Installation, Operating and Mainte-

nance Instructions
2 x 35MW Peat fired Power Plant, Rwanda
YUMN Ltd

Drum Level Indicator Pos. Number: See next page

Project Name: 2 x 35MW Peat fired Power Plant, Document Number:
Rwanda YUMN Ltd C02824924088_0003013_0004194
Project WBS: C-02-824924-088

Contact: ANDRITZ Oy
Division: Recovery and Power Division
Project Manager: Olli Ryymin
Phone: +358 20 450 5207
E-mail: Olli.ryymin@andritz.com
www.andritz.com

Service Contact: ANDRITZ Oy

Division: Kraft and Paper Mill Services
P.O Box 184
78201 Varkaus, Finland
Phone: +358 (0)20 450 5555
E-mail: service.finland@andritz.com
2 x 35MW Peat fired Power Plant, Rwanda YUMN Ltd

INSTRUCTIONS FOR INSTALLATION, OPERATING AND MAINTENANCE

Equipment: 10HAD10CL501 Aquarian 3000 Visual Gauge

Manufacturer: Finkova/Fossil Power Systems Inc.

 ANDRITZ Oy

Order number : 4501990713

WBS-Element : C-02-824924-088-8460-100
Project : SP Hakan Power Boiler 1

TECHNICAL DOCUMENTATION

TABLE OF CONTENTS

Dimensional drawings for LI-10HAD10CL01

1 AQ3010VF Level Gauge with Water Column

2 AQ3000V Level Gauge Side Flange Mounting
3 AQ3000V Illuminator Series 2
4 AQ3000V Level Gauge Display Assembly
5 GV3200 Series 2 Gauge Valve Assembly
6 GV3200 Series 2 Upper Gauge Valve
7 GV3200 Series 2 Lower Gauge Valve

8 AQ3V Gauge Instruction Manual

9 AQ3V Illuminator Series 2 Instruction Manual

Finkova Oy 117/453 | Vantaa 2018-00726

FINKOVA OY EMAIL finkova@finkova.fi VAT N:O FI23525491

SINIKELLONTIE 10B TEL +358 10 229 1570 NORDEA BANK FINLAND
FIN-01300 VANTAA FAX +358 10 229 1579 SWIFT NDEAFIHH
FINLAND www.finkova.fi IBAN FI70 1745 3000 1294 54
 2X35 MW PEAT FIRED POWER
Document AQUARIAN AQ3V GAUGE
Project PLANT AT SOUTH
INSTRUCTIONS MANUAL
AKANYARU, RWANDA. Title
SP – YUMN –XX – XXX – XXX – XX–
Document Number
XXXX
Revision R0 Sheets 1 OF 23

2X35 MW PEAT FIRED POWER PLANT AT

PROJECT:
SOUTH AKANYARU, RWANDA.
EMPLOYER:
YUMN LTD

EMPLOYER’S ENGINEER
(EE):
SWECO INTERNATIONAL AB

SUPPLIER:
SHAPOORJI PALLONJI & CO. PVT. LTD.
(EPC DIVISON)

SUPPLIER’S ENGINEER (SE): FICHTNER CONSULTING ENGINEERS (INDIA)

PVT. LTD, CHENNAI
SUBCONTRACTOR:
ANDRITZ Oy (BOILER)

DOCUMENT TITLE: INSTRUCTIONS MANUAL

SUPPLIER’S DOCUMENT
SP – YUMN – XX – XXX – XXX – XX– XXXX, XX
NUMBER:
SUBCONTRACTOR
DOCUMENT NUMBER:
AQUARIAN AQ3V GAUGE
REVISION STATUS

XX XX XX XX XXXXX XX/XX/XX
PREPARED CHECKED APPROVED
REV DESCRIPTION DATE
BY BY BY
Bi-Colour Water Level Gauge
Installation, Operation
And Maintenance of

Aquarian 3000Visual

FOSSIL POWER SYSTEMS INC.

