Pneumatic Modulevel® & APM Controllers
Installation and Operating Manual
Liquid Level Control
Read this Manual Before Installing This manual provides information on F10 and F50 Flow Switches. It is important that all instructions are read carefully and followed in sequence. Detailed instructions are included in the Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings.
NOTES
Low Voltage Directive For use in Installation Category II. If equipment is used in a manner not specified by the manufacturer, protection provided by the equipment may be impaired. Notice of Trademark, Copyright, and Limitations Magnetrol and Magnetrol logotype, and Modulevel are registered trademarks of Magnetrol International. Copyright © 2009 Magnetrol International, Incorporated. All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol reserves the right to make changes to the product described in this manual at any time without notice. Magnetrol makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol mechanical level and flow controls are warranted free of defects in materials or workmanship for five full years from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol products. Quality Assurance The quality assurance system in place at Magnetrol guarantees the highest level of quality throughout the company. Magnetrol is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available.
Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer.
Cautions
Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
WARNINGS
Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages Follow all standard industry procedures for servicing 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.
48-620 Modulevel Pneumatic Liquid Level Control
Modulevel Pneumatic Liquid Level Control
Table of Contents
1.0 Introduction 1.1 Principle of Operation ..............................................5 1.2 Operating Cycle ........................................................5 1.3 Description ...............................................................6 1.3.1 Controller Action ...........................................6 1.3.1.1 Proportional Control...............................6 1.3.1.2 Transmitter..............................................6 1.3.1.3 Transmitter/Receiver Controller ..............6 1.3.1.4 Proportional Plus Integral Control ..........6 1.3.1.5 Differential Gap ......................................7 1.3.2 Controller Options.........................................7 1.3.2.1 Direct or Reverse Action .........................7 1.3.2.2 Electric Limit Switches............................7 1.3.3 Mounting Arrangements ................................7 1.3.3.1 Flanged Top P51, P61 and P62 Displacer Models ....................................7 1.3.3.2 Top Mounted APM-131 .........................7 1.3.3.3 External Cage P53, P55, P63, P64, P65, P66, P71, P72, P73 and P74 Displacer Models ....................................................7 1.3.3.4 External Cage APM-W251, APM-W254 and APM 291.....................8 1.3.3.5 Side Mounted P68 Float Model ..............8 2.0 Installation 2.1 Unpacking ................................................................8 2.1.1 P51, P61, P62 and APM-131 Models............8 2.1.2 P53, P55, P63, P64, P66, P71, P72, APM-W251, APM-W254 and APM-W291 Models ................................8 2.1.3 P68 Models ....................................................8 2.1.4 Transmitter – Receiver Controller Units.........9 2.1.5 Specifications..................................................9 2.2 Mounting................................................................10 2.2.1 Top Mounted Models – P51, P61 & P62 ....11 2.2.2 External Cage Models – P53, P55, P63, P64, P65, P66, P71 & P72 ..........................11 2.2.3 Side Mount Models – P68 ...........................12 2.2.4 Transmitter – Receiver Models .....................12 2.3 Calibration..............................................................13 2.3.1 Proportional Controllers...............................13 2.3.1.1 Calibration Chart instructions ..............15 2.3.2 Reset Controllers ..........................................16 2.3.3 Transmitters .................................................17 2.3.4 Receiver Controllers .....................................18 2.3.5 Differential Gap ...........................................18 2.3.6 Interface Models...........................................19 2.3.7 Electric High/Low Limit Switches................20 2.3.7.1 Electrical Ratings...................................20 2.3.7.2 Wiring Information ..............................20 2.3.7.3 Adjustment Procedure...........................21 2.4 Field Modifications and Adjustments......................21 2.4.1 Changing Controller Action.........................21 2.4.2 Proportional Band Models to Differential Gap ...........................................21 2.4.3 Pneumatic-to-Current (P/I) Converter .........21 2.4.4 Reset Installation ..........................................22 2.4.5 Reset Cleaning .............................................23 2.4.6 Disabling Reset ............................................23 3.0 Reference Information 3.1 Troubleshooting ......................................................24 3.1.1 Installation ...................................................24 3.1.2 Calibration ...................................................24 3.1.3 Operation.....................................................25 3.2 Specifications ..........................................................27 3.2.1 Standard Flanged Top and Flanged Cage Displacer Models P62, P63, P64, P65 and P66 Dimensional Specifications ............27 3.2.2 High Pressure Flanged Top and Flanged Cage Displacer Models P51, P53 and P55 Dimensional Specifications ............28 3.2.3 Standard Sealed Cage Displacer Models P71 and P72 Dimensional Specifications...........................29 3.2.4 Models APM-131, APM-W251, APM-W254 and APM-W291 Dimensional Specifications ............................................30 3.2.5 Standard Side Mount Float Models P68 Dimensional Specifications .......................31
48-620 Modulevel Pneumatic Liquid Level Control
Modulevel Pneumatic Liquid Level Control
Table of Contents (continued)
3.3 Replacement Parts...................................................32 3.3.1 Model P68 Threaded and Flanged Parts Identification .......................................32 3.3.1.1 Model P68-2F2A Threaded 3" NPT.....33 3.3.1.2 Model P68-2H3A, P68-2H4A and P68-2H5A 4" Flanged ..........................33 3.3.2 Model Series P6x Parts Identification ...........34 3.3.2.1 Series P61, P62, P63, P64, P65, P66, P71 and P72.........................36 3.3.3 Series P51, P53 and P55 Parts Identification................................................37 3.3.3.1 Series P51, P53 and P55 .......................38 3.3.4 Model APM-131 Parts Identification ...........39 3.3.4.1 Model APM-131 Part Number ...............39 3.3.5 Models APM-W251, APM-W254 and APM-W291 Parts Identification............40 3.3.5.1 Models APM-W251, APM-W254 and APM-W291 Parts Numbers .............41 3.3.6 Controller Parts............................................42 3.3.6.1 Controller Replacement Assemblies Parts Identification ..............43 3.3.6.2 Tubing Kit 89-8501-015 @ 3–15 and 6–30 psig ..........................44 3.3.6.3 Nozzle Lever Kit 89-8501-002 @ 3–15 and 6–30 psig ..........................44 3.3.6.4 Carriage Assembly Kit 89-8501-003 @ 3–15 and 6–30 psig.....44 3.3.6.5 Feedback Assembly Kit 89-8501-005 @ 3–15 and 6–30 psig.....45 3.3.6.6 Gasket Kit for Relay Assembly 89-8501-014 @ 3–15 and 6–30 psig ...45 3.3.6.7 Additional Replacement Parts ...............45 3.3.7 Reset Replacement Parts...............................46 3.3.7.1 Reset Replacement Assemblies ..............47 3.3.7.2 Replacement Kits (Reset Valve, O-Ring and Offshore)...........................47 3.3.8 Receiver Controller Parts..............................48 3.3.8.1 Receiver Controller Replacement Assemblies.............................................48 3.3.9 Transmitter Mounted Receiver Controller Parts............................................49 3.3.9.1 Transmitter Mounted Receiver Controller Replacement Assemblies ......49 3.3.10 Pneumatic Modulevel Replacement Head Kits..............................................50 3.4 Model Numbers......................................................52 3.4.1 Standard Flanged Top and Flanged Cage Displacer Models....................52 3.4.2 High Pressure Flanged Top and Flanged Cage Displacer Models....................54 3.4.3 Standard Sealed Cage Displacer Models .......56 3.4.4 Standard Side Mount Displacer Models .......58 3.4.5 APM Pneumatic Control Models .................59
48-620 Modulevel Pneumatic Liquid Level Control
1.0
Introduction
Modulevel pneumatic controls are displacement actuated level sensors that provide output signals in direct proportion to changes in liquid level. Simple modular design and proven magnetic coupling make Modulevel controls versatile, highly stable, vibration resistant and adaptable to extremes of temperature and pressure.
1.1
Principle of Operation The key elements of the Modulevel pneumatic control are the magnetic coupling, which allows the controller to be mechanically isolated from the sealed sensing unit; the range spring, which converts the change in buoyancy force on the displacer into motion; and the controller head, which provides a modulated pneumatic signal in direct proportion to the motion of the spring.
Pilot Nozzle Flapper Cam Attraction Ball Magnet Enclosing Tube Range Spring Displacer
Zero Adjustment Indicator
Proportional Band Adjustment
0
Proportional Band Spring
100
Actuating Lever Set Point Adjustment Feedback Bellows Reset Valve Relay Chamber
OUTPUT SUPPLY
Reset Bellows Check Valve Orifice
1.2
Operating Cycle The result of liquid level changes in the vessel is a change in the buoyancy force acting on the displacer and in the load on the spring from which the displacer is suspended. As the spring extends or compresses with the change in load, an attraction ball attached to the spring via a stem assembly moves within the enclosing tube. A magnet encircling the enclosing tube follows the attraction ball, transferring the motion to a rotating cam, which in turn operates a flapper against a nozzle which increases or decreases the pressure within the pneumatic relay. The output pressure signal can be used in a variety of ways to operate a control valve or signal alarms, indicators, process controls or other devices.
Control Valve
Filter Regulator
Supply Pressure
Output pressure
Pilot Pressure
Reset Pressure
Figure 1
48-620 Modulevel Pneumatic Liquid Level Control
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1.3
Description Modulevel pneumatic instruments are available for a variety of functions to handle different application requirements.
1.3.1 Controller Action 1.3.1.1 Proportional Control
Proportional control instruments are used to maintain the level in a tank within a predetermined band. The output from the Modulevel head controls the opening and closing of a valve to control the increase or decrease of the liquid flow through the vessel.
1.3.1.2 Transmitter
Transmitters provide a pneumatic signal proportional to the level of a liquid. The signal can be fed to a variety of devices as the application requires.
1.3.1.3 Transmitter/Receiver Controller
There are two devices in this version. The transmitter senses level directly at the vessel, and provides a pneumatic signal to the receiver/controller. The receiver/ controller operates in the same manner as a direct connected level device, such as a proportional controller, which allows varying the proportional band and level set point. This unit may be mounted either integrally with the transmitter, or at a more convenient remote location.
1.3.1.4 Proportional Plus Integral Control
Proportional plus integral control instruments (i.e., with reset) operate in the same manner as the proportional unit with one major difference. The offset between the desired level and the actual level is eliminated, thus maintaining the level at a point rather than within a band.
6
48-620 Modulevel Pneumatic Liquid Level Control
1.3.1.5 Differential Gap
A differential gap instrument provides two distinct outputs, either opened or closed. One distinct output value is obtained when the level exceeds the upper switching point. This value remains constant until the level decreases below the lower switching point. At this time the controller changes to another distinct output value. The new value remains constant until the level again rises above the upper switching point causing the output value to return to the first output value. The distance between the two switching points is called the differential gap.
1.3.2 Controller Options
Locking Screw
1.3.2.1 Direct or Reverse Action
Direct acting controllers provide an output signal that increases with level increase. Reverse acting controllers provide an output signal that decreases with level increase.
1.3.2.2 Electric Limit Switches
Electric limit switches allow high and low level alarms to be added to any of the pneumatic instruments described above.
