Magnetic Liquid

Level Indicators

Installation and Operating Manual

Gauges
Switches
Transmitters
Read this Manual Before Installing Notice of Trademark, Copyright, and Limitations
This manual provides information on Magnetic Liquid Magnetrol & Magnetrol logotype, Orion Instruments,
Level Indicators. It is important that all instructions are Aurora, Eclipse, and Jupiter are trademarks of Magnetrol
read carefully and followed in sequence. International.

Conventions Used in this Manual Copyright © 2016 Magnetrol International.

All rights reserved.
Certain conventions are used in this manual to convey
specific types of information. General technical material,
Performance specifications are effective with date of issue
support data, and safety information are presented in
narrative form. The following styles are used for notes, and are subject to change without notice. Magnetrol
cautions, and warnings. reserves the right to make changes to the product
described in this manual at any time without notice.
Notes Magnetrol makes no warranty with respect to the accuracy
of the information in this manual.
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
Warranty
actions. They follow the procedural steps to which
they refer. All Magnetrol/Orion mechanical level controls are
warranted free of defects in materials or workmanship for
Cautions five full years from the date of original factory shipment.
Cautions alert the technician to special conditions that
All Magnetrol/Orion electronic level controls are
could injure personnel, damage equipment, or reduce
warranted free of defects in materials or workmanship for
a component’s mechanical integrity. Cautions are also
one full year from the date of original factory shipment.
used to alert the technician to unsafe practices or the
need for special protective equipment or specific
If returned within the warranty period; and, upon factory
materials. In this manual, a caution box indicates a
inspection of the control, the cause of the claim is
potentially hazardous situation which, if not avoided,
determined to be covered under the warranty; then,
may result in minor or moderate injury.
Magnetrol/Orion will repair or replace the control at no
cost to the purchaser (or owner) other than transportation.
Warnings
Warnings identify potentially dangerous situations or Magnetrol/Orion shall not be liable for misapplication,
serious hazards. In this manual, a warning indicates an labor claims, direct or consequential damage or expense
imminently hazardous situation which, if not avoided, arising from the installation or use of equipment. There
could result in serious injury or death. are no other warranties expressed or implied, except special
written warranties covering some Magnetrol products.
Safety Messages
Follow all standard industry procedures for servicing
Quality Assurance
electrical equipment when working with or around high
voltage. Always shut off the power supply before touch- The quality assurance system in place at Magnetrol guar-
ing any components. antees the highest level of quality throughout the com-
pany. Magnetrol is committed to providing full customer
WARNING! Explosion hazard. Do not connect or satisfaction both in quality products and quality service.
disconnect equipment unless power has been switched off
or the area is known to be non-hazardous. Magnetrol’s Corporate quality assur-
ance system is registered to ISO 9001
Low Voltage Directive affirming its commitment to known
international quality standards pro-
For use in Installation Category II, Pollution Degree 2.
viding the strongest assurance of
If equipment is used in a manner not specified by the product/service quality available.
manufacturer, protection provided by the equipment
may be impaired.
 Magnetic
Liquid Level Indicators
Table of Contents

1.0 Installation 1.9.2.2 Mounting to an Aurora MLI .............12

1.1 Unpacking.............................................................4 1.9.2.3 Wiring...............................................12
1.2 Pre-installation Checklist .......................................4 1.10 Analog Transmitter Installation............................13
1.3 Equipment and Tools ............................................4 1.10.1 OCT Reed Transmitter.............................13
1.4 Side Mount Installation.........................................5 1.11 Internal Electronic Transmitter Installation .........13
1.5 Top Mount Installation .........................................6 1.12 Internal Eclipse® Transmitter Installation.............14
1.6 Top/Bottom Connection Installation.....................6 2.0 Reference Information
1.7 Start-up .................................................................6 2.1 Description..........................................................14
1.8 Special Accessory Installation.................................7 2.2 Theory of Operation ...........................................15
1.8.1 Insulation or Blanket Installation................7 2.2.1 Side Mount...............................................15
1.8.2 Steam Heat Tracing Installation ..................8 2.2.2 Top Mount ...............................................15
1.8.3 Electric Heat Tracing Installation................8 2.3 Troubleshooting...................................................16
1.8.3.1 Units with a fixed-point 2.3.1 Side Mount...............................................16
thermostatic switch..............................8 2.3.2 Top Mount ...............................................17
1.8.3.2 Units with an adjustable “bulb-type” 2.4 Spare Parts...........................................................17
thermostatic switch..............................9
2.5 Maintenance........................................................17
1.9 Switch Installation ...............................................10
2.6 Specifications.......................................................18
1.9.1 OES Cam Operated Switch......................10
2.6.1 Magnetic Level Indicator ..........................18
1.9.1.1 Mounting to an
2.6.2 Model OES Switch ...................................19
Atlas™ or Gemini™ MLI ....................10
1.9.1.2 Mounting to an Aurora® MLI ...........10 2.6.3 Model ORS Switch...................................19
1.9.1.3 Wiring...............................................11 2.6.4 Model OCT Analog Transmitter ..............19
1.9.2 ORS Electric Reed Switch ........................11 2.6.5 Model 2XX Jupiter™ Magnetostrictive
1.9.2.1 Mounting to an Transmitter ...............................................19
Atlas or Gemini MLI.........................12 2.6.6 Model 705 Eclipse Transmitter .................19
 1.0 Installation
Caution: If equipment is used in a manner not specified by manu-
facturer, protection provided by equipment may be
impaired.