10 Mosher Drive
Dartmouth, NS
Canada B3B 1N5

PH# (902) 468-4701 ext 720

FAX# (902) 468-2323
www.fossil.ca
 Aquarian 3000Visual
Instruction Manual
9340-1006
Last Modified: December 1, 2016

Copyright  2003 Fossil Power Systems Inc. All rights reserved.

All trademarks referenced herein are property of their respective corporation.
The information contained herein is subject to change without notice.

i
About this Manual

This instruction manual describes the construction and operation of the Aquarian 3000V
Level Gauge as supplied by Fossil Power Systems Inc.

Additional reference information pertaining to this and related products can be found in:

9340-1106 Aquarian 3000V Bi-Colour Water Level Gauge Brochure

9340-1116 Aquarian 3000V Bi-Colour Gauge Illuminator and Display Brochure
9340-1015 Aquarian 3000V Gauge Illuminator and Level Display Installation,
Operation and Maintenance Manual

9340-1019 Aquarian 3000V Series 2 Gauge Illuminator and Level Display IOM

Although care was exercised to make this Manual specific and complete, it is not intended
that it and its accompanying equipment manuals should provide for all potential operating
and maintenance conditions. It must be recognized that no amount of written instruction can
replace intelligent thinking and reasoning on the part of qualified personnel. It is the
responsibility of these personnel to become completely familiar with the mechanical,
electrical and control systems involved, including their characteristics and performance
under various operating conditions.

This knowledge can be obtained through the basic information provided in this manual,
supplemented by advice and recommendations from this Company’s field agents and by
actual experience.

Operation, maintenance and performance of any equipment not furnished by this Company
are the sole responsibility of others.

The harsh operating environment and the potential hazards associated with live
steam require that only qualified personnel install and maintain the equipment.

ii
Table of Contents
1 INTRODUCTION ................................................................................................................. 1

2 DESCRIPTION ..................................................................................................................... 2
2.1 TRAPEZOIDAL STAINLESS STEEL BODY ..................................................................................... 2
2.2 PORT COVER ............................................................................................................................ 2
2.3 WINDOW .................................................................................................................................. 2
2.4 SEALING GASKET ...................................................................................................................... 2
2.5 MICA ........................................................................................................................................ 2
3 SAFETY INFORMATION................................................................................................... 3

4 EQUIPMENT INSTALLATION ......................................................................................... 3

4.1 GAUGES WITH FLANGED ISOLATION VALVES ............................................................................ 3
4.2 GAUGES WITH TUBULAR PACKING BOX TYPE ISOLATION VALVES ............................................. 3
5 EQUIPMENT OPERATION ............................................................................................... 4
5.1 PLACING GAUGE IN SERVICE .................................................................................................... 4
5.2 REMOVING GAUGE FROM SERVICE ........................................................................................... 4
5.3 PORT INSPECTION ..................................................................................................................... 4
5.4 GAUGE AND WATER COLUMN BLOWDOWN ............................................................................. 4
6 GAUGE PORT SERVICING ............................................................................................... 5

7 PRINCIPLE OF OPERATION ........................................................................................... 6

8 MAINTENANCE .................................................................................................................. 7

9 TROUBLESHOOTING ........................................................................................................ 7
9.1 LEVEL IN GAUGE DOES NOT AGREE WITH OTHER LEVEL INDICATIONS ...................................... 7
9.2 RED/GREEN IMAGE IS POOR, OR RED/GREEN COLORS ARE REVERSED. ..................................... 7
9.3 WATER IS LEAKING FROM PORT COVER .................................................................................... 8
10 PACKING, STORAGE, AND TRANSPORTATION ....................................................... 8

11 SPARE PARTS ...................................................................................................................... 8

11.1 INDIVIDUAL PART LIST ........................................ ERROR! BOOKMARK NOT DEFINED.
12 SPECIFICATIONS ............................................................................................................... 9

