Emerson YARWAY User Manual

YARWAY COLOR-PORT® WATER LEVEL GAUGES

Bi-color, direct reading, ported style water level gauge for low, medium and high pressure boilers

FEATURES

• Combination of design and durable materials
assures long service life.

• Individual port assemblies can be replaced in
minutes with the gauge in place.

• Spring loading maintains proper pressure on
glasses and gaskets at all times.

• Contrasting red and green readings show
water level through high visibility illuminator
display view slots.

• Choice of direct or mirror viewing systems.

• Choice of low, medium or high pressure
designs for use with stuffing box gaugecocks
or Welbloc L200V valves.

• Glasses accurately molded and tempered to
high specifications.

•

Glass, mica and gasket assembly is registered
precisely in the body’s gasket groove.

• High quality mica protects the inner surface
of each glass from the erosive action of
steam, water and alkalis.

• Specially-molded flexible graphite gasket
between mica and gauge body ensures a tight
seal.

• PED 97/23/EC conformance available.

GENERAL APPLICATION

TECHNICAL DATA

Color-Port gauges provide continuous
indication of boiler water levels as required by
the ASME Boiler and Pressure Code PG-60.

Sizes: ½” to ¾” (15 to 19 mm)
Max. pressure
Low pressure design: 850 psi (59 bar)
Medium pressure design: 1800 psi (124 bar)
High pressure design: 3000 psi (207 bar)
Number of ports: 5 to 26

3

9

/

Visibility: 12

16

" to 72

/

16

”

(310 to 1843 mm)

Emerson.com/FinalControl VCTDS-00413-EN 20/06

© 2017 Emerson. All Rights Reserved.

YARWAY COLOR-PORT® WATER LEVEL GAUGES

Individual circular glasses; inner

faces protected by mica.

Each cover held solidly against body by

four 12-point capscrews. Each cover

and its glass may be tightened or

removed without disturbing opposite

set. Spring cones provide proper

Glasses

Cover bolting

sealing force.

Ports

Large diameter port openings
for increased visibility

PG-60.1 WATER LEVEL INDICATORS

Color-Port gauges provide continuous indication of boiler water levels as required by the
ASME* Boiler and Pressure Code. Under PG-60, the Code states:

PG-60.1: all boilers having a fixed water level (steam and water interface) shall have at least one

gauge glass (a transparent device that permits visual determination of the water level).

PG-60.1.1: boilers having a maximum allowable working pressure exceeding 400 psi (2800 kPa)
shall have two gauge glasses. Instead of one of the two required gauge glasses, two independent
remote water level indicators (two discrete systems that continuously measure, transmit, and
display water level) may be provided. Boilers not having a fixed water level, such as forced-flow
steam generators and high-temperature water boilers of the forced circulation type, are not
required to have a gauge glass. Electrode type electric boilers are required to have only one gauge
glass, regardless of MAWP.

PG-60.1.1.1: when the water level in at least one gauge glass is not readily visible to the operator
in the area where control actions are initiated, either a fiber optic cable (with no electrical
modification of the optical signal) or mirrors shall be provided to transfer the optical image of
the water level to the control area. Alternatively, any combination of two of the following shall
be provided: (a) an independent remote water level indicator; (b) an independent continuous
transmission and display of an image of the water level in a gauge glass.

* The American Society of Mechanical Engineers, Boiler and Pressure Vessel Committee, establishes rules of

safety governing the design, fabrication and inspection of boilers and unfired pressure vessels.

2

YARWAY COLOR-PORT® WATER LEVEL GAUGES

1

2

3

4

5

6

7

Water (or Steam) space

Vents

Sealing surface

8

4

4

5

6

11

9

9

10

8

3

7

11

10

A complete Color-Port system includes the gauge, a water column or tie bar, two gauge valves
and an illuminator/display.

Illuminators

Illuminators are designed to be mounted readily to the color-port gauge chamber and comprise
three main components: level display, illuminator and power supply. An LED lighting source is
standard.

All illuminators are complete with a color screen containing two strips of glass - one red and one
green. Due to the difference in the index of refraction of light through water and steam, only the
corresponding color is seen: green for water, red for steam.