Figure 2 Top Mount
1.3.3 Mounting Arrangements 1.3.3.1 Flanged Top P51, P61 and P62 Displacer Models
When mounting inside the tank is possible, flanged top models are the answer (Figure 2). They are used extensively in interface control applications where nonstandard displacers become necessary. An adjustable stainless steel displacer hanger cable is also available. Top mounting models are directly interchangeable with the external cage models.
1.3.3.2 Top Mounted APM-131
Figure 3 P6X External Cage
When mounting inside the tank is possible, threaded top models are the answer. An adjustable stainless steel displacer suspension cable is provided as standard.
1.3.3.3 External Cage P53, P55, P63, P64, P65, P66, P71and P72 Displacer Models
Figure 4 APM External Cage
External cage models (Figure 3) can be easily isolated from the process to simplify maintenance and inspection operations. The in-line design eliminates the need for specifying "right hand" or "left hand" Any mounting . position is possible by rotating the instrument head. A variety of models are available including sealed or flanged cage with either side/side or side/bottom connections. Carbon steel and stainless steel models are available.
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1.3.3.4 External Cage APM-W251, APM-W254, APM-W291
Water Column external cage models (Figure 4) can be easily isolated from the process to simplify maintenance and inspection operations. Sight glass and Try-cock tappings are provided.
1.3.3.5 Side Mounted P68 Float Model
Figure 5
Side mounted models (Figure 5) are ideally suited for narrow level range applications. Carbon steel models are available with either a 3" NPT threaded body or a 4" flanged connection.
2.0
2.1
Installation
Unpacking After unpacking, inspect all the components to see that no damage has occurred during shipment. Care should be taken not to bend the displacer stem or enclosing tube during unpacking or installation. Next, open controller case and remove magnet hold down and nozzle lever retainers. Examine internal controller components for any obvious damage or loosened parts. Check all air connections to make certain they are free of any foreign matter.
2.1.1 P51, P61, P62 and APM 131 Models
Top mounting Modulevel units are shipped from the factory with the controller and displacer removed from the head assembly and packed separately in the same carton or crate.
2.1.2 P53, P55, P63, P64, P66, P71, P72, APM-W251, APM-W254 and APM-W291 Models
All cage type Modulevel units are shipped with the controller removed from the chamber assembly and packed separately in the same carton or crate. A strap and wire assembly retains and protects the displacer within the chamber during shipment. The assembly must be removed through the bottom connection before start-up.
Caution: If reshipping to another location, displacer assembly must again be secured using same strap and wire assembly.
2.1.3 P68 Models
The side mounting Modulevel units are shipped with the controller and float and stem assembly removed from the body and are packed separately in the same carton or crate. After unpacking, inspect all components to see that no damage has occurred during shipment.
8
48-620 Modulevel Pneumatic Liquid Level Control
2.1.4 Transmitter — Receiver Controller Units
Dual head receiver controller models may be supplied to be integrally mounted to the top mounting or external cage style Modulevel controls or to be remotely mounted away from the Modulevel controls. Units supplied with top mounting Modulevels may be shipped assembled and connected to the transmitter head or separately for field assembly. External chambered units will have the receiver controller head connected to the transmitter head, but separate from the chamber. Any heads shipped unassembled from the Modulevel will be packed in the same carton or crate as the control. Handle controllers carefully to avoid damage to the airline piping.
2.1.5 Specifications
Description Process pressure Process temperature Specification Up to 4265 psig at +100° F (Up to 318 bar at +38° C) -150° F to +700° F (-101° C to +371° C) Stainless steel chamber and bolting required for temperatures below -20° F. (Consult factory). Minimum: 0.23 Maximum: 2.20
Specific gravity range Interface detection Process connections Supply pressure
Minimum difference of 0.10 specific gravity between liquids NPT, Socket Weld or Flanged Instrument quality air (clean and dry) Regulated to 5 psig (.3 bar) above maximum output.
Proportional & Output 3–15 psig, 6–30 psig transmitter signal pressure Differential gap 0–20 psig or 0–35 psig Visual Indicator % Span
Level range & proportional Limited only to displacer length. From band adjustment inches to 10 feet (3 meters). Air consumption 3 SCFH at 9 psig output 6 SCFH at 15 psig output 100 cu. in. output volume in 3.2 sec. upon an output pressure increase from 3–15 psig. Trim: 304 or 316 SS Spring: 316 SS or inconel Chamber: Carbon steel or 316 SS Direct or reverse Proportional control, Differential gap, Transmitter NEMA 1, 2, 3, and 3R Max. voltage: 120 VAC/VDC Max. resistive load: 10 VAC/VDC Max. current: 1⁄4" amp switching 1 amp holding
Response speed
Wetted parts Control action Modes of operation Housing (standard)
Limit switch ratings
48-620 Modulevel Pneumatic Liquid Level Control
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2.2
Mounting Before assembling control to vessel, check with spirit level to ensure that the mounting flange is horizontal. Proper operation of the control depends on the Modulevel controller being within 3° of vertical in all directions. The head assembly with sensing components is installed first, then the controller is placed carefully over the enclosing tube, rotated to desired position, and then locked in place by securely tightening the locking screw. Check to be certain the controller magnet can move smoothly throughout its actuating stroke without binding against the enclosing tube. If binding occurs, loosen the slot-head screw, reposition magnet and tighten screw.
Caution: The spring and stem assembly that protrudes below the mounting flange on a top mounted Modulevel is very fragile. DO NOT handle this assembly or place control so that any amount of force is exerted on the spring and stem assembly. Proper operation of the control requires that this assembly is not damaged or bent. Caution: Displacer spring and stem are fragile. Do not drop displacers into tank. Hand feed cable into position to avoid bending stem. Caution: All Modulevel units are shipped from the factory with the enclosing tube tightened and the controller head set screw locked to the enclosing tube (see figure 2, page 7). Failure to loosen the set screw prior to repositioning the supply and output connections may cause the enclosing tube to loosen, resulting in the possible leakage of the process liquid or vapor. NOTE: Since controller is rotatable through 360°, it is important to make certain controller locking screw is tight before installing air or gas connections.
The supply and output air or gas connections provided on the Modulevel are 1⁄4" NPT. These connections are clearly indicated on the side of the controller. The filter-regulator (if furnished) is to be set to deliver a 20 psig supply pressure to a 3–15 psig output controller or a 35 psig supply pressure to a 6–30 psig output controller. The main supply pressure to the regulator should be between 25 and 250 psig (or 40 and 250 psig) and connected to the inlet side of the regulator. In order to protect the instrument from contaminants, clean, dry air or gas must be used as a supply medium.
Caution: Do not overtighten fittings in supply and output connections. Overtightening may crack the housing outlets.
10
48-620 Modulevel Pneumatic Liquid Level Control
Caution: Operation of all buoyancy type level devices should be done in such a way as to minimize the action of dynamic forces on the float or displacer sensing element. Good practice for reducing the likelihood of damage to the control is to equalize pressure across the device very slowly.
Filter Regulator Controller Output Pressure Liquid Level Control Valve
Supply Pressure
2.2.1 Top Mounted Models – APM-131, P51, P61, and P62
Check to be certain there are no tubes, or other obstacles in the vessel to interfere with the operation of the displacer. Stillwells are recommended where a continuous agitation or motion is prevalent.
NOTE: Stillwell installation should be checked to be certain tube (or pipe) is plumb. An out-of-plumb still well may restrict displacer movement. Also, ensure that the stillwell is vented at the top to allow the liquid to rise in the tube with level movement.
Displacer
Figure 6 Top Mounted Units
Figure 6 shows a typical piping installation for a top mounted unit to a tank or vessel.
2.2.2 External Cage Models – APM-W251, APMW254, APM-W291, P53, P55, P63, P64, P65, P66, P71 and P72
Controller
Filter Regulator
Liquid Level
Output Pressure
Supply Pressure
Control Valve
The external cage type Modulevel should be mounted on the side of the tank or vessel with either side/side connections or side/bottom connections, as shown in Figure 7. Mid-range mark on control cage should be aligned to correspond with desired control level in tank or vessel.
NOTE: It is essential that the external cage assembly be mounted plumb to ensure frictionless operation of its internal displacer.
Figure 7 External Cage Units
It is recommended that isolation valves be installed in each equalizing line to the cage as well as a drain valve at the bottom of the chamber (refer to Figure 7). Equalizing lines should be sized at least as large as connections provided on the cage.
48-620 Modulevel Pneumatic Liquid Level Control
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2.2.3 Side Mount Models – P68
Side mount controls mount horizontally to any tank or vessel through a flanged or threaded pipe connection. Refer to the illustrations on page 31 for threaded nozzle and flanged mounting dimensions. It is essential that the control be mounted horizontal.
NOTE: To allow the 3" float to pass through the nozzle, the nozzle bore diameter must not be less than 3.00" schedule 40 pipe size.
2.2.4 Transmitter – Receiver Models
Check installation considerations described for either top mount or cage type mounting units and apply those appropriate for joint installations with receiver controllers. Figure 8 shows a typical piping installation of a receiver controller to a top mounted transmitter type Modulevel control. A chamber type Modulevel installation would be the same, with obvious physical differences on a side of tank installation. Piping for a separate receiver controller would be done in a similar manner except unit would be remotely wall or panel mounted in a control house or installed at or near the control valve.
NOTE: Refer to page 49 for detailed assembly of receiver controller to a transmitter type Modulevel controller.
Check alignment of mounting bracket for receiver controller to be certain top surface of collar is flush with top head assembly so that tops of both controller heads are in the same plane.
Filter Regulator Receiver Controller Transmitter Liquid Level Supply Pressure Output Pressure
Remote Mounted Receiver Recorder (or Indicator)
NOTE: Alignment of controllers is required only to suit factory furnished piping and fittings between controllers. If mounting is to be accomplished using any other method, including remote installations, all piping must be provided by customer.
Displacer
Control Valve
All pneumatic (piping) connections should have threaded joints, sealed with Teflon thread tape or pipe compound suitable for use on pneumatic lines; 1⁄4" pipe size or 5⁄16" O.D. tubing is recommended.
Figure 8 Transmitter – Receiver Controller Units
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48-620 Modulevel Pneumatic Liquid Level Control
2.3
Calibration
2.3.1 Proportional Controllers
Each Modulevel control is calibrated at the factory before shipment. Specified actions have been preset and all scales have been calibrated. However, upon receipt of the instrument the following calibration and adjustment procedure is recommended for all controllers:
1 2 3 4
13 12 11 10
1. Check supply pressure: After appropriate piping has been made to the filter regulator and output connections, and checked for leaks, the supply gauge, shown in Figure 9, should indicate 20 psig (35 psig for 6–30 psig controllers). 2. Check control action: To check controller action, manually rotate the magnet carriage to simulate an increase in level. Note the direction of the output pressure change. (Rising level will increase the output pressure on direct acting controllers. Conversely, rising level will decrease the output pressure on the reverse acting controllers.) The action cam and level adjustment knob must both indicate the same action Should it be required to change the controller action, the action cam can be manually rotated 180° to the desired action. Make certain that the notch in the cam is set into the tab of the pilot nozzle assembly. Cam actions are clearly marked on the cam face as indicated in Figure 10. A zero adjustment will normally be required upon change.
NOTE: It is also important that the level adjustment knob scale action be compatible with the cam action. The level adjustment knob scale is printed DIRECT ACTION on one side and REVERSE ACTION on the other. To change scales, remove level adjustment knob and turn over level scale. Replace knob with same orientation on shaft as before removal.