13 AVAILABLE OPTIONS .................................................................................................... 10

iii
List of Figures
Figure 1 - AQ3000V Gauge Assembly Drawing ............................................................................11
Figure 2 - Flanged Gauge System ...................................................................................................12
Figure 3 - Pipe Nipple Ended Gauge System .................................................................................13
Figure 4 - Pipe Nipple Ended Gauge Installation ...........................................................................14

iv
 installation, operation and maintenance of
Aquarian 3000Visual
bi-colour water level gauge

1 INTRODUCTION
The Aquarian 3000Visual is a 3000 psi (207
BAR) ported gauge that produces a red/green
image to indicate the water level in a high-
pressure steam drum. The body is precision
machined into a trapezoidal shape. Light
projected through steam produces a red image.
Light projected through water is refracted
(bent) and produces a green image. The gauge
fulfills the requirements in the 2001 ASME
Boiler and Pressure Vessel Code Section 1
PG-60.1 that states:

“Boiler with an MAWP of 400 psi or less and

electric boilers of the electrode type, require at
least one gauge glass. Except for electric
boilers of the electrode type, boilers with an
MAWP over 400 psi require at least two gauge
glasses. Forced flow steam generators with no
fixed steam and waterline, and high-
temperature water boilers of the forced
circulation type, do not require a gauge glass.

When two gauge glasses are required, one of

the gauge glasses may be replaced by two
independent remote level indicators. When
both remote level indicators are operating
reliably, the remaining gauge glass may be
shut off, but shall be maintained in serviceable
condition. When fitted with two gauge
glasses, both gauge glasses may be connected
to a singled water column or directly to the
drum.

1
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

At least one gauge glass shall be readily visible
to the operator in the area where immediate
control actions are initiated. Alternately, two
dependable indirect indications shall be
provided, either by transmission of the gauge
glass image or by remote level indicators. A
gauge glass image transmitted to the operator’s
working area by means of a fiber optic signal,
is considered to provide direct reading of the
gauge glass water level.”
2.2 Port Cover
Stainless steel four bolt cover that retains the
port components against gauge body. Two
Bellville spring washers maintain constant
load on internal components. Bolts do not
have to be re-torqued after initial assembly.
2.3 Window
Precision ground tempered Aluminosilicate
glass.

2 DESCRIPTION
2.4 Sealing gasket
Reference:
 Figure 1 - AQ3000V Gauge Assembly Drawing Laminated and die-formed graphoil.
 Figure 2 - Flanged Gauge System
 Figure 3 - Pipe Nipple Ended Gauge System 2.5 Mica
Premium V-1 quality clear ruby muscovite.
The Fossil Aquarian 3000 Visual (AQ3000V)
At boiler pressures above 300 psi (20 BAR),
is a ported bi-colour level gauge designed to
high temperature water will rapidly erode
indicate the water level in steam drums
unprotected gauge glass. Two sheets of Mica
operating at pressures up to 3000 psi (207
are used to protect the glass. However, this
BAR) and temperatures up to 696 F (369C).
protection from the boiler water is not
A complete gauge system would also include
permanent. The Mica slowly erodes and will
gauge isolation valves, water column, gauge
have to be replaced. The rate of erosion is
illuminator and level display. The AQ3000V
dependant on the operating temperature.
gauge is constructed from the major
components listed below.

2.1 Trapezoidal stainless steel body

The body has a continuous center through
hole, with viewing ports machined at specific
intervals. When Red and Green light are
projected into the gauge, the non-parallel front
and back faces cause the observer to see a
color change if steam or water is present in the
gauge. This occurs because light is refracted
(bent) when it passes through regions with
different density. Water will be displayed as a
Green image; steam will be displayed as a Red
image.

