VIZUAL ® Installation and Operating Manual For the Magnetic Level Indicator (MLI) Magnetic Level Indication 7xxx 6xxx 5xxx 4xxx 3xxx 2xxx 1xxx ® 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 Vizual® model number defines: - The Magnetic Level Indicator. - The Vizual® transmitter and/or switches: each of these components have their own modelnumber that refers to their own approvals (as per separate inserted documents). Check and record the Vizual® serial number for future reference when ordering parts. External mount switches/ transmitters partnumber (for spare part / approval ref.). 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. - Locate the float – separately packed. Vizual® nameplate * model number: - Magnetic Level Indicator - Switches and/or transmitters * serial n° * tag n°. CAUTION: When handling units with longer measuring range, assure that these are supported over the entire length to avoid bowing causing deformation / glass breakage. MOUNTING – Magnetic Level Indicator max 2° max 2° S.G. Temp/Pressure model ref. Shut off valves are recommended. Remove bottom flange to install/remove float. Mount always with pointing upwards. Note: The float is packed separately to protect against transport damage. 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, resulting in float damage. 2 MOUNTING – Magnetic Level Indicator Assembly guidelines – switches/scale Both sides can be used to either mount switches and or scale Assembly guidelines – transmitter ➀ Optional springs to protect the float ➁ Indicator rail Reed chain transmitter screwed with clamps on chamber. Switches screwed onto rail. 0 % marking ➀ Remove top cap to insert additional nuts. ➁ Fix switches at the desired switching point (see switching point marked on switch). Switches/transmitter and scale can easily screwed on the indicator rail. Simply, slide the fastening screws down on the rail to the desired location and fasten with the locking screws. IMPORTANT: Floats are designed as per operating conditions. It might occur that the float indication is incorrect at the time of start up under ambient conditions. WIRING – Transmitter The Vizual® reed chain transmitter is pre-calibrated from factory following the level indication of the MLI. The 4 mA setting is marked on the chain and should correspond to the marking on the MLI. Please consult factory if the measuring span needs to be reset to other values than the default factory settings. Cut away view 4 mA marking Customer supplied local meter 0% 100 % 8-35 V DC Ex Non Ex Galvanic barrier for intrinsically safe units (not needed for GP) Only terminals for + and - should be used for wiring up the device in the field. Terminals 3, 4, 5 and 6 are for factory use only. 3 WIRING – Switches Bi Stable reed switch Hermetically sealed and vibrating resistant micro switch CAUTION: Power must be switched OFF before wiring the unit. The switch will actuate slightly above the center of the unit and de-actuate slightly below the center of the unit. Make sure that the switches are always properly retightened on the indicator rail. Switch rating @ 24 V DC CAUTION: Power must be switched OFF before wiring the unit. The switch will actuate slightly above the center of the unit and de-actuate slightly below the center of the unit. Make sure that the switches are always mounted as close as possible to the indicator rail. 240 V AC Switch rating @ 24 V DC 240 V AC Exi - simple apparatus 0,5 A N/A Exi 0,6 A N/A General Purpose - Exd 2 A 2A General Purpose 0,8 A 0,8 A Exm 0,6 A 0,6 A Repeatability: < 2 mm (0,08") Repeatability: < 2 mm (0,08") NO (Brown) NO NC NC (Blue) C C (Black) 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 that 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. REPLACEMENT PARTS ➃ ➁ Item Part number 1 Float – provide S.G, model code on float and