magnetic level gauge type 810 instruction...

Houdec Instrument SAS

Instruction Manual 50466-077A October 2008 Level

Magnetic Level Gauge Type 810 Instruction Manual

1.GENERAL page 4

1.1 Principle page 4

1.2. Description page 4

1.3. Technical data page 5

1.3.1. Version types 806 page 5

1.3.2. Standard version types 810 page 5

1.3.3. Standard version types 811 TOP mounting page 5

2. STORAGE AND INSTALLATION page 5

2.1.Storage page 5

2.2. Prior conditions page 5

2.3. General page 6

2.4. HIGH/ LOW temperatures processes page 6

2.5. Commissioning page 6

3. ATEX SPECIFIC INSTRUCTIONS page 6

3.1 Instrument could be used in hazardous area page 6

3.2. Switch & transmitter Flame-proof version page 7

3.3. Switch & transmitter I.S. transmitter version page 7

4. FITTING page 8

5. OPERATION page 8

6. CHECKING FOR CORRECT OPERATION

page 9

7. WIRING AND USE OF ALARMS page 9

7.1. Alarm contacts page 9

7.2. Location page 9

7.3. Wiring page 9

8. DAMAGED FLOAT INDICATOR / INITIALIZATION

page 10

8.1.Damaged float indicator page 1

8.2.initialization of the flaps / rollers indicator page 1

9. MAINTENANCE page 10

9.1. Glass tube replacement page 10

9.2. Slider replacement page 11

9.3. Rollers/Flaps indicator replacement page 11

9.4. Float replacement page 11

10. SPARE PART LIST page 12

11. WARRANTY page 12

Magnetic Level Gauge

Instruction Manual 50466-077A

October 2008

Handling

Read the manual

OK

DO NOT SHOCK

INTERNAL GLASS PARTS !

Handling carefully

Instruction Manual 50466-077A October 2008 Magnetic Level Gauge

MARKING

Identification number to be given for any request or claim to our technical after sales department



October 2008

1 GENERAL

The CP magnetic level indicator allows to measure directly liquid levels, even corrosive or dangerous, into vessels or under pressurized tanks. The design of this equipment ensures a good accuracy, an excellent reliability and a safe use.

1.1 PRINCIPLE A float equipped with a permanent magnet follows the level variation of liquid to be measured.

Slider version: the float drives a magnetic slider which slides into a Pyrex tube mounted on a graduated scale.

Rollers version: the float reverses magnetically locked bi-coloured Rollers. The red zone indicates the level of liquid in the tank.

Flaps version: the float reverses magnetically locked bi-coloured aluminium Flaps. The red zone indicates the level of liquid in the tank. For high and low temperatures processes

Nota: in case of heat-protected instruments, indicators must not be covered.

1.2 DESCRIPTION The equipment consists of two separate parts comprising the

measuring float chamber and the reading system.

Continuous indicator Mc 1000 indicator for remote measuring (transmitter). Available with standard housing or flameproof version. (See Manual 50466-144)

Slider version Rollers/Flaps version

Process Connections Many option for process tank connections.

Alarm contacts Standard mounting on the float chamber using st.st collars. Standard version or ATEX flame-proof version (Exd) and IS (ia) version .

The tube is also fitted with a Bottom flange assembly equipped with a draining plug for draining and cleaning. Many other connections types available -

Name plate Manufacturer name plate including all main technical data and specifications according to applicable rules and standards.

Reading system see 1.1

Float chamber So called the primary tube, it consists of a stainless steel of synthetic tube fitted with flanges (in standard) for external side mounting.

Vent Plug (NPT or BSP) For air draining according to customer process or application. Many other connections types available

Float Equipped with magnets – follow the variations of liquid inside the chamber. Many material, magnet types and pressure rating on request.


1.3 TECHNICAL DATA Magnetic level gauges types 810-811 are designed to be either top or side mounted . Considering these two standard possibilities, principle still the same, only the design change. Any other special mountings or processes could be considered on request.

1.3.1 Standard version types 810 – Side mounting

ALWAYS REFER TO THE NAME PLATE OF THE INSTRUMENT

Center to center : 0,2 m min. / 5,5m Max or in different section.

Connections Stainless Steel chamber: Loose flanges NP 16, ND20…25 Flange PN 16…/ DN 20…50 Tubes PVC Chambers: Loose flanges NP10, ND25 made of PP PVDF Chambers

Specific gravities: St. Steel chambers s.g. = (0,4 mini) PVC Chambers s.g. =0,9 minimum PVDF Chambers s.g.= acc. to design

Operating pressure (at ambient Temperature) St. Steel chambers : acc. to design up to 400 bar PVC chambers: 6 bar max

Maximum temperature St. Steel chambers: up to 350°C f/w insulation

PVC chambers : 60°C at P.atm 810S… 810R/VA… 810. PVC MOUTING TYPE NOTA: Do not heat-protect the indicators.