5 6
14
9 7 8
Figure 9 Proportional Controller with Reset
1 2 3 4 5 6 7 Proportional band adjustment knob Zero adjustment screw Supply pressure gauge Level adjustment knob Magnet carriage Level indicator Output pressure gauge 8 9 10 11 12 13 14 Output connection Supply connection Action cam Relay Orifice cleanout plunger Flapper nozzle assembly Reset adjustment knob
Proportional Control
Differential Gap Control
Dire ct
Rev er s
Actio
e
Actio
Pilot Nozzle Assembly
48-620 Modulevel Pneumatic Liquid Level Control
n
n
Figure 10
3. Check level indicator zero setting. A level indicator is furnished with each Modulevel pneumatic controller and is conveniently located inside the instrument case. The level indicator, shown in Figure 11, indicates the level as a percentage of the displacer length.
13
Calibration Scale Adjustment Screw
T E M P 100°F 400 700
Figure 11 shows a liquid specific gravity of .8 with a corresponding level reading of 45% and a process temperature of approximately +250° F (+121° C). An adjustment is provided on the level indicator to calibrate the pointer and indicator scale when control is at operating temperature.
Magnet Carriage Slide Bar
20 40 80 60 .80 .60 .50
0
LEVEL % DISPLACER LENGTH
NOTE: Consult factory for procedure to calibrate level indicator if precise reading is required.
Pointer
100 .90 1.0 1. 1
S
P.
G
.70
R.
With the system at operating temperature, adjust level of process liquid in the tank (or vessel) to allow the displacer to "hang-free" above the liquid. The pointer on the level indicator should read zero percent on the indicator scale. Refer to Figure 11. To adjust, loosen calibration adjustment screw at the top of the indicator scale and move scale until the pointer is aligned to zero. Retighten adjustment screw. 4. Adjust the proportional band and the level: (The proportional band is the span setting.) The proportional band adjustment knob, located adjacent to the pilot nozzle assembly, sizes the proportional band as a percentage of the displacer length. When the proportional band is set at 5, the output range will correspond to 50% of the total displacer length. For example; on a control with a 14" displacer, a proportional setting of 5 will result in full output range over a 7" level change. (The level adjustment is the control set point.) The level adjustment knob, located just below the supply pressure gauge, positions the midpoint of the proportional band on the displacer. For example; on a control with a 14" displacer, a level setting of 5 will locate the midpoint of the proportional band 7" from the bottom of the displacer. The proper method for calibrating a proportional controller follows: Calibration example: 1.00 specific gravity liquid, 50% proportional band desired, 50% level adjustment desired, 3–15 psig output, direct action. 4.1 Set the pointer on magnet carriage slide bar to 1.00 specific gravity. 4.2 Set both the level and proportional band knobs to 5 (or 50%) on each scale. 4.3 Move the magnet carriage by hand until the pointer reads 50% of displacer length, hold accurately at this position. 4.4 Adjust the zero screw until the output pressure gauge reads 9 psig. 4.5 Move the magnet carriage pointer to 75% displacer length. Output pressure should read 15 psig.
NOTE: If required, small readjustments can be made at the level and proportional band knobs.
Figure 11 Level Indicator
Inches (mm)
3.50 (89) 9.10 (231)
PB = 7.0 (178)
Level = 2.8 (72)
PB = 4.2 (107) 0.7 (18)
Level = 7.0 (178)
3.50 (89)
PB = 3 Level = 2
PB = 5 Level = 5
Figure 12 Proportional Band & Level
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48-620 Modulevel Pneumatic Liquid Level Control
.1 150 140 130 % DISPLACER LENGTH 120 110 100 90 80 70 60 50 40 30 20 10 0 1 2
.2
.3
.4
.5
.6 .7 .8 .9 1.0 1.2 1.4 1.6 1.8 SPECIFIC GRAVITY
5.
Set the level and proportional band for your application. Use calibration chart and instructions given in Figure 13 to select the level and proportional band dial settings based on the specific gravity of liquid to be measured.
5.1 Set the magnet carriage slide bar to the correct liquid specific gravity for your application. 5.2 To check the zero adjustment, bring the liquid level up until the level indicator reads the desired level set point. Set the zero adjustment screw until output pressure gauge reads 9 psig. 6. To check the level and 3–15 settings: Adjust the liquid level until the level indicator reads the low value of the desired span range in terms of % of displacer length. The output pressure should read 3 psig. Adjust the liquid level to the maximum value of the desired span range in terms of % of displacer length. The output pressure should read 15 psig.
3
4
5
6
7
8
9
10
DIAL SETTING FOR LEVEL & PROPORTIONAL BAND
Figure 13 Dual Setting for Level & Proportional Band
2.3.1.1 Calibration Chart instructions
To set level: 1. Determine the desired level set point in terms of % of displacer length. 2. Trace desired level from left to right to the specific gravity line for the product. 3. Trace down from where the two lines intersect to the appropriate dial setting. 4. Adjust the level setting on the controller to this value. To set proportional band: 1. Determine the desired proportional band in terms of % of displacer length. 2. Trace from left to right to the specific gravity line for the product. 3. Trace down from where the two lines intersect to the appropriate dial setting. 4. Adjust the proportional band setting on the controller to this value.
NOTE: If required, small readjustments can be made at the level and proportional band knobs. To increase proportional band, the band knob is turned to a higher number. For best control, it is normally desirable to set the proportional band at the narrowest setting which will not produce cycling. To raise the level, the level adjustment knob is rotated in the desired direction indicated on the dial face.
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2.3.2 Reset Controllers
Each Modulevel control is factory calibrated before shipment for 30% span and minimum reset. The following calibration and adjustment procedures are recommended for all reset controllers: 1. Check to make sure the reset knob is fully counterclockwise.
NOTE: This effectively reduces the reset time to a minimum, but does not completely eliminate reset.
2. Follow the calibration steps 1 through 4 for proportional controllers beginning on page 13. 3. Use the calibration chart, Figure 13, to select the level and proportional band initial settings, based on the specific gravity of the liquid to be measured. 4. Adjust the reset clockwise until stable control is maintained. 5. Set the magnet carriage slide bar to the correct liquid specific gravity for your application. The following adjustment procedure can be used to calibrate the reset controller to your specific application by adjusting the liquid levels: Alternate method to calibrate reset 1. Set the proportional band index to 10. (This setting is comparable to 100% for S.G. equal to 1.0.) 2. Turn the reset dial fully counterclockwise. 3. Slowly open downstream and upstream manual control valves and close by-pass valve. 4. Adjust control point to desired level by means of level adjustment knob. 5. Narrow the proportional band until a cyclic control condition occurs. Then, widen the proportional band by approximately 20% to give stable control. 6. Decrease the reset time until a cyclic condition again occurs. Then, increase the reset time until stable control is maintained. 7. Normally the narrowest proportional band and fastest reset timing required to obtain stability will produce the optimum control. It is recommended that a momentary load upset is then produced to further check system stability and response. (Load can be imposed by moving magnet carriage manually.)
NOTE: Allow system enough time to stabilize after each adjustment.
16
48-620 Modulevel Pneumatic Liquid Level Control
2.3.3 Transmitters
For Modulevel transmitters, the output signal is directly proportional to the level on the displacer. To calibrate a Modulevel transmitter: 1. Follow steps 1 through 3 for Proportional Controllers (page 13). 2. Set the zero adjustment knob to a vertical position (arrow straight up at 12 o’clock).
NOTE: Don't confuse the zero adjustment knob with the zero screw located on top of the pilot nozzle assembly.
3. Set the pointer on the magnet carriage slide bar to the process specific gravity. 4. Set the specific gravity knob to the process specific gravity.
NOTE: The specific gravity adjustment sets the span for the unit.
5. Rotate the magnet carriage on the visual level indicator by hand, until the pointer reads 50% of displacer length. 6. While holding the magnet carriage at 50%, adjust the zero screw to obtain 9 psig output pressure for 3–15 psig units (or 18 psig output for 6–30 units). 7. Rotate the magnet carriage by hand to 0% displacer length. The output should be 3 psig. If it is not, slightly adjust the specific gravity knob to obtain 3 psig output pressure. 8. Rotate the magnet marriage by hand to 100% displacer length. The output pressure should be 15 psig. If it is not, slightly adjust the specific gravity knob to obtain 15 psig output pressure. 9. Recheck the midpoint (50% displacer). Adjust the zero screw to obtain 9 psig output pressure if it has changed. 10. Recheck the zero output and full scale output. The Modulevel transmitter has now been calibrated using the level indicator to simulate process level. If a more precise calibration to the actual process conditions is required, the above procedure can be performed using actual process level on the displacer to set the calibration points.
48-620 Modulevel Pneumatic Liquid Level Control
17
2.3.4 Receiver Controllers
1. Connect the output from the transmitter to the receiver controller input at the rear of the receiver controller housing. 2. Connect a separate supply and output at the right side of the receiver controller housing. 3. Set the proportional band knob at 100 (100%). 4. Set the direct acting knob at 5 (50%). The output gauge should read the same as the transmitter output. If it does not, adjust the zero knob on the receiver controller until both readings are the same. To increase or decrease span distance, turn the proportional band knob to the setting desired, for example, 50 = 50% of span. To move the span mid-point, turn the direct action knob to the setting desired. For a reverse acting output, from a direct acting transmitter output, invert the spring/bellows assembly so that the bellows are on top. Recalibrate as described above. Remove the direct acting indicator plate, and turn it to reverse acting. Recalibrate as described above. If reset is included with the receiver controller, turn the reset knob fully counterclockwise and calibrate as described above. Adjust reset clockwise until stable control is maintained.
2.3.5 Differential Gap
1. Follow steps 1 through 4 of Proportional Controller Calibration section. Refer to pages 13 through 17, except the output is 0–20 psig or 0–35 psig with no mid-range adjustment.
NOTE: When checking the control action for a direct action differential gap unit, set the cam to reverse action; for a reverse action differential gap unit, set cam to direct action.
2. Check that the pilot nozzle assembly is set up for differential gap operation. Figure 10 on page 13 illustrates the pilot nozzle flapper configurations used for the two control modes, proportional and differential gap. If your unit is already set up for differential gap mode, proceed to step 3.
18
48-620 Modulevel Pneumatic Liquid Level Control
To change the control mode: a. Loosen the tube clamp screw. b. Remove the zero screw from the pilot nozzle assembly. c. Remove both screws and top plate from the pilot nozzle assembly. d. Flip the pilot nozzle assembly 180° and install screws with top plate in position. e. Install the zero screw in the pilot nozzle assembly. f. Rotate the tube clamp to horizontal and tighten the tube clamp screw. The cam follower should now rest on the action cam. If it does not, readjust bracket without crimping the tube.
NOTE: Make sure the tube is not kinked and does not interfere with the carriage and the nozzle lever.
g. Change the controller action. For direct action, set the cam to reverse acting; for reverse action, set the cam to direct acting. 3. Check zero output. Set level adjustment knob to 5 or vertical position. Set proportional band knob to 3. Place level indicator at 35% position (65% position for reverse action units). Adjust zero screw to get supply pressure value output; then, slowly readjust the zero screw until output suddenly decreases to zero. 4. Check 20 psig or 35 psig output. Slowly move the attraction sleeve to 65% (35% for reverse action units), at which point the output should suddenly rise to supply pressure. If not, adjust the proportional band knob until it does. 5. Set the level and proportional band for your application.
