SOR 1600 Series Manuale utente

Form 1636 (03.19) ©SOR Inc.

1/16

Installation



Before beginning installation, inspect the level controller for damage that may have

occurred during shipment and remove all cardboard packing material.



The 1600 Series Level Controllers normally ship unassembled as 3 separate parts:

– The level controller body assembly.

– The displacer with swivel.

– The displacer arm.



Thoroughly clean the vessel connection surface to remove any accumulated debris.

Threaded and gasketed surfaces on the controller’s process connection should also be

cleaned before installing the level controller.



When installing the level controller, apply PTFE tape or pipe thread sealant for units

with NPT connections. For units with flanged connections, install with a suitable gasket

between the flange faces.

The SOR

1600 Series Level Controllers

are designed for use in liquid level

and interface level applications with

pneumatic instrumentation. For

assistance with the calibration and

maintenance procedures found in these

General Instructions, please visit the

SOR Inc. Youtube channel for video

walkthroughs.

1600 Series

Liquid Level Controllers

General Instructions

Registered Quality System to ISO 9001

Design and

specifications are

subject to change

without notice.

For latest revision, go to

SORInc.com

Table of Contents

Installation...................................... 1

Reference Diagram............................ 4

Maintenance.................................... 4

Parts List ........................................ 8

Repair Kits ..................................... 12

Mounting Reference Drawings .............12

Dimensions ....................................13

Troubleshooting ............................... 15

hl l ll f d h h

NOTE: If you suspect that a product is defective, contact the factory or the SOR

Representative in your area for a Return Material Authorization number (RMA). This

product should only be installed by trained and authorized personnel.

2/16

Form 1636 (03.19) ©SOR Inc.

Refer to Page 12 for mounting reference drawings

START UP

Pneumatic Pilot



Connect supply pressure to the connection point labeled “SUPPLY” on the backside of the

controller case. On the model 1600 sealed controller it is the top connection, while on the

model 1601 non-sealed controller it is the right connection when facing the backside of

the controller case. Connect the device the pneumatic signal is being output to with the

connection point labelled “OUTPUT”.

Electric Pilot

If the 1600 Series level controller was supplied with an electronic switch rather than a

pneumatic pilot, the switch will carry the following ratings:

The SPDT electric pilot uses an explosion proof electric switch to eliminate the need

for a pneumatic gas supply. This is beneficial when redusing fugitive emissions by

no longer using natural gas to power on site pneumatic devices. The electric pilot is

typically used to send an electric signal on high or low level to an electric actuator on a

valve or to a pump for pump control.



Connect the displacer arm with the level controller body by inserting the displacer

arm into the body opening, located on the backside of the controller case. Ensure the

displacer arm is aligned within the body before screwing the arm in.

– If the level controller will utilize a vertically-oriented displacer: screw the displacer

swivel onto the displacer arm then connect the swivel and displacer.

–

If the level controller will utilize a horizontally-oriented displacer: if necessary, first unscrew

the swivel from the displacer before connecting the displacer to the displacer arm.

Electrical power must be disconnected before cover is removed.

Failure to do so could result in severe personal injury or substantial

plant damage.

Contact Rating 15A @ 125, 250 & 480VAC

Agency Approval Rating DIV 1&2, Class I, Groups B, C. & D , DIV 1&2, Class II, Groups

E, F & G, II2G ExdIIB + H2 T6 Gb

Agency UL, CSA, ATEX, IECEx, INMETRO

Wiring Diagram

Blue (C)

Black (NO)

Red (NC)

Green (GND)

Form 1636 (03.19) ©SOR Inc.

3/16



Open the controller case and move the torque bar back and forth by hand and verify the

displacer arm moves freely and is not resting against anything. The displacer arm must

be oriented approximately parallel with the ground – if needed, rotate the adjusting

knob under the balance spring to adjust the displacer arm resting position.

LEVEL ADJUSTMENT



After completing Start Up procedure and with the displacer arm oriented parallel with

the ground, the level set point is ready to be adjusted.

a. To Lower the Level Set Point: Rotate the adjusting knob clockwise to increase

spring tension of the balance spring.

b. To Raise the Level Set Point: Rotate the adjusting knob counterclockwise to

decrease spring tension of the balance spring.



