Dover NORRISEAL 1001A Series User Manual

P.O. Box 40525 · Houston, Texas USA 77240-0525
Tel: 713·466·3552 · Fax: 713·896·7386
www.norriseal.com
1001-0113O — ©2013, January 2013
I NTRODUCTION
C A U T I O N !
The instructions provided herein should
be completely reviewed and understood
prior to installing, operating or repairing
this equipment. All ATTENTION, CAU-
T
ION, DANGER and WARNING notes
must be strictly observed to prevent seri-
ous injury or equipment malfunction.
Scope
This manual includes installation,
operation and maintenance infor-
mation for 1.5 through 6.0-in.
Norriseal Series 1001, 1001A, and
1001XL Level Controllers.
Description
The Series 1001, 1001A, and 1001XL
Level Controllers are designed for
general purpose use in liquid level
and interface control applications
calling for either modulating
(Throttle) or on/off (Snap) pneumatic
service and can be direct or reverse
acting. Electric switch models are
also available.
Norriseal level controllers are
equipped standard with horizontal
or vertical PVC 1.88 x 12-in. displac-
ers. Displacer options include Acrylic
and 316L S.S. materials in various
lengths and diameters, including
hinged models, to accommodate a
wide range of control applications.
The 1001 has a smaller case than the
1001A or 1001XL and has a knurled
knob screw type closure. The 1001A
a
nd 1001XL have lever latch door
closing mechanisms and have a
sealed door. The 1001 and 1001A
have the case mounted left or right
of the body, while the 1001XL is cen-
ter-back mounted.
C A U T I O N !
Before disassembly or maintenance, all
pressures in this device must be relieved.
Failure to relieve pressures may result in
personal injury or device damage. The
resulting uncontrolled venting or spilling
of process fluids may cause personal
injury, loss of process control or environ-
mental contamination.
Controller Identification
Controller model numbers are typi-
cally 13 positions long (example:
2SM60-SRDA-BG). Refer to Table 1
— Model Designation on page 2 for
specific information on the controller
nomenclature.
A nameplate attached to the inside of
the case by the lower door hinge
includes the controller model and
serial numbers as well as other infor-
mation pertinent to the controller
assembly, such as supply and out-
put pressures, displacer material and
rating, body size and material, ANSI
class, and pressure and temperature
limits.
Always use only Norriseal replace-
ment parts when servicing level con-
trollers. Please refer to the serial and
model numbers when ordering
replacement parts.
Page 1 of 12
O PERATING AND M AINTENANCE M ANUAL
Series 10 01, 10 01A, 1001XL Level Control
CONTENTS
P
AGE
I NTRODUCTION 1
Scope 1
Description 1
C
ontroller Identification
1
P
RINCIPLE OF O PERATION 3
P
ILOT O PERATION 4
1.0 L
EVEL C ONTROLLER
I NSTALLATION AND
S TART - UP 5
1.0 L E
VEL
A D
JUSTMENT
6
1.2 L IQUID L EVEL I NTERFACE 6
2.0 L
EVEL C ONTROLLER
M AINTENANCE 7
2.1 L EVEL C ONTROLLER
P REVENTIVE M AINTENANCE 7
2.2 L EVEL C ONTROLLER D ISASSEMBLY 7
2.3 L EVEL C ONTROLLER R EASSEMBLY 7
2.4 P ILOT R EMOVAL /R EPLACEMENT 8
2.5 L EVEL C ONTROLLER D ISASSEMBLY
C ASE M OUNTING C ONVERSION 9
2.6 L EVEL C ONTROLLER D ISASSEMBLY
P ILOT A CTION C ONVERSION 9
2.7 L EVEL C ONTROLLER
B ODY D ISASSEMBLY 9
2.8 L EVEL C ONTROLLER
B ODY R EASSEMBLY 9
3.0 R
EPAIR K ITS 10
T
ABLES
Table 1 — Model Designation 2
Table 2 — Wiring Diagrams 10
Tabla 3 — Trouble Diagnosis 11
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Dover NORRISEAL 1001A Series Specifications

General

Series	1001A
Category	Control Systems
Manufacturer	Dover
Type	Level Controller
Specific Gravity	0.5

Summary

Principle of Operation for Level Controllers

Norriseal Force Balance Principle Explained

Explains how the Series 1001, 1001A, 1001XL controllers use force balance for liquid level control.

Level Controller Installation and Start-Up

Safety Precautions for Electric Pilot Installations

Highlights safety requirements for electric switch options, including conduit seals and explosion hazards.

Conduit Seal Installation for Moisture Prevention

Instructions on installing conduit seals with drain loops to prevent condensate entry and protect equipment.

Wiring and Conduit Compliance Requirements

Level Adjustment Procedures

Centering the Displacer Arm

Adjusting the Level Setpoint

How to lower or raise the level by turning the adjusting knob clockwise or counter-clockwise.

Adjusting Proportional Band and Sensitivity

Procedure to adjust proportional band and sensitivity by manipulating the fulcrum on the flapper bar.

Liquid Level Interface Adjustment

Tuning for Liquid Level Interface

Level Controller Maintenance Procedures

Safety Precautions Before Maintenance

Critical safety steps before any repair: isolate from system, release pressure, shut off lines, and disconnect power.

Isolating the Controller from the Process

First step in maintenance: isolating the controller to ensure safety and prevent unintended operation.

Shutting Off Supply and Output Lines

Procedure to shut off and vent supply and output air lines to the controller before proceeding with maintenance.

Releasing Process Pressure

Ensuring all pressure is released from the controller body before any disassembly or repair.

Preventive Maintenance for Level Controllers

Level Controller Disassembly Procedures

Relaxing Balance Spring Tension

Level Controller Reassembly Procedures

Mounting the Controller Case to the Body

Level Controller Reassembly Details

Positioning the Level Adjusting Bar

Pilot Removal and Replacement

Pilot Removal/Replacement Safety

Critical safety steps before pilot maintenance: isolate, release pressure, shut off lines, disconnect power.

Removing Pneumatic Pilots

Instructions for removing pneumatic pilots from 1001 and 1001A/1001XL controllers.

Pilot Rebuild or Replacement Options

Removing Electric Pilots (Explosion Proof)

Steps for disconnecting power, wires, and removing the basic switch for explosion-proof electric pilots.

Electric Pilot Switch Replacement

Replacing Hermetically Sealed Electric Pilots

Procedure for replacing hermetically sealed switches, including removing and reinstalling the adapter and switch.

Level Controller Body Disassembly

Level Controller Body Reassembly

Trouble Diagnosis and Corrective Actions

Troubleshooting Output Pressure Gauge Readings

Diagnoses issues with output pressure gauge indicating incorrect pressure based on fluid level.

Troubleshooting Controller Repeatability

Addresses problems with controller failing to repeat at the same fluid level, including dump/shut-off failures.

Troubleshooting Continuous Air Bleed

Diagnoses continuous air bleeding from a pneumatic pilot, often due to foreign matter under the ball.

Troubleshooting Interface Control Problems