K-Dyne OMP L80-P User manual

MANUAL#OMPL80‐PREV.6
INTRODUCTION
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TheK‐Dyne,Inc.electricversionoftheModelL80isa2"NPTmountedliquidlevelswitch.Itistypically
mountedinaK‐DyneModelC80cageshowninthefigure1forexternalbridlemountingormaybe
internallymountedina2"NPT(F)connection.Bothmountingconfigurationsareshowninfigure2.
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Thesesensorssendorremoveanelectricsignalwhenaliquidin
atankorapressurizedvesselreachesapredeterminedlevel.The
L80operationmodeaseitheralow(direct)orhigh(reverse)
actinglevelswitchisselectedbyrotatingthepivotbody180˚.
SelectionofN.O.orN.C.switchingdependsuponthewiring
configurationutilized.BothSPDTorDPDTsnapactingdry
contactsofferedwiththeswitchareU.L.Tratedforhazardous
locations.
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2.0PRINCIPLEOFOPERATION(RefertoFigure3)
TheelectricversionoftheK‐Dyne,Inc.ModelL802"NPT
mountedliquidlevelswitchisamulti‐functionalpneumaticliquid
levelsensor.Dependingonthemodeofoperation,itfunctions
asathreeway,normalclosed(N.C.)ornormallyopen(N..O.)
electricswitchthatwilloperatewhentheliquidlevelrisesorfalls
belowafixedpointinatankorpressurizevessel.Typeofvoltage
maybeA.C.orD.C.andthemaximumamperagedependsonthe
amountofvoltageused.Consultthedatasheetofthespecific
switchbeingusedfortheswitchrating.
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Theswitchsensesachangeinthebuoyancyofadisplacer
assembly(9)insideeitherapressurizedoranunpressurizedvessel.Apivotingactionisusedtotransmit
thebuoyancychangeofthedisplacerassembly.Theboreofthecone(14)contactsapivot(13)onthe
pivotbody(3).Theo‐ring(8)providesapressuretightsealbetweenhebody(7)andtheshaftofthe
coneprotrudingthroughtheo‐ring.
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Pressureinthevesselactingontheshaftoftheconeforcestheconeagainstthepivot.Thepositionof
thepivotpoint,atthecenteroftheo‐ring,allowsthedisplacerassemblytomoveverticallywiththe
liquidlevel.Thismotionisguidedtoactalongtheaxisofthetransverserod(16)bytwoverticaltabson
thepivotbodythatmatewithnotchesinthecone.Anyverticalmotionofthedisplaceristransmittedby
theconetotheendsofthetransverserod.Arampontheoutsidediameterofthetransverserod
contactsthetipofthepushrod(17)tooperatetheleverontheswitchassembly(2).
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2.1LOWOPERATION
Foruseasalow‐levelsensor(outputonrisinglevel),thepivotbody(13)ispositionedwiththeenlarge
endofthetransverserod(16)uptowardsthespringcap(4).Thedisplacerassemblyweightexertsa
clockwiserotationalforceontheconethroughthepivot.Thespring(5),actingthroughhespringguide
(6)exertsacounterclockwiserotationalforceonthecone.Whentheliquidlevelisbelowthedisplacer
assembly,theclockwiseforceisgreater.Thisforcecausestheconetopushupwardagainstthe
transverserodallowingthetipofthepushrodtobepositionedawayfromtheswitchassemblylever.In