1.1 Unpacking

Unpack the instrument carefully. Inspect all units for

damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip and
purchase order. Check and record the serial number for
future reference when ordering parts.
Caution: Do not discard the shipping container until all parts are
checked.

1.2 Pre-installation Checklist

1. Manually move the float from 0% to 100% to 0% prior

to start up/check out in order to reinitialize accessory
products, if so equipped. Accessories may inadvertently
change state due to rough handling in shipment.
2. Remove float prior to pressure testing tank.
Caution: Float damage will occur if not removed from chamber prior
to pressure testing the tank.
3. Verify the MLI’s center to center distance equals the
vessel’s center to center.

1.3 Equipment and Tools

• Open-end wrenches or adjustable wrench to fit the process

studs and nuts. A torque wrench is highly desirable.
• Flat-blade screwdriver
• Digital multimeter or digital volt/ammeter if transmitters
or switches are attached
• Level
• Gasket for mating flanges
• Teflon tape & “never seize” for threaded units
• Pipe wrench for threaded units

4 46-638 Magnetic Liquid Level Indicators

 1.4 Side Mount Installation
Caution: This instrument is intended for use in Installation
Category II, Pollution Degree 2 locations.

NOTE: Top of gauge nameplates are available as an option.

The MLI nameplate can be used as bottom reference of

the external cage. Install the cage to the vessel with name-
plate at bottom. Isolation valves are recommended for
installation between vessel and external cage. Check to
ensure the external cage is vertical. All piping should be
straight and free of “low spots” or “pockets” so that the
lower liquid connection will drain toward the external
cage. Adjust piping as required.

It is recommended a drain valve be installed in the bottom

flange to allow cleaning and checking level. Close the
isolation valves until start up.

Initial installation of the Magnetic Level Indicator is sim-

ple. Unless otherwise specified, MLIs will be shipped from
the factory fully assembled. All flanges will be torqued to
ANSI specifications. Make sure all process connections
attached to the vessel which the gauge will be mounted to
are vertically level, and flanges, if any are level.

Carefully unpack the MLI and stand it up vertically.

NOTE: Longer units require support of the entire length of the cham-
ber while being lifted in place vertically. This will prevent bow-
ing of the chamber, that could result in glass breakage. Once
the gauge is mounted to the vessel and the liquid level rises
inside the vessel, the gauge will become operational

Isolation valves are recommended, but not required. If

isolation valves are used, care must be used when opening
the valves to prevent a surge of fluid or gases through the
chamber. A surge can cause the float to be propelled to the
far end of the chamber, and float damage could result.
Caution: If for any reason the MLI is pressurized higher than the
maximum pressure indicated on the name tag, the float
inside the chamber is subject to collapsing and causing
float failure.

NOTE: Float is shipped in chamber.

46-638 Magnetic Liquid Level Indicators 5

 1.5 Top Mount Installation

Caution: This instrument is intended for use in Installation

Category II, Pollution Degree 2 locations.

The top mount gauge can be installed as one complete

unit or disassembled to allow access from inside the tank.

Correct vertical installation is required to assure proper

float movement.

To disassemble you need only to unscrew the threaded cap

at the bottom mounting flange or connection.
Caution: Proper precautions should be taken to prevent the
bending of the guide rod.

1.6 Top/Bottom Connection Installation

Caution: This instrument is intended for use in Installation

Category II, Pollution Degree 2 locations.

Carefully unpack the MLI and stand the unit up vertically.

Note the float stop disc at the bottom flange. Note the
float stop bar (welded in place) at the top of the gauge.
This always indicates the top of gauge.

The float is shipped in the chamber.

Caution: Overall length should be ± 1⁄16". Smooth float travel must be
assured by no bending of the chamber pipe.

