The magnetic flip level gauge achieves intuitive display of liquid level through magnetic coupling and can expand remote monitoring function. To ensure measurement accuracy and equipment stability, the following installation, commissioning, operation, and maintenance specifications must be strictly followed:
1、 Preparation and standardized operation before installation
Selection adaptability verification
Medium matching: Confirm that the parameters of medium density, temperature, pressure, corrosiveness, etc. are compatible with the equipment material (such as 304/316L stainless steel, PTFE lining) and temperature and pressure rating (such as -196 ℃~450 ℃, 0~32MPa).
Confirmation of connection form: Select side mounted (vertical installation) or top mounted (fixed to the top with flanges/threads) according to the container structure, and reserve installation space (side mounted requires top opening, top mounted requires bottom support).
Installation steps and precautions
Verticality calibration: Ensure that the liquid level gauge is installed vertically, with a deviation of ≤± 1 °, to avoid float jamming or abnormal flipping of the flap.
Flange connection sealing: Metal wrapped gaskets or corrosion-resistant sealing rings (such as PTFE) are used, and bolts are symmetrically tightened to the specified torque to prevent leakage.
Discharge and cleaning design: The bottom discharge valve should be installed facing downwards to facilitate regular cleaning of sediment; Corrosive media require the installation of a flushing ring to prevent crystal blockage.
Anti static and grounding: In flammable and explosive places, the liquid level gauge housing should be reliably connected to the equipment grounding terminal to eliminate the risk of static electricity.
Signal output module integration (optional)
Reed switch: evenly arranged along the height of the liquid level gauge (with a spacing of 100-200mm), used for high and low liquid level alarm or interlock control, and the deviation between the calibration trigger point and the actual liquid level should be ≤ ± 5mm.
Magnetostrictive sensor: Avoid strong magnetic field interference during installation, calibrate zero and full range, and achieve output accuracy of ± 1mm.
Wireless transmission module: It is necessary to confirm that the communication protocol (such as 4G, LoRa) is compatible with the upper computer, and set the data upload interval (recommended 1-5 minutes).
2、 Debugging and Initial Settings
Flip consistency check
Slowly inject clean water (or simulated medium) and observe whether the flipping plate flips synchronously with the liquid level, without any lag or false flipping phenomenon.
When the flip is found to be stuck or the color is abnormal, it is necessary to replace the damaged flip or clean the impurities inside the display panel.
Signal output calibration
Reed switch: Trigger the alarm point by lifting the float, and use a multimeter to confirm that the switch signal (normally open/normally closed) is consistent with the actual liquid level.
Magnetostrictive sensor: Inject standard liquid level (such as 50%, 100%), compare the displayed value with the actual liquid level deviation, and adjust the sensor parameters.
Remote monitoring system configuration
Connect the 4-20mA signal to PLC/DCS and set the upper and lower limits of the measurement range (e.g. 0-20mA corresponds to 0-1000mm).
Test the alarm function (such as shutting down the pump at low liquid level and stopping feeding at high liquid level), and confirm that the interlock logic is correct.
3、 Daily Operation and Maintenance Guide
Running status monitoring
Visual inspection: Observe daily whether the flipping display is clear, without stains or color fading; LED lighting strips can be installed at night to assist observation.
Signal output inspection: Confirm that the liquid level data is consistent with the on-site display through the upper computer or handheld terminal every week, with a fluctuation range of ≤± 1%.
Regular maintenance plan
Cleaning and maintenance: Wipe the display panel with a soft cloth every month, and wear protective gloves for corrosive media; Remove the flip module every quarter and clean the internal impurities with ultrasonic waves.
Discharge operation: Open the discharge valve every 2 weeks to discharge sediment, and high viscosity media need to be purged with steam.
Sensor calibration: Perform zero and full-scale calibration on magnetostrictive sensors every six months, using laser rangefinders or standard level gauges for comparison and verification.
Emergency handling of faults
Flipping without flipping: Check if the float is stuck (remove the guide rail for cleaning) and if the magnetism is weakened (replace the float).
Signal interruption: Confirm whether the reed switch circuit is open, whether the sensor wiring is loose, and replace the faulty module if necessary.
Leakage treatment: Immediately shut down, close upstream and downstream valves, replace seals or re tighten flange bolts.
4、 Key operating points for special working conditions
High temperature medium (≥ 200 ℃)
Install vacuum jacket or heat tracing tape to prevent medium crystallization or magnetic weakening caused by flipping; Record liquid level data every 2 hours to avoid sensor overheating and damage.
Low temperature medium (≤ -50 ℃)
Select low-temperature alloy materials (such as 304L stainless steel) and antifreeze type flip plates, and check the flexibility of flip plate rotation every shift; The signal line needs to be equipped with insulation sleeves to prevent freezing.
High viscosity medium (≥ 500mPa · s)
The float needs to increase its diameter (≥ 50mm) and optimize its streamlined design to reduce resistance; Perform a drainage operation every 4 hours to prevent the medium from adhering to the guide rail.
5、 Precautions for safe operation
Prohibit overpressure operation: Ensure that the medium pressure does not exceed the rated value of the liquid level gauge (such as 25MPa), and install a buffer tank when the pressure fluctuation is too large.
Explosion proof area regulations: It is strictly prohibited to open the cover with electricity in explosive gas environments. Before maintenance, the power supply must be cut off and wait for 10 minutes for discharge.
Media change approval: If other media need to be measured, material compatibility must be re evaluated and confirmed by the technical department before implementation.
Through the above standardized operations, it can ensure the long-term stable operation of the magnetic flip level gauge, accurately provide liquid level data, and ensure the safety and efficiency of industrial processes.