thispositionN.O.orN.C.contactsareinthenormalposition(i.e.N.O.contactsareopenandN.C.
contactsareclosed).
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Astheliquidlevelrisesandbeginstocoverthedisplacerassembly,itsbuoyancy,intheliquid,reduces
theclockwiserotationalforceonthecone.Whenthespringexertsagreatercounterclockwiserotational
forcetheconemovesthetransverseroddownwardandthetransverserodrampmovesthepushrodto
operatedtheswitchassemblylever.Whentheswitchoperates,thestatofthecontactsreverse(i.e.N.O.
contactsareclosedandN.C.contactsareopen).
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2.2HIGHOPERATION
Foruseasahighlevelsensor(outputonfallinglevel),thepivotbodyisorientedwiththeenlargedend
ofthetransverseroddownawayfromthespringcap.Whentheliquidlevelisabovethedisplacer
assembly,thecounterclockwiserotationalforceofthespringontheconeisgreaterthanthe
counterclockwiserotationalforceofthebuoyantdisplacer.Thislargerforcemaintainsthetransverse
rodinthedownpositionwhilethetransverserodramppushingonthepushrodkeepstheswitch
assemblyleverintheoperatedposition.Theswitchcontactsremaininthereversedposition.
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Astheliquidlevelfalls,thedisplacerassemblylosesitsbuoyancyandtheclockwiserotationalforceon
theconebecomesgreaterthanthecounterclockwiserotationalforceofthespring.Thetransverserodis
shiftedupwardallowingthepushrodtomoveawayfromtheswitchassemblylever.Whentheswitch
operatesthecontactsreturntotheirnormalstate.
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3.0INSTALLATION
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3.1EXTERNALCAGETOVESSEL
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ItissuggestedthattheModelL80beinstalledinanexternalcageformaintenanceandtestingpurposes.
ArecommendedpipingsystemformountinganexternalcagetoavesselisshowninFigure2.Thevalves
aboveandbelowthecagearerequiredfortestingandmaintenancepurposes.
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Ifacagewithweldconnectionsisused,thelevelswitchshouldberemovedfromthecagebefore
welding.Thiswillpreventweldsparksformdamagingthedisplacerassembly.Removetheswitchfrom
thecageasperinstructionsinparagraphs5.2.1through5.2.2oftheFULLDISASSEMBLYsectionofthis
manual.AfterweldinginstallthelevelswitchasperinstructionsinSection3.2INSTALLINGSWITCHIN
CAGE.
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Ifthecagehasthreadedorflangedprocessconnections,thelevelswitchdoesnothavetoberemoved
beforemountingtheswitchtothevessel.Cageswith1"NPTprocessconnectionsmaybeinstalledon
thevesselwith1",¾",or½"O.D.piping.CAUTION:Thepressureratingofallpipe,valve,andpipe
fittingsmustmeetorexceedtheworkingpressureofthevesseltheyaretobeinstalledon.Adequate
supportforlongpiperunsshouldbeprovidedtopreventexcessivevibrationsofthelevelswitch.
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Itisrecommendedthatexternalcagesbeinstalledwiththeprocessconnectionsasclosetoverticaland
thecagelengthasclosetohorizontalaspossible.Thiswillinsuretheproperfluidflowthroughthecage.
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3.2LEVELSWITCHINSTALLATION
Beforeinstallingalevelswitchintoanexternalcageormatingflangeverifythatthelevelswitchis
configuredfortheoperationmoderequired(i.e.direct(low)orreverse(high)action).SeeSection4.0
CHANGINGMODEOFOPERATIONandFigure5.NOTE:Whendirectmountingalevelswitchtoatankor
vesselverifythatthebackofthedisplacerassemblywillbeatleast½"(13mm)longerthanthe2"
connectionitisbeinginstalledinto(SeeFigure4).
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TOOLREQUIRED:
2.125"openendorsuitableadjustablewrenchorpipewrench
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3.2.1Cleananydirtordebrisformthe2"NPTpipethreadsoftheswitchandmatingconnection
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3.2.2ApplyTeflontapeorothertreadsealingcompoundtothe2"NPTthreadsontheswitch
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3.2.3Applyandanti‐gallingcompoundtothe2"NPTfemalethreadthattheswitchistobeinstalled
into.
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3.2.4Screwtheswitchintothemountingtreadandtightenwiththewrench.Whentight,thespring
capmustbeupasshowninfigure5.

CAUTION:Ifusingapipewrenchdonot
allowthewrenchjawstocontactthespring
cap.Wrenchforcesmaydamagethecap
andpreventtheswitchfromoperating
properly.