2
Aquarian 3000Visual Instruction Manual
3 SAFETY INFORMATION
Every customer must establish an inspection
and maintenance schedule that insures the
mica-glass-gasket (port kit) assembly is
replaced before the mica protective shield is
dissolved. Gauge glass that appears white or is
opaque should be immediately replaced. The
red/green image will appear blurred when the
mica is worn and the glass is in contact with
the harsh environment.
Warning
Failure to promptly replace the
mica-gasket-glass assembly that
appears white or opaque can result
in sudden and catastrophic failure
of the glass and violent discharge
of hazardous high temperature
steam. The discharge of high
temperature steam at high velocity
can result in severe personal injury
and property damage. To manage
maintenance, replace all port kits at
the same time, stack and measure
the cone height of the Belleville
washers. See Port Kit instruction
sheet for details.
The gauge should not be subjected to acid
wash cleaning. The gauge must be isolated
from this process, or replaced with a boil out
gauge during cleaning.
The gauge must be operated with a gauge
illuminator and level display to accurately
show the water level and meet the
requirements of the ASME Boiler and
Pressure Vessel Code section PG-60.
Fossil Power Systems Inc.
Use extreme caution when putting a newly
repaired gauge back into service. Do not stand
immediately in front of the gauge ports while
initially pressurizing the gauge.
Do not look directly into gauge ports with the
Illuminator removed while the gauge is
pressurized.
This equipment operates at high temperatures
and pressures. Wear protective gloves, glasses,
and other clothing as necessary to prevent
personal injury.
4 EQUIPMENT INSTALLATION
4.1 Gauges with flanged isolation valves
Reference:
 Figure 2 - Flanged Gauge System
1. Insert gaskets into groove of large
groove face flanges and mount
gauge with studs and nuts
provided.
2. Follow Illuminator and Level
display IOM for installation
procedure.
4.2 Gauges with tubular packing box
type isolation valves
Reference:
 Figure 3 - Pipe Nipple Ended Gauge System
 Figure 4 - Pipe Nipple Ended Gauge Installation
1. Install packing nut, packing
bushing, two packing rings and
spacer ring on gauge upper pipe
nipple.
2. Install packing nut, packing
bushing and two packing rings on
gauge lower nipple.
3
Aquarian 3000Visual Instruction Manual
3. Install spacer ring in lower valve.
4. Install gauge by pushing gauge
upper nipple into upper valve,
swing gauge into place and drop
gauge lower nipple into lower
gauge valve. Insure this pipe
nipple is fully seated.
5. Install packing for lower gauge
valve and tighten packing nut.
6. Rotate gauge to the desired
viewing angle.
7. Install spacer ring and packing for
upper valve and tighten packing
nut.
8. Follow the Illuminator and Level
Display IOM for installation
procedure.
5 EQUIPMENT OPERATION
5.1 Placing Gauge in Service
1. Open the gauge drain valve fully.
2. Open upper and lower drum
isolation valves, if provided.
3. Crack open the upper gauge
isolation valve.
4. Allow the gauge to heat without
pressure buildup for 10 minutes.
5. Gradually close the drain valve
over a 15 minute interval to allow
pressure to increase slowly in the
gauge.
6. Shut the gauge drain valve fully.
7. Fully open the upper gauge
isolation valve.
8. Open the lower gauge isolation
valve.
5.2 Removing Gauge from Service
1. Close the upper and lower drum
isolation valves, if provided.
2. Close the upper and lower gauge
isolation valves.
4
Fossil Power Systems Inc.
3. Crack open the drain valve to very
slowly depressurize the gauge.
Depressurization should take 15
minutes.
4. Fully open the drain valve.
5.3 Port Inspection
1. Remove the gauge from service
following the procedure 5.2 above.
2. Remove the Illuminator and Level
Display.
3. Using a flashlight, visually check
the mica-glass in each port for a
white or opaque appearance.
Check both sides of the gauge,
while illuminating the port with the
flashlight from the backside. Ports
with a white or opaque appearance
must be replaced before the gauge
is put back into service. Continued
operation with white or opaque
ports can result in catastrophic
glass failure and violent discharge
of high temperature steam.
4. Replace all port kits at the same
time. Stack the Belleville Washers
2 high and measure the cone
height. Replace Belleville
Washers that are cracked or out of
height specification 0.285"
(7.24mm).
The level gauge, connecting pipes and valves