serial n° of MLI – 2 Indicator rail Consult factory ➂ Micro switches Switches ➀ Transmitter Last 3 digits specify measuring range in 1 cm increments ➃ 4 4 Reed switches 3 Body gasket General Purpose 048-8510-003 Exi simple apparatus 048-8510-001 Exd 048-8508-001 General Purpose 048-8509-002 Exi 048-8509-001 Exm 048-8507-001 General Purpose 039-4052-xxx Ex i 039-4053-xxx Exd 039-4054-xxx 150 lbs 012-1301-027 300/ 600 lbs 012-1301-028 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 if float is present or for float obstruction (see maintenance). Switch does not actuate with level change. Check switch for continuity. Replace if damaged, if O.K, remove switch from piping column and test switch magnet assembly with re-alignment 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 slowly or not at all. Make sure the MLI is levelled vertically. The process fluid being measured may be too viscous and heat tracing may be required to make the material more fluid. 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. 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 process 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. PHYSICAL SPECIFICATIONS Description Measured value Density range Measuring range Indicator Resolution Scale (Optional) Materials Process connections Design standards Hydro test Specification Liquid level and liquid-liquid interface Standard models: min S.G. 0,56 - max S.G. 1,5 - Consult factory for different S.G.’s Interface units: min. S.G. difference between upper and lower liquid > 0,1 (consult factory for smaller differences) From 30 cm (12") up to 570 cm (224"). Consult factory for longer lengths ≤ +250 °C (+480 °F): Polycarbonate window / aluminium rail / SST flags > +250 °C (+480 °F): Glass window / aluminium rail / SST flags Red-white flags (optional float failure warning: blue-white) 10 mm (0.4") - height of flapper In cm or tailor made (at request) in 304 stainless steel Cage/Flanges: 316/316L stainless steel Float: 316 Ti SST (1.4571) standard. Titanium for custom made floats Threaded, socket welded or flanged (ANSI - EN/DIN) In compliance to PED regulations and essential safety requirements 1,5 x operating pressure (without float) 5 ELECTRICAL SPECIFICATIONS Description Specification Micro switch Switch ratings Reed switch Switches Transmitter Approvals Micro switch Temperature ranges Reed switch Reed chain transmitter Micro switch Reed switch Housing 0,5 A / 30 V A / 20 W 240 V AC 2 A / 100 V A / 40 W – Exi (simple apparatus) – General Purpose / Exd 24 ... 240 V AC / V DC 0,8 A / 60 V A / 40 W 0,6 A / 45 V A / 45 W – General Purpose – Exm/Exi < 2 mm (0.08") Switch Repeatability Signal output 24 ... 240 V AC / V DC Reed chain transmitter SPDT micro-switches (optional DPDT), bi-stable SPDT reed switches 8-30 V DC Loop powered transmitter: reed chain type: 4-20 mA output (opt. HART®) Accuracy: < 5 mm. LRS (marine applications) ATEX II 1G EEx ia II C T6, intrinsically safe (for reed chain transmitters) ATEX II 2G EEx d II C T6, explosion proof (for micro switches) ATEX II 2G EEx ia II C T6, intrinsically safe (for reed switches) ATEX II 2G EEx m II C T6 (for reed switches) -50 °C to +380 °C (-55 °F to +715 °F) – General Purpose / Exi (simple apparatus) -50 °C to +300 °C (-55 °F to +570 °F) – Exd -25 °C to +75 °C (-10 °F to +165 °F) – General Purpose -25 °C to +85 °C (-10 °F to +185 °F) – Exm/Exi -40 °C to +150 °C (-40 °F to +300 °F) – General Purpose -40 °C to +120 °C (-40 °F to +250 °F) – Exi/Exd (higher temp. at request) IP 65, Aluminium with M20 x 1.5 cable entry (cable gland incl.) – GP/Exi (simple apparatus) IP 65, Cast aluminium with dual 3/4" NPT cable entries – Exd IP 67, Polyamide with flying leads (5 m of cable included) – General Purpose IP 67, Cast aluminium with flying leads (5 m of cable included) – Exm/Exi IP 67, ABS with M16 x 1.5 