OPERATING AND MAINTENANCE MANUAL

Series EVS Liquid Level Control

INTRODUCTION brochure for specific information on

CONTENTS the controller nomenclature.
PAGE CAUTION!
A nameplate attached to the inside
INTRODUCTION 1 The instructions provided herein should of the case includes the controller
Scope 1 be completely reviewed and understood model and serial number. Also
Description 1 prior to installing, operating, or repairing included is information pertinent to
Controller Identification 1 this equipment. All CAUTION and the controller assembly, i.e., supply
Principle of Operation 2 WARNING notes (displayed in boxes)
and output pressures, displacer mate-
must be strictly observed to prevent seri-
Pilot Operation 2 ous injury or equipment malfunction.
rial and rating, body size and mate-
rial, ANSI class and pressure, and
1.0 LEVEL CONTROLLER temperature limits.
INSTALLATION AND
START-UP 3 Scope
CAUTION!
1.1 LEVEL ADJUSTMENT 4 This instruction manual includes
installation, operation and mainte- Before disassembly or maintenance, all
1.2 LIQUID LEVEL INTERFACE 4 nance information for Norriseal EVS pressures in this device must be relieved.
Liquid Level Controllers. Failure to relieve pressures may result in
2.0 LEVEL CONTROLLER personal injury or device damage. The
MAINTENANCE 4 This product is covered by U. S. resulting uncontrolled venting or spilling
2.1 LEVEL CONTROLLER Patents 4,700,738 and 6,497,246 B1. of process fluids may cause personal
PREVENTIVE MAINTENANCE 4 injury, loss of process control or environ-
Description mental contamination.
2.2 LEVEL CONTROLLER
DISASSEMBLY 5 The EVS Liquid Level Controller (LLC)
is designed for general-purpose use WARNING!
2.3 LEVEL CONTROLLER
in liquid level and interface control
RE-ASSEMBLY 5 applications. It uses the patented
Maximum allowable pressures for the
level controller body and the maximum
2.4 LEVEL PILOT REMOVAL/ Norriseal Envirosave direct-acting, allowable pressure at the maximum tem-
REPLACEMENT 5 on/off (snap) pneumatic pilot. The LLC perature for the level controller are shown
2.5 LEVEL CONTROLLER body is back-mounted on the case. on the nameplate mounted in the case. If
PILOT ACTION CONVERSION 5 Pilot action can be reversed and mod- pressure to the level controller is capa-
ulating (throttle) service is optionally ble of exceeding these limits, install relief
2.6 LEVEL CONTROLLER valves or other over-pressure protection
available.
BODY DISASSEMBLY 6 devices in the pressure lines.
2.7 LEVEL CONTROLLER The standard EVS Liquid Level
BODY RE-ASSEMBLY 6 Controller is equipped with a 1.88- x
12-in. PVC displacer that can be CAUTION!
3.0 REPAIR KITS 6 attached for either horizontal or verti- When ordered, the displacer material and
cal service. Optional displacer materi- configuration were selected to meet par-
TABLE als, lengths and diameters can be ticular pressure, temperature, and fluid
Table 1 — Trouble Diagnosis 7 supplied by Norriseal to accommodate conditions. Bodies and displacers are lim-
a wide range of control applications. ited in their operating pressure and tem-
perature ranges as well as their ability to
Controller Identification resist corrosion. Do not apply any other
conditions to the controller without first
Controller model numbers are typi-
contacting your Norriseal sales office or
cally 12 positions long (example: your sales representative.
2SM36-BBDB-N). Refer to the product

