Manual for Magnetic Flip Plate Liquid Level Gauge (with Remote Transmission)

1、 Product Overview

Magnetic flap level gauge (with remote transmission) is an advanced liquid level measuring instrument that combines on-site display technology of magnetic flap with remote signal transmission function. It can accurately measure the liquid level height inside various containers, providing reliable data for liquid level monitoring and control in industrial production processes. The liquid level gauge has a sophisticated structure and stable performance, and can be widely used in many industries such as petroleum, chemical, power, metallurgy, food, medicine, etc. It can excellently complete liquid level measurement tasks in environments with normal or high pressure, normal or high temperature, ordinary or highly corrosive media .

2、 Working principle

2.1 Principle of Magnetic Flip Plate Indication

The main body of the liquid level gauge is composed of a measuring tube connected to the container. The measuring tube is equipped with a magnetic float. When the liquid level in the container changes, the float will move up and down due to buoyancy. On the outside of the measuring tube, there is an indicator composed of red and white magnetic flip plates. The magnetism of the float will pass through the measuring tube wall and interact with the magnetic flip plate. When the float rises, it will drive the lower magnetic flip plate to flip, and the white surface will turn into a red surface; When the float descends, the magnetic flap above flips from red to white. In this way, the actual height of the liquid level is intuitively displayed, and the junction of the two colors is the current liquid level position .

2.2 Remote transmission principle

The remote type magnetic flap level gauge is equipped with a remote transmitter, which contains a sensor composed of a reed switch and a precision resistor. When the float moves with the liquid level in the measuring tube, the magnet inside the float and the reed tube produce magnetic coupling. As the liquid level changes, the reed switches of different heights corresponding to the float are closed in sequence, which changes the number of resistors connected to the circuit, and then the sensor generates a resistance signal corresponding to the liquid level change. The resistance signal is processed by a conversion module and converted into a standard two-wire system 4～20mAOutput current signals for remote transmission to control systems, display instruments, or data acquisition devices to achieve remote monitoring and control of liquid levels.

3、 Product Structure

1. Measuring tubeMade of high-quality stainless steel or other corrosion-resistant materials, it forms a connector with the container to ensure that the internal liquid level is consistent with the container liquid level, providing stable movement space for the float.

2. floatBuilt in high-performance magnets with excellent corrosion resistance and sealing, capable of accurately following changes in liquid level, and driving the magnetic flip plate and remote transmitter through magnetic coupling .

3. Magnetic flap indicatorInstalled on the outside of the measuring tube, consisting of multiple red and white alternating magnetic flip plates, it clearly and intuitively displays the liquid level height and can work without external energy .

4. Remote transmitterContains sensors and conversion modules that convert liquid level changes into standard electrical signal outputs, which can be stacked according to requirements 485 Communication protocolHARTProtocol, etc., facilitate integration with different systems.

5. Install flangeUsed to firmly connect the liquid level gauge to the container, ensuring a secure installation, good sealing, and preventing medium leakage .

6. junction boxProtect internal circuit connections, facilitate signal wiring and debugging, have good protective performance, and can adapt to different working environments .

4、 Technical parameters

1. measurement range：300mm - 8000mm(Special measurement ranges can be customized according to customer needs).

2. accuracy class：±10mm.

3. work pressure: Conventional type ≤ 4.0MPaHigh voltage type can be customized, up to a maximum of32MPa.

4. Operating Temperature：-40℃ - +200℃(There may be differences depending on the medium and material, please refer to the selection manual for details).

5. medium density：≥0.45g/cm³.

6. Remote signal output: Two line system 4～20mA DCStandard current signal, load resistance≤500Ω.

7. transmission distanceIn general, ordinary shielded cables are used, and the transmission distance can reach1000mIf longer distance transmission is required, special cables or signal amplifiers can be used.

8. Explosion-proof rating: Explosion proof typeExdIIBT4TheExdIICT6; Intrinsic safety typeExiaIICT4Wait (choose the appropriate explosion-proof type according to the usage environment).

9. Protection level：IP65(Protect dust from entering and prevent water from entering rapidly from large waves or spray holes).

5、 Installation Guide

5.1 Pre-installation preparation

1. Carefully check whether the model and specifications of the liquid level gauge match the actual usage requirements, whether the product appearance is damaged, and whether all components are complete .

2. Prepare the necessary installation tools, such as wrenches, screwdrivers, level gauges, multimeters, etc .

3. Confirm that the installation site environment is safe and free of flammable and explosive materials, cut off the power and medium supply related to the container, and take necessary protective measures .

4. Clean the debris and oil stains at the container installation interface to ensure a smooth and clean connection surface .

5.2 Installation steps

1. Installation of the main body of the liquid level gauge：

◦Install the level gauge vertically on the side wall of the container using a suitable mounting bracket or directly through the mounting flange. Ensure that the centerline of the liquid level gauge is parallel to the vertical centerline of the container, with a deviation not exceeding ±1°To ensure that the float can move smoothly up and down.

◦Use a spirit level to check the levelness of the level gauge, and adjust the installation bracket or gasket to make the level gauge in a horizontal state .

