Reliance EA100G-300SW, EA100G-150, EA100G-600SW, EA100G-300, EA100G-600 Installation, Operation & Maintenance Instructions Manual

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Installation, Operation, & Maintenance Instructions

R500.E253A 03/16/2016

Levalarm®Gold

™

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

www.clark-reliance.com ● sales

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STORAGE and HANDLING

The Reliance

Levalarm®Gold™ meets or exceeds all applicable specifications when shipped from the factory.

All units should be inspected upon receipt to ensure that no damage has been incurred during transit. If there is a

claim due to damage, it should be filed with the carrier immediately. Clark-Reliance

Boiler Trim products should be stored in a dry and sheltered area prior to installation. The equipment provided may consist of electrical items that are intended for either indoor or outdoor use. As a matter of good practice, dry storage will prevent the products from exposure to the outdoor elements. This will eliminate the potential for water damage. The temperature of the storage area should not exceed 150 Deg. F (84 Deg. C) or drop below 32 Deg. F (0 Deg. C).

OPERATION

A stainless steel float is attached to the end of a rod with a stainless steel encapsulated magnet. The magnet travels vertically in the pressure tube. The primary magnet on the float rod inside the pressure tube drives the secondary magnet, which in turn drives the tertiary magnet. The tertiary magnet is mounted to the switch arm and activates the switch. See Figure 1. The use of repelling magnetic fields creates a positive interlo cking switch that is both vibration resistant and compensates for installation misalignment. A buoyed float will cause the reaction of the magnets to hold the switch open or closed, depending on which terminals are used. As liquid falls in the chamber, the float drops and directs the magnets to the opposite position which activates the switch in the opposite direction.

MAGNET SWITCH LAYOUT

INSTALLATION

Caution: Before proceeding, follow any and all plant lock out - tag out procedures required. Verify that all power is turned

off to the Levalarm®s. If under pressure, the equipment should be isolated, or the boiler should be shut down before proceeding with the installation. Open drain valve to eliminate any trapped pressure. All inspection and installation steps should be performed by a qualified technician and should be executed in accordance with all applicable national and local codes

EA100G Series Levalarm Standard connections for the EA100G Series Levalarm connections. The Levalarm

dimensional information is available upon request.

should be installed with the reference arrow (switch point) at the level where the alarm or trip is specified. Shut off valves above and below the Levalarm However, these valves must be locked open when the boiler is in service. Also, a drain connection with a shut off valve

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

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FIGURE 1

s are 1” FNPT for threaded connections or 1” FSW for socket weld

should be installed for safe inspection or repair of the unit.

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should be installed to a point of safe discharge to facilitate blowdowns. Below in Figure 2 is a typical arrangement for the installation of the Levalarm After the piping has been installed to the body of the Levalarm

. Verify that installation conforms to local and national Codes and Standards.

, the switch should be connected by following this

procedure:

1. Remove the switch cover in order to access the connections on the switch assembly by loosening the three button

head cap screws on the outside of the gold housing, do not remove screws completely. Pull upward on gold housing to expose switch.

2. Use the ½” conduit opening in the switch housing assembly for connecting flexible or rigid conduit when wiring

the unit. CAUTION: Make sure that all wire leads to the switch do not interfere with the action of the switch before replacing the switch cover!

3. Example wiring diagrams for connecting the low water cutout, alarms (such as lights or and audible signal), etc,

are illustrated below:

4. After checking that all connections are tight and correct, replace the switch cover, as the unit is now ready to be put

in operation.

LEVALARM

LAYOUT

Boiler Steam Connection

Low Water Cutout Level

Boiler Water Connection

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

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FIGURE 2

NOTE: It is recommended that periodic inspection and routine maintenance be conducted to ensure that the Levalarm

continues to work properly. This can be conducted by following the procedure:

1. Isolate the Levalarm

2. Disconnect power from Levalarm

by closing the steam and water isolation valves.

3. Open the drain valve to drain the unit and relieve any internal pressure.

4. Disconnect the wiring and conduit.

5. Remove the switch housing to access all of the flange bolts.

6. Using a wrench or socket for the bolt and a wrench or socket for the nut, remove the nuts/bolts on the flanged

cover. Discard old gasket.

7. Removing the flange provides complete access to the float and switch assembly. To remove the flange assembly

pull straight up until float is clear from body.

8. Inspect the float to make sure that water has not leaked directly into the float.

9. Check to make sure the float and rod assembly freely moves up and down and does not stick or bind.

10. Reassemble the unit. Reinstall the Switch head assembly onto the body with a new gasket.

11. Lubricate the threads on the bolts with a high temperature nickel based lubricant. Torque the bolting in the proper

sequence (see below in Figure 3) to required ft-lbs in 1/3rd increments found in the below chart.

12. Re-install the conduit and the wiring.

13. Verify proper function.

MODEL 1

Torque 2

Torque Final Torque

EA100G-150 33 66 100 EA100G-300/ EA100G-300SW 60 120 180 EA100G-600/ EA100G-600SW 116 233 350

Bolt Torque Sequence

BLOW-DOWNS

Note that the frequency and method of blow-down may affect service life and performance of the Levalarm

The connection lines to the Levalarm

may be low. After performing the blow-down procedure, if the water level does not appear to return to normal promptly, the connecting piping may be partially restricted and need to be cleaned.

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

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Figure 3

can become restricted with sediment and indicate normal water levels when water

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1. Close both the steam and water valves between the boiler drum and the Levalarm

2. Open the drain valve fully on the bottom of the Levalarm

suggests the following blow-down procedure:

piping.

unit.

