® AURORA TM Installation and Operating Manual For the Magnetic Level Indicator (MLI) and Level Switches Guided Wave Radar and Magnetic Level Indication for Redundant Level 7xxx 6xxx 5xxx 4xxx 3xxx 2xxx 1xxx ® Measurement UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number (Model number/approvals as per inserted separate sheet) to be sure it agrees with the packing slip and purchase order. The Eclipse® AuroraTM model number defines: - The Magnetic Level Indicator. - The Eclipse® Guided Wave Radar transmitter and switches/transmitters: each of these components have their own modelnumber that refers to their own approvals / instruction manuals (as per separate inserted documents). Check and record the Eclipse® AuroraTM serial number for future reference when ordering parts. Pre-installation checklist: - Verify if the units’ center to center distance equals the center to center distance of the vessel. - Locate the external mounted switches/transmitters. These are seperately packed (for proper mounting/installation; see included instruction manuals). - Locate the Eclipse® amplifier head (for proper mounting/installation – see Eclipse® instruction manual). Eclipse® partnumber (for spare part / approval ref.). Eclipse® GWR probe partnumber (for spare part / approval ref.). External mount switches/ transmitters partnumber (for spare part / approval ref.). Eclipse® AuroraTM nameplate * model number: - Magnetic Level Indicator - Eclipse GWR switches and transmitters * serial n° tag n°. * CAUTION: When handling longer units, assure that these are supportered over the entire length to avoid bowing causing deformation / glass breakage. MOUNTING – Magnetic Level Indicator Springs protect the float during transport/operation. Shut off valves are recommended. Note: The float and the guided wave radar probe are pre-mounted into the magnetic level indicator. The float is protected against transport damage and operational conditions by means of internal springs. CAUTION: In case shut off valves are used, care must be taken when opening the valves to prevent a surge of fluid and gases through the chamber. A surge can cause the float to be propelled to the far end of the chamber, and float damage could result. 2 MOUNTING – Magnetic Level Indicator Reassembly guidelines Reassembly guidelines for the float / GWR probe in case these need to be dismantled for eg. cleaning of the cage: - Verify that the “TOP” marking on the float is pointing upwards when re-installing. - Make sure that the float is positioned in between the cage wall and the baffle plate, when re-installing. - Verify that the GWR probe is installed the farthest away from the flapper rail. - Assure proper sealing of the gaskets. Baffle plate Eclipse GWR probe Float “Top” upwards GWR probe Float Top View Indicator rail CAUTION: Do not reposition the indicator rail from its original delivered position. Repositioning of the rail may disrupt the magnetic coupling between the float’s magnet and the flappers in the indicator rail (and any other magnetic coupled equipment with the float e.g. external mount switches). MOUNTING – Eclipse amplifier Remote Max. rotation 270° 360° rotatable: Position for optimum wiring/viewing (a) (b) Size: 38 mm (1 1/2") or adjustable wrench Recommended torque 20 Nm (15 foot-pounds) Remove protection Remove protection CAUTION: be careful not to bend or dirty the gold, high frequency male connector (a) and its female connector (b). Clean with isopropyl alcohol and cotton swabs, if necessary 3 TROUBLESHOOTING Problem Solution Flags do not rotate with level change. Test flags with a magnet from bottom to top (magnet not included). If flags test O.K, check for float obstruction (see maintenance). Switch does not actuate with level change. Check micro switch for continuity. Replace if damaged, if O.K, remove switch from piping column and test switch magnet assembly with realignment magnet, by moving magnet over the housing face. If the switch magnet assembly fails to respond, replace the switch. If the switch