2.3.6 Interface Models
For an interface application, the Modulevel has been factory precalibrated to operate in liquids with specific gravities supplied by the customer. The displacer is weighted to obtain a zero (3 psig or 6 psig signal) with the displacer fully submerged in the lighter liquid only [15 psig or 30 psig with displacer covered with the heavier fluid]. The indicator arrow should be set to the difference between the two specific gravities of the liquids. Follow the procedures given for installation and calibration of proportional controllers. Refer to pages 13 through 17. Keep in mind that the "hang–free" or zero setting is obtained with the displacer fully submerged in the lighter liquid, and completely uncovered by the interface (heavier liquid).
48-620 Modulevel Pneumatic Liquid Level Control
19
As is indicated in the Calibration section for proportional controllers, the signal should be at 9 psig or 18 psig output with the interface level at the control set point (level knob setting) on the displacer. Because of the reduced displacer motion for interface applications, the proportional band should be set as wide as possible, with a minimum of 50%.
2.3.7 Electric High/Low Limit Switches
The Pneumatic Modulevel is available with optional builtin, adjustable electric high/low level limit switching. This economical, optional feature is well-suited to numerous applications where a combination pneumatic control and electric switch actuation is desired. The Pneumatic Modulevel is used to pneumatically position a diaphragm-type feedwater control valve in response to water level changes in the steam drum. The convenient addition of electric limit switching provides economical high and low level alarm indication. These switches are not intended for primary control purposes.
NOTE: Not suitable for Class I, Div. 1 applications.
2.3.7.1 Electrical Ratings
Figure 14
Each reed switch carries the following electrical ratings:
Maximum voltage............................120 VAC or 120 VDC Maximum resistive load ...........................10 VAC or VDC Maximum current ...........................1⁄4 ampere switching, 1 ampere holding
NOTE: For lamp or capacitive applications, the reed switches are rated six (6) watts maximum.
2.3.7.2 Wiring Information
Each reed switch assembly is wired at the factory and furnished with number-coded, 24.00 inch long silicone rubber insulated copper lead wires. Each reed switch is SPDT in operation. Standard wiring follows: High level reed switch No. 5 lead is common No. 6 lead energizes at high level No. 4 lead de-energizes at high level Low level reed switch No. 2 lead is common No. 3 lead energizes at low level No. 1 lead de-energizes at low level
20
48-620 Modulevel Pneumatic Liquid Level Control
NOTE: Use extreme care in handling the reed switches during wiring and adjustment procedures.
Reed Switch Adjuster Screw
2.3.7.3 Adjustment Procedure
Magnet Attractor Pivoted Magnet
Prior to adjusting the reed switches, the Pneumatic Modulevel should be calibrated to obtain the desired pneumatic proportional band and level position adjustment. After wiring the reed switches to the device to be operated, they may be adjusted manually to actuate at the desired high and low liquid level positions. Move the liquid indicator by hand to the desired low level actuating point on the indicator scale.
NOTE: Scale readings are expressed in percent of displacer length.
Liquid Level Indicator Scale
Non-Magnetic Enclosing Tube
Level Sensing Displacer
Hold the indicator at the desired low level actuating point. Turn the left hand adjuster screw until the reed switch actuates. The high level reed switch is adjusted in the same manner by moving the level indicator to the desired high level actuating point, and by turing the right hand adjuster screw until the high level reed switch actuates.
Figure 15
2.4
Field Modifications and Adjustments
2.4.1 Changing Controller Action
The controller can be changed from direct acting to reverse acting or vice versa. Should it be required to change the controller action, refer to step 2 in the Proportional Controllers section of Calibration. Refer to page 13.
2.4.2 Proportional Band Models to Differential Gap
A proportional band controller can be changed to operate in the differential gap mode. For the appropriate procedures, see the Differential Gap section on page 18.
2.4.3 Pneumatic-to-Current (P/I) Converter
Modulevel units are available with a P/I transducer to provide an electronic output signal proportional to liquid level change. Refer to the manufacturer's instructions supplied with the transducer.
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21
2.4.4 Reset Installation
Reset Bellows Spring
Reset, when added to a proportional controller, acts to maintain the controlled liquid level at the desired control point while eliminating any sustained offset from this point. The reset adjustment is accomplished by manually adjusting a precision needle valve. The reset dial is calibrated from .03 to 1.0 minutes per repeat, with short intervals at the low end of the scale to give precise settings. The reset timing refers to the time in minutes required for the reset to produce an additional output pressure change equal to the previous change caused by proportional action. The reset module assembly may be added to any Modulevel Proportional Controller in the field. The following procedure is recommended for adding reset to a proportional controller in the field. 1. The knob on the reset assembly should point to the 12 o'clock position. Tear foam rubber from between the two plates on the reset assembly. Make sure knob remains at the 12 o'clock position.
Feedback Assembly Reset Valve
Cut Here Existing Tube
Figure 16 Reset Assembly
NOTE: Do not move the front plate or knob on the reset valve or the reset assembly will not work.
2. Remove both screws from the reset valve assembly. 3. Drop the reset valve into position on the frame. 4. Install and tighten the two screws. 5. Add one clamp to each end of both tubes. 6. Slide the long piece of tube onto the barb at rear of reset valve. Slide the clamp into position. 7. Slide the middle prong of the barbed tee onto short piece of tube. Slide the clamp into position. 8. Slide the short piece of tube opposite the barbed tee onto the vertical barb on bottom of reset valve. Slide the clamp into position. 9. Cut the tube adjacent to the barbed tee below the reset valve assembly. Refer to Figure 16. 10. Slide the clamps over the cut ends of the tube. 11. Slide the cut tubes onto the barbed tee. 12. Insert the reset bellows in the feedback assembly so that the bellows end bushings are piloted in the bracket locating holes. 13. Rotate the reset nipple to the 2 o’clock position as you look down at the reset bellows.
22
48-620 Modulevel Pneumatic Liquid Level Control
14. Route the long piece of tube from the reset valve, under the relay assembly, behind the enclosing tube and to the reset bellows. 15. Slide the long piece of tube onto the reset bellows. Slide the clamp into position. 16. Add the washer and screw through the lever assembly and into the reset bellows. Tighten the screw. 17. Add the reset bias spring to the tail end of the lever assembly. 18. Refer to the reset calibration procedure on page 16.
2.4.5 Reset Cleaning
Should it be required to clean the reset orifice, refer to the reset replacement parts drawing on page 46 and proceed as follows: 1. Disconnect the reset line adaptor fitting from the valve body and remove the reset valve mounting screws. 2. Remove the reset valve and disassemble bushing along with all related parts.
NOTE: Shaft and bracket assembly must not be disassembled.
3. Clean orifice and plunger set by dipping in carbon tetrachloride or any suitable solvent being careful not to mar any finished surfaces.
2.4.6 Disabling Reset
In the case that the proportional controller is supplied with reset that is no longer required, the reset can be disabled to modify the controller head to proportional only. To disable this action: 1. Turn the reset knob fully counter-clockwise 2. Disconnect hose (attached to rear of reset assembly) by removing the compression fitting and pulling the hose from the nozzle. 3. Trace the hose to the bellows assembly and remove the bias spring completely from this assembly. Leave this end of the hose attached to the bellows nozzle. Unit will now be configured as a direct acting proportional and is ready for calibration.
48-620 Modulevel Pneumatic Liquid Level Control
23
3.0
3.1
Reference Information
Troubleshooting
3.1.1 Installation
The magnet carriage assembly binds at either the magnet or the indicator scale. 1. The magnet binds on the enclosing tube. Loosen the retaining screw on magnet bracket and adjust the magnet alignment. 2. The carriage binds on the indicator scale. Check for damaged, bent, or loose parts. 3. Check for proper mounting of the controller head.
3.1.2 Calibration
Signal pressure does not change with simulated level change or unit won't calibrate properly. 1. Make certain the output gauge is operational. 2. Make certain the supply gauge reads 20 psig for 3–15 models or 35 psig for 6–30 models. 3. Check for proper calibration settings, refer to appropriate calibration instructions on pages 13 through 18. 4. Check the proportional band and level settings for proper process specific gravity. Refer to the calibration chart, Figure 13 on page 15, in the Calibration section, for settings corresponding to process specific gravities other than 1.0. 5. The level indicator should be set for the proper process temperature. Cannot obtain proper midspan output (9 psig for 3–15 models or 18 psig for 6–30 models). 1. Adjust the zero adjustment screw. 2. Check if reset is included, the output signal will not be steady. Constant high output (pressure does not drop after manually moving the carriage so that the flapper drops away from the nozzle). 1. Clogged exhaust nozzle from contamination or poor quality air supply. Clean nozzle by removing the small screw on the top of the nozzle and blow out any foreign material, or run fine monofilament type line through the opening.
24
48-620 Modulevel Pneumatic Liquid Level Control
Nozzle
1/16"
2. Damaged or bent flapper spring. The flapper should stroke approximately 1⁄16" away from the nozzle in the free hanging position. If it does not, carefully bend the spring down with a screwdriver forcing the flapper away from the nozzle. Refer to Figure 17. 3. Obstructed output. Check connection at signal output. Constant low output, cannot obtain full scale signal. 1. Check for a clogged relay/wiper by depressing the orifice clean out plunger. If this does not solve the problem, the relay may be internally damaged. Consult the factory. 2. Check for proper supply pressure, described above. 3. Check for leaks at all field connections and tubing. 4. Check calibration settings.
Flapper spring Differential gap units adjustment screw is inverted as shown by dotted line
Flapper
Figure 17 Reset Assembly
3.1.3 Operation
Control valve continually oscillates or hunts. 1. Proportional band setting is too narrow. To ensure that the optimum proportional band setting has been made, create a momentary load upset by manually moving the magnet carriage and allowing the controller to again come into balance. If a cyclic condition recurs, widen the band slightly and repeat the above procedure until stability is maintained. 2. Distance between the control valve and Modulevel controller is too great (time lag). Install volume booster in the signal line. 3. If reset is included: The reset response setting may be too fast. Increase the reset time until stable control is maintained Excessive offset. Check the reset line for leaks; these connections must be airtight. No output change as level changes. 1. Check that all gasketed joints on the relay are tight. 2. Check for leaks. 3. Depress relay/wiper plunger since the orifice may be plugged. 4. Remove the enclosing tube and inspect it for internal buildup. 5. Unbolt the head assembly and check for displacer interference.
48-620 Modulevel Pneumatic Liquid Level Control
25
6. Remove parts from the head assembly and inspect internal components. 7. Consult factory. 8. Check sizing and operation of control valve. An oversized valve or excessive friction are possibilities. 9. Check the output capacity. Controllers tend to be unstable when dead-ended due to their high degree of sensitivity. This condition is particularly aggravated when coupled with 1 and 8 above.
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48-620 Modulevel Pneumatic Liquid Level Control
3.2
Specifications
3.2.1 Standard Flanged Top and Flanged Cage Displacer Models P61, P62, P63, P64, P65 and P66 Dimensional Specifications
Inches (mm)
NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator (4) 1/4" NPT
1 13.71 (348)
1/4"
NOTE: Controller head may be rotated through 360°.
NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
(4) 1/4" NPT
1/4"
7.68 (195) 3.84 (98)
7.68 (195) 3.84 (98)
6.50 (165)
1 9.77 (248)
6.50 (165)
1
18.71 (475) 5.00 (127)
ANSI standard flange
1
14.25 (362)
C
2 5.00 (127)
1.00 (25) 2.56 (65) Level range + 2.00 (51)
Level range
Level range A
Mid Range
Figure 18 P61 and P62 Series Top Mounting
B 3.25 8.62 (82) (219)
Optional 3/4" NPT gauge glass tapping (2) 11/2" or 2" NPT or socket weld (2) 11/2" or 2" ANSI standard flange
9.00 (229) 8.38 (213)
1/4" 1/4"
8.75 (222)
Figure 19 P63 and P64 Series with Side/Bottom Connections
NPT output
NPT supply
Vent 5.94 (151) .63 (16) 2.00 (51)
7.68 (195)
3.84 (98)
1/4" NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
Figure 20 Controller Head (side view)
1
(4) 1/4" NPT 6.50 (165)
1
Outlet Size 11⁄2" NPT or Socket Weld 2" NPT or Socket Weld Outlet Size 11⁄2" Flanged 2" Flanged Flange Size & Class 11⁄2" or 2", 150 lb. 11⁄2" or 2", 300 lb. 11⁄2" or 2", 600 lb.
Dimension A 3.19 (81) 3.31 (84) Dimension B 6.25 (159) 6.25 (159) Dimension C 7.50 (191) 8.25 (210) 8.25 (210)
18.71 (475) 5.00 (127)
C
14.77 (375) 1.00 (25)
Level range (2) 11/2" or 2" ANSI standard flange 3.00 (76) (2) 11/2" or 2" NPT or socket weld A
B
2.56 (65)
Mid Range
Level range + 2.00 (51)
Distance without stem extension is 5.00 (127) standard. Can be furnished to a minimum distance of 3.00 (76). 48-620 Modulevel Pneumatic Liquid Level Control
Add 3.12 (79) for units with specific gravity and temperature codes 4, 5 or 6.
(2) Optional 3/4" NPT gauge glass tapping 1" NPT
Figure 21 P65 and P66 Series with Side/Side Connections
27
3.2.2 High Pressure Flanged Top and Flanged Cage Displacer Models P51, P53 and P55 Dimensional Specifications
Inches (mm)
1/4" NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
NOTE: Controller head may be rotated through 360°.
1/4" NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
7.68 (195) 3.84 (98)
7.68 (195) 3.84 (98)
(4) 1/4" NPT 6.50 (165) B A E F C ANSI standard flange K 6.50 (165) D
(4) 1/4" NPT
1.00 (25)
Level range
Figure 22
P51 Series with Top Mounting
Level range M
L
Mid Range
G
3.75 Max. Level (95) range + 2.00 (51)
H
1/4"
7.68 (195) 3.84 (98)
NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator (4) 1/4" NPT
(2) Optional 3/4" NPT gauge glass tapping (2) 11/2" or 2" NPT or socket weld (2) 11/2" or 2" ANSI standard flange (See chart for size and class)
Figure 23 P53 Series with Upper Side/Bottom Connections
6.50 (165) E K D F 1.00 (25) 3.75 Max. (95) 9.00 (229) 8.38 (213)
1/4"
8.75 (222)
NPT output
Figure 20 Controller Head (side view)
Level range (2) 11/2" or 2" ANSI standard flange (see chart for size and class) (2) 11/2" or 2" NPT or socket weld G
Mid Range
Level range + 2.00 (51)
1/4"
NPT supply
Vent 5.94 (151) .63 (16) 2.00 (51)
J L
(2) Optional 3/4" NPT gauge glass tapping
Flange Size & Class 11⁄2" –900 lb.
Dimensions A B C D E F G H J K 8.43 (214) 3.44 11.50 9.38 (87) (292) (238)
Figure 24 P55 Series with Side/Side Connections
Dimensions L M 4.00 (102) 4.38 (111) 3.44 (87) 3.50 (89)
7.25 8.48 12.41 9.31 17.96 21.89 9.31 (184) (215) (315) (236) (456) (556) (236) 8.18 2"–900 lb. (208)
11⁄2" –1500 lb. Outlet Size 11⁄2" NPT or Socket Weld 2" NPT or Socket Weld
7.93 9.13 8.86 12.79 9.31 18.34 22.27 9.31 (201) (232) 3.44 12.25 (225) (325) (236) (466) (566) (236) 8.87 10.13 (87) (311) 2"–1500 lb. (225) (257)
11⁄2" – 2500 lb.
9.06 10.25 9.73 13.66 9.31 19.21 23.14 9.31 (230) (267) 3.44 14.00 (247) (347) (236) (488) (588) (236) 9.87 11.13 (87) (356) 2"–2500 lb. (251) (283)
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48-620 Modulevel Pneumatic Liquid Level Control
3.2.3 Standard Sealed Cage Displacer Models P71 and P72 Dimensional Specifications
Inches (mm) NOTE: Controller head may be rotated through 360°.
1/4"
7.68 (195) 3.84 (98)
NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator (4) 6.50 (165)
1/4"
1/4"
7.68 (195)
3.84 (98)
NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator (4) 1/4" NPT
NPT
1
6.50 (165) 20.69 (525)
1
1
20.69 (525)
1
16.75 (425) 1.00 (25) 2.56 (65) Level range + 2.00 (51) (2) 11/2" or 2" ANSI standard flange
16.75 (425)
1.00 (25)
Level range
Mid Range
Level range
Mid Range
2.56 (65) Level range + 2.00 (51)
A B 3.00 (76) (2) Optional 3/4" NPT gauge glass tapping (2) 11/2" or 2" NPT or socket weld (2) 11/2" or 2" ANSI standard flange A (2) 11/2" or 2" NPT or socket weld B
3.25 8.62 (82) (219)
(2) Optional 3/4" NPT gauge glass tapping 1" NPT
Figure 26 P72 Series with Side/Side Connections 150, 300, 600 lb. Class
Outlet Size 11⁄2" NPT or Socket Weld 2" NPT or Socket Weld Dimension A 3.19 (81) 3.31 (81) Dimension B 6.25 (159) 6.25 (159)
Figure 25 P71 Series with Upper Side/Bottom Connections 150, 300, 600 lb. Class
Outlet Size 1 ⁄2" Flange
8.75 (222)
1
2" Flange
9.00 (229) 8.38 (213)
1/4" 1/4"
Add 3.12 (79) for units with Specific Gravity Codes 4, 5 or 6.
NPT output
600 lb. Pressure/temperature ratings
Temperature Pressure °C 37.7 93 149 204 260 315 371 psig 1440 1240 1120 1020 940 900 860 Bar 99 85 77 70 65 62 59
NPT supply
Vent 5.94 (151) .63 (16) 2.00 (51)
°F 100 200 300 400 500 600 700
Figure 20 Controller Head (side view)
48-620 Modulevel Pneumatic Liquid Level Control
29
3.2.4 Models APM-131, APM-W251, APM-W254 and APM-W291 Dimensional Specifications
inches (mm)
7.69 (195) 3.85 (98)
11.25 (285)
21/2" NPT Adjustable 6.00 (152) to 120.00 (3048) Span adjustable 2.80 (71) to 14.00 (355)
14.75 (374)
2.00 (50)
Figure 28 APM-W251, APM-W254, and APM-W291
Figure 27 APM-131
Catalog Number
A
B C D Gauge Drum Mid glass connector range centers centers of and and throttling pipe size pipe size band 13.50 NPT 15.00 3⁄4" NPT 15.00 3⁄4" NPT
1⁄2"
E Try-Cock tappings and pipe size Three NPT Six 3⁄4" NPT Three 3⁄4" NPT
1⁄2"
APM-W251 APM-W254 APM-W291
25.62 29.50 30.50
13.50 1" NPT 16.00 11⁄4" NPT 15.00 11⁄4" NPT
6.00 8.00 7.50
Dimensions are in inches and subject to change without notice. Certified and detailed submittal drawings are available from the factory.
Figure 29 Controller Head (side view)
30
48-620 Modulevel Pneumatic Liquid Level Control
3.2.5 Standard Side Mount Float Models P68 Dimensional Specifications
Inches (mm) NOTE: Controller head may be rotated through 360°.
7.68 (195) 3.84 (98)
1/4" NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
1/4"
NPT Supply
(4) 1/4" NPT 6.50 (165) 6.12 (155)
1/4"
10.00 (254) Vent NPT output
Maximum length to inside of tank 2.38 (60) 38° Maximum 8.50 level (216) change
19° 3" NPT .63 (16) 2.00 (51) 5.93 (150)
3.50 (89) Diameter
10.25 (260)
3.00" (76) Diameter float
Figure 30 P68 Series with Threaded Side Mounting
1/4" NPT x 2.00 (51) Long min. nipple required Optional nipple mounted filter regulator
7.68 (195) 3.84 (98)
1/4"
NPT Supply
(4) 1/4" NPT 6.50 (165) 10.00 (254) Vent
1/4"
6.50 (165)
Maximum length to inside of tank
NPT output .63 (16) 2.00 (51) A
10°
20°
7.38 Maximum (187) level change
3.00" (76) Diameter float B
Figure 31 P68 Series with Flanged Side Mounting
9.00 (229) 8.38 (213)
1/4" 1/4"
8.75 (222)
NPT output
Figure 20 Controller Head (side view)
Flange Size and Class 4", 150 lb. 4", 300 lb.
Dim. A 5.38 (137) 5.38 (137) 5.88 (149)
Dim. B 20.12 (511) 20.12 (511) 19.62 (498)
No. of Dia. of Bolt Bolt Holes Holes 8 8 8 .75 (19) .88 (22) 1.00 (25)
NPT supply
Vent 5.94 (151) .63 (16) 2.00 (51)
4", 600 lb.
48-620 Modulevel Pneumatic Liquid Level Control
31
3.3
Replacement Parts
1
1 3
2 18
2
3
18 17 4 5 6 17 9 12 13 15 4 5 6 9 12 13 15
11 11 8 7 16 10 14 16 10 8 7
14
Figure 32 Typical Side Mounted Threaded Assembly
Figure 33 Typical Side Mounted Flanged Assembly
3.3.1 Model P68 Threaded and Flanged Parts Identification
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Description Attraction sleeve Hex nut #8-32 Stem Stem retaining bracket Screw #6-32 Bracket Cotter pin Washer Pivot pin Fulcrum Lock washer Hex nut #1/4-20 Stem Hex nut #10-32 Float Body E-tube gasket Enclosing tube
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of control. B. Name and number of replacement part.
48-620 Modulevel Pneumatic Liquid Level Control
32
3.3.1.1 Model P68-2F2A Threaded 3" NPT (See Figure 32)
Sleeve and stem kit (includes items 1 through 14) Float Body E-tube gasket Enclosing tube 089-5562-001 Z07-1102-005 Z33-6120-003 012-1204-001 Z32-6201-006
15 16 17 18
3.3.1.2 Models P68-2H3A, P68-2H4A and P68-2H5A 4" Flanged (See Figure 33)
Item Flanged cage Sleeve and stem kit (includes items 1 through 14) Float Body E-tube gasket Enclosing tube 150# 300# 089-5562-002 Z07-1102-005 Z33-6118-002 012-1204-001 Z32-6201-006 600#
15 16 17 18
Z33-6118-001
Z33-6118-002
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of control. B. Name and number of replacement part.