After the level set point is satisfactorily set, the proportional band (dump cycle) is ready

to be adjusted. A larger dump cycle corresponds to a larger span between the controller

on and off points, while conversely a smaller dump cycle results in less time passing

between dumping due to the shortened span between the on and off points.

a. Loosen the thumb screw, located on the sensitivity fulcrum.

b. To Decrease the Dump Cycle: Move the sensitivity fulcrum along the flapper bar in

the direction of the pilot, i.e. towards the smaller numbers.

c. To Increase the Dump Cycle: Move the sensitivity fulcrum along the flapper bar

opposite the direction of the pilot, i.e. towards the larger numbers.

d. A larger dump cycle corresponds to a larger span between the controller on and

off points, while conversely a smaller dump cycle results in less time passing

between dumping due to the shortened span between on and off.

e. Once the dump cycle is appropriately set, tighten the thumb screw on the sensitivity

fulcrum.

LIQUID LEVEL INTERFACE



Loosen the thumb screw, located on the sensitivity fulcrum, and position the

sensitivity fulcrum 1/4” away from the snap ring (see reference diagram Page 4).

a. Begin by slowly rotating the adjusting knob counterclockwise to reduce tension

on the spring, and then allow the upper liquid level to rise until the displacer is fully

submerged.

b. Once the displacer is submerged in only the upper liquid, this adjustment can be

fine-tuned by slowly rotating the adjusting knob clockwise to increase

spring tension until the level controller emits an output pressure signal.

c. Slowly rotate the adjusting knob counterclockwise to reduce spring tension until

the level controller stops sending an output pressure signal.

4/16

Form 1636 (03.19) ©SOR Inc.

Reference Diagram

Cap Screw

Pivot Pin

Torque Bar

Sensitivity Fulcrum

Thumb Screw

Displacer

Arm

Lock Nut

Upper Spring Retainer

Balance Spring

Adjusting Knob

Shaft

Pilot Snap Ring Flapper Bar

Output Connection

Supply Connection

1601 Non-Sealed

Displacer

Arm

Output

Connection

Supply

Connection

1600 Sealed

Displacer

Arm

Torque Arm

Adjusting Screw

Body

Case

Body

Case

The torque arm calibration is pre-set at the factory and should not be

adjusted. If the torque arm calibration has been tampered with, adjust it such

that the torque bar is parallel with the case bottom while the displacer arm is

positioned in the middle of the body. See reference diagram on Page 4.



Allow the lower liquid level to rise until it reaches the appropriate interface level set point.

a. The interface level set point can be fine-tuned by slowly rotating the adjusting knob

clockwise to increase spring tension until the level controller emits an output

pressure signal.

b. Slowly rotate the adjusting knob counterclockwise to reduce spring tension until the

level controller stops sending an output pressure signal.



If a longer dump cycle is required, loosen the thumb screw and slide the sensitivity

fulcrum away from the snap ring (towards the larger numbers). Re-tighten the thumb

screw and then repeat steps 1) and 2) of the above procedure.

Form 1636 (03.19) ©SOR Inc.

5/16

Maintenance

The following procedure is only for the level controller and does

not apply to the pilot. See Page 6 for pilot removal/replacement

instructions.

LEVEL CONTROLLER FIELD DISASSEMBLY



Slowly rotate the adjusting knob counterclockwise until there is no tension on the

balance spring.



Remove the balance spring and upper spring retainer from the controller case.



Unscrew the lock nut from the flapper bar. Separate the flapper bar from the pivot pin.

Do not remove either of the pivot pins from the controller case.

Do not remove the sensitivity fulcrum or the thumb screw from the

apper bar.



Unscrew the lock nut from the torque bar. Separate the torque bar from the shaft.



Hold the torque arm in place and then loosen the two cap screws until the torque

arm moves freely about the shaft.



Separate the torque arm and the spacer from the shaft.



There are two hex bolts located behind the torque arm that attach the controller

case to the body. Unscrew these bolts and separate the controller case and body.

LEVEL CONTROLLER FIELD REASSEMBLY



Reattach the controller case to the body with two hex bolts, tightening the bolts to

6 ft-lbs.



Slide the washer then the spacer onto the shaft.



If the torque arm adjusting screw has been removed or adjusted, situate the

adjusting screw such that there is an equal amount of thread above and below the

torque arm.



Slide the torque arm back onto the shaft and position the torque arm adjusting

screw perpendicular to the controller body. Loosely attach the two cap screws that

hold the torque arm on the shaft. The torque arm should still move freely about the

shaft.