must be kept free from obstructions caused by
sediment in order for the gauge to provide
proper level indication. In addition, sediment
deposits on the mica will reduce the gauge
visibility. The gauge should be blown down
as required to eliminate sediment. Each plant
should establish a preventative maintenance
blowdown schedule. However, excessive
gauge blowdown will reduce the mica life and
should also be avoided. This procedure begins
Aquarian 3000Visual Instruction Manual
with gauge in service. If gauge is not in
service, follow procedure 5.1 above before
beginning.
1. Close the upper gauge valve.
2. Crack open the water column drain
valve for about a minute. This will
clear sediment from the lower
drum pipeline and water column.
Shut the column drain valve.
3. Crack open the gauge drain valve
for about a minute. This will clear
sediment from the lower gauge
piping and lower valve. Shut the
gauge drain valve.
4. Open the upper gauge valve.
5. Shut the lower gauge isolation
valve.
6. Crack open the gauge drain valve.
This will clear sediment from the
gauge, the upper gauge piping and
upper valve. Shut the gauge drain
valve.
7. Open the lower gauge isolation
valve.
8. Check the gauge for clarity.
Repeat the procedure again if
necessary.
6 GAUGE PORT SERVICING
Reference:
 Figure 1 - AQ3000V Gauge Assembly Drawing
A port Replacement DVD, PN 9340-2903-
NTSC is available that shows the replacement
procedure. Contact FPS to obtain this DVD at
no charge. This gauge is designed to be
repaired while still connected to the boiler
piping system. However, if more than one
port must be replaced, it is recommended that
the gauge be removed from the line and
Fossil Power Systems Inc.
repaired on a workbench. It is easier to control
the cleanliness and alignment of parts if the
repairs are performed on a workbench.
1. Ensure that the gauge is properly
isolated, depressurized and cooled
down before performing any
maintenance. Follow section 5.2 to
remove gauge from service.
2. De-energize and remove the gauge
Illuminator and Level Display.
3. If it is planned to replace all ports,
it is recommended that the gauge
be removed from the line and the
overhaul be performed on a
workbench. If only a few ports
will be replaced, this can be done
with the gauge in line.
4. Use a 3/8" socket wrench to
remove the capscrews and remove
the port cover.
5. Discard the old port assembly
(glass, mica, gasket, gasket
retainer) items (1) to (4).
6. Remove the glass retaining spring
(6) and discard the old cushion
gasket (5).
7. Inspect the flat washer (7),
Belleville springs (8), glass
retaining spring (6), port cover (9)
and bolts (10) for damage. The
minimum free height of two
Bellville springs nested together is
0.285" (7.24mm). Replace if
damaged or out of height
specification.
8. Carefully clean the gauge body
recess, paying particular attention
to the groove for the sealing
gasket. Ensure all traces of the old
gasket are removed. Carefully
inspect the groove. No visual
damage is permitted.
5
Aquarian 3000Visual Instruction Manual
9. Carefully clean the port cover (9).
Install the two Belleville spring
washers (8) in the port cover with
the cone pointing toward you (up).
The conical spring contacts the
cover on the large diameter.
Orientation of these parts is
critical.
10. Install the flat washer (7) new
cushion gasket (5) and glass
retaining spring (6).
11. Install the new repair kit assembly
(items 1 to 4) into the glass
retaining spring. Handle the glass
by the edges and do not contact the
sealing gasket or mica surfaces.
Ensure that it is properly centered
and fully seated against the
cushion gasket.
12. Lubricate the cover bolts with a
high temperature anti-seez
compound.
13. Insert the cover assembly into the
body groove with the cover vent
slot oriented toward the wide side
of the gauge body. Install two
cover bolts (10) finger tight to hold
the assembly in place.
14. Install the remaining cover bolts
and torque uniformly to 30 to 35
ft-lbs (41 to 48 Nm). Do not use a
power driver to torque the bolts. A
torque wrench must be used. The
cover should be metal to metal
against the gauge body. It is not
required to retorque the bolts after
the gauge has been put in service.
15. Re-install the illuminator and level
display.
16. When all repairs are complete,
place the gauge in service by
following the procedure in section
5.1.
6
Fossil Power Systems Inc.
7 PRINCIPLE OF OPERATION
Water level gauges use the manometric
principle of a liquid seeking a common level