48-620 Modulevel Pneumatic Liquid Level Control
33
3.3.2 Model Series P6x Parts Identification
15 CONTROLLER (Ref.)
1 2
8
7 3
9
8
7
Serial No. Tag (Ref.) 5 6 4
16 10 1
9 10
2
11
3
12
14
13
14
Figure 34 Typical Top Mounting Head Assembly (Series P6x Shown)
Items not furnished on Series P50. Series P50 head flanges are ANSI standard.
Figure 35 Typical Fabricated External Cage Assembly (Series P6x Shown)
34
48-620 Modulevel Pneumatic Liquid Level Control
3.3.2
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Series P61, P62, P63, P64, P65, P66, P71 and P72 Parts Identification (See Figures 34 & 35)
Description Enclosing tube Enclosing tube gasket Mounting head kit Head flange gasket Studs Hex nuts Stem and spring kit Adjusting sleeve Jam nut Cotter pins Spacer tube Stop ring Stop Displacer Controller case only Filter regulator Gauge (not shown)
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of control. B. Name and number of replacement part.
48-620 Modulevel Pneumatic Liquid Level Control
35
3.3.2.1 Series P61, P62, P63, P64, P65, P66, P71 and P72 (See Figures 34 & 35)
Item 1 Matl. Enclosing tube C.S. 304 316 Enclosing tube gasket Mounting head kits 150# flange 0.23 – 0.54 SG 0.55 – 1.09 and 1.10 – 2.20 SG 300# flange 0.23 – 0.54 SG 0.55 – 1.09 and 1.10 – 2.20 SG 600# flange 0.23 – 0.54 SG 0.55 – 1.09 and 1.10 – 2.20 SG Head flange gasket Studs Hex nuts 150# 012-1301-017 010-1701-004 (4 required) 010-2104-011 (8 required) 0.23 – 0.54 SG 089-5533-001 089-5533-002 Part Number 400° F Max. 700° F Max Z32-6201-006 Z32-6201-002 Z32-6201-007 Z32-6201-008 Z32-6201-001 Z32-6201-003 012-1204-001 Carbon Steel Stainless Steel 089-4217-001 089-4238-001 089-4218-001 089-4238-002 089-4219-001 089-4238-003 089-4220-001 089-4238-004 089-4221-001 089-4238-005 089-4222-001 089-4238-006 300# 600# 012-1301-018 012-1204-021 010-1701-007 010-1701-020 (8 required) (8 required) 010-2104-012 010-2104-012 (16 required) (16 required) 0.55 – 1.09 SG 1.10 – 2.20 SG 089-5532-001 089-5531-001 089-5532-002 089-5531-002
2 3
4 5 6
Stem and spring kits 4th digits 1, 2 & 3 (+400° F/+204° C maximum) 7 Stem and spring kits 4th digits 4, 5 & 6 (+700° F/+371° C maximum) 8 Adjusting sleeve 9 Jam nut 10 Cotter pins Lgth. 14 Displacer 14" 32" 48" 60" 72" 84" 96" 108" 120" 15 Controller case only Receiver 16 Filter regulator Gauge (not shown) Adjustable Hanger Adjustable stainless suspension cable for flanged top mounting models
7
004-5359-123 010-2107-004 010-5203-001 (2 required) 0.23 – 0.54 SG and 0.55 – 1.09SG 089-6125-001 089-6125-002 089-6125-003 089-6125-004 089-6125-005 089-6125-006 089-6125-007 089-6125-008 089-6125-009 Pneumatic 046-1505-001 046-1505-002 006-9501-002 006-9501-003 Lgth. (in) Lgth. (m) 96 2.4
1.10 – 2.20 SG 089-6126-001 089-6126-002 089-6126-003 089-6126-004 089-6126-005 089-6126-006 089-6126-007 089-6126-008 089-6126-009
032-3110-001
36
48-620 Modulevel Pneumatic Liquid Level Control
3.3.3 Series P51, P53 and P55 Parts Identification (See Figures 34 & 35)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Enclosing tube Enclosing tube gasket Head flange Head flange gasket Studs Hex nuts Stem and spring kit Adjusting sleeve Jam nut Cotter pins Displacer Controller case only Filter regulator Gauge (not shown)
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of control. B. Name and number of replacement part.
48-620 Modulevel Pneumatic Liquid Level Control
37
3.3.3.1 Series P51, P53 and P55 (See Figures 34 & 35)
Item 1 2 3 4 5 6 7 8 9 10 11 Matl. Enclosing tube C.S. Enclosing tube gasket Head flange Head flange gasket Studs Hex nuts Stem and spring kit 0.55 – 1.09 SG Adjusting sleeve Jam nut Cotter pins Lgth. Displacer 14" 32" 48" 60" Controller case only Filter regulator Gauge (not shown) 900# flange Z04-8606-001 012-1204-009 010-1701-022 (4 required) 010-2104-016 (8 required) Part Number +700° F Max Z32-6206-001 012-1204-001 1500# flange 2500# flange Z04-8606-002 Z04-8606-003 012-1204-010 012-1204-011 010-1701-017 010-1701-023 (6 required) (8 required) 010-2104-017 010-2104-019 (12 required) (16 required) 032-8120-002 004-5359-123 010-2107-004 010-5203-001 (2 required) 0.55 – 1.09 SG 089-6125-010 089-6125-011 089-6125-012 089-6125-013 Pneumatic 046-1505-001 Receiver 046-1505-002 006-9501-002 006-9501-003
12 13 14
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of receiver controller. B. Name and number of replacement assembly (kit).
48-620 Modulevel Pneumatic Liquid Level Control
38
Controller mechanism
20
3.3.4
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Model APM-131 Parts Identification
Description Enclosing tube Gasket (E-tube) Spacer tube Mounting bushing Snap ring Stop washer Range spring Connecting link Lock nut Spring cup (upper) Screw Spring cup (lower) Retaining bracket Jam nut Attraction ball & stem assembly Displacer Clamp screw Displacer cable Connector nut Controller case only
15 14 1
4
2 7
10 13 3
12
11 6 8
19 18 17 16
9
5
3.3.4.1 Model APM-131 Part Number
1 2 Enclosing tube Gasket (E-tube) Mounting bushing kit (includes items 2 through 5) Stem and spring kit (includes items 5 through 15) Displacer kit (includes items 16 through 19) Controller case only Z32-6201-006 012-1204-001 089-5703-001 089-5505-001 089-6106-001 046-1505-001
20
Figure 36 Typical Top Mounting Head Assembly
48-620 Modulevel Pneumatic Liquid Level Control
39
3.3.5
Models APM-W251, APM-W254 and APM-W291 Parts Identification
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Enclosing tube C.S. Enclosing tube gasket Head flange kit Head flange gasket Studs Hex nuts Head flange gasket Spring mounting plate Jam nut (not shown) Cotter pin Spring cup Spring & stem assembly Attraction sleeve (not shown) Screws (not shown) Chamber assembly Displacer Chamber liner (not shown) Filter regulator (not shown) Gauge (not shown) Controller case only (shown on page 39)
1
6 5
2
3
4 12
8
7
11
10
15
16
Figure 37 Typical Carbon Steel Fabricated External Cage Assembly
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of receiver controller. B. Name and number of replacement assembly (kit).
40
48-620 Modulevel Pneumatic Liquid Level Control
3.3.5.1
Models APM-W251, APM-W254 and APM-W291 Parts Numbers Model APM-W254 Part Number
1 Enclosing tube C.S. 2 Enclosing tube gasket Head flange kit (includes items 3 through 6) Stem and spring kit (includes items 7 through 14) 10 Cotter pin 15 Chamber assembly 16 Displacer 17 Chamber liner (not shown) 18 Filter regulator (not shown) 19 Gauge (not shown) 20 Controller case only (shown on page 39) Z32-6201-006 012-1204-001 089-4202-001 089-5320-001 010-5202-005 089-4608-001 Z07-5421-121 089-4404-001 006-9501-002 006-9501-003 046-1505-001
Model APM-W251 Part Number
1 Enclosing tube C.S. 2 Enclosing tube gasket Head flange kit (includes items 3 through 6) Stem and spring kit (includes items 7 through 14) 10 Cotter pin 15 Chamber assembly 16 Displacer 17 Chamber liner (not shown) 18 Filter regulator (not shown) 19 Gauge (not shown) 20 Controller case only (shown on page 39) Z32-6201-006 012-1204-001 089-4202-001 089-5320-001 010-5202-005 089-4607-001 Z07-5422-121 089-4403-001 006-9501-002 006-9501-003 046-1505-001
Model APM-W291 Part Number
1 Enclosing tube C.S. 2 Enclosing tube gasket Head flange kit (includes items 3 through 6) Stem and spring kit (includes items 7 through 14) 10 Cotter pin 15 Chamber assembly 16 Displacer 17 Chamber liner (not shown) 18 Filter regulator (not shown) 19 Gauge (not shown) 20 Controller case only (shown on page 39) Z32-6201-006 012-1204-001 089-4203-001 089-5320-001 010-5202-005 Z33-1004-001 Z07-5421-121 N/A 006-9501-002 006-9501-003 046-1505-001
48-620 Modulevel Pneumatic Liquid Level Control
41
3.3.6 Controller Parts
16
2
10
31
15 14 32
23 30 22 1 12
33
11
33
17 18 19
20
21
3
7
5
2
6 6 8 4 9 3
Figure 38 Controller Replacement Parts
Controller Replacement Parts
42
48-620 Modulevel Pneumatic Liquid Level Control
3.3.6.1 Controller Replacement Assemblies Parts Identification (See Figures 38 & 39)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Description Tube, Tube, Tube, Tube, 2.25" 4.75" 7.75" 3.13" length length length length
Barbed tee Barbed elbow Tube elbow Silicone tape, 1.25" length Silicone tape, 2.00" length Silicone tape, .75" length Cable clamp #10-32 x .25 round head screw Tube, 30" length Nozzle level assembly Plate #4-40 x .25 round head screw Bridge adjustment screw assembly Selector cam Spring washer Magnetic carriage assembly Palnut Nameplate Feedback assembly Gasket O-ring, Viton® O-ring, Viton® O-ring, Viton® O-ring, Viton® Gasket Gasket, relay mounting Wiper assembly Relay assembly Pressure gauge
48-620 Modulevel Pneumatic Liquid Level Control
43
NOTE:
Replacement assemblies listed are furnished in preassembled kit form only for standard temperature model proportional (P), proportional/reset (PR), differential gap (D), and transmitter (T) pneumatic controllers.
