1. Calibration mode LED color green2. Push button

Hold until LED turns red (4 mA)or hold until LED turns yellow (20 mA)

3. Release button, observe, LED flashesto acknowledge

Note: When calibrating radar sensor, lowdielectric materials mode must be OFFSee reference page for instructions.

Calibration Push ButtonLED Indicator

FULL

Calibration Push ButtonLED Indicator

EMPTY

A single push button is used to set the zero and span. Calibration can be done in the vessel by varying thematerial level, the sensor can be calibrated on the bench by aiming it at a target or it can be set by usingprogramming. Factory-calibrated sensors can be provided; consult factory. The zero and span points areindependent of each other, fully adjustable over the sensor’s range and stored in a non-volatile memory.Calibration feedback uses LED lights in green, yellow and red. For radar and long-range ultrasonicapplications, please use the programmable calibration that is demonstrated in the instruction manual.

Note: Factory-supplied installation manuals are packaged with each sensor.



Calibration of Non-Contact Level Sensors

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1. How can ultrasonic sensors help my customer?

They can provide a cost-effective, non-contact level measurement method with unique advantages notoffered by other sensing technologies. With the Madison line of Standard models, a full range of distanceoptions are offered. To address specific application conditions, engineered designs can be developed inconjunction with the customer.

2. What are the advantages of ultrasonic sensors?

When compared to other more conventional level measurement sensors, theMadison ultrasonic sensors…

– are not affected by dust, dirt or wet environments– have varying distance ranges that can detect many types of materials– are impervious to most materials, colors and surfaces– have a virtually unlimited, maintenance-free life– are resistant to external vibration, ambient noise and infrared or EMI radiation– adapt power and sensitivity automatically to any environmental conditions

3. How are specific application problems solved?

Madison Company has a staff of trained sales personnel and engineers that can assist the customer inselecting the appropriate standard model or recommend an engineered model based on the applicationconsiderations provided by the customer. Customers should use the Specification Work Sheet to help giveour staff a complete understanding of their needs.

4. How do the ultrasonic and radar sensors work with the software?

Madison’s standard ultrasonic and radar sensor models can be selected with a communication option. This option is a choice of an RS-232 or an RS-485 connection. The RS-232 is for a one sensor to one PC link, and the RS-485 is for up to multiple sensors (up to 128) to one PC. Madison supplies user-friendly software for sensors purchased with this option. Once the software is loaded onto the user’s PC,the user can tailor several characteristics of the sensor so that the graphs and displays of the sensor'ssignals can be representative of the measurements being taken in the vessel.

5. How do I mount the sensor to assure proper performance?

Although there are several different options that can be offered, the most common is where the sensor isscrewed into a standard fitting that is attached to the outside of the vessel. The sensor’s face or lens isinside and just below the vessel’s inside surface. The sensor should be relatively upright, aiming at thelowest part of the vessel and away from any filling source, piping, ladders, propellers, etc. that could bewithin the beam spread and cause a false echo. See diagrams on previous reference pages.

6. What about dust and foam on the material surface?

Whether or not the ultrasonic echo will be interfered with depends on how dense and how reflective thedust or foam is. Once we understand what the material is and the depth of the dust/foam above the targetmaterial, the sensor selection can be made so that the signal strength can be greater, to penetrate theinterference and provide reliable level measurement. If the application cannot be solved with the ultrasonicsensor, the radar sensor will most likely do the job.




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7. If I have a small vessel, and the blanking distance is too great, can it be reduced?

Yes; complete the Specification Work Sheet and return it to Madison Company’s sales account manager

for a technical evaluation and quote. Each application and mounting area/method is different, so the fit up

envelope will be an important set of dimensions to make reference to (outline drawings are best). Madison

has several non-standard, alternative designs already in use that may be suitable.

8. Can the transducer housing on the end of the ultrasonic sensor be used in food applications or

applications that are not suitable for the standard PVC housing?

Yes, the transducer housing is offered in a sanitary design on several standard models; refer to the

catalog listing for the standard models. The transducer housing can also be designed in Teflon®, Kynar

and other materials.