Item No. Part Name

2

1 Gauge Body
2 Cover
3 Glass*
4 Spring Cone(s)
5 Washer
6 Cushion Gasket*
7 Clip Ring*
8 Retaining Spring
9 Mica*
10 Cap Screws
11 Sealing Gasket*

*Furnished in kit - P/N 7Y584-000
Groove clean up tool - (stainless wire brush) P/N 301160

Illuminator

Color port gauge

Power supply

Level display

SHOWING STEAM PRESENT

Illuminator (ILCP)

SHOWING WATER PRESENT

Gauge

LED PORTED GAUGE ILLUMINATOR AND

Light beam (steam indication)

Level display (ILCPd)

Light beam (water indication)

LEVEL DISPLAY

View
slot

View
slot

Illuminator (ILCP) Gauge

Level display (ILCPd)

3

YARWAY COLOR-PORT® WATER LEVEL GAUGES

TYPICAL VIEWING SYSTEMS

Illuminator

Level display

Features and benefits

• Meets ASME Boiler Code requirements for
direct gauge viewing.

• Up to 100,000 hours service.

• Designed to be assembled and disassembled
from the gauge easily.

• Power supply housed in an aluminum
explosion-proof housing with ¾" NPTF
electrical connection.

• Input voltage 115 or 230 VAC at 50-60 Hz.

• Power consumption up to 400 mA max at
115 / 230 V AC.

• Power supply can be mounted integrally
or remote mounted up to 200 feet from
illuminator. Consult factory for longer
distance requirements.

Display hoodLevel displayIlluminator

Level displayIlluminator

Hooded mirror

4

YARWAY COLOR-PORT® WATER LEVEL GAUGES

COLOR-PORT GAUGE COLUMN CHARTS

4511N

1800 psi (124 bar) 850 psi (59 bar)3000 psi (207 bar)

4511N w/spacer

4511N w/780 gaugecocks

4511N w/spacer and 780

gaugecocks

4511N w/780 gaugecocks

assembled to column

4511N w/spacer and 780

gaugecocks assembled to column

Dual 4511N w/780 gaugecocks

assembled to column

Dual 4511N w/spacer and 780

gaugecocks assembled to column

4595F 4595F w/Welbloc L200V

4595F w/Welbloc L200V assembled

tocolumn

4595FG

Dual 4595F w/Welbloc L200V assembled

to column

4595F w/Welbloc L200V and

circulating tie bar

5

YARWAY COLOR-PORT® WATER LEVEL GAUGES

STANDARD INSTALLATION ARRANGEMENTS

Wide range of assemblies

Various assemblies and visibilities are available
with low, medium or high pressure gauges by
using single or multiple gauges and various
columns.

How to order Color-Port gauges

For proper Color-Port gauge assembly,
pressure, visibility and gauge connections
consult selection and visibility charts.

When ordering a separate replacement gauge,
provide the serial number of the existing gauge.

Vision Vision

'A'

'B'

C

L

Visibility

'A'

'B'

C

L

Other gauge glass availability

Medium and high pressure flat glass gauges
as well as low pressure (250 psi to 650 psi)
armored transparent and reflex gauges are
available.

'A'

Visibility

Vision

C

L

'B'

Visibility

'A'

'B'

Vision

C

L

Visibility

4511N/780 up to 850 psig 4511N/780 with spacer up to 1800

psig

4595F/Welbloc L200V up to

3000 psig

495FG up to 3000 psig

VISIBILITY CHART, inches (mm)

12.188 15.063 17.938 20.813 23.688 26.563 29.438 32.313 35.188 38.063 40.938
Visibility
No. of ports 5 6 7 8 9 10 11 12 13 14 15
4511N with 780 gaugecocks - up to 850 psi (59 bar)

Dimension 'A' 24.75 27.625 30.5 33.375 36.25 39.125 42 44.875 47.75 50.625 53.5
Minimum (629) (702) (775) (848) (921) (994) (1067) (1140) (1213) (1286) (1359)
Dimension 'B' 12.375 13.813 15.25 16.688 18.125 19.563 21 22.438 23.875 25.313 26.75
Minimum (314) (351) (387) (424) (460) (497) (533) (570) (606) (643) (679)

4511N with 780 gaugecocks and spacer - up to 1800 psi (124 bar)

