ITY & QUAL LESS D E R T ASSU ICE COS V R E 1 S ® 900 O IS STEEL FABRICATED MODELS Pneumatic Modulevel® controls are displacement actuated level sensors. They 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. Pneumatic Modulevel® Liquid level control Modulevel series P-60 control FEATURES * * * * * * * * * * * * * Standard models handle service temperatures from -100°C to +370°C (-150°F to +700°F) and pressure to 294 bar (4265 PSIG). Stable output signal is unaffected by surface turbulence. Prevents control valve "hunting" and extends valve life. Controller head may be removed and bench calibrated without dismantling or even depressurizing the tank. Accurate output signal provided over a wide specific gravity range. 316 SS displacer and trim. Easily field calibrated without moving tank liquid level, for reduced installation time and cost. Controller head rotates 360°, simplifies pneumatic piping hookup. Pilot relay provides a 4 to 1 amplification of pilot pressure signal to speed valve response. Built-in visual level indicator is independent of air supply. Optional pneumatic to current interface transducer for use in electronic control applications. Optional proportional plus integral control. Optional differential gap (on-off) control. Optional Hi-Lo electronic alarm signal provides inexpensive backup alarm. APPLICATIONS Pneumatic Modulevel® liquid level controls are widely used in utility power generation, chemical and petroleum processing operations, such as: • Steam generator feedwater heater regulation • Fractionating column level transmitter • Ethanolamine level transmitter • Vent gas scrubber level control • Drip pot condensate level control • Flash tank level transmitter Worldwide level and flow solutions PRINCIPLE OF OPERATION Zero Adjustment 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 dampens the action of the displacer, and the control head, which provides a modulated pneumatic signal in direct proportion to the input from the vertical motion of the displacer. As the liquid level in the vessel increases or decreases, the buoyant displacer rises or falls. This motion, dampened by the action of the range spring to prevent response to the rapid fluctuations of turbulence, is mechanically coupled to an attractor ball, within an enclosed tube. A magnet encircling the tube follows the attractor 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 to alarms, indicators, process controls or other devices. With optional integral control, the pilot nozzle proportional signal is conditioned through an additional metering valve system, which will eliminate offset from the desired control point. Supply medium Output pressure Pilot pressure Pilot Nozzle Indicator Flapper Cam Attraction Ball Magnet 0 Enclosing Tube Proportional Band Spring 100 Range Spring Actuating Lever Set Point Adjustment Displacer Feedback Bellows Reset Bellows Reset Valve Check Valve Relay Chamber Orifice OUTPUT Control Valve SUPPLY Filter Regulator Reset pressure SPECIFICATIONS Description Specification Process pressure Process temperature Specific gravity Interface detection Process connections Supply pressure ① Up to 294 bar at 40° C -100°C to +370°C (-150°F to +700°F) Min.: 0.11, max.:2.20 Min. difference of 0.10, specific gravity between liquids NPT, socket weld or flanged 17 bar (250 PSIG) max. to regulator. Instrument quality air (clean and dry). Regulator set to 0.3 bar (5 PSIG) above max. output. 