1.7 Start-up

Increase system pressure slowly while commissioning the

instrument. Thoroughly check for leaks, and verify that
the local indicator device accurately tracks the liquid level.
Verify external accessory devices (switches, transmitter, etc.)
are functional and properly calibrated.
Caution: Do not open the bottom isolation valve quickly. Allow the
level to rise until the MLI displays the correct level in the
vessel.

6 46-638 Magnetic Liquid Level Indicators

1.8 Special Accessory Installation
1.8.1 Insulation or Blanket Installation

Factory recommended high temperature insulation specifications:

Temperature Thickness Liner Jacket
0 to +250 °F (-18 to +121 °C) 1
⁄2"
Weather resistant silicone cloth
+251 to +500 °F (+122 to +260 °C) 1" Weather resistant silicone cloth
+501 to +1000 °F (+261 to +538 °C) 2" Weather resistant aluminized silicone cloth

• Thickness is 1⁄2" when the MLI has switches or a transmitter.

• Insulation used is 8 lb. density ceramic blanket
• All removable insulated blankets are fastened to the MLI by
velcro and straps. Quilting pins available as an option.
• All removable insulation blankets are sewn with fire retardant
teflon thread.
• High temperature guide for the level flow gauge side mount:
Consult factory for specific temperature guide lines.
Figure 1
Low Temperature
Insulated Magnetic
Level Indicator

Factory recommended cryogenic insulation specifications:

Temperature Thickness Liner Jacket
+32 to -100 °F (0 to -73 °C) 2" Outdoor .016 smooth aluminum Polyurethane with all
-101 to -320 °F (-74 to -196 °C) 4" jacket with vapor barrier service jacket vapor barrier

• Purpose: To maintain the required low temperature of the

service fluid to be measured.
• All insulation joints will be staggered.
• All insulation joints will be sealed with a non-breathing
moisture resistant mastic.
• All weather resisting jacketing seams will be sealed with a
weather resistant caulk.
• The weather resistant jacket will be sealed to the 2" or 4"
plexiglass frost extension, with weather resistant caulk.
• The face of the frost extension must always be exposed.
• Cryogenic units will be flipper style indicators.

46-638 Magnetic Liquid Level Indicators 7

 1.8.2 Steam Heat Tracing Installation
Steam Heat Tracing is available as a factory installed
option. Steam traced units are generally supplied with a
factory installed insulation blanket (also optional).
Two steam connections (typically 3⁄8" × 0.035" tubing)
protrude from the unit. See Figure 2. The following
installation procedure is suggested:
• Remove factory installed plastic caps from the tube ends.
• Inspect tube ends for dents and burrs. Tubing length may
be adjusted (cut), if required.
• Compressed air may be applied to either end to verify that
no foreign material exists in the tube tracing assembly.
• A suitable saturated steam source and drain should be con-
nected. Do not exceed applicable pressure ratings for the
particular tubing size. Standard compression fittings may
Figure 2 be used to make the connections, and either connection
may be used as inlet or outlet.
• Apply steam to the unit and check for leaks.
• Contact factory or local representative for assistance, if
required.

1.8.3 Electric Heat Tracing Installation

Electric Heat Tracing is available as a factory installed
option. Electric traced units are generally supplied with a
factory installed insulation blanket (also optional).

Electrical connections are supplied, based on specific

customer requirements. Operating voltage and power
consumption will vary for each particular configuration.
More specific information is supplied with each unit,
and is also available from the factory (unit serial number
is required).

The two most common configurations are units with a

fixed-point thermostatic switch or units with an adjustable
“bulb-type” thermostatic switch.

1.8.3.1 Units with a fixed-point thermostatic switch

Figure 3 With a fixed-point thermostatic switch (customer specified
temperature set point), a wiring harness, or optional
junction box with terminal strip will be available to
accommodate field wiring. See Figure 3 (typical).

NOTE: It is the responsibility of the customer to comply with applica-

ble installation codes and practices. Installation should be per-
formed by qualified personnel.

8 46-638 Magnetic Liquid Level Indicators

 1. Locate specific power specification and wiring diagram
supplied with unit.
2. Provide appropriate conduit and wiring to the unit.
3. Apply sufficient operating power.
4. Verify that unit will generate sufficient heat and maintain
proper temperature.
NOTE: Wiring diagrams are supplied with units manufactured with
this option.

1.8.3.2 Units with an adjustable “bulb-type” thermostatic

switch
With an adjustable “bulb-type” thermostatic switch, the
temperature may be preset at the factory, however field
personnel should verify this setting during installation. A
wiring harness, or optional junction box with terminal
strip will be available to accommodate field wiring.
NOTE: For supply connections, use wire with a minimum rating of
+167 °F (+75 °C) as required by process conditions. Use a
minimum of 14 AWG wire for power and ground field wires.