9. What are the thread options on the sensors?

The catalog chart lists the thread for each Madison standard sensor model. The standard thread

configuration is 1” NPT. Madison can also quote the price of sensors with BSP threads, for customers

who require them.

10. What are the sensor housings made of?

The Madison ultrasonic sensors’ housings are PVC in dark gray. The PVC can be quoted in white

and light gray as well. For ultrasonic models carrying CE approval, the housing is aluminum. The Madison

radar sensors’ housings are aluminum, and it can also be quoted in 316L Stainless Steel. The radar

antenna is white polypropylene and can be quoted in Teflon®.

11. Is the Madison radar antenna only available in the cone shape?

No, although the cone shape is preferred in applications that require sanitary surfaces or have media that

tend to build up.

12. My gateway PC software doesn’t communicate with my radar or ultrasonic sensor, or the

communication has long delays?

The default serial port settings for the transmit and receive buffers are likely set too high in Windows. To

correct this, go to the Control Panel; select System; select Hardware; select Device Manager; select Ports

(COM and LPT); select Communications Port (the COM port the sensor is connected to); select Port

Settings; select Advanced; move the arrows on both Receive and Transmit Buffers to their lowest settings.

Then click OK. This should correct the problem.




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C - CE

A - Underwriter’s Laboratories

Underwriter’s Laboratories is one of the world’s premier safety testing andcertification sources. Many applications require UL approval for insuranceand/or other compliance purposes. There are several areas of interest,

but the most applicable is UL 508, the Standard for Industrial Control Equipment. For moreinformation on UL, check their Web site at www.ul.com.

Madison Company offers many sensors with UL approval. Those product approvals are to aspecific design. Some modifications to an approved design may cause the approval to beinvalid. Should that be a critical issue for you, contact us to determine what course of actionwould be best.

B - Canadian Standards Association

Canadian Standards Association (CSA) tests products for compliance to nationaland international standards and issues certification marks for qualified products.Certification marks tell potential users that a product has been evaluated by aformal process involving examination, testing and follow-up inspection, and that it

complies with applicable standards for safety and performance. CSA is recognizedthroughout Canada as the premier certification organization for electrical products. Formore information on CSA, visit their Web site at www.csa-international.org.

As with UL approval, CSA certification is design-specific. Therefore, modifications to acertified design may cause the certification to be invalid. Please confer with MadisonCompany if this certification is crucial for your application.

The 15 member nations of the European Union (EU) have created a set ofproduct-specific regulations with which those companies doing business in thosenations must comply. The EU’s “New Approach Directives” constitute its unified set

of health and safety regulations, symbolized by the CE mark. The mark is required for abroad range of products, including machinery, medical devices and electrical/electronicproducts. Madison Company self-certifies all of its level switches to CE specificationsEN60730-1 and EN60730-2, and Low Voltage Directive (72/73/EEC).

Continued on next page



Approval Reference

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E - Explosion-ProofNOTE: Individual Madison product explosion-proof approvals vary. Consult Madison Company forcurrent product listings.

Certain Madison product models have been tested and approved byUnderwriters Laboratories, Inc. for use in hazardous locations. The liquid levelswitch product is normally approved as a recognized component to be used

with a UL Listed component in hazardous locations for Class I, Groups A, B, C and D; Class II,Groups E, F and G; and Class III. Visit www.ul.com for more information.

Certain Madison product models have been tested and approved by CSA Internationalfor use in hazardous locations. The liquid level switch product is normally approved asa Class 2258 02 Process Control Equipment for hazardous locations classified as Class

A, B, C and D; Class II, Groups E, F and G; Class III. For more information on CSA, visit theirWeb site at www.csa-international.org.

ATEX Directive 94/9/EC (also known as ATEX 95 or ATEX 100A) is used in theEuropean Union (EU) to test and certify products designed for use in potentiallyexplosive atmospheres. Madison’s liquid level switch products would normally fallunder Equipment Group II, Equipment Category 2, for atmosphere group G, zones 0,

1 and 2. For more information on DEMKO, visit their Web site at www.demko.dk.