Viscosity 100 Cpoise max.

1.3.2 Version type 811 –Top mounting

The bottom dead band (BMB) and/or the top dead band (BMH) are directly depending of the ratio level/ specific gravity and the pressure.

L max : 3m

Operation pressure with standard st.st. Float 3 bar (max. 12 bar)

Flanges > ND65 / NP16 or ANSI 150#

Others connection types or spec on request

2 STORAGE AND INSTALLATION

2.1 STORAGE In case of storage we recommend to keep the instrument into its original packing and in the suitable conditions until the installation.

2.2 PRIOR CONDITIONS Ensure that all safety regulations are observed, in particular those relating to hazardous areas. As far as inherent safety is concerned, check that the classification of the instrument corresponds to the classification required at the installation site.

IMPORTANTE NOTE: In order not to disturb the magnetic coupling an area, of about 200mm free from any magnetic component, must be provided all around the indicator unit extension..

> 200mm > 200mm

No

n m

agn

etic

are

a



October 2008

2.3 GENERAL This equipment must only be handled empty, with all essential precautions taken to avoid impact or major stresses, which would be likely to alter its geometry and damage internal measuring devices, or the contact pattern of the connecting component seals. The various parts must be connected without engendering any mechanical or other stresses, other than those provided for when installing the equipment, and sealing the connection. Under no circumstances must the equipment be used as a support or for mounting any part or component not originally provided for.

Welding is prohibited. If welded connections or fastenings are required by the equipment definition, these must be produced by qualified personnel, using recognized operating procedures and the required materials, meeting current standards.

Grinding, cutting or heating are prohibited on any parts of the equipment which are subject to pressure. Make the connections using seals suitable for the fluid contained and the type of connection required. For flanges, make sure the seals used are new, compatible with the seal contact pattern and the service pressure and temperature. Use standard fastenings which match the flange rating and service conditions required by the type of seal and the process.

2.4 HIGH / LOW TEMPERATURES PROCESSES For heat-protected instruments, let the indicator (flaps or slider housing) free from any heat protection.

If any Orientation of the reading system is needed, take any precautions to slide the heat shield stripe too.

For very low temperatures processes, heat protection should be applied up the external face of the anti-frost option window.

2.5 COMMISSIONING Following the receipt and before mounting, check first if the float is not locked in the lower part of the equipment body by a wood or plastic rod, inserted in the lower connection pipe. If existing remove this rod and check that the float moves freely in the chamber before erecting.

Prior to operating the unit, make sure that the lines have been bled and that they are free from any solid particles ( metallic or non metallic particles). The instrument must be mounted 100% vertically. Gradually build up the pressure while checking that it does not exceed the maximum operating pressure rated for the unit.

During the first commissioning procedure make sure that the magnetic slider follows the level changes.If necessary, magnetically couple the follower to the float, by performing a bleeding operation followed by a new filling operation.

Ensure that the rated dimensions of the coupling flanges match those of the instrument and that the pipes are sufficiently rigid and properly secured in order to prevent vibration being transmitted to the instrument.

After verifying the condition of the seal contact pattern, tighten the bolts in several stages (see fig.3), using appropriate tools, torque or pneumatic wrench and respecting the torque settings recommended by the seal manufacturer.

Run a prior tightness test under service conditions before commissioning the equipment.

3 INSTRUCTION SPECIFIC TO HAZARDOUS AREA INSTALLATIONS

3.1 DIRECTIVE 94/9/CE -Instrument could be used in hazardous area limited to inox & VA indicator models Reference standard: EN13463-1 et 13463-5 In case of switch, please see the corresponding specifications. The marking shall be : … II 1/2 G c IIC T…*

*See table below LCIE 08 ATEX 6099 X

Maximum fluid temperature 400°C 290°C 195°C 130°C 95°C 80°C

Temperature Class T1 T2 T3 T4 T5 T6

- Always refer to the safety specifications instructions of the installation place and more particularly with regard to the hazardous zones as well as the dangerous products.

1 7

4

6

5

3

8 2

1

2

3

4

ANTI-FROST OPTION

HEAT PROTECTION

Fig 3.


(REFERENCE EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6.)

3.2 EXPLOSION-PROOF SWITCH & TRANSMITTER VERSION (apply to the flame-proof detection box type B4: certificate number LCIE01ATEX6060X) (S2/S4 option)

BEFORE ANY INTERVENTION ON THE INSTRUMENT, USUAL PRECAUTIONS SHOULD BE TAKEN.