NOTE: Housing must be grounded via protective ground screw in the

base of the housing.

NOTE: It is the responsibility of the customer to comply with applica-

ble installation codes and practices. Class I, Division 1 loca-
tions may contain explosive gas mixtures. Appropriate
precautions must be taken. Installation should be performed
by qualified personnel.
1. Locate specific power specification and wiring diagram
supplied with unit.
2. Provide appropriate conduit and wiring to the unit.
3. Verify thermostat setting. Adjust, if necessary.
4. Apply sufficient operating power. Circuit breaker should
be a GFI (ground fault interrupter) type with maximum
30 mA ground leakage current trip setting. GFI should
be sized at 125% of rated load.
5. Verify that unit will generate sufficient heat and maintain
proper temperature.
NOTE: Wiring diagrams are supplied with units manufactured with
this option.

Caution: In hazardous areas, do not power the unit until the conduit
is sealed and the enclosure cover is screwed down securely.

46-638 Magnetic Liquid Level Indicators 9

 inches (mm) 1.9 Switch Installation
3.0 (76)
REF. 1.9.1 OES Cam Operated Switch
The Model OES snap switch is utilized to expand the con-
5.5 (139) 8.375 (212) trol capabilities of Orion’s extensive line of magnetic level
REF. REF. indicators. This cam-operated double pole double throw
.5 (12)
mechanism is clamp-mounted to the outside of the MLI.
REF.
(2) 3/4" NPT This mounting style allows easy addition or repositioning
conduit connections of switches without disruption of the process.

The OES switch(es) are pre-installed, calibrated, and

checked for proper orientation at the factory. Your unit
may be equipped with one or more switches for alarming
or control. To change the location of the switch in the
field, simply unscrew the clamp and slide the switch to a
new location. See Figure 4.
1.9.1.1 Mounting to an Atlas™ or Gemini™ MLI

Caution: If equipment is used in a manner not specified by the

manufacturer, protection provided by the equipment may
be impaired.

Remove the cover of the enclosure. Position the OES cam-

operated snap switch on the MLI body so that the center-
line of the switch enclosure is at the desired switch point
Figure 4 level. Ensure that the switch is oriented so that the arrow
on the switch mechanism is pointing toward the top of the
MLI. Install the clamps around the MLI and over the
mounting brackets on the top and bottom of the switch
ORION INSTRUMENTS housing. Tighten the clamps so that the switch is secured
to the MLI. Replace housing cover. If required, place the
INSTALL
THIS SIDE
UP
insulation between the MLI body and the switch before
tightening the clamps.

1.9.1.2 Mounting to an Aurora® MLI

The Aurora may be ordered with one or more OES clamp-
on switches. During assembly Orion can ensure proper
function of the switches. Special care must be taken when
adding OES switches to an Aurora after initial purchase.
For proper function, the switch must be located as close to
FLOAT BELOW SWITCH the internal float magnet as possible. This is achieved by
marking the location of the indicator on the Aurora body.
Figure 5 The indicator must be rotated on the chamber so that the
Wiring of OES switch can be positioned closest to the float. Loosen the
cam operated switch
indicator clamps, rotate the indicator 90 degrees around the
Contact closure is shown with the
magnetic float below the switch
chamber and retighten the clamps. Mount the OES switch
where the indicator was originally located. Move the float,
or move level, to verify proper operation of the switch.

10 46-638 Magnetic Liquid Level Indicators

 1.9.1.3 Wiring
The lower conduit opening is protected with a plastic
shipping plug. The upper opening is sealed with a steel
plug. If it is preferable to wire through the upper conduit
entry, the steel plug may be moved to the lower opening.

NOTE: For supply connections, use wire with a minimum rating of

+167˚ F (+75˚ C) as required by the process conditions. Use a
minimum of 14 AWG wire for power and ground field wires.

NOTE: Housing must be grounded via protective ground screw in

base of housing.

Caution: In hazardous areas, do not power the unit until the conduit
is sealed and the enclosure is screwed down securely.

The DPDT switch has two sets of contacts. See Figure 5

on page 10 and label on mechanism. To wire switch, strip
about 1⁄2" of insulation from end of wire. Using a flat head
screwdriver or pliers, push orange tab away from the wire
opening on the terminal block. DO NOT pry up on the
orange tab as damage to the terminal block may result.
Insert wire into opening and release tab. Check that the
wire is securely fastened within the terminal block. Repeat
for balance of connections.