cable entry (cable gland included) – General Purpose / Exi IP 65, Cast aluminium with 1/2" NPT cable entry – Exd MOUNTING CONFIGURATIONS AND DIMENSIONS in mm (inches) 120 (4.72) 100 (3.94) measuring range measuring range 120 (4.72) measuring range ±250➀ (9.84) GU Type Top-Bottom 6 ±250➀ (9.84) GR Type Side-side GS Type Side-side Depending float size. measuring range ±250➀ (9.84) ±250➀ (9.84) ➀ 100 (3.94) GT Type Top-Bottom 100 (3.94) measuring range ±250➀ (9.84) GA Type Side-Bottom 120 (4.72) measuring range ±250➀ (9.84) GB Type Side-Bottom MODEL IDENTIFICATION A complete measuring system consists of: 1 Code for Vizual® MLI cage (for modified models or adders, put an “X” in front of the closest matching order code and X = with material certification EN 10204-3.1 specify the modifications separately. E.g. XGSD-H23F-120 2. Always specify operating temperature/ pressure/ S.G. and viscosity if > 80 cP 3. Code for options: - Reed chain transmitter / Micro-switches / Bi-stable (reed type) switches: consult factory - Scale: standard 304 stainless steel Code: 032-3930-xxx: scale in cm. Consult factory for tailor made scales 3-last digits represent the measuring range in cm increments (e.g. 120 = 120 cm) BASIC MODEL NUMBER - ANSI CLASS CAGES IN 316/316L (1.4401/1.4404) - FLANGES AND CAGE G G G G G G A B S R T U Side/bottom process connection with sealed top cap Side/bottom process connection with flanged top Side/Side process connection with sealed top cap Side/Side process connection with flanged top Top/bottom process connection with sealed top cap Top/bottom process connection with flanged top SPECIFIC GRAVITY RANGE AND FLOAT HYDROTEST PRESSURE➀ ALWAYS SPECIFY EXACT OPERATING S.G, max temp & pressure when ordering Vizual Hydrotest 36 bar @ +40 °C Hydrotest 52 bar @ +40 °C Hydrotest 85 bar @ +40 °C A 0,56 to 0,60 F 0,58 to 0,61 M 0,62 to 0,70 B 0,61 to 0,70 G 0,62 to 0,70 N 0,71 to 0,80 C 0,71 to 0,80 H 0,71 to 0,80 O 0,81 to 0,90 D 0,81 to 0,90 J 0,81 to 0,90 P 0,91 to 1,50 E 0,91 to 1,50 K 0,91 to 1,50 ➀ Consult factory for low S.G, interface applications or high pressure floats MATERIALS OF CONSTRUCTION CAGE & FLANGES: 316/316L (1.4401/1.4404) – FLOAT: 316 Ti (1.4571) except code A: Titanium Indication rail without scale ➀ Aluminium rail / SST flappers / Polycarbonate window Aluminium rail / SST flappers / Polycarbonate window Aluminium rail / SST flappers / Polycarbonate window Aluminium rail / SST flappers / Polycarbonate window Aluminium rail / SST flappers / Glass window Aluminium rail / SST flappers / Glass window Aluminium rail / SST flappers / Glass window H J K L M N P ➀ Temperature range -20 °C upto +160 °C (-5 °F upto +320 °F) -50 °C upto +125 °C (-60 °F upto +260 °F) -20 °C upto +200 °C (-5 °F upto +390 °F) -20 °C upto +250 °C (-5 °F upto +480 °F) -20 °C upto +300 °C (-5 °F upto +570 °F) -20 °C upto +350 °C (-5 °F upto +660 °F) -20 °C upto +400 °C (-5 °F upto +750 °F) See options for scales PROCESS CONNECTION: SIZE 0 1 2 3 4 1/2" 3/4" 1" 1 1/2" 2" ➀ ➀ Z A B C D DN DN DN DN DN 15 20 25 40 50 ➀ 2"/DN 50 process flanges are machined to 1" size PRESSURE RATING - FLANGE TYPE (if applicable) EN/DIN ANSI 3 150 lbs - RF flange PN A 4 300 lbs - RF flange PN B 5 600 lbs - RF flange PN D E PN 16 25/40 63 100 EN EN EN EN 1092-1 1092-1 1092-1 1092-1 B1 B1 B2 B2 flange flange flange flange PROCESS CONNECTION: STYLE N S F NPT-F coupling (size: max 1") Socket weld coupling (size: max 1") Flanged (all sizes) MEASURING RANGE (as per drawings at left page) – per 1 cm (0.39") increments minimum 30 cm (12") 0 3 0 5 7 0 maximum 570 cm (224") Note: segmented cage for lengths > 570 cm (224"), consult factory G complete code for Vizual® Magnetic Level Indicator 7 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 46-637.2 APRIL 2007 March 2004 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]