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

Principle of Operation Pilot Level Adjustment

Torque The spring is used to balance the
Force Balance Principle Bar weight of the displacer. As level
The operation of the EVS Liquid Level increases, the apparent weight of the
Controller is based on the Force displacer decreases. The spring ten-
Balance Principle. A spring balances sion increases and is transmitted to
the weight of a displacement-type the pilot thrust pin through the lever
sensor. As liquid rises around the dis- and fulcrum.
placer, the amount of force available Fulcrum Pivot Pin Increasing tension on the spring low-
to the pilot is proportional to the ers the sensed level. Decreasing ten-
weight of the displaced liquid. The Figure 2 — Reverse-Acting Controller sion on the spring raises the level
available force is transmitted to the required to produce the toggle force.
pilot thrust pin through a lever and Dump Span
fulcrum. The higher the level, the A snap pilot provides on/off action of Interface
greater the available force to the pilot. output pressure that can be set any-
Spring compression can be suffi-
where within the displacer length. The
The control is direct-acting (rising ciently reduced so that a hydrocar-
differential between on and off (dump
level increases pilot output) when the bon liquid can rise above the displacer
span) is set by positioning the fulcrum
fulcrum is on the right of the pivot pin without transmitting enough force to
along the torque bar (Figure 3).
as shown in Figure 1. the pilot to produce an output. If prop-
erly adjusted, water (with a higher
Fulcrum Proportional Band
specific gravity) can then rise on the
Pilot Torque The term Proportional Band is most displacer, changing its weight, and
Bar commonly associated with throttling produce an output. This wide range
pilots. It is the ratio of used displacer of control makes liquid interface sens-
length to total length of the displacer. ing possible.
For example, if 6 in. of level change
will develop a 3 to 15 psi output sig- Pilot Operation
nal with a 12-in. long vertical dis-
As described in Principle of
placer, the level controller is said to
Operation, force from the balance
Pivot Pin
have a 50% proportional band.
spring is transmitted via the lever and
Figure 1 — Direct-Acting Controller fulcrum to the thrust pin of the pilot.

The control can be made reverse- Envirosave (Snap) Pilot (Figure 4)

acting (rising level decreases pilot out- This patented* pilot has two (2) elas-
put) by moving the fulcrum to the left tomer seats that ensure zero leakage.
Figure 3 — Adjusting Dump Span The upper seat (D) is sealed by a ball
of the pivot pin as shown in Figure 2. and Proportional Band
(A). The upper seat controls supply
air and holds the ball in the closed

*Patent No. 6,497,246 B1

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

position. Upward mechanical force to maintain equilibrium by either de- required. Insert the displacer arm
on the thrust pin (B) overcomes the creasing (exhausting) output loading into the opening in the controller
supply air pressure holding the ball pressure or increasing output loading body. Carefully align and screw
to the seat. The ball snaps upward pressure. Supply air does not flow the arm into the body shaft. For
and supply air flows out the output when the loading pressures of the vertical installation, screw the
port (H). The lower port is sealed by pilot are balanced. swivel onto the free end of the dis-
the spherical end of the thrust pin pre- placer arm. Screw the displacer
venting supply air from escaping. onto the free end of the swivel.
1.0 LEVEL CONTROLLER For horizontal applications, screw
As the upward force INSTALLATION AND the displacer (no swivel used)
on the thrust pin de- START-UP
A directly onto the free end of the
creases, supply air pres-
displacer arm.
D H sure overcomes the CAUTION!
upward force. The ball 4. Install the controller using good
B When making connection to the vessel,
once again seals the piping practice. Use TFE tape or
observe all safety requirements of the
supply air and simulta- area where the work is being done. Be pipe thread sealant.
neously opens the especially careful of pressure vessels.
Force

lower exhaust port, CAUTION!

venting gas from the The bodies are rated ANSI 1500 class. Do
Figure 4 — 1. After unpacking the controller,
control-valve actuator. not install in a system where the work-
Snap Pilot visually inspect the unit for any
ing pressures can exceed those marked
evidence of shipping damage. on the nameplate.
Throttle Pilot (Figure 5) Shipping damage claims must be
The throttle pilot also has two seats filed with the carrier who handled
to admit supply gas and exhaust the the package(s). Remove any for- 5. Connect instrument air to the sup-
actuator gas. A diaphragm (E) is used eign material that may have col- ply connection on the controller.
to sense pressure/force lected during crating and Connect the control valve signal
feedback and a spring shipment. Remove the thread line to the output connection. The
assists closing pressure protectors from the body end supply and output connections
on the thrust pin. The connection. are clearly marked.
throttle pilot is opera- 6. Open the case and rock the
C 2. Insure that screwed surfaces on
tionally similar to the torque bar by hand to verify the
both the controller and the vessel
snap pilot, except that displacer arm moves freely and
are free of foreign materials.
E
the output pressure is is NOT resting against the vessel
proportional to the me- 3. The controller normally ships in nozzle or other obstruction. The
Force

chanical force applied four (4) pieces: the controller arm must be reasonably centered
to the thrust pin (C). As body/case assembly, the displacer, in the connection opening, paral-
Figure 5 —
the thrust pin force the displacer arm, and the swivel. lel to the ground.
Throttle Pilot
changes, the pilot seeks Therefore, some assembly is