3. Crack open the steam valve and allow a gentle rush of steam to pass through the device. The steam should not pass through for longer than 20 seconds.

4. Close the steam valve.

5. Blow-down the water line.

6. Close the blow-down valve and simultaneously open the steam and water valves, slowly bringing the equipment back to a normal operating level.

7. Water should enter the Levalarm

quickly when the blow-down valve is closed. Th is will indicate that the lines are free

of sludge, sediment, or scale buildup.

NOTE:

1. Any trip or alarm circuits that are actuated by the equipment being blown-down should be bypassed to prevent false alarms during the blow-down process. A Clark-Reliance

Holding Switch model HS-0 or HS-1 can be used to by-pass the

Low Water Cutout to prevent a false trip during the blow-down procedure.

2. Blow-down should be conducted on a weekly basis, or as necessary, based on water quality.

SPECIFICATIONS

Agency Approvals

UL 353 FM 7710

Connection sizes: EA100G-150: 1” FNPT

EA100G-300/EA100G-300SW: 1” FNPT / 1” FSW EA100G-600/EA100G-600SW: 1” FNPT / 1” FSW

Pressure Rating: EA100G-150: 200 PSI @ 388° F

EA100G-300/EA100G-300SW: 570 PSI @ 483° F EA100G-600/EA100G-600SW: 1104 PSI @ 558° F

Float Switch Rating: UL listed and CSA approved SPDT

UL Code 35 5 A, 125, 250 or 480 Vac 1⁄2 A, 125 Vdc; 1⁄4 amp 250 Vdc Switch Max. Temperature: 400° F.

Environment: Indoor or outdoor

TROUBLESHOOTING THE EA100 SERIES LEVALARM

Caution: Before proceeding, follow any and all plant lock out - tag out procedures required. All installation steps should be

performed by a qualified technician and should be executed in accordance with all applicable national and local codes.

Symptom Probable Cause

1) Float is stuck in the “up” position” a) Contamination on Switch Magnet Action b) Water Trapped in Unit c) Sediment / Contamination in Chamber

Possible remedies:

1. Conduct a blow-down, to ensure there is no water trapped in the unit.

2. Inspect the internal portion of the Levalarm a. Isolate the Levalarm

and make sure there is no pressure in the unit.

Chamber

b. Remove the flange head assembly c. Examine inside the flange assembly to make sure there is no debris trapped inside the device.

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

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d. Examine the drain path to make sure water has a clear drain path. e. Inspect magnets on the action of the switch to make sure no debris have stopped the action.

3. Test the unit for proper functioning a. To test the switch assembly, set the unit in a vise and make sure that the switch housing is

vertical as if it were mounted on the boiler piping.

b. Attach an ohm meter to the common and normally open switch contact and manually move the

float up and down and verify the switch operates on both directions. The meter should indicate continuity only when the switch is operated in the closed position.

c. Then, move the ohm meter terminal from the normally open terminal to the normally closed

terminal and repeat the test. The meter should indicate an open circuit only when the switch is in the open position.

4. If the unit fails to test properly, contact Clark-Reliance

for further instructions to adjust the switch mechanism or to obtain authorization to return the unit for factory inspection. If the switch tests OK, return unit to service.

5. Reassemble the unit. Reinstall the Switch head assembly onto the body with a new gasket. Lubricate the

bolts with a Nickel based high temperature lubricant and torque to requirements in the Installation section.

6. Verify proper function.

Symptom Probable Cause

2) Float is stuck in the “down” position” a) Float encased in contamination b) Failed float c) Contaminants in Pressure Tube.

Possible remedies:

1. Inspect the internal portion of the Levalarm a. Isolate the Levalarm

and make sure there is no pressure in the unit.

Chamber

b. Remove the flange head assembly c. Remove, inspect the float assembly. d. If the float contains water or shows signs of obvious damage, such as collapse or a crack near the

spud where the float rod attaches, replace the float and use Loctite or equal on the threads of the float and float rod with a lock washer. Tighten the new float securely onto the float rod.

2. Test the unit for proper functioning a. To test the switch assembly, set the unit in a vise and make sure that the switch housing is

vertical as if it were mounted on the boiler piping.

b. Attach an ohm meter to the common and normally open switch contact and manually move the

float up and down and verify the switch operates on both directions. The meter should indicate continuity only when the switch is operated in the closed position.

c. Then, move the ohm meter terminal from the normally open terminal to the normally closed

terminal and repeat the test. The meter should indicate an open circuit only when the switch is in the open position.

3. If the unit fails to test properly, contact Clark-Reliance

for further instructions to adjust the switch

mechanism or to obtain authorization to return the unit for factory inspection.

4. Reassemble the unit. Reinstall the Switch head assembly onto the body with a new gasket and apply a

Teflon based sealant to both sides of the gasket. Lubricate the bolts with a Nickel based high temperature lubricant and torque to requirements in the Installation section.

16633 Foltz Parkway ● Strongsville, OH 44149 USA Telephone: +1 (440) 572-1500 ● Fax: +1 (440) 238-8828

www.clark-reliance.com ● sales

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Symptom Probable Cause

3) Float arm operates properly, but the switch

does not change state.

a) The REA1351 switch is out of adjustment b) The REA1351 switch has failed

1. Test the REA1351 Microswitch a. Isolate the Levalarm

and make sure there is no pressure in the unit.

b. Remove the flange head assembly c. Remove the Switch cover

2. Test the unit for proper functioning a. To test the switch assembly, set the head assembly in a vise and make sure that the switch

housing is vertical as if it were mounted on the boiler piping.