1.9.2 ORS Electric Reed Switch

The Model ORS reed switch is available to augment the
control capabilities of Orion’s extensive line of magnetic
level indicators. Housed in an explosion proof stainless
steel enclosure, the ORS mounts to the outside of the
MLI via clamps. This mounting style allows addition or
repositioning of switches at any time, without disruption
of the process.

The ORS switch(es) are pre-installed, calibrated, and

checked for proper orientation at the factory. Your unit
may be equipped with one or more switches for alarming
or control. To change the location of the switch in the
field, simply unscrew the clamp and slide the switch to a
new location.

46-638 Magnetic Liquid Level Indicators 11

 1.9.2.1 Mounting to an Atlas or Gemini MLI

Caution: If equipment is used in a manner not specified by the

inches (mm) manufacturer, protection provided by the equipment may
be impaired.
8-32 Ground Screw
With mounting clamps loosened, position ORS reed
switch on the MLI body so that the centerline of the stain-
3.00 less steel tube which houses the switch is at the desired
(76.2)
0.84 3.00 switch point level. The switch should be oriented so that
(21.3) (76.2) the green ground screw is closest to the top of the MLI.
See Figure 6. Tighten the clamps so that the switch is
1/2" secured to the MLI. If required, place the insulation
MNPT
between the MLI body and the switch before tightening
1.00 the clamps.
(25.4)

Figure 6
1.9.2.2 Mounting to an Aurora MLI
Follow procedure for mounting to Atlas or Gemini, but
ensure that the switch is positioned on the circumference
of the Aurora body as close to the indicator as possible.

FLOAT ABOVE SWITCH 1.9.2.3 Wiring

1 (RED)
The leads protruding from the potted end of the switch
C (WHITE)
housing are color coded as follows:
2 (BLACK)
White = Common
FLOAT BELOW SWITCH
Black = Normally Closed
1 (RED) Red = Normally Open
C (WHITE)
NOTE: For supply connections, use wire with a minimum rating of
2 (BLACK) +167° F (+75° C) as required by the process conditions. Use a
minimum of 14 AWG wire for power and ground field wires.

Figure 7 NOTE: Housing must be grounded via protective ground screw on

Wiring of ORS upper mounting tab.
Reed Switch
Contact closure shown for
both conditions of the switch
relative to the magnetic float

12 46-638 Magnetic Liquid Level Indicators

 inches (mm)
1.10 Analog Transmitter Installation
1.10.1 OCT Reed Transmitter
3.8 (140) Label bracket
REF. 0.4 (10) REF. The OCT analog transmitter mounts directly to the side
of the Atlas or Gemini chamber, providing a continuous
3.5 (90) 4.5 (115) 4–20 mA output signal proportional to liquid level. Using
REF. REF.
simple and reliable reed switches surface mounted to a
3/4" NPT printed circuit board, the unit provides level accuracy of
conduit ±0.50" (13 mm).
connection
The OCT reed transmitter is shipped attached to the MLI
XXX = Span gauge and is precalibrated to the customer specified span.
active length
See Figure 8. Refer to Figure 9 for wire terminations for
the OCT.

Installation is simplified by utilizing gear clamps that can

4.0 (102) REF. be repositioned with a screw driver.
Inactive length
Caution: If the MLI is insulated, the analog transmitter probe must be
located outside of the insulation blanket.

NOTE: For supply connections, use wire with a minimum rating of

Figure 8 +167 °F (+75 °C) as required by process conditions. Use a
minimum of 14 AWG wire for power and ground field wires.

NOTE: Housing must be grounded via protective ground screw in the

base of the housing.
NOTE: It is the responsibility of the customer to comply with applicable
installation codes and practices. Class I, Division 1 locations
may contain explosive gas mixtures. Appropriate precautions
must be taken. Installation should be performed by qualified
Resistor personnel.
Chain

Reed Caution: In hazardous areas, do not power the unit until the conduit
Switch is sealed and the enclosure cover is screwed down securely.

1.11 Internal Electronic Transmitter Installation

The Gemini Model enables the customer to install several

red different types of either continuous measuring instruments
yellow
black (transmitters) or point level control devices (switches). The
electronic instrument is installed in the 2" or 3" secondary
black: common connection of reed contacts
chamber of the Gemini MLI. The factory should be con-
yellow: upper end of the resistor chain
sulted for these applications to review operating parameters
red: lower end of the resistor chain
and to ensure that the desired instrument is properly
Figure 9 applied.

As the electronic instrument is supplied separately from

the Gemini MLI, the instruction manual for the electronic
unit should be carefully reviewed prior to installation in
the chamber. The instruction manual will be shipped with
the instrument.