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

1.1 LEVEL ADJUSTMENT fulcrum bar away from the pivot 2.0 LEVEL CONTROLLER
pin to DECREASE proportional MAINTENANCE
NOTE: All controllers are factory set band and INCREASE SENSITIV-
for average level and sensitivity. Use only Norriseal replacement parts
ITY. Tighten the thumbscrew on when servicing level controllers.
1. To decrease level (increase com- the sensitivity fulcrum when the Please refer to the model and serial
pression on the balance spring), proper span is selected. numbers when ordering replacement
turn the adjusting knob on top of parts.
the balance spring CLOCKWISE. 1.2 LIQUID LEVEL INTERFACE
To increase level (decrease com- WARNING!
pression on the balance spring), NOTE: All controllers are factory set
Before attempting any repairs, isolate the
turn the knob on top of the balance for average level and sensitivity.
controller from the system and make sure
spring COUNTER-CLOCKWISE. 1. Set the sensitivity fulcrum 1⁄2-in. that all pressure is released from the con-
from the pivot pin. Reduce the troller body. Shut off and vent supply and
spring tension slowly by turning output (signal air) lines to the controller.
the adjusting knob COUNTER-
CLOCKWISE, and let the UPPER 1. Isolate the controller from the
fluid rise to submerge the dis- process.
placer. Fine tune after the dis-
2. Shut off and vent supply and out-
placer is fully submerged in the
Adjusting put (signal air) lines to the controller.
Knob UPPER fluid by slowly increasing
Balance spring tension (turning adjusting 3. Release the process pressure.
Spring knob CLOCKWISE) until an out-
Controller parts are built to withstand
Pivot Pin put signal is obtained. Then back
a great deal of wear under normal
the tension off slowly (turning
operating conditions and will rarely
adjusting knob COUNTER-
Torque
need to be repaired. Should repair be
CLOCKWISE) until the output sig-
Bar necessary, the following sections
nal pressure returns to zero.
describe the procedures for disas-
2. Let the lower fluid rise until the sembling and re-assembling the con-
desired interface level is reached. troller.
Fine tune by slowly increasing
spring tension (turning adjusting
Sensitivity 2.1 LEVEL CONTROLLER
Fulcrum knob CLOCKWISE) until an out-
PREVENTIVE MAINTENANCE
put signal is obtained. Then back
Figure 6 — How to Make Level Adjustments
the tension off the balance spring 1. O-rings and main-shaft bearings
slowly (turning adjusting knob last for many years. If a leak
2. Adjust the proportional band COUNTER-CLOCKWISE) until the occurs, Norriseal has O-ring Seal
(dump span) by first loosening the output signal pressure returns to Kits (LSK) available.
thumbscrew on the sensitivity ful- zero.
crum. Slide the fulcrum along the 2. Controllers used in high-paraffin
fulcrum bar toward the pivot pin 3. If a shorter dump span is desired, service or interface control with a
to INCREASE proportional band move the fulcrum farther away horizontal displacer should be
and DECREASE SENSITIVITY. from the pivot pin and repeat the removed and inspected after their
Slide the fulcrum along the above procedure. initial three (3) months of service.

