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Level Indicators
Installation and Operating Manual
Gauges
Switches
Transmitters
A Magnetrol Company
Notes
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that
could injure personnel, damage equipment, or reduce
a components mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific
materials. In this manual, a caution box indicates a
potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
Warnings
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, if not avoided,
could result in serious injury or death.
Safety Messages
Follow all standard industry procedures for servicing
electrical equipment when working with or around high
voltage. Always shut off the power supply before touching any components.
WARNING! Explosion hazard. Do not connect or
disconnect equipment unless power has been switched off
or the area is known to be non-hazardous.
Low Voltage Directive
For use in Installation Category II, Pollution Degree 2.
If equipment is used in a manner not specified by the
manufacturer, protection provided by the equipment
may be impaired.
Magnetic
Liquid Level Indicators
Table of Contents
1.0 Installation
1.1 Unpacking.............................................................4
1.2 Pre-installation Checklist .......................................4
1.3 Equipment and Tools ............................................4
1.4 Side Mount Installation.........................................5
1.5 Top Mount Installation .........................................6
1.6 Top/Bottom Connection Installation.....................6
1.7 Start-up .................................................................6
1.8 Special Accessory Installation.................................7
1.8.1 Insulation or Blanket Installation................7
1.8.2 Steam Heat Tracing Installation ..................8
1.8.3 Electric Heat Tracing Installation................8
1.8.3.1 Units with a fixed-point
thermostatic switch..............................8
1.8.3.2 Units with an adjustable bulb-type
thermostatic switch..............................9
1.9 Switch Installation ...............................................10
1.9.1 OES Cam Operated Switch......................10
1.9.1.1 Mounting to an
Atlas or Gemini MLI ....................10
1.9.1.2 Mounting to an Aurora MLI ...........10
1.9.1.3 Wiring...............................................11
1.9.2 ORS Electric Reed Switch ........................11
1.9.2.1 Mounting to an
Atlas or Gemini MLI.........................12
1.0
Installation
Caution: If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be
impaired.
1.1
Unpacking
Unpack the instrument carefully. Inspect all units for
damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip and
purchase order. Check and record the serial number for
future reference when ordering parts.
Caution: Do not discard the shipping container until all parts are
checked.
1.2
Pre-installation Checklist
1. Manually move the float from 0% to 100% to 0% prior
to start up/check out in order to reinitialize accessory
products, if so equipped. Accessories may inadvertently
change state due to rough handling in shipment.
2. Remove float prior to pressure testing tank.
Caution: Float damage will occur if not removed from chamber prior
to pressure testing the tank.
1.4
1.5
1.6
1.7
Start-up
Increase system pressure slowly while commissioning the
instrument. Thoroughly check for leaks, and verify that
the local indicator device accurately tracks the liquid level.
Verify external accessory devices (switches, transmitter, etc.)
are functional and properly calibrated.
Caution: Do not open the bottom isolation valve quickly. Allow the
level to rise until the MLI displays the correct level in the
vessel.
1.8
(-18 to +121 C)
Thickness
2"
Liner
Jacket
1"
2"
Liner
Jacket
+32 to -100 F
Temperature
(0 to -73 C)
2"
-101 to -320 F
(-74 to -196 C)
4"
Figure 2
1.9
inches (mm)
3.0 (76)
REF.
Switch Installation
.5 (12)
REF.
(2) 3/4" NPT
conduit connections
The Model OES snap switch is utilized to expand the control capabilities of Orions extensive line of magnetic level
indicators. This cam-operated double pole double throw
mechanism is clamp-mounted to the outside of the MLI.
This mounting style allows easy addition or repositioning
of switches without disruption of the process.
The OES switch(es) are pre-installed, calibrated, and
checked for proper orientation at the factory. Your unit
may be equipped with one or more switches for alarming
or control. To change the location of the switch in the
field, simply unscrew the clamp and slide the switch to a
new location. See Figure 4.
1.9.1.1 Mounting to an Atlas or Gemini MLI
Figure 4
ORION INSTRUMENTS
INSTALL
THIS SIDE
UP
Remove the cover of the enclosure. Position the OES camoperated snap switch on the MLI body so that the centerline of the switch enclosure is at the desired switch point
level. Ensure that the switch is oriented so that the arrow
on the switch mechanism is pointing toward the top of the
MLI. Install the clamps around the MLI and over the
mounting brackets on the top and bottom of the switch
housing. Tighten the clamps so that the switch is secured
to the MLI. Replace housing cover. If required, place the
insulation between the MLI body and the switch before
tightening the clamps.
1.9.1.2 Mounting to an Aurora MLI
Figure 5
Wiring of OES
cam operated switch
Contact closure is shown with the
magnetic float below the switch
10
The Aurora may be ordered with one or more OES clampon switches. During assembly Orion can ensure proper
function of the switches. Special care must be taken when
adding OES switches to an Aurora after initial purchase.
For proper function, the switch must be located as close to
the internal float magnet as possible. This is achieved by
marking the location of the indicator on the Aurora body.
The indicator must be rotated on the chamber so that the
switch can be positioned closest to the float. Loosen the
indicator clamps, rotate the indicator 90 degrees around the
chamber and retighten the clamps. Mount the OES switch
where the indicator was originally located. Move the float,
or move level, to verify proper operation of the switch.