46-638 Magnetic Liquid Level Indicators 13

 1.12 Internal Eclipse Transmitter Installation

The Eclipse Guided Wave Radar Transmitter can be

mounted in either the Gemini or the Aurora MLIs. The
Aurora is designed to support operation of the Eclipse in
the same chamber as the float. Due to this, the coaxial
type probe must be used. With the dual chamber Gemini
design, either the twin rod, coaxial, or single rod types
may be used. Caution should be exercised in probe selec-
tion to take into account, media dielectric, viscosity, tem-
perature, pressure, transition zone distances and overfill
requirements. Each Eclipse will be supplied complete with
an instruction manual. A review of the manual is recom-
mended prior to installation of the Eclipse transmitter in
the Gemini or Aurora MLI.
Figure 10 NOTE: Flag or shuttle indicator can be designed for mounting at any
angle. Do not rotate indicator after gauge is manufactured,
due to inability to rotate baffle plate once welding has been
completed.

2.0 Reference Information

2.1 Description

Magnetic Level Indicators (MLIs) are suitable for installa-

tion on process applications that will not restrict float travel
in the piping column. It is a magnetic coupled, local level
indicator which is isolated from the process in a sealed
non-magnetic external cage. Bi-color flags provide visual
indication of level up to 100 feet. Field-adjustable level
switches and transmitters are available as options.

The Atlas is a magnetically coupled local level indicator

isolated from the process via a sealed non-magnetic exter-
nal chamber. A fluorescent orange shuttle or series of bi-
colored flags provide visual indication of liquid level from
distances of up to 100 feet. Available switches for point
alarms include electronic DPDT, reed and pneumatic
technologies. Transmitter technologies for continuous
4–20 mA outputs include reed and guided wave radar.

Atlas is suitable for installation on process applications

including corrosive services that do not impede the move-
ment of the float in the piping column.

Aurora and Gemini incorporate a combination of the

Atlas magnetic level gauge and Magnetrol’s Eclipse
Guided Wave Radar. This represents the industries first
totally redundant mag gauge/transmitter combination.

14 46-638 Magnetic Liquid Level Indicators

 Local indication, 4–20 mA output, HART and Fieldbus
protocols are available. Float damage will not result in loss
of the 4–20 mA signal

Aurora: The Eclipse Guided Wave Radar probe is mount-

ed directly inside of the Gemini chamber. a minimum
3" chamber is utilized to accommodate the Eclipse probe
and allow unobstructed float travel. Patent pending.

Gemini: The dual chamber approach also accomplishes

total redundancy but increases the ease of gauge or trans-
mitter isolation. The Atlas gauge provides local indication
while the Eclipse is mounted directly inside a connected
second chamber. The units perform independently of
each other.

2.2 Theory of Operation

2.2.1 Side Mount
A float equipped with a strong magnet assembly inside and
weighted to the specific gravity of the fluid to be measured,
moves up and down in a non-magnetic chamber, as the
fluid inside rises and falls with the level of the liquid in
the vessel.

Figure 11
Attached to the external wall of the non-magnetic chamber
is a non-porous glass tube. Inside this hermetically sealed
glass tube is a highly visible fluorescent orange indicator or
flags with a strong magnetic assembly inside. See Figures
11 and 12.

Stainless steel The indicator is always coupled to the float magnetically,

chamber wall to indicate the exact measurement of the fluid.
Flux ring
2.2.2 Top Mount
A top mounted float assembly consisting of a magnet
Liquid
Indicating assembly at the top, a guide rod in the middle, and a float
flags
level at the bottom. The float at the bottom is submerged in the
liquid inside the vessel. The entire guide rod assembly is
Float weighted to the specific gravity of the fluid to be measured.
magnets
Attached to the external wall of the non-magnetic chamber
Flux
ring Magnet is a non-porous glass tube. Inside this hermetically sealed
spacer glass tube is a highly visible fluorescent orange indicator or
flags with a strong magnetic assembly inside. See Figures
11 and 12.
Float
The indicator or flags are always coupled to the magnetic
Figure 12 assembly, to indicate the exact measurement of the fluid.

46-638 Magnetic Liquid Level Indicators 15

2.3 Troubleshooting
2.3.1 Side Mount
Problem Solution
Flags do not rotate with level change. Test flags with a magnet from bottom to top (magnet not
included). If flags test okay, check for float obstruction.
(See Section 2.5, Maintenance on page 16)
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 Make sure the MLI is level vertically.
slow or not at all.
The process fluid being measured may be too viscous and
heat tracing may be required to make the material more fluid.
Heat tracing can be purchased from the factory.