Continued on next page

D - NSF InternationalNSF International sets standards for products and systems related to public health,safety and the environment with focus on the essential elements of water, foodenvironment and air. The NSF Certification programs are accepted and frequently

mandated by public health regulators throughout the United States, as well as internationally.Madison Company offers over 30 NSF-approved sensors which meet NSF Standard C-169 – FoodEquipment and Related Products, Components and Materials. For more information on NSF, visittheir Web site at www.nsf.org.

F - International Protection Codes (IP)An IP number is used to specify the environmental protection of enclosures aroundelectronic equipment.

First Number0 – No protection (sometimes X)

1 – Protected against solid objects up to 50mm2


3 – Protected against solid objects up to 2.5mm2


5 – Protected against dust, limited ingress (no harmful deposit)

6 – Totally protected against dust

Second Number0 – No protection (sometimes X)1 – Protected against vertically falling drops of water (i.e. condensation)2 – Protected against direct sprays of water up to 15˚ from vertical3 – Protected against direct sprays of water up to 60˚ from vertical4 – Protected against water sprayed from all directions - limited ingress permitted5 – Protected against low-pressure jets of water from all directions – limited

ingress permitted6 – Protected against low-pressure jets of water, limited ingress permitted (i.e. ship deck)7 – Protected against the effect of immersion between 15cm and 1m 8 – Protected against long periods of immersion under pressure



Approval Reference

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G - NEMA

NEMA 1 Indoor Use Protects against accidental contact by personneland falling dirt

NEMA 2 Indoor Use Protects against falling dirt, liquid and light splash

NEMA 3 Outdoor Use Protects against rain, sleet, snow, dirt and dust

NEMA 3A Outdoor Use Protects against rain, sleet, snow, dirt and ice buildup

NEMA 4 In- or Outdoor Protects against dirt, dust, hosedown andheavy splash

NEMA 4X In- or Outdoor Protects against dirt, dust, hosedown and prolonged submersion

NEMA 6 In- or Outdoor Protects against dirt, dust, hosedown andoccasional submersion

NEMA 6P In- or Outdoor Protects against dirt, dust, hosedown and prolonged submersion

NEMA 7 Indoor Use For use in areas of explosive gases or vaporsor combustible dust

NEMA 9 Indoor Use For use in areas of atmospheres containingcombustible dust

NEMA 12 Indoor Use Protects against dirt, dust, light splash and oilor coolant seepage

NEMA 13 Indoor Use Protects against dirt, dust, light splash and oil orcoolant spray

National Electrical Manufacturers Association (NEMA) Standards Publication No. 250guidelines are as follows:



Approval Reference

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H - entelaentela is an OSHA (Occupational Safety and Health Administration) approved testing laboratory.It is accredited by the SCC (Standard Council of Canada), for electrical product safety;participating National Certification Board (NCB) within the IECEE (the IEC System for ConformityTesting and Certification of Electrical Equipment).

Products have been tested and certified to:CSA C22.2 No. 1010.1-M92 and A2IEC 61010-1:90 and A1:92 and A2:95UL 61010A-1 (2002)

I - ABSABS (American Bureau of Shipbuilding) Type Approval certifies that the approved equipment hasbeen designed and manufactured per ABS Rules for use on shipboard applications. Any limitationof use will be listed as part of the applicable approval.

Sensors have been tested and found to comply with the limits for Class A digital device, pursuantto Part 15 of the FCC rules. These limits are designed to provide reasonable protection againstharmful interference when the equipment is operating in a commercial environment.

J - FCC



Approval Reference

K - FM GlobalFM Approvals are intended to verify that the product will meet stated conditionsof performance, safety and quality. The purpose of FM Approval Standards is topresent the criteria for FM Approval of various types of products as guidance forFactory Mutual personnel, manufacturers, users and authorities havingjurisdiction. Madison Company products having this approval reference would

require the purchaser to contact Madison Company for the specific class of product approval.