checks O.K, check float travel. Reed transmitter does not track level. Remove transmitter assembly from piping column and test with realignment magnet. Run magnet from bottom to top of reed chain. Check zero and span calibration. If no change in output, replace. Flags rotate at different height than actual level. Float selected for different specific gravity. Replace float with a float with correct specific gravity rating. Confirm correctness of float orientation. Top is up. Float inside the level gauge is moving slow or not at all. Make sure the MLI is level vertically. The process fluid being measured may be too viscous and heat tracing may be required to make the material more fluid. Heat tracing can be purchased from the factory. The specific gravity of the process fluid and the float weight may need to be reverified. The liquid being measured may contain magnetic particles collecting on the magnetic section of the float causing drag. If this happens, magnetic trap assemblies can be purchased from the factory. Visual inspection of the float may be required to see if the float has collapsed. Scale is at zero to the center of the bottom proces connection, but the indicator is above or below zero. The scale assembly is mounted to the chamber using stainless steel gear clamps. It can be easily adjusted in the field using a screwdriver. make sure the scale zero is in line with the center of the process connection. The float stop spring at each end of the chamber is there to cushion as well as position the float assembly to the center of the process connection. Make sure top or bottom float stop springs are not bent or broken. Indicator has uncoupled and fallen to the bottom of the glass tube. In some “flashing” applications, the float may rise or fall quickly. Consult factory for suggestions to help avoid this. To re-couple the indicator to the float, simply use a small magnet and run it along the length of the chamber to locate the float. Mark the location of the float on the outside chamber. Use the small magnet to couple with the indicator and pull the indicator up to meet and couple with the float. Make sure all stainless steel gear clamps are tight. The scale channel must be tight against the chamber. * Assure unit installation is level. MAINTENANCE If the process liquid is clean (no solids or deposits), the MLI should require minimum maintenance. If the process liquid is dirty (solids and deposits), it is recommended the external cage be isolated from the process and flushed periodically. For complete cleaning, after draining the unit, remove the bottom flange and float, inspect cage and float for build up and clean if required. Magnetic traps are available to prevent magnetic particulate travel from the vessel to the chamber. 4 REPLACEMENT PARTS For the magnetic level indicator: consult factory. For the Eclipse Guided Wave Radar: consult instruction manual BE 57-600 MAGNETIC LEVEL INDICATOR – SPECIFICATIONS Measured value Measuring range Liquid level (consult factory for liquid-liquid interface) From 300 mm (11.81") up to 5700 mm (224") Indicators Metal flag (red/white) – all indicators are hermetically sealed and assured by the “Insta-Seal” technology Scale Specific gravity Visual indication Float Cage Type Materials Materials Size Rating Configuration Insulation material Process connections Design Constructions In cm or % of span As low as 0.5 kg/dm3 Visible from a distance up to 30 m (100 feet) With magnetic flux ring – assembly – see page 2 316 SST (1.4401), Titanium, others at request 316/316L SST (1.4401/1.4404), others at request 3" or 4" depending configuration Up to 2500 lbs / PN 320 class ratings Side/side connection with 1/2" NPT plugged vent and drain Weather resistant silicone cloth (high temperature application) Polyurethane + aluminium jacket with polymeric frost extension for flag-rail (cryogenic application) Threaded, socket welded or flanged All cages are designed to meet the European PED (Pressure Equipment Directives) 97/23 EC guidelines Standard commercial