Dimension 'A' 25.125 28 30.875 33.75 36.625 39.5 42.375 45.25 48.125 51 53.875
Minimum (638) (711) (784) (857) (930) (1003) (1076) (1149) (1222) (1295) (1368)
Dimension 'B' 12.563 14 15.438 16.875 18.313 19.75 21.188 22.625 24.063 25.5 26.938
Minimum (319) (356) (392) (429) (465) (502) (538) (575) (611) (648) (684)

4595F with Welbloc L200V valves - up to 3000 psi (207 bar)

Dimension 'A' 20.25 23.125 26 28.875 31.75 34.625 37.5 40.375 43.25 46.125 49
Minimum (514) (587) (660) (733) (806) (879) (953) (1026) (1099) (1172) (1245)
Dimension 'B' 7.625 9.063 10.5 11.938 13.375 14.813 16.25 17.688 19.125 20.563 22
Minimum (194) (230) (267) (303) (340) (376) (413) (449) (486) (522) (559)

4595FG with Welbloc L200V valves - up to 3000 psi (207 bar)

Dimension 'A' 17.5 20.375 23.25 26.125 29 31.875 34.75 37.625 40.5 43.375 46.25
Minimum (445) (518) (591) (664) (737) (810) (883) (956) (1029) (1102) (1175)
Dimension 'B' 7.625 9.063 10.5 11.938 13.375 14.813 16.25 17.688 19.125 20.563 22
Minimum (194) (230) (267) (303) (340) (376) (413) (449) (486) (522) (559)

(310) (383) (456) (529) (602) (675) (748) (821) (894) (967) (1040)

6

YARWAY COLOR-PORT® WATER LEVEL GAUGES

VISIBILITY CHART, inches (mm) (continued)

43.813 46.688 49.563 52.438 55.313 58.188 61.063 63.938 66.813 69.688 72.563
Visibility
No. of ports 16 17 18 19 20 21 22 23 24 25 26
4511N with 780 gaugecocks - up to 850 psi (59 bar)

Dimension 'A' 56.375 59.25 62.125 65 67.875 70.75 73.625 76.5 79.375 82.25 85.125
Minimum (1432) (1505) (1578) (1651) (1724) (1797) (1870) (1943) (2016) (2089) (2162)
Dimension 'B' 28.188 29.625 31.063 32.5 33.938 35.375 36.813 38.25 39.688 41.125 42.563
Minimum (716) (752) (789) (826) (862) (899) (935) (972) (1008) (1045) (1081)

4511N with 780 gaugecocks and spacer - up to 1800 psi (124 bar)

Dimension 'A' 56.75 59.625 62.5 65.375 68.25 71.125 74 76.875 79.75 82.625 85.5
Minimum (1441) (1514) (1588) (1661) (1734) (1807) (1880) (1953) (2026) (2099) (2172)
Dimension 'B' 28.375 29.813 31.25 32.688 34.125 35.563 37 38.438 39.875 41.313 42.75
Minimum (721) (757) (794) (830) (867) (903) (940) (976) (1013) (1049) (1086)

4595F with Welbloc L200V valves - up to 3000 psi (207 bar)

Dimension 'A' 51.875 54.75 57.625 60.5 63.375 66.25 69.125 72 74.875 77.75 80.625
Minimum (1318) (1391) (1464) (1537) (1610) (1683) (1756) (1829) (1902) (1975) (2048)
Dimension 'B' 23.438 24.875 26.313 27.75 29.188 30.625 32.063 33.5 34.938 36.375 37.813
Minimum (595) (632) (668) (705) (741) (778) (814) (851) (887) (924) (960)

4595FG with Welbloc L200V valves - up to 3000 psi (207 bar)

Dimension 'A' 49.125 52 54.875 57.75 60.625 63.5 66.375 69.25 72.125 75 77.875
Minimum (1248) (1321) (1394) (1467) (1540) (1613) (1686) (1759) (1832) (1905) (1978)
Dimension 'B' 23.438 24.875 26.313 27.75 29.188 30.625 32.063 33.5 34.938 36.375 37.813
Minimum (595) (632) (668) (705) (741) (778) (814) (851) (887) (924) (960)

(1113) (1186) (1259) (1332) (1405) (1478) (1551) (1624) (1697) (1770) (1843)

GAUGE ACCESSORIES

Gauge valves

780 gaugecocks are designed to be used with stuffing box type (nipple end) low and medium
pressure gauges (up to 1800 psi, 124 barg) to isolate the gauges from the pressure vessel when it
becomes necessary to drain and service them. These models feature:

• Outside screw and yoke.