POWER SUPPLY SHOULD BE SWITCHED OFF BEFORE ANY INTERVENTION.

FLAME-PROOF HOUSING MUST NOT BE OPENED WHILE ENERGIZED.

- Always refer to the safety specifications instructions of the installation place and more particularly with regard to the hazardous zones as well as the dangerous products.

- The level switch can be used with flammable gases and vapours belonging to groups IIA, IIB and IIC and temperatures class of T6.

- The installation of the instrument will be carried out by sorted personnel in conformity with the local installation standards.

- The integrator is responsible of the compatibility of connections of the instrument with the process conditions, with the sealing joint regarding the flange and of the electric connection in compare with the technical data of the instrument.

3.3 I.S. SWITCH & TRANSMITTER VERSION (APPLY TO THE I.S. CERTIFICAT : LCIE 05ATEX6034X)

BEFORE ANY INTERVENTION ON THE INSTRUMENT, USUAL PRECAUTIONS SHOULD BE TAKEN.

- Always refer to the safety specifications instructions of the installation location and more particularly with regard to the hazardous zones as well as the dangerous products.

- The level switch can be used with flammable gases and vapours belonging to groups IIA, IIB and IIC and temperatures class of T6, T5 or T4.

- The installation of the instrument will be carried out by sorted personnel in conformity with the local installation standards.

- The customer is responsible of the compatibility of connections of the instrument with the process conditions, with the sealing joint regarding the flange and of the electric connection in compare with the technical data of the instrument.

XT42-NIV I.S.

XT PRO–HARTprotocol I.S.

For ATEX instruments installation, read the attached leaflet

“safety instructions for detection box type B4 “

For intrinsically safe instruments which may be installed in hazardous areas, read the ATEX leaflet: « safety instructions for detection box type B5/...»



October 2008

4 FITTING

Fit the instrument into the pipe work/on the tank, inserting appropriate seals (not supplied) between the flanges. Ensure that the coupling flanges are parallel to those on the instrument and that the distance between centers is suitable in order to avoid strain other than that needed to provide sealing.

Tighten the bolts to obtain a sealed joint (retighten after a period of operation if necessary). When fitting the instrument with PTFE lining, special precautions must be taken as PTFE is readily distorted when cold; the recommended tightening torques below should not be exceeded:

ND15: lONm ND2O:2ONm ND5O:4ONm ND8O:5Onm

Important note: The PTFE gasket must have the same dimensions as that of the level gauge flange raised face and perfectly centered before tightening. ESSENTIAL SAFETY REQUIREMENTS

Instruments must be mounted vertically in rigidly fixed pipelines/tank connections

Sudden changes of pipe section at inlet or fittings that cause violent flow disturbances must be avoided.

Care must be taken to avoid inducing torsion stress on instrument when installing into the pipeline/ on the vessel.

Prior to installation ensure pipelines are flushed/drained to ensure they are free from any solid particles & pressure.

Ensure pipelines are fully primed before commencing normal use.

Valves must be opened or closed progressively to avoid shock/vibration.

Do not exceed maximum working pressure as stated on the label.

Only use with the fluid/gas stated on the label.

Solvents must not be used to clean the protective flaps box cover.

Do not exceed min/max. Working temperature as stated in manual. For heat-protected instruments, let the indicator free from anyprotection. Check regularly for its correct status. Periodically replace the indicator as needed.

Do not subject meter to sudden/extreme changes of temperature.

The instrument must be regularly inspected for corrosion & wear.

5 OPERATION

SAFETY WITH REGARD TO PRESSURE This pressurized equipment is part of a unit, so the integrator must fit the installation with safety devices (valves, rupture disk, sensor,…) to protect the equipment against the risk of excess pressure. The opening pressure of these devices must equal the maximum allowable pressure (PS) of the equipment. These mechanisms must also allow evacuation of full-flow steam under rated calculated conditions. The exhaust must be piped freely and without danger to personnel or the environment. The integrator must also provide a device for measuring residual pressure in the equipment (pressure gauge …) and a bleeder (piped if the product so requires), to guarantee the safety of personnel working on the equipment. Isolation valves are recommended to be installed between the equipment and the unit to which it is mounted, so that maintenance operations can be performed. Any other way (or design) may be achieved if they provide a acceptable safety level in accordance with the Directive 97/23/EC and/or present standards

SAFETY WITH REGARDS TO TEMPERATURE As far as this pressurized equipment is a part of an unit, all required measures regarding risks induced by temperature (regarding working personnel and the type of the material around according to the device’s specification) shall be taken by the integrator. For example, a kind of protection could be achieved, by the insulation of warm components, by using protection devices for access, or using any other devices suitable with the site of the unit and standards in force. Do not either subject the instrument to significant temperature variations or fire exposure.