between two connected vessels. The top of the
gauge glass is connected to the vessel steam
space. The bottom of the gauge glass is
connected to the vessel water space.
The water in the gauge will be cooler than the
water in the steam vessel and therefore will be
denser. This difference in density between the
steam drum and the gauge will cause the gauge
to indicate a level that is lower than the true
drum level. The magnitude of this error is
dependant on operating pressure, distance
from the gauge water level to the lower drum
connection, and piping. Other conditions that
can reduce gauge accuracy are piping/valves
plugged with sediment, pockets of water
collecting in the upper steam valves/piping,
and steam leaks.
The requirements for boiler level gauges are
defined in the ASME Boiler and Pressure
Vessel Code section PG-60. Among other
things, this code requires that connecting
piping from the boiler to the gauge be at least
1" NPS. There shall be no sag or offset in the
piping that will permit the accumulation of
water. To accomplish this, we recommend
that the steam piping slope down from the
steam vessel toward the gauge.
The ASME B & PV Code also requires that
"Segmented gauge glasses, such as ported or
end-connected strip gauges, shall be equipped
to provide obvious visual discrimination
between water and vapor in the individual
sections." The reason for this requirement is
that the user cannot see the steam/water
interface in ported gauges, and therefore
cannot determine the water level.
Manufacturer have met this ASME
Aquarian 3000Visual Instruction Manual
requirement by manufacturing the ported
gauge body in a trapezoidal shape and using
the principle of light refraction to create a
red/green color change indicating water level.
Additional descriptions of the AQ 3000V
Gauge and Illuminator can be found in the
references listed in the Introduction.
8. MAINTENANCE
The gauge glass mica shields protect the glass
from the erosive effects of high temperature
steam and water. Every customer must
establish an inspection and maintenance
schedule that insures the mica-glass-gasket
assembly is replaced before the mica
protective shield is dissolved. Gauge glass
ports that appears white, opaque or the
red/green image is blurred must be
immediately replaced. Failure to promptly
replace the mica-gasket-glass assembly that
appears white or opaque can result in sudden
and catastrophic failure of the glass and violent
discharge of hazardous high temperature
steam. The discharge of high temperature
steam at high velocity can result in severe
personal injury and property damage.
New gauges should be inspected monthly,
following the "Port Inspection" procedure
listed in section 5.3. After the preventative
maintenance schedule has been established,
port inspection frequency can be reduced, as
determined by the Maintenance Manager.
The level gauge, connecting pipes and valves
must be kept free from obstructions caused by
sediment in order for the gauge to provide
proper level indication. In addition, sediment
deposits on the mica will reduce the gauge
visibility. The gauge should be blown down
as required to eliminate sediment. Each plant
should establish a preventative maintenance
blowdown schedule. However, excessive
Fossil Power Systems Inc.
gauge blowdown will reduce the mica life and
should also be avoided. To clean the mica
surface, blowdown the gauge as described in
section 5.4.
To reduce the frequency of maintenance, FPS
recommends that all port kits are replaced at
the same time and that the Belleville Washers
are stacked 2 high and the cone height
measured. Replace all that measure less than
0.285" (7.24mm).
9 TROUBLESHOOTING
9.1 Level in gauge does not agree with
other level indications
1. Check that gauge is installed at
proper elevation. Installed
positions are normally referenced
to the steam drum centerline.
2. Check the steam supply and water
return piping and valves. All
valves must be fully open.
Blowdown the gauge and
connecting piping to ensure
sediment is not plugging lines.
3. Check that there are no steam leaks
in the connecting valves and
piping.
4. Check the temperature of the
gauge at the lower outlet pipe.
Excessive gauge sub cooling will
lower the water level in the gauge.
Gauge upper steam pipe bend
should not be insulated.
9.2 Red/Green image is poor, or
Red/Green Colors are reversed.
1. Follow troubleshooting procedure
listed in AQ3000V Illuminator
IOM #9340-1015 or 9340-1019
7
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