NOTE:THESPRINGCAPMUSTALWAYSBE
INTHEVERTICALPOSITIONASSHOWNIN
FIGURE5FORTHESWITCHTOOPERATEPROPERLY.
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4.0ELECTRICALCONNECTIONS
CAUTION:REMOVEANDLOCKOUTALLELECTRICALPOWERBEFOREWORKINGONELECTRICALSWITCH
LEADS.
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4.1.1CAUTION:Besuretofollowallapplicableelectricalcodesandregulationswheninstalling
electricalconnectionsorconduittotheswitch.
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4.1.2Whenconnectingorremovingconduitconnectionstotheswitchassembly½"NPTthread,usea
7/8"open‐endwrenchorandadjustablewrenchonthehexportionofthewitchassemblytoprovidea
properback‐up.Thiswillpreventdamagetotheconnectionthreadbetweentheelectricswitch
assemblyandthelevelswitchbody.
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4.1.3Theelectricswitchleadsarelabeledandcolorcodedforthetypeofswitchcontact.Connection
oftheseleadsforthedesiredswitchoperatingfunctionisshownonTable#1.
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SPDTSWITCH
LOWOPERATION
COLORLEVELCONTACTFUNCTION
BLUEN.O.CLOSESONRISINGLEVEL
BROWNCCOMMONCONTACT
REDN.C.OPENSONRISINGLEVEL
HIGHOPERATION
COLORLEVELCONTACTFUNCTION
BLUEN.O.CLOSESONFALLINGLEVEL
BROWNCCOMMONCONTACT
REDN.C.OPENSONFALLINGLEVEL
DPDTSWITCH
LOWOPERATION
COLORLEVELCONTACTFUNCTION
BLUEN.O.CLOSESONRISINGLEVEL
BROWNCSW.1COMMONCONTACT
REDN.C.OPENSONRISINGLEVEL
PURPLEN.O.2CLOSESONRISINGLEVEL
YELLOWC.2SW.2COMMONCONTACT
BLACKN.C.2OPENSONRISINGLEVEL
HIGHOPERATION
COLORLEVELCONTACTFUNCTION

BLUEN.O.CLOSESONFALLINGLEVEL
BROWNCSW.1COMMONCONTACT
REDN.C.OPENSONFALLINGLEVEL
PURPLEN.O.2CLOSESONFALLINGLEVEL
YELLOWC.2SW.2COMMONCONTACT
BLACKN.C.2OPENSONFALLINGLEVEL
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5.0CHANGINGMODEOFOPERATION(RefertoFigure3)
TOOLREQUIRED:3/16"Allenwrench
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Thelevelswitchmodeofoperationmaybeeasilychanged.Ifthelevelswitchisinstalledinapressurized
cageorvessel,thepressuredoesnothavetoberemoved.Figure5showstheproperorientationofthe
levelswitchfunctionstampingforlowandhighactingoperation.
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5.1UPRESSURIZEDCAGEORVESSEL
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5.1.1Verifythatnopressureispresentinthecageorvessel.Ifthiscannotbeverified,follow
instructionsinSection4.2PRESSURIZEDCAGEORVESSEL.
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5.1.2CAUTION:REMOVEANDLOCKALLELECTRICALPOWERBEFOREWORKINGONELECTRICAL
SWITCHLEADS.Disconnectallelectricalswitchleadconnections.DONOTattempttoremovethe
electricswitchassemblyuntiltheleadsaredisconnected.Followallapplicablecodeswhenworkingwith
electricalequipment,especiallyinareasthatareclassifiedashazardous.

5.1.3Withthe3/16"Allenwrenchremovethefourhexsocketheadcapscrews.(1).Rotatethepivot
body180˚tochangethemodofoperationfromlowtohighorformhightolowasdesired.SeeFigure5
forproperpivotbodyorientation.

5.1.4Replacethefourhexsocketheadcapscrewsandtighten.

5.1.5Reconnectallelectricalswitchleads.
5.2PRESSURIZEDCAGEORVESSEL


5.2.1CAUTION:REMOVEANDLOCKALLELECTRICALPOWERBEFOREWORKINGONELECTRICAL
SWITCHLEADS.Disconnectallelectricalswitchleadconnections.DONOTattempttoremovethe
electricswitchassemblyuntiltheleadsaredisconnected.Followallapplicablecodeswhenworkingwith
electricalequipment,especiallyinareasthatareclassifiedashazardous.