OPENING AND CLOSING OF PRESSURIZED EQUIPMENT

Prior to any action on pressurized equipment, the suitability of pressure and temperature conditions with thought operations must be checked by the permitted and qualified technician. Regarding equipments fitted with alarm switches, use shall be made with care: voltage, current, devices (or security devices) controlled by theses switches… Appropriate tools must be used when stripping parts to get access to the pressurized equipment. Refer to drawings or appropriate instruction note. Gaskets could be replaced if needed, check for bolt tightening… Security rules must be checked (even for new devices) by the operator before pressurize. Operating conditions must comply with the instructions given. This equipment must not contain any fluid other than that (or those) for which it is designed. It is strictly prohibited to make any temporary or permanent modification, or to perform any operation likely to alter the physical, mechanical or metallurgical characteristics of any part, without the manufacturer's prior written agreement. A danger analysis has been performed, in accordance with appendix I of Directive 97/23/EC, based on the information provided. Any change with respect to this information, likely to call into question the safety of using the equipment, can only be made outside the manufacturer's responsibility. Before commissioning, the operator must make sure that the safety regulations applicable to pressurized equipment are respected and that the connected components work properly. This equipment is designed for static loads appropriate for the device's own weight and the specific stresses due to pressure and temperature as defined in the specifications. No additional load or stresses due to vibrations are accounted for, unless if specifically agreed during thepreliminary studies.


Rollers/Flaps versions Slider version

6 CHECKING FOR CORRECT OPERATION

The operator should periodically verify the equipment's ability to continue in service. Periodic monitoring and inspections must be made in accordance with current regulations in the country in which the equipment is used. This instrument is designed and calculated with a defined corrosion allowance. It is up to the user to check it periodically (according to the corrosiveness of fluids or the processes used for any reduction in this allowance in the main components of the instrument, so that any steps needed to maintain it's durability and resulting safety, can be taken. MAINTENANCE: This instrument is maintenance-free during normal operation. However, it should be cleaned at regular intervals if it is used with fluids that contain sediment or other deposits.

7 WIRING AND USE OF ALARMS

Installation of the instruments contacts will be carried out by sorted personnel in conformity with the local installation standards.

7.1 ALARM CONTACTS

STANDARD HOUSING FLAME-PROOF HOUSING SMALL Each level gauge could be equipped with alarm contacts. Fitted along the main tube, they are adjusted to switch on as the level rise to the chosen level of liquid. . The contact housing is IP65 in standard ATEX flame-proof (Exd) or I.S. (ia) on request.

Electric Characteristics Max voltage : 220VAC/ 110VDC Max current : see below schedule

Voltage Max. Current AC DC 230V 0,25A /////// 110V 0,55A 48V 1A 24V 1A

Light alloy material housing IP65 wiring connection using contact

screwed terminal. dimensions 80x75x57mm Output connection using one or

two PG9 synthetic cable gland(s) (diam 5-9mm).

S1, S3, S6, S7 Models ATEX "ia" certified II 1/2 G Exia IIC T6

LCIE05ATEX6034X (see §.3.)

Light alloy material housing IP65

Output connection using a flame-proof 3/4NPT cable gland (diam 5-12mm).

ATEX conformity

II 2G Exd IIC T6

LCIE01ATEX6060X (see §.3.) S2, S4 Models

Direct mounting Fitted with a

3meters electric wire

Sealing protection IP65

Dimensions : 75x15x15mm

-20°V <T < 80°C S5 Model

7.2 LOCATION In order to make easier operations on instruments alarm contacts, housing should be fitted near as possible from the flaps/ slider housing (see below figure). Position has no effect on signal quality.

7.3 WIRING During the wiring procedure, refer to electrical and technical characteristics specified on instrument contact label located under the electrical terminal box (see diagram below)

Before fully withdrawing the instrument from the tank, it is advisable to check that

the indicator is operating correctly:

Float Under Above RED

BLUE

WHITE



October 2008

8 DAMAGED FLOAT INDICATOR / INITIALIZATION

8.1 8.2 DAMAGED FLOAT INDICATOR In a normal use, rollers or flaps located below the black sticker on the indicator screen must be red. If those are blue, it means that the float is either damaged or uncorrectly fitted inside the gauge. Anyway, float should be checked by removing it from the gauge. (See 9.4.) This feature is for rollers/flaps versions only.

