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 care-
fully 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, protec-
tion 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 war-
ranted 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 guar-
antees 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 elec-
trical equipment when working with or around high
voltage. Always shut off the power supply before touch-
ing any components.
WARNING!
Explosion hazard. Do not connect or dis-
connect 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 propor-
tion 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 dis-
placer 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, trans-
ferring the motion to a rotating cam,
which in turn operates a flapper
against a nozzle which increases or
decreases the pressure within the pneu-
matic 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
5
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