5.2.2Usea3/16"Allenwrenchandremovetwoofthehexsocketheadcapscrews(9)thatare
diagonallyapart.Replacethetwohexsocketheadcapscrewsjustremovedwithtwo1/4"‐20screwsor
boltsthatare1‐1/4"to1‐1/2"long.Theseserveasasafetystopintheeventthelevelswitchhas
receivedunknowndamage.Rotatetheremainingtwoscrewsoneturnatatime,alternatingbetween
thetwo.Theprocesspressure,actingontheendofthecone(14)thatisprotrudingthroughthebody,
willmovethepivotbodyoutwardasthetwoscrewsareturned.Whenthepivotbodyhasstopped
moving,removethefourscrewscompletely.Rotatethepivotbody180˚tochangethemodeof
operation(ifnecessary).SeeFigure5forproperpivotbodyorientationmodes.

CAUTION:THEPIVOTBODYSHOULDMOVEOUTWARDAPPROXIMATELY1/16"ANDSTOPASTHE
DISPLACERASSEMBLYCONTACTSTHEBODY.IFTHEPROCESSPRESSUREISSTILLEXERTINGAFORCEON
THEPIVOTAFTERITMOVES5/64",THENSTOPTURNINGTHETWOSCREWS.THEUNITMAYHAVE
DAMAGETHATWILLALLOWTHECONETODISENGAGETHEO‐RING(8)ANDTHEPROCESSPRESSURE
ANDMEDIUMWILLESCAPETHROUGHTHEBODY.THEPROCESSPRESSUREWILLHAVETOBEREMOVED
FROMTHECAGEORVESSELBEFOREANYFURTHERDISASSEMBLYISPOSSIBLE.

5.2.3Replacethefourhexsocketheadcapscrewsandtighten.

5.2.4Reconnecttheelectricalswitchleads.

6.0DISASSEMBLY(Refertofigures1&3)
TOOLSREQUIRED:
7/16",5/8",&7/8"openendwrenchoradjustablewrench
3/16"and1/8"Allenwrenches
pliers
o‐ringpickorsmallscrewdriver

CAUTION:ONLYTHESWITCHASSEMBLYANDPIVOTBODYCANBEREMOVEDFROMTHELEVELSWITCH
UNITWITHOUTDEPRESSURIZINGTHECAGEORVESSEL.ANYFURTHERDISASSEMBLYWITHPRESSURE
PRESENTONTHECAGEORVESSELWILLRESULTINSEVEREPERSONALINJURYORDAMAGETO
EQUIPMENT.

6.1SWITCHREMOVAL

CAUTION:REMOVEANDLOCKOUTALLELECTRICALPOWERBEFOREWORKINGONELECTRICALSWITCH
LEADS.

6.1.1Disconnectallelectricalswitchleadconnections.DONOTattempttoremovetheelectricswitch
assemblyuntiltheleadsaredisconnected.Followallapplicablecodeswhenworkingwithelectrical
equipment,especiallyinareasthatareclassifiedashazardous.

6.1.2Usinga7/8"openendwrenchoranadjustablewrenchothehexportionoftheelectricswitch
assemblytoprovideaproperbackup,removeallconduitorenclosuresattachedtotheelectricswitch

assembly.DONOTusechannellockpliers,pipewrenches,oretc.onthecylindricalportionofthe
electricswitchassembly.

6.1.3Takingcarenottoletthepushrod(17)falloutoftheelectricswitchassembly,removethe
electricswitchassemblyformthepivotbody(3)usingthe7/8"wrench.

6.1.4Pullthepushrodoutoftheelectricswitchassembly.Theelectricswitchassemblycannotbe
disassembledanyfurther.

6.2PIVOTBODYDISASSEMBLY

6.2.1Forpivotbodyremovalfromanon‐pressurizedcageorvesselusea3/16"Allenwrenchand
removethefourhexsocketheadcapscrews(1).

6.2.2Forpivotbodyremovalfromapressurizedcageorvesselusea3/16"Allenwrenchandremove
thetwoofthehexsocketheadcapscrewsthatarediagonallyapart..Replacethetwohexsockethead
capscrewsjustremovedwithtwo1/4"‐20screwsorboltsthatare1‐1/4"to1‐1/2"long.Theseserveas
asafetystopintheeventthelevelswitchhasreceivedunknowndamage.Rotatetheremainingtwo
screwsoneturnatatime,alternatingbetweenthetwo.Theprocesspressure,actingontheendofthe
cone(14)thatisprotrudingthroughthebody,willmovethepivotbodyoutwardasthetwoscrewsare
turned.Whenthepivotbodyhasstoppedmoving,removethefourscrewscompletely.