Madison Company products are in compliance with European RoHS (Restriction of HazardousSubstances) and WEEE (Waste Electrical and Electronic Equipment) directives. Our products areadditionally ESA (Electrical Safety Authority) registered in Canada.

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RoHS, WEEE (Europe); ESA (Canada)

Thermocouple Wire Color CodesColor codes have been adopted by various national and international standard agencies for identification ofthermocouple wire and thermocouple products. In the United States, thermocouple-grade wire normally has a brownoverall jacket. For Types B, R and S, the color codes relate to the compensating cable normally used.

Type

E

J

K

N

B

R

S

T

United StatesANSI96.1

Purple+ Purple– Red

Black + White– Red

Yellow + Yellow– Red

Orange+ Orange– Red

Grey+ Grey– Red

Green+ Black– Red

Green+ Black– Red

Blue+ Blue– Red

United KingdomBS

1843

Brown+ Brown– Blue

Black + Yellow– Blue

Red + Brown– Blue

—

—

Green+ White– Blue

Green+ White– Blue

Blue+ White– Blue

West GermanyDIN

43714

Black+ Red– Black

Blue + Red– Blue

Green + Red– Green

—

Grey+ Red– Grey

—

White+ Red– White

Brown+ Red– Brown

JapanJIS

C1610-1981

Purple+ Red– White

Yellow + Red– White

Blue + Red– White

—

Grey+ Red– White

Black+ Red– White

Black+ Red– White

Brown+ Red– White

FranceNF

C42-323

—

Black + Yellow– Black

Yellow + Yellow– Purple

—

—

—

Green+ Yellow– Green

Blue+ Yellow– Blue

National Standards



RF

Comparison of Temperature Transducers

Thermocouple Reference

Time Constants

The time constant of any sensor isdefined as the time required for thatsensor to respond to 63.2% of itstotal output signal when subjectedto a step change. The step changecan be either an increase ordecrease in the parameter beingmeasured. Five constants arerequired for a sensor to reach 99%of its total change. The graph to theright illustrates this relationship.

Type

Advantages

Disadvantages

Thermocouple

Self-powered

Simple, rugged

Lower cost

Wide temperature range

Nonlinear

Low voltage

Least stable

Least sensitive

Reference required

RTD

Most stable

Most accurate

Better linearity

Expensive

Current source required

Small resistance change

Low absolute resistance

Self-heating

Thermistor

High output

Fast

Nonlinear

Limited temp. range

Fragile

Current source required

Self-heating

0 1 2 3 4 5

63

100

Per

cen

t o

f C

han

ge

Time Constant

99%

Type

Material

Temperature Range

J

Iron (+)vs.

Constantan (-)

0˚C to 760˚C

K

Nickel (10%) Chromium (+)vs.

Nickel (5%) AluminumSilicon (-)

0˚C to 1370˚C

T

Copper (+)vs.

Constantan (-)

-160˚C to 400˚C



RF

Time Constant of Exposed Thermocouples

Time Constant as a Function ofWire Size for Exposed Wire

Thermocouples in Air T=200˚F

Radiation Error of Exposed Thermocouples

Radiation Error as a Function ofWire Sizes for Thermocouples in

Air at 2000˚F, at 1 Atmosphereand Mach 0.3

0

0

0.5

1.0

1.5

2.0

.004 .008 .012 .016 .020 .024

4

Tim

e C

on

stan

t, se

c.

Wire Diameter, in. Wire Diameter, in.

T

MICRO-MINIATURE THERMOCOUPLE

40 GAUGE

36 GAUGE

30 GAUGE

28 GAUGE

26 GAUGE

24 GAUGE

22 GAUGE

400

300

200

100

00 .02 .04 .06 .08 .10 .12

T

Rad

iati

on

Err

or,

˚F

Wire Diameter, in.

T

40 GAUGE

36 GAUGE32 GAUGE30 GAUGE

26 GAUGE

24 GAUGE

20 GAUGE

16 GAUGE

10 GAUGE

8 GAUGE

MICRO-MINIATURE THERMOCOUPLE

Time Constants and Radiation Error



RF

madison company product catalog

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