◦According to the specified torque value, use bolts to firmly connect the level gauge to the container, while ensuring that the sealing gasket is installed correctly to prevent medium leakage .

1. Installation of remote transmitter：

◦Fix the sensor part of the remote transmitter on the outside of the main tube of the level gauge with a stainless steel clamp (iron clamps are strictly prohibited to avoid affecting the magnetic coupling effect), so that it is in the same magnetic coupling system as the level gauge .

◦During installation, it is essential to ensure that the transmitter 0The position mark and the zero position indication of the liquid level gauge are on the same horizontal line to ensure the accuracy of the remote transmission signal.

◦Check the fit between the transmitter and the main tube of the liquid level gauge to ensure there are no gaps or looseness .

1. wiring：

◦Open the junction box of the liquid level gauge and connect the power and signal wires correctly according to the wiring diagram. The power line provides stable working power for the remote transmitter, while the signal line is responsible for 4～20mAThe liquid level signal is transmitted to the receiving device.

◦When wiring, ensure that the wires are firmly connected without any loose connections or short circuits, and the wire ends need to be insulated. After the wiring is completed, seal the junction box tightly to prevent rainwater, dust, etc. from entering .

◦For places with explosion-proof requirements, wiring operations must be strictly carried out in accordance with explosion-proof standards to ensure that explosion-proof performance is not affected .

5.3 Installation precautions

1. The installation position of the liquid level gauge should be easy to observe, maintain and repair, avoiding installation in areas with high temperature, high pressure, strong magnetic field or large vibration .

2. During the installation process, it is strictly prohibited to violently collide or strike the measuring tube, float, magnetic flap and other components of the liquid level gauge to avoid damaging the internal structure .

3. If the medium inside the container contains impurities, particles, or fibers, a suitable filter should be installed at the liquid level inlet to prevent impurities from entering the measuring tube and affecting the normal movement and measurement accuracy of the float .

4. For application scenarios containing corrosive media, it is necessary to select suitable corrosion-resistant material level gauges based on the characteristics of the media, and ensure that the sealing materials of each connecting part also have good corrosion resistance during installation .

5. The connection between the remote transmitter and the display instrument or control system should use shielded cables and be laid separately through pipes to reduce the impact of electromagnetic interference on signal transmission The waterproof joint at the inlet of the junction box should be rotated downwards to prevent rainwater from flowing back .

6、 Usage method

6.1 First use

1. After the installation of the liquid level gauge is completed, first check whether the connections of each component are firm and whether the wiring is correct .

2. Slowly open the inlet valve of the container to gradually increase the liquid level. Observe the magnetic flap indicator to confirm if the liquid level display is normal and if the magnetic flap flips flexibly .

3. Use a multimeter or other tools to check the output of the remote transmitter 4～20mADoes the current signal correspond to the actual liquid level. The accuracy of the signal output can be checked by simulating the float position change with magnetic steel within the measurement range of the liquid level gauge.

4. If abnormal liquid level display or inaccurate remote signal is found, the liquid inlet should be stopped immediately, the cause of the fault should be investigated, and common problems and solutions can be referred to in this article “8、 Troubleshooting and Resolution”part.

6.2 daily use

1. The operator can observe the on-site situation of the liquid level in the container in real time through the magnetic flap indicator. The red part represents the area below the liquid level, the white part represents the area above the liquid level, and the boundary between the two colors is the current liquid level height .

2. If remote monitoring of liquid level is required, the remotely transmitted liquid level data can be viewed through the connected display instrument, control system or upper computer. These devices should be calibrated and maintained regularly to ensure accurate data display .

3. According to the production process requirements, upper and lower limit alarm values for liquid level can be set in the control system. When the liquid level reaches or exceeds the set alarm value, the system will automatically emit an audible and visual alarm signal to remind the operator to take corresponding measures in a timely manner .

4. During the use of the liquid level gauge, frequent opening and closing of the inlet and outlet valves of the container should be avoided to prevent sudden and significant fluctuations in the liquid level, which may cause damage to the gauge .

6.3 Operation precautions

1. It is strictly prohibited to disassemble, repair or adjust the liquid level gauge while it is in operation. If maintenance is required, the power and medium supply related to the level gauge must be cut off first, and ensure that the liquid level in the container has been emptied or lowered to a safe position .

2. Operators should regularly inspect the liquid level gauge to check for any damage or leakage on the appearance, clear display on the magnetic flip plate, and normal remote signal transmission If any abnormal situation is found, it should be promptly recorded and reported to the relevant departments .

3. For level gauges used in cold regions, measures should be taken to keep them warm in winter to prevent the medium inside the measuring tube from freezing and causing damage to the level gauge Insulation can be achieved through methods such as heat tracing cables and steam tracing .

4. The medium measured by the level gauge should meet its design requirements. It is strictly prohibited to measure media beyond the scope of the level gauge to avoid affecting measurement accuracy or damaging the level gauge .