CAUTION:THEPIVOTBODYSHOULDMOVEOUTWARDAPPROXIMATELY1/16"ANDSTOPASTHE
DISPLACERASSEMBLYCONTACTSTHEBODY.IFTHEPROCESSPRESSUREISSTILLEXERTINGAFORCEON
THEVALVEBODYAFTERITMOVES5/64",THENSTOPTURNINGTHETWOSCREWS.THEUNITMAYHAVE
DAMAGETHATWILLALLOWTHECONETODISENGAGETHEO‐RING(8)ANDTHEPROCESSPRESSURE
ANDMEDIUMWILLESCAPETHROUGHTHEBODY.THEPROCESSPRESSUREWILLHAVETOBEREMOVED
FROMTHECAGEORVESSELBEFOREANYFURTHERDISASSEMBLYISPOSSIBLE.

6.2.3Removethetransverserodformthepivotbody.

6.2.4UseplierstoholdtheO.D.ofthepivotpointandrotateitcounterclockwisetoremoveitform
thepivotbody.

6.2.5Thetransverserodwearringsshouldnotberemovedunlessdamageoranexcessiveamountof
debrishasaccumulatedonthetransverserod.TheseringsaresplitandmayberemovedsimilarlytoO‐
ringremoval.Thewearringsareplasticandcanbebroken.Exercisecarewhenremovingthem.

6.3FULLDISASSEMBLY

CAUTION:ALLPRESSUREMUSTBEREMOVEDFROMTHECAGEORVESSELBEFOREFULLDISASSEMBLY
CANBEPERFORMED.FAILURETOREMOVETHEPRESSUREMAYRESULTINPERSONALINJURYOR
DAMAGETOEQUIPMENT.

6.3.1Forfulldisassembly,itisnecessarytocompletelyremovethepressureformthecageorvessel
theswitchisinstalledin.Allliquidsshouldbedrainedtoapositionbelowthelevelswitch.

6.3.2Loosenandremovethelevelswitchfromthetank,vesselorcagethatitismountedto.


6.3.3Holdtherod(11)withthepliersandrotateitcounter‐clockwisetoremoveitfromthelevel
switch.

6.3.4Normallyitisnotnecessarytoremovethedisplacerassemblyfromtherod.Ifrequired,loosen
thelocknut(10)andunthreadthedisplacerassemblyfromtherod.

6.3.5FollowinstructionsinSection6.1and6.2toremoveanddisassembletheswitchandpivotbody.

6.3.6Usethe5/8"wrenchandrotatethespringcap(4)counterclockwisetoremoveitfromthebody
(7).Careshouldbetakennotolosethespring(5)andspringguide(6).

6.3.7Pushthethreadedendofthecone(14)throughthebody.

6.3.8Usingano‐ringpickorsmallscrewdriverremovetheO‐ring(8)formthebody.
7.0REPAIRANASSEMBLYREFERTOTHESWITCHDATASHEETFORREPLACEMENTPARTNUMBERS
TOOLSREQUIRED:
7/16",5/8",&7/8"openendwrenchoradjustablewrench
3/16"and1/8"Allenwrenches
needlenosepliers
pliers
safetysolvent
siliconebasedo‐ringlubricant


7.1Usinganappropriatesafetysolvent,cleanallparts.

7.2InspecttheI.D.ofthetransverserodboreinthepivotbody(13)andtheO.D.ofthetransverse
rod(16)forcorrosionandexcessivewear.Thesurfaceoftheboreandtheramponthetransverserod
shouldhaveamirrorlikeappearance.Replaceanywornordamagedparts.

7.3Examinethepushrod(17)forcorrosionandexcessivewear.Ensurethatthetipisstillpointed.
Replaceanywornordamagedparts.

7.4Ifthelevelswitchhasastainlesssteeldisplacerassembly,itshouldbefreeofdents,cracksor
holes.

7.5Re‐installthewearringsifremoved.

7.6Installthepushrodintotheswitchassemblyandthetransverserodintothepivotbody.Both
shouldmovefreely.NOTE:Careshouldbetakennottolosethesepieceswhilehandling.

7.7Threadandtightentheswitchassembly(2)intothepivotbody.

7.8InstallthebodyO‐ring(8)intothebody(7).