3.3.6.2 Tubing Kit 089-8501-015
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Tube, 2.25" length Tube, 4.75" length Tube, 7.75" length Tube, 3.13" length Barbed tee Barbed elbow Tube elbow Silicone tape, 1.25" length Silicone tape, 2.00" length Silicone tape, .75" length Cable clamp #10-32 x .25 round head screw Tube, 30" length
@ 3-15 and 6-30 psig (See Figure 38)
Qty. 1 2 2 1 1 4 2 1 1 1 1 1 1
31 24 25
26 27 28
29
3.3.6.3 Nozzle Lever Kit 089-8501-002@ 3-15 and 6-30 psig (See Figure 38)
Item 10 11 12 13 14 15 16 Silicone tape, .75" length Cable clamp #10-32 x .25 round head screw Tube, 4.75" length Nozzle level assembly Plate #4-40 x .25 round head screw Qty. 1 1 1 1 1 1 2
28 30
Figure 39 Relay Assembly (Item 32)
3.3.6.4 Carriage Assembly Kit 089-8501-003
Item 17 18 19 20 21 Qty. 1 1 1 1 1
@ 3-15 and 6-30 psig (See Figure 38)
Bridge adjustment screw assembly Selector cam Spring washer Magnetic carriage assembly Palnut
44
48-620 Modulevel Pneumatic Liquid Level Control
3.3.6.5 Feedback Assembly Kit 089-8501-005 @ 3–15 psig and 89-8501-006 @ 6–30 psig (See Figure 38)
Item 1 22 23 Tube, 7.50" length Nameplate Feedback assembly Qty. 1 1 1
3.3.6.6 Gasket Kit for Relay Assembly 089-8501-014 @ 3–15 psig and 6–30 psig (See Figure 39)
Item 24 25 26 27 28 29 30 Qty. 1 1 1 1 2 1 1
O-Ring, Viton® Gasket Gasket, relay mounting
Gasket O-Ring, Viton® O-Ring, Viton® O-Ring, Viton®
3.3.6.7 Additional Replacement Parts (See Figures 38 & 39)
Item 33 31 32 Qty. 1 1 1 3-15 psig 6-30 psig 006-8112-030 006-8112-060 089-7833-001 089-7803-001
Pressure gauge Wiper assembly Relay assembly
NOTE:
Use tubing kit 089-8501-015 for units with brass fittings. Controller heads with reset require 4 compression rings. All others require 2. Use tubing kit 089-8501-001 for units with the plastic fittings (items 6, 7, and 8) and process temperature below +450° F (+232° C). Consult factory for units with plastic fittings and process temperatures above +450° F. Customer is to cut tube lengths to correspond to those previously supplied on the unit. Carriage assembly kit part number 089-8501-004 for Model P68 only. Appropriate nameplate to be applied by customer, depending on application.
Used only when mating surface has counter bore, otherwise discard. Relay assembly includes wiper assembly. Clear tubing does not require compression ring (as did older white tubing). Plastic settings are obsolete. Call factory for replacement parts. Brass fittings are now supplied.
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of receiver controller. B. Name and number of replacement assembly (kit).
48-620 Modulevel Pneumatic Liquid Level Control
45
3.3.7 Reset Replacement Parts
7 2 14 1 15 3 4 8
10 9
11
16
6
5 12 13
Figure 40 Reset Replacement Parts
18 17 19
20
22
21
Figure 41 Offshore Kit
46
48-620 Modulevel Pneumatic Liquid Level Control
3.3.7.1 Reset Replacement Assemblies (See Figures 40 & 41)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Qty. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 Description Valve assembly Spacer Dial Set screw Knob assembly #2-56 x .33 round head screw #4-40 x 16 bridge head screw Washer Spring, bias Bellows assembly Tube 8.50" length Tube .81" length Barbed tube tee O-Ring, Viton® O-Ring, Viton® O-Ring, Viton® O-Ring, Viton® Seal washer O-Ring, Viton® Adapter Air relief valve O-Ring, Viton®
3.3.7.2 Replacement Kits (See Figures 40 & 41)
Reset valve kit includes items 1 through 13 O-ring kit includes items 14 through 16 Offshore kit includes items 17 through 22
NOTE:
Replacement assemblies listed are furnished in preassembled kit form only, complete with gaskets for field installation. The offshore kit allows air to exit the controller case while preventing air intake to the unit. Clear tubing does not require compression ring (as did older white tubing). Plastic settings are obsolete. Call factory for replacement parts. Brass fittings are now supplied.
3-15 psig 6-30 psig 089-8501-008 089-8501-009 089-8501-010 089-8501-007
IMPORTANT: When ordering replacement parts, please specify:
A. Model and serial number of receiver controller. B. Name and number of replacement assembly (kit).
48-620 Modulevel Pneumatic Liquid Level Control
47
NOTE:
Replacement assemblies listed are furnished in preassembled kit form only for standard temperature model proportional (P), proportional/reset (PR), differential gap (D), and transmitter (T) pneumatic controllers.
3.3.8 Receiver Controller Parts (See Figure 42)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Qty. 1 1 1 1 2 1 1 1 1 1 2 1 1 1 Description Nozzle lever Bushing Adjustment screw Spring #4-40 round head screw Plate #2-56 flat head screw O-Ring, Viton®
Tube 7.75" length Tape, silicone #8-32 round head screw Tube 4.75" length Inlet connector Input module
3.3.8.1 Receiver Controller Replacement Assemblies (See Figure 42)
3-15 psig Receiver controller nozzle lever kit includes items 1 through 10 Input module kit includes items 11 through 14
NOTE:
6-30 psig
089-8501-011 089-8501-012 089-8501-013
Clear tubing does not require compression ring (as did older white tubing).
3 1 5 2
9 10
7
8
11
14 12
13
6
4
Figure 42 Receiver Controller Parts
48
48-620 Modulevel Pneumatic Liquid Level Control
3.3.9 Transmitter Mounted Receiver Controller Parts
Transmitter Receiver/Controller 3 4
UT INP OU TP UT OU TP UT
SU PP LY
1 2
SU
PP
LY
5
6
10
7 13 12 8
11 9
Figure 43 Transmitter Mounted Receiver Controllers (Configuration A Shown)
3.3.9.1 Transmitter Mounted Receiver Controller Replacement Assemblies (See Figure 43)
Replacement Assemblies Configuration A Configuration B (not shown) Qty. Part No. Qty. Part. No. 1 Consult Factory 1 Consult Factory 1 Consult Factory 1 Consult Factory 2 011-4102-042 3 011-4102-042 2 011-2212-001 2 011-2212-001 2 011-4707-002 1 011-4707-002 2 011-1102-007 1 011-1102-007 1 011-1102-016 2 011-1102-016 1 036-3802-001 1 036-3802-001 1 1 1 010-1706-001 006-9501-002 006-9501-003 1 2 2 010-1706-001 006-9501-002 006-9501-003
Item 1 2 3 4 5 6 7 8
12 13
Output tube (item 1) Supply tube (item 2) Male elbow (item 3) Tee (item 4) Male connector (item 5) 7 ⁄8" Close Nipple (item 6) 13⁄4" nipple (item 7) Bracket assembly (item 8) Saddle, U-bolt, hex nuts (items 9 through 11) Filter regulator (item 12) Gauge (item 13 – not shown)
CONFIGURATION: A. For receiver-controller installation on transmitter with same input/output range. B. For receiver-controller installation on transmitter with different input/output range, requiring use of two filter regulators.
48-620 Modulevel Pneumatic Liquid Level Control
49
3.3.10 Pneumatic Modulevel Replacement Head Kits
8th, 9th & 10th digits PAA PAB PBA PBB PCA PCB PDA PDB PIA PIB PJA PJB PKA PKB PLA PLB PEA PEB PFA PFB PGA PGB PHA PHB PMA PMB PNA PNB POA POB PPA PPB Supply Pressure 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 20 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig Limit Switches no no no no no no no no yes yes yes yes yes yes no no no no no no no no no no yes yes yes yes yes yes yes yes Model Fourth Digit 2 or 5 3 or 6
Function proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap
Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig
Action direct direct direct direct direct direct direct direct direct direct direct direct direct direct direct direct reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse
1 or 4
089-8502-001 089-8502-033 089-8502-065 089-8502-002 089-8502-034 089-8502-066 089-8502-003 089-8502-035 089-8502-067 089-8502-004 089-8502-036 089-8502-068 089-8502-005 089-8502-037 089-8502-069 089-8502-006 089-8502-038 089-8502-070 089-8502-007 089-8502-039 089-8502-071 089-8502-008 089-8502-040 089-8502-072 089-8502-017 089-8502-049 089-8502-081 089-8502-018 089-8502-050 089-8502-082 089-8502-019 089-8502-051 089-8502-083 089-8502-020 089-8502-052 089-8502-084 089-8502-021 089-8502-053 089-8502-085 089-8502-022 089-8502-054 089-8502-086 089-8502-023 089-8502-055 089-8502-087 089-8502-024 089-8502-056 089-8502-088 089-8502-009 089-8502-041 089-8502-073 089-8502-010 089-8502-042 089-8502-074 089-8502-011 089-8502-043 089-8502-075 089-8502-012 089-8502-044 089-8502-076 089-8502-013 089-8502-045 089-8502-077 089-8502-014 089-8502-046 089-8502-078 089-8502-015 089-8502-047 089-8502-079 089-8502-016 089-8502-048 089-8502-080 089-8502-025 089-8502-057 089-8502-089 089-8502-026 089-8502-058 089-8502-090 089-8502-027 089-8502-059 089-8502-091 089-8502-028 089-8502-060 089-8502-092 089-8502-029 089-8502-061 089-8502-093 089-8502-030 089-8502-062 089-8502-094 089-8502-031 089-8502-063 089-8502-095 089-8502-032 089-8502-064 089-8502-096
50
48-620 Modulevel Pneumatic Liquid Level Control
3.3.10 Pneumatic Modulevel Replacement Head Kits (cont.)
8th, 9th & 10th digits RAA* RAB* RBA* RBB* REA* REB* RFA* RFB* TAA TAB* TBA* TBB* TEA* TEB* TFA* TFB* PAJ PAK PBJ PBK PCJ PCK PDJ PDK PEJ PEK PFJ PFK PGJ PGK PHJ PHK Supply Pressure 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 20 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig 20 psig 35 psig Limit Switches no no no no no no no no no no no no no no no no no no no no no no no no no no no no no no no no Model Fourth Digit 2 or 5 3 or 6
Function proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap proportional proportional prop. w/reset prop. w/reset transmitter transmitter differential gap differential gap
Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0 or 20 psig 0 or 35 psig
Action direct direct direct direct reverset reverse direct direct direct direct direct direct direct direct direct direct direct reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse reverse
1 or 4
089-8502-129 089-8502-145 089-8502-161 089-8502-130 089-8502-146 089-8502-162 089-8502-131 089-8502-147 089-8502-163 089-8502-132 089-8502-148 089-8502-164 089-8502-133 089-8502-149 089-8502-165 089-8502-134 089-8502-150 089-8502-166 089-8502-135 089-8502-151 089-8502-167 089-8502-136 089-8502-152 089-8502-168 089-8502-137 089-8502-153 089-8502-169 089-8502-138 089-8502-154 089-8502-170 089-8502-139 089-8502-155 089-8502-171 089-8502-140 089-8502-156 089-8502-172 089-8502-141 089-8502-157 089-8502-173 089-8502-142 089-8502-158 089-8502-174 089-8502-143 089-8502-159 089-8502-175 089-8502-144 089-8502-160 089-8502-176 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 089-8502-097 089-8502-098 089-8502-099 089-8502-100 089-8502-101 089-8502-102 089-8502-103 089-8502-104 089-8502-105 089-8502-106 089-8502-107 089-8502-108 089-8502-109 089-8502-110 089-8502-111 089-8502-112 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a
* Kits for receiver controllers include both heads
48-620 Modulevel Pneumatic Liquid Level Control
51
3.4
Model Numbers
3.4.1 Standard Flanged Top and Flanged Cage Displacer Models
DESIGN TYPE P6 Standard design Pneumatic Modulevel
MOUNTING AND CHAMBER MATERIALS flanged top cage side/bottom cage side/side steel 1 316 SS 2 steel 3 316 SS 4 steel 5 316 SS 6
tank connection chamber material code
Adjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 5.00"
SPECIFIC GRAVITY AND PROCESS TEMPERATURE +400° F (+204° C) +700° F (+371° C) 1 2 3 4 5 6
maximum temperature 0.23 – 0.54 specific gravity 0.55 – 1.09 specific gravity 1.10 – 2.20 specific gravity
Inconel spring furnished on models P62, P64 and P66 with codes 4, 5, or 6
TANK CONNECTION Top mounted connection type External cage models RF 150 lbs RF 300 lbs RF 600 lbs G3 H3 K3 G4 H4 K4 G5 H5 K5 ANSI Head Flange rating Size 3" 4" 6" RF 150 lbs RF 300 lbs RF 600 lbs Size / Type C5 C6 P3 D5 D6 Q3 C7 C8 P4 D7 D8 Q4 C9 C0 P5 D9 D0 Q5 11⁄2" NPT 11⁄2" S.W. 11⁄2" flanged 2" NPT 2" S.W. 2" flanged ANSI Cage rating
Maximun pressure rating for units with 600 lb.