0.2 - 1.0 bar, 0.4 - 2.0 bar (3 - 15 PSIG, 6 - 30 PSIG) 0 - 1.4 bar or 0 - 2.4 bar (0 - 20 PSIG or 0 - 35 PSIG) Limited only to displaced length. From fractional cm to 3 m (inches to 10 ft) 085 l/h at 0.6 bar output (3 SCFH at 9 PSIG output) 170 l/h at 1.0 bar output (6 SCFH at 15 PSIG output) 1639 cm3 (100 ci3) output volume in 3.2 sec upon an output pressure increase from 0.2 - 1.0 bar (3 - 15 PSIG) Trim: 304 or 316 SS Spring: 316 SS or inconel Chamber: Carbon steel or 316 (L) SS Direct or reverse Proportional control, differential gap, transmitter NEMA 1, 2, 3 and 3R / IP53 Max. voltage: 120 V AC/V DC Max. resistive load: 010 V AC/V DC Max. current: 1/4 A switching 1/1 A holding Output proportional & signal transmitter pressure differential gap Level range & proportional band adjustment Air consumption Response speed Wetted parts Control action Modes of operation Housing Limit switch ratings ① Max. supply pressures with customer supplied regulator is 7 bar (100 PSIG). 2 Proportional Band Adjustment MOUNTING Top Mounted Model: P61 Flanged External Cage Models: P63, P64, P65 and P66 Side Mounted (for narrow differential) Model P68 PNEUMATIC CONTROLLER HEADS Pneumatic Modulevel® controllers are available in a variety of functions and styles to handle different application requirements. Single function heads Single function heads fulfill one of the functions as described below. Single function heads are available with electric limit switches. Limit switches allow separate high/low level alarms separate from the normal function of the unit. Transmitter/receiver heads Transmitter/receiver heads combine the transmitter function with one of the controller functions as described below. Action All controller heads can be set in direct or reverse action. Direct action: level increases-output increases (eg. from 0,2 to 1 bar). Riverse action: level increases-output decreases (eg. from 1 to 0,2 bar) Functions: Proportional: the unit keeps the level within a calibrated band (wide differential). Proportional with reset: the unit keeps the level at a specific level (narrow differential). Transmitter: continuous measurement, different field instruments can be actuated/deactuated from the output signal transmitter heads can be factory calibrated to detect an INTERFACE under following conditions: 1. Minimum difference of 0.10 specific gravity between both liquids. 2. The interface band does not exceeds the length of the displacer. 3. The displacer is at all times immerged in liquid. Consult factory when consulting units for interface applications. Both specific gravities must be supplied at the time the order is placed. Differential gap: the unit shows an output that remains stable once the level exceeds the highest switching point until the level drops under the lowest switch point. The unit shows another output until the highest switch point is exceeded again. EXPEDITE SHIP PLAN (ESP) Magnetrol has implemented a quick delivery programme ‘ESP’, for the most popular units and options. The colour coded selections represent those that benefit from the shortest lead times. 3 SELECTION DATA A complete measuring system consists of: 1. Order code for Pneumatic Modulevel® control 2. Options: Filter regulator to filter air and adapt pressure: order code 06-9501-002. Gauge: order code 06-9501-003. Adjustable displacer hanger: order code 32-3110-004 (std. length 2,5 m (8')), is required when distance between top displacer and mounting flange is > 236 mm (9.30"). Special process connections: consult factory. Gauge glass tappings for caged models only: Specify location and distance between the tappings at the time the order is placed. P/I converters: transform pneumatic output to 4-20 mA or 10-50 mA (2 wire system). Order code for top mounted and flanged cage models MOUNTING AND MATERIALS OF CONSTRUCTION flanged top fabricated steel 316SS 1 cage side/bottom fabricated steel 316SS 2 3 cage side/side fabricated steel 316SS 4 5 tank connection materials of construction 6 SPECIFIC GRAVITY AND TEMPERATURE mounting 205° C 370° C max. temp. (400°F) (700°F) 1 4 0.11 - 0.54 specific gravity 2 5 0.55 - 1.09 specific gravity 3 6 1.10 - 2.20 specific gravity TANK CONNECTION (for DIN flanges consult factory) a. For flanged connection type (P61, P62) - head flange rating RF = raised face RJ = ring joint RF 150 lb RF 300 lb RF 600 lb G3 G4 G5 3" size H3 H4 H5 4" size K3 K4 K5 6" size b. For external cage models (P63, P64, P65, P66) - ANSI rating RF150lb RF300lb RF600lb connection C5 C7 C9 1 1/2" NPT connector C6 C8 C0 1 1/2" socket weld P3 P4 P5 1 1/2" ANSI flanges D5 D7 D9 2" NPT D6 D8 D0 2" socket weld Q3 Q4 Q5 2" ANSI flanges LEVEL RANGE 356 813 14 32 A B 1219 48 1524 60 1829 72 2134 84 2438 96 2743 108 3048 120 C D E F G H I P 6 mm inches complete order code for Pneumatic Modulevel® Control PNEUMATIC CONTROLLER HEAD Transmitter/Receiver Controllers Single Function Models Function Proportional Pressure bar (PSIG) 0.2-1.0 (3-15) 0.4-2.0 (6-30) Proportional w/Reset Transmitter 0.2-1.0 (3-15) 0.4-2.0 (6-30) 0.2-1.0 (3-15) 0.4-2.0 (6-30) Differential Gap 4 0-1.4 (0-20) 0-2.4 (0-35) Integral Mount Direct Acting Reverse Acting Direct Acting Reverse Acting Remote Mount Direct Acting Reverse Acting Standard Head w/Limit Switches Standard Head w/Limit Switches Standard Head Standard Head Standard Head Standard Head 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 RAA RAB RBA RBB - REA REB RFA RFB - TAA TAB TBA TBB - TEA TEB TFA TFB - Order code for top mounted and flanged cage models P 6 8 Standard side mounted float controller - carbon steel construction with 316 SST float 2 0.60 minimum specific gravity, max temperature 205°C (400°F) TANK CONNECTION F 2 A Threaded 3" NPT H 3 A Flanged 4" - 150 lbs RF H 4 A Flanged 4" - 300 lbs RF H 5 A Flanged 4" - 600 lbs RF P 6 8 2 A P complete order code for Pneumatic Modulevel® Control CONTROLLER HEAD Proportional 0.2 - 1.0 0.4 - 2.0 (3 - 15) (6 - 30) PAJ PAK PEJ PEK Proportional with reset 0.2 - 1.0 0.4 - 2.0 (3 - 15) (6 - 30) PBJ PBK PFJ PFK Transmitter 0.2 - 1.0 0.4 - 2.0 (3 - 15) (6 - 30) PCJ PCK PGJ PGK Differential gap 0 - 1.4 0 - 2.4 (0 - 20) (0-35) PDJ PDK PHJ PHK Pressure bar (PSIG) direct reverse 5 DIMENSIONS IN mm (inches) Standard side mount model P68 NOTE: Controller head may be rotated thru 360°. 1/4" NPT x 51 (2.00) Long Min. Nipple Required 195 (7.69) P68 Series with threaded side mounting 98 (3.85) 1/4" NPT Supply Optional Nipple Mounted Filter Regulator Maximum Length to Inside of Tank 165 (6.50) 60 (2.38) 254 (10.00) 1/4" NPT 155 (6.12) Vent Maximum 216 Level (8.50) Change 38° 1/4" NPT Output 89 (3.50) Diameter P68 Series with flanged side mounting 19° 3" NPT 16 (0.63) 51 (2.00) 150 (5.93) 1/4" NPT Supply 1/4" NPT x 51 (2.00) Long Min. Nipple Required 195 (7.69) Optional Nipple Mounted Filter Regulator 98 (3.85) 165 (6.50) 76 (3.00) Diameter Float 260 (10.25) Maximum Length to Inside of Tank 268 (10.50) 165 (6.50) Vent 20° 10° 1/4" NPT Output 16 (0.63) 76 (3.00) Diameter Float 51 (2.00) A 1/4" NPT Maximum 187 Level (7.38) Change B 213 (8.38) Controller Head Swing Radius 171 (6.75) 1/4" NPT Supply Vent 1/4" NPT Output 6 16 (0.63) 51 (2.00) Flange size and Class DIM. A DIM. B Number of bolt holes Dia. of bolt holes 4” - 150 lb 4” - 300 lb 4” - 600 lb 137 (5.38) 137 (5.38) 149 (5.88) 511 (20.12) 511 (20.12) 498 (19.62) 8 8 8 19 (0.75) 22 (0.88) 25 (1.00) DIMENSIONS IN mm (inches) Top mounted/flanged cage models: P61, P62, P63, P64 and P65 NOTE: Controller head may be rotated thru 360°. 