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

Check for debris buildup inside 2.3 LEVEL CONTROLLER 2.4 LEVEL PILOT REMOVAL /
the controller body that might RE-ASSEMBLY REPLACEMENT
interfere with displacer arm move-
ment. Future inspections can be 1. Slide the level-adjusting bar with WARNING!
gauged by how much buildup spring onto the left end of the
shaft and snug the two (2) cap Before attempting any repairs, isolate the
occurred in the initial three (3) controller from the system and make sure
months of service. screws. Do not completely tighten
that all pressure is released from the con-
at this time. troller body. Shut-off and vent supply and
2. Install spring retainer stud. output (signal air) lines to the controller.
2.2 LEVEL CONTROLLER
DISASSEMBLY 3. Replace the sensitivity fulcrum
1. The pilot is held in place by four
NOTE: These instructions do not and fulcrum bar together by push-
(4) cap screws in the pilot clamp.
apply to the pilot or body. See para- ing the assembly into the level-
Remove these four (4) cap screws
graph 2.4 for instructions for remov- adjusting bar with spring. Slide
and lift the pilot from the case.
ing and/or replacing the pilot. See the level-adjusting bar onto the
paragraph 2.6 for removing body. right end of the shaft and onto the 2. If necessary, replace pilot. Use
fulcrum bar. Snug, but do not only genuine Norriseal pilots.
1. Remove the balance spring, tighten, the two (2) cap screws
spring retainer and the spring- 3. Re-install the pilot by reversing
that secure the bar to the shaft.
adjustment cap screw. instructions 1 through 3 above. It
4. Center the displacer arm in the may appear that the pilot gasket
2. Remove the retaining ring from body opening. It may be helpful does not need replacing, but
the torque bar. Slide the torque to put a temporary spacer under replacement is recommended.
bar off of the pivot pin. Remove the displacer arm to hold it in
and discard Teflon back-up ring. place.
NOTE: DO NOT attempt to 2.5 LEVEL CONTROLLER
remove the pivot pin. It is press-fit 5. Temporarily slide the sensitivity PILOT ACTION CONVERSION
into the body and is not meant to fulcrum fully to the right. Position
EVS Controllers are normally shipped
be removed. the fulcrum bar so that it is paral-
from the factory set for Direct Action.
lel with the bottom edge of the
3. Remove spring retainer stud. The following procedure converts the
case. Tighten the two (2) cap
unit from Direct to Reverse Action.
4. Loosen the two (2) cap screws screws on the level-adjusting bar
NOTE: When the sensitivity fulcrum
holding the level-adjusting bar with spring and the two (2) cap
is to the right of the pivot pin, the unit
and slide it off the right end of the screws on the level-adjusting bar.
is set for Direct Action (figure 1).
fulcrum bar and shaft end. 6. Replace the Teflon back-up ring, when the sensitivity fulcrum is to the
5. Remove the sensitivity fulcrum torque bar and then replace the left of the pivot pin, the unit is set for
and fulcrum bar together by retaining ring that secures them Reverse Action (Figure 7). It may be
pulling the assembly from the to the pivot pin. NOTE: The
Pilot
level-adjusting bar with spring. torque bar must move freely.
Torque
6. Loosen the two (2) cap screws 7. Install the spring adjustment cap Bar
holding the level-adjusting bar screw, balance spring and spring
with spring and slide it off the left retainer.
end of the shaft.

Fulcrum Pivot Pin

Figure 7 — Reverse-Acting Controller

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

necessary to relax the tension from 3. Remove the four (4) cap screws 6. Reassemble the controller per
the balance spring to freely move the holding the case to the body. The paragraph 2.3.
fulcrum. gasket should be discarded. Do
Bearing Block
not attempt to reuse the gasket.
1. Remove the thumbscrew from O-ring
the front of the sensitivity fulcrum.
2.7 LEVEL CONTROLLER
2. Grasp the top of the sensitivity ful-
BODY RE-ASSEMBLY Shaft
crum and pull out and downward
to completely rotate the fulcrum 1. Install the case/body gasket and
on the fulcrum bar. Slide the sen- mount the case to the Body with Figure 8 — End-on Cutaway of Controller Body
sitivity fulcrum to the left side of four (4) cap screws. Tighten the
the fulcrum bar and replace the screws to 6 ft-lbs.
thumbscrew to lock the fulcrum
3.0 REPAIR KITS
2. Using new O-rings, install the Norriseal provides repair kits for use
in its new inverted position.
large O-ring over the threads of in controller maintenance. Contact
3. If necessary, re-adjust the tension the bearing block. Install the new your Norriseal sales office or your
on the balance spring to establish Teflon back-up rings in each bear- sales representative for more infor-
the desired switch point. ing block, pressing them into mation.
place with a 5⁄16-in. diameter rod.
Install the new O-rings in each CAUTION!
2.6 LEVEL CONTROLLER bearing block, pressing them into If the bearing blocks are removed from
BODY DISASSEMBLY place with a 5⁄16-in. diameter rod. the body for any reason, the back-up rings
1. Disassemble the controller by fol- and O-rings must be re-packed (pressed
3. Replace one (1) bearing block on into place). It is recommended that new
lowing the disassembly instruc-
the either side of the body. NOTE: back-up rings and new O-rings be used.
tions in paragraph 2.2 above.
Light oil applied to the O-rings will
2. Remove the two (2) bearing assist in the assembly.
blocks (11⁄4-in. wrench) and the
4. Insert the shaft into the body and
shaft. Remove and discard the
firmly seat in the bearing.
O-rings and Teflon back-up rings
in the body, on the shaft, and in 5. Replace the remaining bearing
the bearing blocks. block on the body and tighten.

