TANK FITTINGS & GAUGING

MODEL 92302 Liquid Level Indicator (Using Metal Boards)

INSTRUCTION MANUAL 92-017

FOREWORD
Before starting the installation, account for all parts listed on the packing list and a special bracket location drawing separately attached to this instruction. The procedures below are also applicable to 1/2 and 1/3 travel indicators. This instruction is not applicable to movable roof tanks and bolted tanks. Study the drawings carefully paying strict attention to the dimension and alignment requirements. This instruction refers only to parts made of steel and aluminum and using the standard float that fits on 13-1/4 guide wire centers. Refer to any special drawings or lists detailing variations from this instruction.

SHEAVE INSTALLATION
Screw vertical one (1) inch pipe into the cable entry. Mount 90 o sheave assemblies 18 with one (1) inch horizontal pipe sufficiently long to place the bottom opening of outboard sheave assembly 18 directly over the opening in top angle 1. Install outboard one (1) inch pipe allowing 1/4 inch inch to extend through the opening in top angle 1. Weld the pipe to the top angle. Change pipe lengths when necessary.

CABLE ENTRY
See drawing on page 3. A. Locate the cable entry 12 minimum from the inner tank wall and as far as possible from the tank inlet or other source of turbulence for float protection. If unavoidable, guide wires should be used as directed below and in the drawing. The float should be changed for one with guides. To aid installation and future service, install a JB3530-1 Inspection Frame and Cover behind the entry as shown in the drawing. B. Cut the hole in the tank roof for the tank entry and weld the coupling with its axis vertical to prevent the cable when installed from rubbing on the inside surface of the pipe. See back page if optional guide wires are used. See the installation drawing if the inspection frame is used.
FIGURE 1

CABLE INSTALLATION
A. Loosen sheave cover screws and allow the covers to hang from their captive screws. Thread cable over sheaves extending one end to the tank floor and the other end extending down in front of the indicator board. B. Fasten cable to float with clamp 8 with cable between clamp screws. Set clamp snug to float hanger to prevent the cable from coming out of the groove in the float hanger. C-1. For full travel boards: Remove the target from the bottom indicator board. Remove the target from the top flat head screw with the hardware. Thread the cable through this top hole from the inside of the target to the outside then add the flat washer, lockwasher and nut. Temporarily tighten the nut to clamp the cable. See installation drawing. Reinstall the target onto the indicator board and the board to the tank brackets. With the float at the tank bottom, measure the distance the center of the float is from the datum plane, then adjust the cable at the target to position the target to indicate the level the float center is from the datum plane. Tighten the nut to clamp the cable securely. Leave a few inches excess cable to allow for further adjustment when necessary.
(Continued on back page)

INDICATOR BOARD

A. See the special bracket location drawing. Weld brackets 7 (not 13) to the tank wall at dimensions given on the drawing with the centers of the brackets directly in line with the cable entry. The top surface of the brackets are to be horizontal. B. Mount the bottom board, slide target 10 onto it, then mount the remaining boards. Adjust brackets 7 as necessary for the boards to present a smooth vertical surface and prevent target hang-up. It is necessary that two 7/16 diameter holes for 3/8 bolts be drilled in the bottom board to fasten it to bottom bracket 7. C. Attach top angle 1 to top indicator board 6 and mount the board. It is necessary to drill two 7/16 diameter holes for 3/8 bolts in the board to fasten it to topmost bracket 7. D. Bolt intermediate support bracket 13 onto the board at the mid-position holes then weld the brackets to the tank wall (top of the brackets are horizontal). Boards 4 feet and shorter do not have mid-position holes and should not require intermediate support. 1

PARTS LIST FOR MODEL 92302 LIQUID LEVEL INDICATOR USING METAL BOARDS
ITEM DESCRIPTION Indicator Board Components Top Bracket (Full Travel) Top Bracket (1/2 Travel) Top Bracket (1/3 Travel) 1/3 Travel Includes: Cotter Pin 1/16 x 3/4 Washer 3/8 Shaft Sheave 2 3 4 5 6 7 8** 9 10 11* 12 (TH) 13 14 15 (TH) 16 18 Sheave Bushing Truss Hd Screw 1/4-20 x 3/4 Flat Washer 1/4 Split Lockwasher 1/4 Hex Nut 1/4-20 Indicator Board Bracket Cable Clamp Assembly Fixture Clamp Target (Full Travel) (1/2 Travel) (1/3 Travel) S-Hook (For Cast Iron Target) Chain (Specify Tank Height) Intermediate Support Cable (Specify Tank Height) Float MATERIAL Steel Aluminum Steel Steel Stain St Stain St Stain St Brass Teflon Aluminum Aluminum Steel Aluminum Aluminum Steel Aluminum Stain St. Steel Steel Steel Steel Steel Aluminum Steel Aluminum PART NO. 509-772 509-833 509-775 090864 228-10 241-61 802-611 691-2684 605-1 222-172 579-617 241-40 225-13 See Note 1 509-826 509-831 090142 209-10 JB3615-1 JC3617-1 JC3617-2 567-518 101-1 9399-18000 9399-18001