WHITE Rollers (no liquid/empty) RED Rollers (Liquid/ filled) RED Rollers ( Float: OK) BLUE Rollers ( Float: Problem)

8.3 INITIALIZATION OF THE FLAPS/ROLLERS INDICATOR

1/ The float must be in rest

position on the bottom of the

gauge. Put the south of the

magnet on the housing

bottom and then move it to

the top

2/ Move the magnet until all

the red rollers or flaps

become white.

3/ When all the flaps or rollers

are white, then the

instrument is ready to work.

9 MAINTENANCE

9.1 GLASS TUBE REPLACEMENT Remove the lower manufacturer plate. Remove the defective tube. Slightly loosen the metal clip attaching screws (see figure 5.) in order to facilitate the installation of the new tube. Once the tube mounted, tighten all the clips by pinching them against the glass tube. For tubes made of several parts, do not forget to install the thermo formable connecting sleeve perpendicularly to each junction (see fig.6.). Make sure that it is fitted with the end plugs and the magnetic follower. Slide it up to the extreme position. Magnetically couple the follower to the float. Re-install the manufacturer plate

When locking the clamps, make

sure they are set to extreme

position

Caution, make sure that both glass tubes are perfectly coaxial Connecting sleeve

(thermoformable 200°C)

Fig.5.

Fig.6.

North

Red tag

Float on

the bottom

of gauge

Red

South


9.2 SLIDER REPLACEMENT Remove the lower manufacturer plate.

Remove the end plug.

Replace the defective follower.

Re-intall the plug.

Magnetically couple the follower to the float.

Re-install the manufacturer plate.

9.3 FLAPS/ROLLERS INDICATOR REPLACEMENT

Release the housing clamps on each sides and middle if any.

Remove the indicator.

While re-installing the indicator on the gauge, make sure that the upper side of the damaged float sticker is in line with the connection tube (see right figure).

Lock the clamps while making sure that the flap-type strip lies flat on the primary tube, by keeping the flap-type strip firmly flat on the primary tube (see fig.7.).

9.4 FLOAT REPLACEMENT (See previously §5) Remove the bottom flange.

Remove the bottom limit stop.

Replace the float (caution: upper indication on the upper cup of the float).

Check the seals for proper condition. Replace if necessary (it is recommended to install new seal set).

Re-install the limit stop and the bottom flange (see.fig.9.)

Check for a correct tightness (see § 2.2. and 2.3.).

Fig.9.

Float

Float limit stop

PrimaryTube

Seal

Bottom fange

Drain plug



October 2008

Houdec Instrument S.A.S. Z.A. de la Tour– ABREST– France

Tel: +33 (0)4.70.59.81.81.

Fax: +33 (0)4.70.59.96.37. Email : [email protected]

www.houdec.com

copyright information

10 SPARE PART LIST

When ordering any spare parts, it is recommended even essential to quote the serial number of the instrument as well as the type of spare part required. - Index , Ref.: 60190401 - Float, indicator assembly, flaps housing, transmitter, glass tube …, etc. according serial number given.

- contacts code S1 : 1 contact in alu. housing IP65 < 200°C ref : 60190301 - contacts code S3 : 2 contacts in alu. housing IP65 < 200°C ref : 60190302 - contacts code S2 : 1 contact in alu. flameproof housing < 200°C ref : 60190201 - contacts code S4 : 2 contacts in alu. flameproof housing < 200°C ref : 60190202 - contacts code S6 : 1 contact in alu. housing IP65 HT 200 à 300°C ref : 60190303 - contacts code S7 : 2 contacts in alu. housing IP65 HT 200 à 300°C ref : 60190304 - contacts code S5 : 1 contact f/w 3m wireref : 60191401 - contacts code S8 : 1 contact in alu. Housing ATEX ia ref: 60190305 - contacts code S9 : 2 contacts in alu. Housing ATEX ia ref: 60190306

11 WARRANTY

This equipment includes a number of parts which can be replaced in the event of operational failure.. To be sure of identifying the exact references for these parts according to the type of construction, it is essential to transmit the serial n° given on the label or marking plate found on the instrument

Telephone n° of the After-Sales Service to contact: France: +33 (0)4 70 59 81 81

Other countries: contact the local representative

This equipment is supplied under guarantee (see the contractual terms of the order for its duration). We would call your attention to the fact that using parts which do not comply with original parts or required standards (materials certified according to harmonized standards, classes of standard parts, fastenings, flanges, connections….), is liable to jeopardize this guarantee and call into question the associated responsibility.

mailto:[email protected]

http://www.houdec.com/

magnetic level gauge type 810 instruction...

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