design NACE construction Others at request: eg. IBR, ASME - ANSI B31.3 5 MODEL IDENTIFICATION – GUIDED WAVE RADAR TRANSMITTER TRANSMITTER 7 7 7 7 Type ➀ Eclipse - blind transmitter Eclipse - transmitter with digital display and keypad Eclipse - blind transmitter Eclipse - transmitter with digital display and keypad 3 4 5 6 ➀ Signal output 4-20 mA with HART® communication 4-20 mA with HART® communication Foundation Fieldbus® communication Foundation Fieldbus® communication Power 24 V DC 2-wire loop powered Standard electronics: SFF > 85 %. Consult factory for SIL enhanced electronics: SFF > 91 % MOUNTING/CLASSIFICATION (Consult factory for FM/CSA approvals) 1 Integral, General purpose (&IS: FM/CSA) 2 Remote, General purpose (&IS: FM/CSA) A Integral, ATEX II 1 G EEx ia II C T4 - FISCO ATEX, intrinsically safe for units with Fieldbus Foundation B Integral, ATEX II 1 G EEx ia II C T4 - FISCO ATEX, intrinsically safe for units with Fieldbus Foundation C Integral, ATEX II 1/2 G D EEx d[ia] II C T6 D Remote, ATEX II 1/2 G D EEx d[ia] II C T6 Integral, ATEX II 3 G EEx nA II T6 E F Remote, ATEX II 3 G EEx nA II T6 HOUSING 1 Cast aluminium dual compartiment, 3/4" NPT cable entry (2 entries – one plugged) 2 Cast aluminium dual compartiment, M20 x 1,5 cable entry (2 entries – one plugged) 3 Stainless steel dual compartiment, 3/4" NPT cable entry (2 entries – one plugged) 4 Stainless steel dual compartiment, M20 x 1,5 cable entry (2 entries – one plugged) PROBE TYPE - all coaxial type, overfill safe GWR probes R 7MR - Overfill safe GWR probe D 7MD - High Temp / High Pressure (HTHP) GWR probe S 7MS - Saturated steam GWR probe (dielectric range ≥ 1,4) - WHG approved (dielectric range ≥ 2,0) - WHG approved (dielectric range ≥ 10,0) - Stoomwezen approved PROBE MATERIAL A 316 / 316 L (1.4401/1.4404) stainless steel B Hastelloy C (2.4819) not for “S” probe (7MS) C Monel (2.4360) not for “S” probe (7MS) PROCESS SEAL-MATERIAL ➀ For the 7MR GWR probe ➁ 0 1 2 Viton® GFLT - for universal use / steam applications min -40°C (-40 °F) / max +200 °C (+400 °F) EPDM (Ethylene Propylene) - for e.g. caustic soda applications min -50°C (-60 °F) / max +125 °C (+250 °F) min -40°C (-40 °F) / max +200 °C (+400 °F) Kalrez 4079 - for aggressive media ➀ Consult factory for alternative seal materials ➁ For ammonia/chlorine applications use the 7MD GWR probe. For the 7MD GWR probe N Borosilicate - for non condensing applications min -195 °C (-320 °F) / max +400 °C (+750 °F) For the 7MS GWR probe 8 PEEK - for saturated steam applications min -40 °C (-40 °F) / max +345 °C (+650 °F) MEASURING RANGE (Select the same measuring range as per page 6) English ranges (dimensions as per specified inch dimension) 0 0 F 84" / 2134 0 0 A 14" / 356 mm 0 0 G 96" / 2438 32" / 813 mm 0 0 B 0 0 H 108" / 2743 48" / 1219 mm 0 0 C 0 0 I 120" / 3048 0 0 D 60" / 1524 mm 0 0 E mm mm mm mm 72" / 1829 mm Metric ranges (specify per cm increments) 0 3 0 4 1 0 5 7 0 7 minimum 30 cm (11.81") maximum 410 cm (161") - for 7MS maximum 570 cm (224") - for 7MD/7MR complete order code for the Aurora - Eclipse 705 Guided Wave Radar transmitter Viton® is a registered trademark of Dupont Performance Elastomers 6 MODEL IDENTIFICATION – CROSS REFERRENCE PARTNUMBERS ECLIPSE AURORA The Eclipse Aurora partnumber defines the Eclipse transmitter and the GWR probe partnumbers into one model code. The original model code of the Eclipse electronics should be used for approval and spare part referrence of the electronics. This number is available on the nameplate of the Eclipse transmitter (see page 2) or you can use the below cross refererence partnumber to rebuild the equivalent Eclipse partnumber from the Eclipse Aurora partnumber. TRANSMITTER & GWR PROBE Electronics 7 7 7 7 TRANSMITTER Electronics 3 4 5 6 7 7 7 7 0 0 0 0 5 5 5 5 5 5 5 5 1 1 2 2 0 0 0 0 0 A 0 A Mounting/Classification Mounting/Classification 1 2 A B C D E F 1 2 A B C D E F Housing Housing 1 2 3 4 7 0 5 GWR Probe Type 5 * 0 * * 1 1 2 2 0 1 0 1 * * GWR Probe Type R D S X 7 M R X 7 M D X 7 M S Probe Material