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.
If this happens, magnetic trap assemblies can be purchased
from the factory.

Visual inspection of the float may be required to see if the float

has collapsed.
Switch does not actuate with level change. Check micro switch for continuity. Replace if damaged. If
okay, remove switch from piping column and test switch mag-
net 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 tests okay, check
float travel.
Reed transmitter does not track level. Remove transmitter assembly from piping column and test
with re-alignment magnet. Run magnet from bottom to top of
reed chain. Check zero and span calibration. If no change in
output, replace.
Scale is at zero to the center of the bottom The scale assembly is mounted to the chamber using stainless
process connection, but the indicator is above steel gear clamps. It can be easily adjusted in the field using a
or below zero. screwdriver. Make sure the scale zero is in line with the center
of the process connection.

The float stop spring at each end of the chamber is there to

cushion as well as position the float assembly to the center of
the process connection. Make sure top or bottom float stop
springs are not bent or broken.
Shuttle indicator has uncoupled and In some “flashing” applications, the float may rise or fall quickly.
fallen to the bottom of the glass tube. Consult factory for suggestions to help avoid this.

To re-couple the indicator to the float, simply use a small mag-

net and run it along the length of the chamber to locate the
float. Mark the location of the float on the outside chamber.
Use the small magnet to couple with the indicator and pull the
indicator up to meet and couple with the float.

Make sure all stainless steel gear clamps are tight. The scale
channel must be tight against the chamber.

NOTE: Ensure unit installation is level.

16 46-638 Magnetic Liquid Level Indicators

 2.3.2 Top Mount
Problem Solution
The float assembly or visual indicator is Make sure the vessel opening or flange connection that the to
moving slowly or not at all. mount flange connects to is level.

The top mount guide rod assembly may be bent. Visual inspec-
tion is required.

The process fluid in the vessel may be too viscous, Heating the
vessel to make the process fluid more liquid may be required.

The specific gravity of the process fluid and the float may need
to be reverified.

Visual inspection of the float inside the process fluid may be

required to see if the float has collapsed.
My scale is at the center of the zero mark on The scale assembly is mounted to the chamber using stainless
the outside of the top mount chamber but steel gear clamps. It can be easily adjusted in the field using a
the indicator is above or below zero. screwdriver. Make sure the scale zero is in line with the zero
mark on the outside of the top mount chamber.

The float stop spring at the top of the chamber is there to cush-
ion the magnet assembly. Make sure the bottom float stop tube
is not bent or broken

The float stop tube is at the bottom inside the chamber. It is

there to stop the magnet assembly at the zero mark on the out-
side of the chamber

2.4 Spare Parts

Spare parts are available for Magnetrol/Orion MLIs and

certain switches and transmitters. Please consult the factory.
Have the unit model number and serial number available
for reference.

2.5 Maintenance

Periodic inspections are a necessary means to keep your

level control in good working order. This control is a safety
device to protect the valuable equipment it serves.

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 the
external cage be isolated from the process and flushed peri-
odically. For complete cleaning, after draining the unit,
remove the bottom flange and float, inspect cage and float
for buildup and clean if required.

Magnetic traps are available to prevent magnetic particu-

late travel from the vessel to the chamber.

46-638 Magnetic Liquid Level Indicators 17

2.6 Specifications
2.6.1 Magnetic Level Indicator

Design Atlas and Aurora – single chamber

Gemini – dual chamber
Materials of construction – MLI Metal alloys 316/316L or 304/304L stainless steel,
321 stainless steel, 347 stainless steel,
Titanium, Monel, Hastelloy B,
Hastelloy C-276, Inconel 625, Inconel 825,
Alloy 20, Electropolished 316 stainless steel,
904L stainless steel and other non-magnetic alloys
Plastics Fiberglass, PVC, CPVC, kynar, polypropylene
Materials of construction – Float Same as chamber materials, 316 SS or titanium standard
Construction options Conformance to ASME B31.1, ASME B31.3 or NACE MR0175
available
Certified material test reports (CMTR) Available upon request
Pressure class ratings ANSI 150#, 300#, 600#, 900#, 1500#, 2500#
DIN PN16, PN25/40, PN64, PN100, PN160, PN250, PN320
Process connection sizes ⁄2" to 8"
1

