Manufacturer’s Suggested
Annual Maintenance Protocol
For
High Level Alarm testing using
transducers with a test port*
(Manual activation of the high level alarm by direct simulation of a high liquid level)
Back Ground: The EFG-8000 series of liquid level gauges operate as a very simple gauging devise with level alarm
options that require almost no maintenance. Measuring the current liquid level in the tank and comparing the gauge reading to the
charted amount can confirm normal gauge accuracy. The comparison between the gauge readout and the charted amount should
differ no more than 2%, and typically operates with less than 1 % error.
The High and Low liquid level alarms are user set points in the gauge programming as a percent of the total tank capacity.
Access to these alarm values may be reviewed by stepping through the setup program as detailed in the owners’ manual*. The
Low-level alarm may be set to “off” at a zero value or any value 5% under the High-level alarm value. The High-level alarm
cannot be turned off and may not exceed 95% of tank capacity. We strongly recommend against setting the High-level alarm any
higher than 90% in normal conditions.
Preferred Method of Testing
- Make note of the current gallons displayed. (Needed in step 5) The tank needs to be less than 75%
full to perform repeatable tests, otherwise you may only get one alarm test until lower tank levels.
- Go up on top of the tank to locate the transducer and unscrew the small hex nut. If your transducer
does not have a test port one can be ordered to replace yours.
- Carefully and slowly pull up (NEVER should more than 3 pounds of pulling force be applied) to the
nut which is attached to a very small S.S. bead chain, which in-turn is connected to the probe down
inside the tank. This needs to trigger a High-level alarm as you pull up (about 1 ½”) and before it
reaches the full length of pull. Depending on your current tank liquid level, you may have to reset
the alarm for each pull up on the nut doing multiple tests. If you have a person in front of the gauge
reading the display you can determine the quantity at which it alarms. It will be the percent setting of
The High-level in the gauge program. The alarm trip point is set as a corresponding percentage of
total tank capacity. IF THE HIGH LEVEL ALARM FAILS TO ACTIVATE PLEASE PROCEED
TO THE LAST OPTION, otherwise after successful tests proceed to step 4.
- Feed the chain back down into the hole (checking placement and condition of the small O-ring, use a
small amount of silicone grease if needed) and screw the hex nut carefully back into place. ONLY tighten it down enough to make firm contact against the o-ring to seal out the elements. If it is
damaged or missing it MUST be replaced. If the o-ring has been damaged or it is missing, you must
tape or keep in place a sealing cover over the transducer to keep the elements away from the nut until
a replacement o-ring or replacement of the transducer can be made. Call Greenleaf Gauge for the
protocol to replace this o-ring. It is serviceable in the field, but it is a delicate procedure. After
considering all the conditions at your tank site, as an example; extreme cold, very tall tank, very
remote location, it may be best just to order a new part and change out the existing transducer.
- The last step is to check the current reading on the gauge display to see if it reads within 2% on the
reading taken for step one. See back page for a example. If not you may try repeating steps two thru
five to get the correct results or proceed to the last option.
Alternate Test Method: Although this is not the preferred method, High Level alarms may always be
observed during filling as the liquid level reaches the set percentage of fill. This method is not preferred
only because it is not always practical to be present to observe this event. You also only have one alarm
event to observe. The preferred method of a High level alarm activation is provided on the transducer on
top of the tank by means of a small hex nut assembly mounted on the 2” bell reducer.
Last Option: transducer removal
- The last option starts again with reading and making note of the current gauge display.
- Next go up on top of the tank and temporarily un-wire and un-screw the transducer just up off the
2” pipe nipple on top of the tank. Depending on the site wiring means, it may require a small
additional length of wire to re-connect to the gauge.
- After temporarily re-connecting the three transducer wires and losing the 0--0 error code, very
gently and slowly pull up on the beaded chain or the top of the probe sticking down in the tank. To
do this it usually requires the transducer to be above the tank nipple about 5 inches. Pulling up on
the chain or probe will simulate an actual High-level liquid tank condition and will activate the
High-level alarm. DO NOT handle the movable transducer rod which will normally only travel
about 5/8 of an inch empty to full. Lifting up must activate the High-level alarm before the rod
stops moving into the top up most position while lifting up on the bead chain or top of the probe.
IF THE HIGH LEVEL ALARM FAILS TO ACTIVATE PLEASE PROCEED with HIGH LEVEL ALARM FAILS TO ACTIVATE.
- Next you must test to make sure the transducer rod moves very freely in and out of the base. You
can do this test by lifting up slowly on the bead chain or probe top and let back down slowly several
times just before re-assembly to the pipe nipple. If the transducer rod does not move freely and you
can not clean it so it does, the transducer MUST be replaced.
- Just before returning the transducer to the original position on the tank nipple make sure the small
bead chain is loose. After screwing the transducer back down on to the tank pipe nipple and
connecting the wires, check the current reading on the gauge display to see if it reads with-in 2% of
the total tank capacity compared to the first reading you noted before you started this procedure.
% of Error Example: Total tank capacity 10,000 gallons. 10,000 X .02 would equal 200 gallons. The
difference would then need to be less than 200 gallons plus or minus of the first and current reading.
- If you are within the percentage of error then finish securing all wire and wiring means. If it is not,
repeat the steps above because the rod may have been twisted and needs to be moved back and forth
to the extreme ends again and then the transducer can be re-mounted carefully back into place and
checked again for the % of error.
IF THE HIGH LEVEL ALARM FAILS TO ACTIVATE
- Determine if the annunciator operates on the alarm plate, if not replace it.
- Determine if there is moisture present behind the alarm plate. Dry out the cavity. Seal off all
the conduit openings and replace alarm connector board if needed. DO NOT use any alarm
board with any corrosion on it. It MUST be replaced.
- Determine if gauge displays the correct quantity in the tank, if not, check the program settings
in the gauge. Call if you need assistance determining the setup values.
- If steps 1 thru 3 are found correct then the gauge may need removed and replaced.
IF YOU CAN NOT DETERMINE THE PROBLEM AND THEN ACTIVE THE HIGH LEVEL
ALARM, PLACE A SIGN OF “NO HIGH LEVEL ALARM, OUT OF SERVICE” ON THE
GAUGE FACE AND NOTIFY THE TANK OPERATOR. LEAVE THE SIGN ON THE
GAUGE FACE UNTIL REPLACEMENT PARTS ARE AVAILABLE TO RETURN THE
GAUGE TO NORMAL SERVICE. If you can determine that the gauge is reading the tank
quantity correctly, but the High-level alarm is not sounding, make note of that to the tank
operator.
*Owners’ manuals are always available on the web at www.solargauge.com
*Pictures are available on the web site for clarification as to the different styles of transducers
that have been produced. |