Slide the torque bar back onto the shaft. With the round tip of the torque arm

adjusting screw touching the torque bar, adjust the torque arm until the torque bar

is parallel with the displacer arm.

Unless the case mounting orientation is being converted, the torque

arm adjusting screw position does not need to change.

6/16

Form 1636 (03.19) ©SOR Inc.

Do not overtighten the lock nut to the torque bar. The lock nut should

be loose enough for the torque bar to rotate with ease.



Slide the torque bar back off of the shaft. Beginning with the cap screw closest to

the slotted end of the torque arm, secure the torque arm to the shaft by tightening

the cap screws to 100 in-lbs.



Slide the torque bar back onto the shaft, making sure the hole for the spring re-

tainer is facing downward. Screw the lock nut back onto the shaft while still leaving

1/16” of space between the lock nut and torque bar.

Slide the flapper bar back onto the pivot pin and re-attach the lock nut – if

converting the case mounting orientation:

a. Unscrew the thumb screw from the sensitivity fulcrum and screw it back into

the opposite side of the sensitivity fulcrum. The sensitivity fulcrum should be

secured in approximately the same position on the flapper bar.

b. For Left Hand Direct Acting / Right Hand Reverse Acting, slide the flapper bar

onto the left pivot pin.

c. For Right Hand Direct Acting / Left Hand Reverse Acting, slide the flapper bar

back onto the right pivot pin.

Position the upper spring retainer so it is seated in the hole on the underside of the

torque bar, and then re-install the balance spring between the adjusting knob and

upper spring retainer.

LEVEL CONTROLLER CASE MOUNTING CONVERSION



Completely disassemble the level controller following the procedure on Page 4.

Reassemble the level controller with the following modifications:

a. The torque arm adjusting screw should be rotated 90° from its original position.

b. The thumb screw should be removed from the sensitivity fulcrum and re-

installed on the opposite side.

c. The torque arm, torque arm adjusting screw, sensitivity fulcrum, torque bar,

flapper bar, balance spring and stud bolt should all be re-assembled into the

opposite side of the controller case.

Do not overtighten the lock nut to the apper bar. The apper bar must

rotate freely around the pivot pin.

Do not overtighten the cap screws.

Form 1636 (03.19) ©SOR Inc.

7/16

Pneumatic Pilot Removal/Replacement

Disconnect the supply and output lines from the backside of the controller case.

For the 1600 sealed controller, the pilot is attached to the case by four bolts

mounted through the pilot clamp. Undo these bolts and remove the pilot from the

controller case.

For the 1601 non-sealed controller, the pilot is attached to the case by two cap

screws mounted through the top of the case. Undo the cap screws and remove the

pilot from the controller case.

Either replace the pilot completely or rebuild it using a pilot repair kit. See Page 12

for part numbers of replacement pilots and pilot repair kits.

Re-install the pilot by reversing the steps followed above. For the 1600 sealed

controller, it is recommended that the pilot gasket be replaced even if it does not

appear to be damaged.

Level Controller Pilot Action Conversion

Slowly rotate the adjusting knob counterclockwise until there is no tension on the

balance spring.



Unscrew the lock nut from the flapper bar. Separate the flapper bar from the pivot pin.

Unscrew the thumb screw from the sensitivity fulcrum and screw it back into the

opposite side of the sensitivity fulcrum.

Slide the flapper bar onto the opposite pivot pin it was removed from. The thumb

screw on the sensitivity fulcrum should be facing outwards.

Screw the lock nut back on to secure the flapper bar to the pivot pin.

The pilot action conversion is now complete and the level controller is ready for

recalibration. See Page 2 for Level Adjustment procedure.

For best performance with your 1600 series Liquid Level Controller,

only genuine SOR replacement parts and repair kits should be used.

See Page 12 for part numbers.

Do not overtighten the lock nut to the apper bar. The apper bar must

rotate freely around the pivot pin.

For electric switch pilot, consult factory for repair-replacement.

8/16

Form 1636 (03.19) ©SOR Inc.

Parts List

1600 SEALED LEVEL CONTROLLER

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9/16

1600 SEALED

LEVEL CONTROLLER

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 25,1*%81$1'

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  72/(5$1&(5,1*

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Linear = mm/inches

Drawing 5678301

10/16

1601 NON-SEALED LEVEL CONTROLLER

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

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  /(16+2/'(5

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

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  25,1*%81$1'

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  72/(5$1&(5,1*

  :$6+(52';,';7+.66

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