• A vertical rising lower and horizontal leaky upper ball check shut-off.

• An offset pattern that allows the inside of the gauge glass to be cleaned easily with a minimum
of disassembly.

• Solid shank vessel connection (NPT, socketwelding or flanged ends).

• Threaded renewable seat and backseating stem.

Welbloc L200V
(upto 3000psig, 207barg).

type gauge valves are designed to be used with flanged end high pressure gauges

Welbloc L200V gauge valves feature a Stellite disc and integral Stellite

seat. Internals are completely accessible with the valve connected in the line.

Chain and line pulls are available for 780 and Welbloc L200V gauge valves.

Drain connections

780 stuffing box gaugecocks: ½” and ¾” NPTF and socketwelding available; located on lower
gaugecock.

Welbloc L200V gauge valves: ¾” socketweld connection located at bottom on lower valve block.

Water columns: ¾” socketweld connection located at bottom of column.
Tie bar: ¾” socketweld connection located at bottom of tie bar assembly.

780 upper stuffing box gaugecock (side view)

Vent connection

Handwheel

(standard)

Vessel
connection

Gauge connection

Upper Welbloc L200V gauge valve

(Left hand plan view shown)

Alternate boiler connections

Chainwheel

To gauge

(standard)

Determining gauge valve 'hand': when facing chain
wheels, valve is left hand when gauge is on your left;
valve is right hand when gauge is on your right.

7

YARWAY COLOR-PORT® WATER LEVEL GAUGES

GAUGE ACCESSORIES

Ball check shut off

Series Hy-P ball checks are designed for high pressure applications (up to 3000 psig, 207 barg) to
limit the flow of process fluid due to sudden downstream pressure loss such as glass breakage.
The benefit of the ball check is to safeguard personnel and property from the sudden escape
of high pressure steam or water. These models are supplied in pairs (upper and lower) with a
vertical rising ball for the lower mount application and a horizontal ball with leaky seat for upper
mounting to meet ASME Boiler and Pressure Vessel Code Section I applications.

Welbloc L200V

Color-Port Gauge

Gauge

Series HY-P upper ball check

Gauge

Hy-P Ball CheckWater Column

Series HY-P lower ball check

8

YARWAY COLOR-PORT® WATER LEVEL GAUGES

Water column

As an option, gauge glasses can be supplied with any of our electronic remote level indicator
systems, which consist of a water column with low voltage conductivity probes, a detection and
verification unit and a remote display (optional with some systems).These systems can be installed
for pressures up to 3000 psig (207barg) and temperatures up to 1200°F (650°C).

Customers can select the number and spacing of the probes, which are mounted horizontally in
the column at the desired distance from the normal water level or lower tap either to indicate
level or energize alarms and/or trips for high and low water. A low voltage signal is supplied and
sensed by the detection and verification unit and is used to activate the display device(s) and/or
relays to perform the required functions. For more detailed information, please see the brochures
for the following models:

1 probe: Model 1001
2 probes: Model 1002
3-4 probes: Model 1004
5+ probes: Model 2000
Model 3000

Water column: for working pressure up to 3000 psi (207 bar). Can be provided with special boiler
centers and special connections for level control probes.

Circulating tie bar: for working pressure up to 3000 psi (207 bar). This compact design reduces
installation space, provides greater rigidity and assures minimum temperature differential by
allowing more direct flow between drum and gauge. 27" (686 mm) standard gauge and boiler
connections.

Circulating tie bar

Boiler connection

1½” SW (38 mm)

Vessel

centers

¾” SW (19 mm)

Column with optional level probe control system

1-½” stub vessel

connections

NWL

(12)

(10)

(8)

(6)

(4)

(2)

(11)

(9)

Vessel

(7)

centers

(5)

(3)

(1)

¾” stub drain
connection

9

YARWAY COLOR-PORT® WATER LEVEL GAUGES

10

YARWAY COLOR-PORT® WATER LEVEL GAUGES

11

© 2015, 2020 Emerson Electric Co. All rights reserved 05/20. Yarway is a mark owned by one of the companies in the Emerson Automation Solutions business unit of
Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.

Emerson Electric Co. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Emerson Electric Co. product remains solely with the purchaser.

Emerson.com/FinalControl

12