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

TA B L E 1 — T R O U B L E D I A G N O S I S

TROUBLE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Pilot output pressure gauge indicates output 1. Balance spring is too compressed and puts 1. Back-off the spring retainer until the out-
pressure signal when fluid level is below dis- too much pressure on the torque bar. put pressure signal goes off. Re-check when
placer on a direct-acting controller OR when the fluid level rises (direct-acting) or falls
fluid level is above displacer on a reverse- (reverse-acting).
acting controller.
2. The displacer arm is set too low or the dis- 2. Check the displacer arm by moving the lev-
placer is hitting something inside the vessel. eling adjusting bar up and down. If the
adjusting bar will move in only one direction,
this indicates the displacer arm is riding at
either the top or bottom of the vessel con-
nection. If it moves too freely, the displacer
has become disconnected from the dis-
placer arm. Re-center the displacer arm in
the vessel connection.

Pilot output pressure gauge indicates no out- 1. Balance spring is insufficiently compressed 1. Compress the spring retainer until an out-
put pressure signal when fluid level is above and doesn’t put enough pressure on the put pressure signal is indicated on the out-
displacer on a direct-acting controller OR when torque bar. put pressure gauge. Re-check when the
fluid level is below displacer on a reverse- fluid level falls (direct-acting) or rises
acting controller. (reverse-acting).
2. The displacer arm is set too high or the dis- 2. Check the displacer arm by moving the lev-
placer is hitting something inside the vessel. eling adjusting bar up and down. If the
adjusting bar will move in only one direction,
this indicates the displacer arm is riding at
either the top or bottom of the vessel con-
nection. If it moves too freely, the displacer
has become disconnected from the dis-
placer arm. Re-center the displacer arm in
the vessel connection.
Controller does not repeat at the same fluid Paraffin or debris has built up inside the level Remove controller from service and clean out
level after each dump and sometimes fails to control body. the body with a solvent.
either dump or shut-off. (The torque bar does
not bounce back fast when depressed and
appears to be hard to move.)

A pneumatic pilot bleeds air continuously. Foreign matter under the ball on a snap con- Remove the pilot following the instructions in
trol pilot or under the peanut on a throttle paragraph 2.4. Remove the two cap screws
control pilot. from the bottom of the pilot. Clean the pilot
OR thoroughly. If a snap pilot, make sure the
dimension between the tru-arc ring and the
The tru-arc ring on the snap pilot thrust pin bottom of the pin is 3⁄4 in. If not, gently tap the
may have been dislocated. tru-arc ring into the proper location.
Reassemble the pilot.

On interface control, the vessel occasionally The displacer is not big enough to handle the Provide exact specific or API gravities of both
loses all fluid or the vessel overflows, espe- interface differential. Close specific gravity of fluids to Norriseal Engineering for exact siz-
cially with temperature change. The displacer two fluids and a temperature change can ing of the displacer that should be used.
arm is free and the displacer is not hitting cause this problem.
inside the vessel.

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 OPERATING AND MAINTENANCE MANUAL
Series EVS Liquid Level Control

HEADQUARTERS, MANUFACTURING PLANT AND SALES

ISO 9001
Cert. #30080

P.O. Box 40525 • Houston, Texas USA 77240-0525

11122 West Little York • Houston, Texas USA 77041-5016
Tel: 713·466·3552 • Fax: 713·896·7386
www.norriseal.com

Due to the continuous improvement at Norriseal,

specifications and/or prices are subject to change
without notice or obligation.

Series EVS controllers are protected by U.S. Patents 4,700,738 and 6,497,246 B1.
©2004 Norriseal. All rights reserved.
™Norriseal and Envirosave are marks of Dover Corporation.
®Teflon is a mark of DuPont.

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