7、 Maintenance and upkeep

7.1 regular maintenance

1. Visual inspectionAt least once a month, conduct a visual inspection to check for corrosion, deformation, damage, or looseness in the liquid level gauge housing, mounting bracket, connecting flange, and other parts. If there are any problems, repair or replace them in a timely manner .

2. Magnetic flap cleaningThe magnetic flap indicator should be cleaned quarterly. Gently wipe the surface of the magnetic flip board with a clean soft cloth to remove dust, oil stains, and other impurities, ensuring clear display and flexible flipping of the magnetic flip board During the cleaning process, be careful to avoid damaging the magnetic flip plate .

3. Remote transmitter calibrationCalibrate the remote transmitter every six months. Using a standard signal source, input a known liquid level signal and check the output of the remote transmitter 4～20mAIs the current signal accurate. If the deviation exceeds the allowable range, it can be adjusted through the zero and range adjustment potentiometers on the transmitter. Calibration operations must be carried out by professionals and calibration records must be kept.

4. Connection line inspectionRegularly check whether the power and signal lines of the liquid level gauge are securely connected, and whether there is any damage, aging, short circuit, or open circuit. Promptly replace or repair any problematic circuits discovered At the same time, check whether there is water accumulation, dust, etc. inside the junction box, and keep the junction box clean and dry .

7.2 special maintenance

1. Media replacement and maintenanceWhen the medium measured by the level gauge is replaced, if the corrosiveness, density, and other characteristics of the new medium differ significantly from the original medium, a comprehensive inspection and evaluation of the level gauge should be conducted based on the characteristics of the new medium. If necessary, replace the measuring tube, float, seal and other components of the level gauge to ensure that the level gauge can work properly .

2. Post fault maintenanceAfter repairing the malfunction of the liquid level gauge, the repaired parts and related components should be inspected and tested with emphasis. Apart from checking if there is a malfunctionCBottom elimination, it is necessary to confirm whether the performance indicators of the repaired liquid level gauge meet the requirements For example, after repairing the remote transmitter, it is necessary to recalibrate the signal output; After repairing the leakage of the measuring tube, a pressure test is required to ensure good sealing performance .

7.3 Long term shutdown maintenance

1. If the liquid level gauge needs to be stopped for a long time (more than three months), the medium in the container should be emptied first, and then the measuring tube, float and other components of the liquid level gauge should be rinsed with clean water or suitable cleaning agent to remove residual medium .

2. After flushing, remove the liquid level gauge from the container and store it in a dry, ventilated, and non corrosive gas environment. When storing, the level gauge should be protected from compression, collision, or severe vibration .

3. For remote transmitters, the internal battery (if any) should be removed to prevent battery leakage and equipment damage. At the same time, package and protect the transmitter to prevent dust, moisture, and other contaminants from entering .

4. Before putting the liquid level gauge back into use, it is necessary to conduct a comprehensive inspection, cleaning, calibration, and debugging according to the installation and usage requirements to ensure that all performance is normal .

8、 Troubleshooting and Resolution

9、 Safety precautions

1. The installation, operation, and maintenance personnel of the liquid level gauge must undergo professional training, be familiar with the working principle, structural characteristics, installation methods, operation procedures, and safety precautions of the liquid level gauge .

2. During the installation and maintenance of the liquid level gauge, it is necessary to strictly follow the relevant safety operating procedures and take necessary safety protection measures, such as wearing safety helmets, protective gloves, goggles, etc It is strictly prohibited to carry out live or pressurized operations on the liquid level gauge without cutting off the power and medium supply .

3. For level gauges used to measure flammable, explosive, toxic and harmful media, products that meet the corresponding explosion-proof level and protection requirements must be selected, and installation, wiring and other operations must be ensured to comply with explosion-proof standards Smoking and hot work are strictly prohibited around the liquid level gauge during use to prevent dangerous accidents such as fires and explosions .

4. If any abnormal situations are found during the use of the liquid level gauge, such as leakage, smoking, odor, abnormal sound, etc., the use should be immediately stopped and corresponding emergency measures should be taken, such as cutting off the power supply, evacuating personnel, reporting to relevant departments, etc Before the fault is resolved, it is strictly prohibited to forcefully continue using the liquid level gauge .

5. Regularly conduct safety inspections on the liquid level gauge, with a focus on checking the integrity, sealing, and grounding of the equipment to ensure the safe and reliable operation of the level gauge For level gauges that have exceeded their service life or pose serious safety hazards, they should be updated and replaced in a timely manner .

10、 Product Warranty

Our company provides magnetic flap level gauges (with remote transmission) produced by us1The quality assurance period is one year (calculated from the date of product delivery). During the warranty period, if the product malfunctions due to quality issues, our company will provide free repair or replacement services However, malfunctions caused by non product quality reasons such as improper use by users, self disassembly and modification, and force majeure are not covered by the warranty If users encounter any problems during use, they can contact our after-sales service department at any time, and we will wholeheartedly provide you with high-quality technical support and solutions .

Company Address:Instrument Factory in Niusida Toy Lane, Tianjia Industrial Park, Tianchang City, Anhui Province

Company Name：Anhui Chuchen Technology Co., Ltd

Release Date：2025year08moon16day