19 20 21 22 23* 25* 26* 27 43 44 45 46 47* 48 49 50 51 60 61 (TH) 62 63 64 65* 66

Stain St 117-2 Polypropylene 9399-11000 Aluminum JB3561-1 1", 90o Sheave Assembly - Side Cover Access Nod. Iron JB3561-2 Sheave assemblies Include Items 18 to 27. Also see Note 4 Aluminum 9399-13200 Sheave Housing Nod. Iron 9399-13320 Aluminum 9399-13220 Cover Nod. Iron 9399-13360 Shaft Stain St 9399-13250 Clamp Stain St 9399-13240 Sheave Assembly Delrin 9399-13410 Gasket Asbestos Fiber 9399-13230 Hex Hd Screw 3/8-16 x 1 Steel SP-7-B Guide Wire Spring Assembly Steel JB3486-11 Guide Wire Spring Assemblies Include Items 44 to 51 Cap 1-1/4 NPT Steel 229-34 Pipe Nipple 1-1/4 x 7 Steel 229-337 Retainer Steel 851421-011 Spring Steel 567-511 Guide Tube Assembly Steel 851419-011 Pipe Coupling 1-1/4 NPT Steel 229-35 Washer Steel 579-502 Steel 805-502 Tank Nipple Aluminum 805-666 Anchor Bar Assembly Steel JA3540-3 Guide Wire-Specify Tank Height Stain. St. 117-5 Nut 3/8-16 Steel 221-11 Sq. Hd. Screw 3/8-16 x 3/4 Steel 221-68 Cover Steel 517-527 Hydroil 530-626 Gasket Asbestos Fiber 530-941 Inspection Frame Steel JB3530-1

NOTES:
1. Reorder of individual boards must include marking, board length, serial & model numbers and any other helpful information. Parts with * are recommended spares. Quantity recommended on hand for 1 to 20 tanks denoted by number of *s. Double quantity for each 20 tanks in service. TH indicates Tank Height is required. Use a Buna-N base adhesive to cement gaskets to covers. Order parts through nearest GPE Controls office.

2.

3. 4.

FIGURE 2: INSTALLATION AND PARTS DRAWING

C-2. For 1/2 travel board: See Figure 3. Thread cable around pulley on target and through the hole in the top angle. Fasten with second cable clamp 8 after setting the target to indicate the level the float center is from the datum plane. Leave a few inches excess cable to allow for adjustment when necessary. C-3. For 1/3 travel board: See Figure 3. Thread cable around pulley on target through outer hole in top angle, around pulley on top angle, through inner hole in the top angle ending at hole above target sheave. Fasten with clamp 9 after positioning the target to indicate the level the float is from the datum plane. Leave a few inches excess cable to allow for future adjustment when necessary. D. Making certain the target hangs level to prevent binding.

B. Weld coupling and tank nipples at these positions with axis vertical to prevent the cable from rubbing on the pipes insides. Weld the inspection frame in place. C. Drop the plumb line through each tank nipple 51 to locate the position on the tank bottom the end holes of anchor bar 60 is to lie over. Position the bar holes over these marks and weld the bar at the ends and middle to the tank bottom. D. Cut the length of guide wire 61 in half. Enter the wires into the tank through the tank nipples and fasten the lower ends of the wire to the anchor bar as shown in Detail 1, Figure 2. E. Hold the wires up through the tank nipples making sure they are free of any loops or kinks and not fouled on any structural members. Slip the guide tubes with the springs and washers in place down over them until they come to rest on top of the tank nipples inside the couplings. F. Hold the wire taut and mark it at the point it emerges from the guide tube. Raise the tube and mark the wire 4-1/2 inches below the first. Using a pair of pliers and a foot (Drawing 1), compress the springs to the second mark while pulling the wire taut. Bend the wire sharply down over the guide tube (Drawing 2) and install the retainer (Drawing 3). Bend the wire up alongside and over the tops of the retainers (Drawing 3). Cut off excess wire and install the pipe nipples and the pipe caps (Drawing 4). G. If the spring height is not 4-1/2 inches (Drawing 2) the wires must be straightened and the spring height adjusted as given above. H-1. For floats with formed loops, turn float top parallel to the guide wires and insert one guide wire into the guide o eye then turn it 180 to insert the other guide wire. H-2. For floats with safety pins, remove the pins from the float eyes, install the float between the guide wires, then install the safety pins. I. Add gasket 65 and inspection frame cover 64 to close the tank opening.

FINAL INSTRUCTIONS
A. When sash chain 12 is furnished, attach to target at bottom screw. If not furnished, an additional amount of cable 15 is furnished. Attach to target as shown in the drawing on page 15. B. Pull target 10 down full travel to check float end for cable twist which will turn float against guide wires (when used) and target against the board. Reset cable fastening at the target or float to remove cable twist. C. Close covers of the sheave housings being careful not to damage the gaskets. Tighten screws securely. D. Making certain the target hangs level to prevent binding.

GUIDE WIRE AND INSTALLATION FRAME INSTALLATION

A. Burn two additional holes in the tank top at the cable entry with the centerline of the two holes common with the cable entry centerline and parallel to the plane of the indicator board. See Figure 2. Diameter of the holes for 1-1/4 inch pipe nipples supplied with the guide wire assemblies. At this time if the optional inspection frame is used, burn the 6 inch by 18-1/2 inch cutout.
All designs subject to change. Certified dimensions and specifications available upon request.

5911 Butterfield Road Hillside, Illinois 60162 Phone: (708) 236-6000 Fax: (708) 236-6006 w w w. l j t e c h n o l o g i e s . c o m