1.9.1.3 Wiring
11
inches (mm)
3.00
(76.2)
0.84
(21.3)
3.00
(76.2)
1/2"
MNPT
1.00
(25.4)
Figure 8
Figure 9
Wiring of ORS
Reed Switch
1.9.2.3 Wiring
12
inches (mm)
Label bracket
0.4 (10) REF.
3.5 (90)
REF.
4.5 (115)
REF.
3/4" NPT
conduit
connection
XXX = Span
active length
Figure 10
Caution: In hazardous areas, do not power the unit until the conduit
is sealed and the enclosure cover is screwed down securely.
red
yellow
black
black:
Figure 11
13
2.0
Reference Information
2.1
Description
Magnetic Level Indicators (MLIs) are suitable for installation on process applications that will not restrict float travel
in the piping column. It is a magnetic coupled, local level
indicator which is isolated from the process in a sealed
non-magnetic external cage. Bi-color flags provide visual
indication of level up to 100 feet. Field-adjustable level
switches and transmitters are available as options.
The Atlas is a magnetically coupled local level indicator
isolated from the process via a sealed non-magnetic external chamber. A fluorescent orange shuttle or series of bicolored flags provide visual indication of liquid level from
distances of up to 100 feet. Available switches for point
alarms include electronic DPDT, reed and pneumatic
technologies. Transmitter technologies for continuous
420 mA outputs include reed and guided wave radar.
Atlas is suitable for installation on process applications
including corrosive services that do not impede the movement of the float in the piping column.
Aurora and Gemini incorporate a combination of the
Atlas magnetic level gauge and Magnetrols Eclipse
Guided Wave Radar. This represents the industries first
totally redundant mag gauge/transmitter combination.
14
Theory of Operation
Figure 12
Stainless steel
chamber wall
Flux ring
Liquid
level
Float
magnets
Flux
ring
Magnet
spacer
Float
Figure 13
15
2.3
Troubleshooting
Solution
Test flags with a magnet from bottom to top (magnet not
included). If flags test okay, check for float obstruction.
(See Section 2.5, Maintenance on page 16)
Float selected for different specific gravity. Replace float with
a float with correct specific gravity rating. Confirm correctness
of float orientation. Top is up.
Make sure the MLI is level vertically.
The process fluid being measured may be too viscous and
heat tracing may be required to make the material more fluid.
Heat tracing can be purchased from the factory.
The specific gravity of the process fluid and the float weight
may need to be reverified.
The liquid being measured may contain magnetic particles
collecting on the magnetic section of the float causing drag.
If this happens, magnetic trap assemblies can be purchased
from the factory.
16
Solution
Make sure the vessel opening or flange connection that the to
mount flange connects to is level.
The top mount guide rod assembly may be bent. Visual inspection is required.
The process fluid in the vessel may be too viscous, Heating the
vessel to make the process fluid more liquid may be required.
The specific gravity of the process fluid and the float may need
to be reverified.
2.4
Spare Parts
Spare parts are available for Magnetrol/Orion MLIs and
certain switches and transmitters. Please consult the factory.
Have the unit model number and serial number available
for reference.
2.5
Maintenance
Periodic inspections are a necessary means to keep your
level control in good working order. This control is a safety
device to protect the valuable equipment it serves.
If the process liquid is clean (no solids or deposits), the
MLI should require minimum maintenance. If the process
liquid is dirty (solids and deposits), it is recommended the
external cage be isolated from the process and flushed periodically. For complete cleaning, after draining the unit,
remove the bottom flange and float, inspect cage and float
for buildup and clean if required.
Magnetic traps are available to prevent magnetic particulate travel from the vessel to the chamber.
17
2.6
Specifications
Metal alloys
Plastics
Construction options
2" to 8"
DN 20 to DN 150
Process connection types
Measuring range
Temperature range
Pressure range
Indicators
Visual indication
Scale options
Switch options
Transmitter options
18
24 VDC
Maximum Range:
Up to 20 feet standard
(Consult factory for longer lengths)
0.5" (13 mm)
420 mA
-40 to +500 F (-40 to +260C)
Accuracy:
Output:
Temperature range:
24 VDC
Maximum Range:
Accuracy:
Output:
Temperature range:
19
Service Policy
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
Application
5300 Belmont Road Downers Grove, Illinois 60515-4499 630-969-4000 Fax 630-969-9489 www.magnetrol.com
145 Jardin Drive, Units 1 & 2 Concord, Ontario Canada L4K 1X7 905-738-9600 Fax 905-738-1306
Heikensstraat 6 B 9240 Zele, Belgium 052 45.11.11 Fax 052 45.09.93
Regent Business Ctr., Jubilee Rd. Burgess Hill, Sussex RH15 9TL U.K. 01444-871313 Fax 01444-871317
2105 Oak Villa Boulevard Baton Rouge, Louisiana 70815 225-906-2343 Fax 225-906-2344 www.orioninstruments.com
Copyright 2011 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Viton is a registered trademark of DuPont Performance Elastomers.
BULLETIN: 46-638.5
EFFECTIVE: August 2010
SUPERSEDES: August 2004