7.9Threadthereplacementpivot(13)ontothepivotbodyandtighten.


7.10Lubricatetheshaftandthetreadsonthetreadedendofthecone.Installtheconeintothebody
byturningtheconeclockwiseandpushinggently.

7.11Alignthetabsonthepivotbodywiththeslotsintheconeandslidethepivotbodyintothelevel
switchbody.

7.12Alignthevalvebodyinthecorrectpositionforthedesiredloworhighoperation,seeFigure5.
Installandtightenthefourhexsocketandheadcapscrews(1).

7.13Threadthefloatrodontotheconeandtightensecurelywithpliers.Ifthedisplacerassembly
wasremoved,reinstallandtightenthelocknutsecurely.

7.14Insertthespring(5)andspringguide(6)intothespringcap.Installthespringcapintothebody
andtighten.

7.15ReplacethelevelswitchassemblyintothetankvesselorcageasperinstructionsinSection3.0
INSTALLATION.

8.0SWITCHCALIBRATION
8.1Duetomanufacturingtolerancesorpartwear,itmaybenecessarytoadjustthelengthofthe
pushrod(10)afterinstallinganelectricswitchassembly(2).

8.2Installtheswitchassemblyperproceduresinparagraph7.6and7.7ofthismanual.
8.3Connectasuitabledevicetotestswitchcontinuitytotheappropriateswitchleads.

8.4Iftheswitchisnotinstalledinavesselitmaybetestedbyraisingandloweringthedisplacer
assemblymanually.Foraswitchinstalledinavesselorexternalcageitisrecommendedtousethe
actualprocessfluidtocheckforproperswitchoperation.

8.5Switchesthatareinstalledbutnotpracticaltooperatewiththeprocessfluidsmaybetestedby
removingthespringcap(4)andthespring(5)thendepressingandreleasingthespringguide(6).

8.6Shouldtheswitchoperationhaveoneofthemalfunctionsasgiveninthetableof8.7,use
proceduresgiveninparagraphs8.8thru8.9tocalibratetheswitch.

8.7
SwitchResponseCalibration
N.O.contactsstayclosedShortenPushRod
N.O.contactsstayopen
N.O.contactsstayopenLengthenPushRod
N.O.contactsstayclosed


8.8Removetheswitchassemblyandpushrodperproceduresinparagraphs6.1.3and6.1.4.


8.9Useplierstoholdthebodyofthepushrodanda5/64"Allenwrenchtoturnthesetscrewon
thetopofthepushrod.Rotatethesetscrewapproximately30˚counterclockwisetolengthenand
clockwisetoshortenthepushrod.

8.10Re‐installtheswitchassemblyandretestthelevelswitch.Repeattheseproceduresasrequired
untiltheswitchfunctionsproperly.

9.0RECOMMENDEDMAINTENANCE
PROCEDUREINTERVAL
Testinstalledswitchwithprocessliquidtocheck
forproperoperation.every30days
Replacebodyseal(8)asrequired

TROUBLESHOOTING:
PROBLEMPOSSIBLECAUSESRECOMMENDEDACTION
LevelSwitchdoesnotfunctionLooseconnectionVerifythattheswitchleadsare
properlyterminatedandall
connectionsaretight.
DamagedwiringCheckswitchleadsforcuts.
Switchassembly(2)damagedFollowproceduresinsection6.0
andreplaceswitchassembly.
Debrisaccumulationonpushrod
(17),transverserod(16)or
undercone(14)
Followproceduresinsections
6.0and7.0todisassembleand
clean.
Trashaccumulationondisplacer
assembly(9).
Removeswitchformvesselor
cageperproceduresinSection
6.3andcleandisplacer.
Levelswitchnotinstalled
properly.Springcapnotinthe
'UP'position
UseinstructionsgiveninSection
3.0toproperlyinstalltheswitch.
Stainlesssteeldisplacer
assembly(ifused)damaged
Removeswitchfromvesselor
cageperproceduresinSection
6.3andreplacedisplacer
assembly.
Specificgravityoffluidtoolight
forswitchtofunction
Consultfactoryforoptional
Modelsavailable.
Liquidorgasleakagefrombody
vent
Bodyseal(8)damagedorwornReplacebodyseal(8)per
instructionsinSections6.0&7.0.