ANSI flange construction is 1330 psi @ 100° F (967 bar @ 38° C).
LEVEL RANGE 14 356 A 32 813 B 48 1219 C 60 1524 D 72 1829 E 84 2134 F 96 2438 G 108 2743 H 120 3048 I inches mm CODE
PNEUMATIC INSTRUMENT (see opposite page)
P
52
6
complete order code for Standard Pneumatic Modulevel
48-620 Modulevel Pneumatic Liquid Level Control
3.4.1 Standard Flanged Top and Flanged Cage Displacer Models (continued)
PNEUMATIC INSTRUMENT Single Function Heads Direct Acting Std PAA PAB PBA PBB PCA PCB PDA PDB Limit Sws PIA PIB PJA PJB PKA PKB PLA PLB Reverse Acting Std PEA PEB PFA PFB PGA PGB PHA PHB Limit Sws PMA PMB PNA PNB POA POB PPA PPB Function Proportional Proportional Proportional w/reset Proportional w/reset Transmitter Transmitter Differential Gap Differential Gap Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0–20 psig 0–35 psig Mounting Integral Integral Integral Integral Integral Integral Integral Integral
TRANSMITTER/RECEIVER CONTROLLER Dual Heads Direct Acting Std RAA RAB RBA RBB TAA TAB TBA TBB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Reverse Acting Std REA REB RFA RFB TEA TEB TFA TFB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Function Proportional Proportional Proportional w/reset Proportional w/reset Proportional Proportional Proportional w/reset Proportional w/reset Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig Mounting Integral Integral Integral Integral Remote Remote Remote Remote
48-620 Modulevel Pneumatic Liquid Level Control
53
3.4.2 High Pressure Flanged Top and Flanged Cage Displacer Models
DESIGN TYPE P5 High pressure design Pneumatic Modulevel
MOUNTING AND CHAMBER MATERIALS flanged top steel 1 cage side/bottom steel 3 cage side/side steel 5 tank connection chamber material code
P50 Series displacer material is 304 stainless steel. Adjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 9.31."
SPECIFIC GRAVITY AND PROCESS TEMPERATURE +700° F (+371° C) maximum temperature 5 0.55 – 1.09 specific gravity
TANK CONNECTION Top mounted connection type External cage models ANSI HEAD Flange rating RF 900 lbs RF 1500 lbs RF 2500 lbs H6 H7 H8 Size 4" ANSI Cage rating RF 900 lbs RF 1500 lbs RF 2500 lbs Size / Type L5 M5 P6 L6 M6 Q6 L7 M7 P7 L8 M8 Q7 L9 M9 P8 L0 M0 Q8 11⁄2" NPT 11⁄2" S.W. 11⁄2" flanged 2" NPT 2" S.W. 2" flanged
LEVEL RANGE 14 32 356 813 A B
48 1219 C
60 1524 D
inches mm code
PNEUMATIC INSTRUMENT
P
5
5
complete order code for High Pressure Pneumatic Modulevel
54
48-620 Modulevel Pneumatic Liquid Level Control
3.4.2 High Pressure Flanged Top and Flanged Cage Displacer Models (continued)
PNEUMATIC INSTRUMENT Single Function Heads Direct Acting Std PAA PAB PBA PBB PCA PCB PDA PDB Limit Sws PIA PIB PJA PJB PKA PKB PLA PLB Reverse Acting Std PEA PEB PFA PFB PGA PGB PHA PHB Limit Sws PMA PMB PNA PNB POA POB PPA PPB Function Proportional Proportional Proportional w/reset Proportional w/reset Transmitter Transmitter Differential Gap Differential Gap Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0–20 psig 0–35 psig Mounting Integral Integral Integral Integral Integral Integral Integral Integral
TRANSMITTER/RECEIVER CONTROLLER Dual Heads Direct Acting Std RAA RAB RBA RBB TAA TAB TBA TBB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Reverse Acting Std REA REB RFA RFB TEA TEB TFA TFB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Function Proportional Proportional Proportional w/reset Proportional w/reset Proportional Proportional Proportional w/reset Proportional w/reset Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig Mounting Integral Integral Integral Integral Remote Remote Remote Remote
48-620 Modulevel Pneumatic Liquid Level Control
55
3.4.3 Standard Sealed Cage Displacer Models
DESIGN TYPE P7 Sealed cage design Pneumatic Modulevel
MOUNTING AND CHAMBER MATERIALS Carbon steel chamber material tank connections code side/bottom 1 side/side 2
Inconel spring furnished on all models.
SPECIFIC GRAVITY AND PROCESS TEMPERATURE +400° F (+200° C) +700° F (+371° C) 1 2 3 4 5 6
maximum temperature
0.23 – 0.54 specific gravity 0.55 – 1.09 specific gravity 1.10 – 2.20 specific gravity
TANK CONNECTION EXTERNAL CAGE MODELS ANSI Mounting flange rating NPT C9 D9 SW C0 D0 RF 150 lbs P3 Q3 RF 300 lbs P4 Q4 RF 600 lbs P5 Q5 Size 11⁄2" 2"
Maximun pressure rating for units with 600 lb. ANSI flange construction is 1330 psi @ 100° F (967 bar @ 38° C).
LEVEL RANGE 14 356 A 32 813 B 48 1219 C 60 1524 D 72 1829 E 84 2134 F 96 2438 G 108 2743 H 120 3048 I inches mm CODE
PNEUMATIC INSTRUMENT (see opposite page)
P
7
complete order code for Sealed Cage Pneumatic Modulevel
56
48-620 Modulevel Pneumatic Liquid Level Control
3.4.3 Standard Sealed Cage Displacer Models (continued)
PNEUMATIC INSTRUMENT Single Function Heads Direct Acting Std PAA PAB PBA PBB PCA PCB PDA PDB Limit Sws PIA PIB PJA PJB PKA PKB PLA PLB Reverse Acting Std PEA PEB PFA PFB PGA PGB PHA PHB Limit Sws PMA PMB PNA PNB POA POB PPA PPB Function Proportional Proportional Proportional w/reset Proportional w/reset Transmitter Transmitter Differential Gap Differential Gap Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0–20 psig 0–35 psig Mounting Integral Integral Integral Integral Integral Integral Integral Integral
TRANSMITTER/RECEIVER CONTROLLER Dual Heads Direct Acting Std RAA RAB RBA RBB TAA TAB TBA TBB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Reverse Acting Std REA REB RFA RFB TEA TEB TFA TFB Limit Sws n/a n/a n/a n/a n/a n/a n/a n/a Function Proportional Proportional Proportional w/reset Proportional w/reset Proportional Proportional Proportional w/reset Proportional w/reset Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig Mounting Integral Integral Integral Integral Remote Remote Remote Remote
48-620 Modulevel Pneumatic Liquid Level Control
57
3.4.4 Standard Side Mount Displacer Models
DESIGN TYPE P68 Side mount in tank, carbon steel body, 316 SS float and trim
SPECIFIC GRAVITY AND PROCESS TEMPERATURE +400° F (+200° C) maximum temperature 2 0.60 minimum specific gravity
TANK CONNECTION SIDE MOUNTING CONNECTION TYPE ANSI Head Flange rating NPT F2A N/A RF 150 lbs N/A H3A RF 300 lbs N/A H4A
RF 600 lbs N/A H5A
Size 3" 4"
Maximum pressure rating is limited to 800 psig @ 100° F due to float.
PNEUMATIC INSTRUMENT Single Function Heads for P68 model only Direct Acting Std PAJ PAK PBJ PBK PCJ PCK PDJ PDK Reverse Acting Std PEJ PEK PFJ PFK PGJ PGK PHJ PHK Function Proportional Proportional Proportional w/reset Proportional w/reset Transmitter Transmitter Differential Gap Differential Gap Output 3–15 psig 6–30 psig 3–15 psig 6–30 psig 3–15 psig 6–30 psig 0–20 psig 0–35 psig Mounting Integral Integral Integral Integral Integral Integral Integral Integral
P
6
8
2
complete order code for Side Mount Pneumatic Modulevel
58
48-620 Modulevel Pneumatic Liquid Level Control
3.4.5 APM Pneumatic Control Models
DESIGN TYPE APM Pneumatic Liquid Level Controls
MOUNTING AND MATERIALS OF CONSTRUCTION Model Code 131L 131H W251 W254 W291 Output Signal 3–15 6–30 3–15 6–30 3–15 6–30 3–15 6–30 Mounting Arrangement Top Top External Flange Cage External Flange Cage External Flange Cage Body Material Carbon steel Carbon steel Cast iron Cast iron Carbon steel Maximum Pressure 230 psig (16 bar) 230 psig (16 bar) 250 lb. WSP 250 lb. WSP 300 lb. WSP Maximum Temperature +250° F (+120° C) +250° F (+120° C) +406° F (+208° C) +406° F (+208° C) +422° F (+217° C) Minimum S.G. 0.90 0.90 0.86 0.86 0.85 Displacer Size 2" x 14" 2" x 14" 2.5" x 9" 2" x 12" 2" x 12"
PNEUMATIC INSTRUMENT Single Function Models Direct Acting Reverse Acting Standard w/Limit Standard w/Limit Head Switches Head Switches PAA PIA PEA PMA PAB PIB PEB PMB
Function
Pressure psig 3–15 6–30
Proportional
A
P
M
48-620 Modulevel Pneumatic Liquid Level Control
59
ASSURED QUALITY & SERVICE COST LESS
Service Policy Owners of Magnetrol may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequential damage will be allowed.
Return Material Procedure So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material’s return. This is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application
Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory.
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
Copyright © 2009 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Viton® is a registered trademark of DuPont Performance Elastomers.
BULLETIN: 48-620.17 EFFECTIVE: November 2009 SUPERSEDES: September 2008
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