1/4" NPT x 51 (2.00) Long Min. Nipple Required 195 (7.69) 1/4" NPT x 51 (2.00) Long Min. Nipple Required 195 (7.69) 98 (3.85) Optional Nipple Mounted Filter Regulator Optional Nipple Mounted Filter Regulator 98 (3.85) 165 (6.50) 1/4" NPT ① 348 (13.71) 1/4" NPT ① 475 (18.71) 165 (6.50) ① 248 (9.77) ① 375 (14.77) 127 (5.00) 25 (1.00) C 127 (5.00) 65 (2.56) ANSI Standard Flange Level Range Level Range + 51 (2.00) Mid Range A B Level Range 219 (8.62) 89 (3.50) Optional 3/4" NPT Gauge Glass Tapping (2) 1 1/2" or 2" NPT or Socket Weld (2) 1 1/2" or 2" ANSI Standard Flange Dia. P61 & P62 series top mounting 150, 300 & 600 lb. Class. P63 & P64 series with side/bottom connections 150, 300 & 600 lb. Class. 1/4" NPT x 51 (2.00) Long Min. Nipple Required 195 (7.69) 213 (8.38) Optional Nipple Mounted Filter Regulator 98 (3.85) Swing Radius 171 (6.75) 1/4" NPT Supply 165 (6.50) 1 1/4" NPT 475 (18.71) Vent 1 127 (5.00) 16 (0.63) 1/4" NPT Output 375 (14.77) 51 (2.00) 25 (1.00) C Controller head – side view 65 (2.56) Level Range Level Range + 51 (2.00) Mid Range (2) 1 1/2" or 2" ANSI Standard Flange 76 (3.00) A (2) 1 1/2" or 2" NPT or Socket Weld B (2) Optional 3/4" NPT Gauge Glass Tapping 1" NPT Dimensions Outlet Size A 1 1/2" S.W. 2" S.W. 1 1/2" NPT 2" NPT 78 (3.07) 82 (3.23) 69 (2.72) 65 (2.56) 1 1/2" flanged 2" flanged B 151 (5.94) 159 (6.25) Pressure Dim. C 150 300 600 190 (7.50) 210 (8.25) 210 (8.25) ① Add. 51 (2.00) for units that will operate on S.G range 0,11 P65 & P66 series with side/side connections 150, 300 & 600 lb. Class. 0,54 or interface service. Add. 79 (3.12) for units that will operate above 200°C (400°F). ② Distance "D" without stem extension is 127 (5.00) standard. Can be furnished to min. distance of 76 (3.00). 7 QUALITY ASSURANCE - ISO 9001 THE QUALITY ASSURANCE SYSTEM IN PLACE AT MAGNETROL GUARANTEES THE HIGHEST LEVEL OF QUALITY DURING THE DESIGN, THE CONSTRUCTION AND THE SERVICE OF CONTROLS. OUR QUALITY ASSURANCE SYSTEM IS APPROVED AND CERTIFIED TO ISO 9001 AND OUR TOTAL COMPANY IS COMMITTED TO PROVIDING FULL CUSTOMER SATISFACTION BOTH IN QUALITY PRODUCTS AND QUALITY SERVICE. PRODUCT WARRANTY ALL MAGNETROL ELECTRONIC AND ULTRASONIC LEVEL CONTROLS ARE WARRANTED FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP FOR ONE FULL YEAR 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 INTERNATIONAL 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 THE EQUIPMENT. THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED, EXCEPT, SPECIAL WRITTEN WARRANTIES COVERING SOME MAGNETROL PRODUCTS. UNDER RESERVE OF MODIFICATIONS BELGIUM DEUTSCHLAND FRANCE ITALIA UNITED KINGDOM INDIA Heikensstraat 6, 9240 Zele Tel. (052) 45.11.11 Fax. (052) 45.09.93 Schloßstraße 76, D-51429 Bergisch Gladbach-Bensberg Tel. (02204) 1485 Fax. (02204) 1487 11, Rue A. Einstein, Espace Descartes, 77420 Champs-sur-Marne adresse postale: 77436 Marne-la-Vallée Cédex 2 Tel. (0) 164.68.58.28 Fax. (0) 164.68.58.27 Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) Fax. (02) 668.66.52 Unit 1 Regent Business Centre Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 Fax (01444) 871317 B4/115 Safdurjung Enclave, New Delhi 110 029 Tel. 91 (11) 6186211 Fax 91 (11) 6186418 BULLETIN N°: EFFECTIVE: SUPERSEDES: OUR NEAREST REPRESENTATIVE BE 48-110.15 JUNE 1998 July 1996