DN 20 to DN 150
Process connection types MNPT, FNPT, weldolet®, sockolet®, threaded couplings,
threaded nipples, buttweld nipples, plain-end nipples,
slip-on flanges, weldneck flanges, lap joint flanges,
tri-clamp fitting, Van Stone flanges
Measuring range 12 to 600 inch (30 to 1524 centimeters) standard
Consult factory for lengths over 600 inch (50 feet)
Temperature range -320 to +1000 °F (-196 to +538 °C)
Pressure range Full vacuum to 4500 psig (310 bar)
Specific gravity range As low as 0.35 S.G.U.
Indicators Magnetically actuated flag assembly in contrasting orange/black,
yellow/black, red/white colors, or high visibility shuttle follower
Flag assembly seal Inert gas filled and hermetically sealed with Insta-seal valve
Visual indication Easily visible from 75 to 100 feet (23 to 30 meters)
Scale options Etched stainless steel with either height, volume, or
percentage units
Switch options Model OES electric cam operated snap action
Model ORS electric reed type
Transmitter options Model 705 Eclipse Guided Wave Radar
Model 2xx Jupiter Magnetostrictive
Model OCT analog reed chain
High temperature options Electric or steam tracing with or without special high
temperature insulation
Low temperature options Cryogenic insulation with special polymeric frost extension

18 46-638 Magnetic Liquid Level Indicators

 2.6.2 Model OES Switch
• Electric snap action switch
• 10 amp DPDT
• ±0.75" (19 mm) float travel
• -58 to +392 °F (-50 to +200 °C)
• Cast aluminum enclosure, (2) 1⁄2" NPT conduit entries
See bulletin OES-100 for further information

2.6.3 Model ORS Switch

• Electric reed switch, hermetically sealed
• 1 amp SPDT
• Stainless steel enclosure with mounting tabs
• ±0.5" (13 mm) float travel
• -58 to +482 °F (-50 to +250 °C)
• Stainless steel enclosure with mounting tabs
See bulletin ORS-300 for further information

2.6.4 Model OCT Analog Transmitter

Power: 24 VDC
Maximum Range: Up to 20 feet standard
(Consult factory for longer lengths)
Accuracy: ±0.5" (13 mm)
Output: 4–20 mA
Temperature range: -40 to +500 °F (-40 to +260 °C)
See bulletin OCT-400 for further information

2.6.5 Model JM4 Jupiter ® Magnetostrictive Transmitter

Power: 16–36 VDC
Maximum Range: Up to 400" (999 cm)
Accuracy: ±0.01% full scale or ±0.05" (1.3 mm),
whichever is greater
Output: 4–20 mA (HART optional),
FOUNDATION fieldbus™
Temperature range: -40 to +176 °F (-40 to +80 °C)
See bulletin ORI-150 for further information

2.6.6 Model 706 Eclipse® Transmitter

See bulletin 57-106 for details

46-638 Magnetic Liquid Level Indicators 19

 ASSuREd quALITy & SERvICE COST LESS

Service Policy Return Material Procedure

Owners of Magnetrol/Orion Instruments controls may So that we may efficiently process any materials that are
request the return of a or any part of an instrument for returned, it is essential that a “Return Material
complete rebuilding or replacement. They will be rebuilt Authorization” (RMA) number be obtained from the
or replaced promptly. Instruments returned under our factory, prior to the material's return. This is available
service policy must be returned by prepaid transporta- through Magnetrol’s local representative or by contact-
tion. Magnetrol will repair or replace the control at no ing the factory. Please supply the following information:
cost to the purchaser (or owner) other than transporta- 1. Company Name
tion if: 2. Description of Material
1. Returned within the warranty period; and 3. Serial Number
2. The factory inspection finds the cause of the claim 4. Reason for Return
to be covered under the warranty. 5. Application
If the trouble is the result of conditions beyond our Any unit that was used in a process must be properly
control; or, is NOT covered by the warranty, there will cleaned in accordance with OSHA standards, before it is
be charges for labor and the parts required to rebuild or returned to the factory.
replace the equipment. A Material Safety Data Sheet (MSDS) must accompany
In some cases it may be expedient to ship replacement material that was used in any media.
parts; or, in extreme cases a complete new instrument, All shipments returned to the factory must be by pre-
to replace the original equipment before it is returned. paid transportation.
If this is desired, notify the factory of both the model
and serial numbers of the instrument to be replaced. In All replacements will be shipped F.O.B. factory.
such cases, credit for the materials returned will be
determined on the basis of the applicability of our war-
ranty.
No claims for misapplication, labor, direct or conse-
quential damage will be allowed.

705 Enterprise Street • Aurora, Illinois 60504-8149 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306
Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93
Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317

2105 Oak Villa Boulevard • Baton Rouge, Louisiana 70815 • 225-906-2343 • Fax 225-906-2344 • www.orioninstruments.com
BuLLETIN: 46-638.6
Copyright © 2016 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. EFFECTIvE: July 2016
SuPERSEdES: August 2010