Probe Material A B C A B C Process connection * * Process Seal-Material defined by magnetic level indicator P/N Process Seal-Material 0 1 2 N 8 0 1 2 N 8 Measuring Range 7 * * * * * * * * * * * * Probe length * * * X 7 M * * * * * * * * 7 0 5 5 * 0 * * * * 7 MODEL IDENTIFICATION – MAGNETIC LEVEL INDICATOR BASIC MODEL NUMBER Code B B B B B B B B B B G G G G G G G G G G Min. S.G. A B C D E F G H J K 40 °C (100 °F) 27,6 (400) 41,3 (600) 55,2 (800) 41,3 (600) 51,7 (750) 75,8 (1100) 75,8 (1100) 62,0 (900) 103 (1500) 103 (1500) 0,75 0,65 0,50 0,76 0,76 0,65 0,50 0,75 0,65 0,50 Pressure rating in bar (psi) 200 °C 315 °C (400 °F) (600 °F) 26,6 (386) 23,4 (340) 24,3 (352) 18,1 (262) 32,3 (469) 24,1 (349) 39,9 (579) 35,2 (510) 49,9 (723) 43,9 (637) 44,5 (645) 33,1 (480) 44,5 (645) 33,1 (480) 59,9 (868) 52,8 (765) 60,7 (880) 45,2 (655) 60,7 (880) 45,2 (655) 400 °C (750 °F) 22,2 (322) 4,1 (60) 5,5 (80) 33,3 (483) 41,6 (603) 7,6 (110) 7,6 (110) 49,9 (724) 10,3 (150) 10,3 (150) float mat. cage size 316 SST Titanium Titanium 316 SST 316 SST(*) Titanium Titanium 316 SST(*) Titanium(*) Titanium(*) 3" 3" 4" 3" 3" 3" 4" 4" 4" 4" (*) pressurised float MATERIALS OF CONSTRUCTION Code with Code with scale in % scale in cm of span B C E F H J L M Code flags only A D G K Flanges Cage Indication rail Carbon steel 316/316L SST (1.4401/1.4404) Carbon steel 316/316L SST (1.4401/1.4404) 316/316L SST (1.4401/1.4404) Aluminium 316 SST (1.4401) CAGE AND FLANGE RATING A B C D E F 150 lbs 300 lbs 600 lbs 900 lbs 1500 lbs 2500 lbs (max 345 bar (5000 psi)) PROCESS CONNECTION – SIZE 2 1" 3 1 1/2" 4 2" 1 2 3 4 5 6 7 PN PN PN PN PN PN PN B C D 16 25/40 63 100 160 250 320 EN 1092-1 Type B1 EN 1092-1 Type B1 EN 1092-1 Type B2 EN 1092-1 Type B2 DIN 2638 Form E DIN 2628 Form E DIN 2629 Form E DN 25 DN 40 DN 50 DIN sizes only in combination with flanged process conn. PROCESS CONNECTION - TYPE A B D F 1 Threaded NPT-F Socket weld ANSI RF Slip on flanges up to 600 lbs rating ANSI RJ Weld Neck flanges for 600 lbs up to 2500 lbs rating EN/DIN Weld Neck flanges MEASURING RANGE (center-to-center) English ranges (dimensions as per specified inch dimension) 0 0 0 0 0 0 0 0 0 0 A B C D E 14" 32" 48" 60" 72" / / / / / 356 813 1219 1524 1829 mm mm mm mm mm 0 0 0 0 0 0 0 0 F G H I 84" 96" 108" 120" / / / / 2134 2438 2743 3048 mm mm mm mm Metric ranges (specify per cm increments) 0 3 0 4 1 0 5 7 0 B G 8 minimum 30 cm (11.81") maximum 410 cm (161") - for 7MS maximum 570 cm (224") - for 7MD/7MR complete order code for the Aurora - Magnetic Level Indicator DIMENSIONS in mm (inches) 1/2" NPT plugged vent 1/2" NPT plugged vent Measuring range Measuring range 254 (10)➀ 1/2" 254 (10)➀ NPT plugged drain 1/2" Flanged ➀ NPT plugged drain Threaded/Welded For S.G. < 0.8 and/or flange rating > 1500 lbs / PN 250, dimension will increase 83 (3.28) 105 (4.12) 45° View 102 (4.00) 70 (2.75) 2 cable entries 76 (3.00) 51 (2.00) 89 (3.50) 95 (3.75) 45° 840 (33.00) 2 holes 214 (8.43) 108 (4.25) 126 (4.94) Remote Eclipse housing 111 (4.38) Eclipse Housing, (45° View) 9 NOTES 10 NOTES 11 IMPORTANT SERVICE POLICY Owners of Magnetrol products 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. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour 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, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. 6. Purchaser Name Description of Material Serial Number and Ref Number Desired Action Reason for Return Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS www.magnetrol.com ® BE 57-638.2 NOVEMBER 2005 May 2002 BENELUX Heikensstraat 6, 9240 Zele, België Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected] FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard Tél. 01.34.44.26.10 • Fax. 01.34.44.26.06 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) • Fax. (02) 668.66.52 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 • Fax (01444) 871317 • E-Mail: [email protected] INDIA E-22, Anand Niketan, New Delhi - 110 021 Tel. 91 (11) 41661840 • Fax 91 (11) 41661843 • E-Mail: [email protected]