9.3 Water is leaking from port cover

1. Replace the port, following the
procedure in section 6.
10 Packing, Storage,
Transportation
The AQ3000V is a precision machined and
assembled level gauge. The following
precautions should be taken if it is necessary to
ship this product:
1. Wrap the gauge in plastic to
prevent the possibility of
environmental contamination.
2. Cover and protect flange faces
from damage.
3. Ship in a sturdy crate. Securely
clamp the gauge in the center to
prevent damage
11 SPARE PARTS
and It is recommended that enough port repair kits
to fully rebuild the gauge should be kept on
hand. The minimum repair kit is 2 times the
number of ports. For example, a 7 port
visibility gauge will require 14 Port Rebuild
Kits, part number 9320-0109. It is also
recommend that a supply of Belleville
Washers P/N 1020-0002 are also kept on hand.
The other gauge parts are not normally
replaced, but stocking a few spares is still
recommended.

If required to store the gauge before

installation, store it in a dry location, protected
from the elements.

10.1 Individual Part List

8
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

12 SPECIFICATIONS

Operating Pressure
Maximum: 3000 psi (207 bar)

Operating Temperature
Maximum: 696 F (369 C)

Visibility
Minimum: 5 port 12 ½” (318 mm)
Maximum: 20 port 57 ½” (1461 mm)

End Connections
Flanged: ¾” Class 2500 Flanged. Other flange ratings available.
Pipe Nipple: ¾” OD pipe nipple, for use with tubular packing box valves.

Flange Centers
Standard: As shown on the reference drawing, Figure 1
Custom centers available for retrofit applications.

Standards: Constructed to the ASME Boiler and Pressure Vessel Code Section 1
requirements for design, materials and construction.
Fossil Steam is an ISO 9002 Registered Company

Specifications and descriptions are subject to change without notice.

9
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

13 AVAILABLE OPTIONS
Additional options can be purchased to
customize the Aquarian 3000 Visual System to
individual applications:

 Visibility: Gauges are available in a

range of standard visibilities from
12½” (318 mm) up to 57½” (1461
mm) to suit every application
 End Connection options: Flanged with
pipe expansion loop, or pipe nipple
ended for use with tubular packing box
valves
 Gauge flange spacing: Standard flange
centers, or customized to suit retrofit
applications
 Solid-state Illuminator with Level
Display provides clear red/green image
and a 10 year maintenance free service
life. Illuminator can be easily
modified for use in hazardous
(explosive) areas. See Fossil Gauge
Illuminator Brochure 9340-1116 for
more information
 Gauges can be incorporated with other
standard components and provided as
part of a complete boiler level
equipment package including:
- Plain water column to match drum
centers and gauge flange centers
- Aquarian electronic level column
with probes, remote indication and
controls
- Gauge isolation valves with chain
wheel operators and chain
- Column isolation valves and drain
valves

10
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

Figure 1 - AQ3000V Gauge Assembly Drawing

11
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

Figure 2 - Flanged Gauge System

12
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

Figure 3 - Pipe Nipple Ended Gauge System

13
Aquarian 3000Visual Instruction Manual Fossil Power Systems Inc.

UPPER PACKING BOX

GAUGE VALVE

UPPER SPACER

PACKING

PACKING BUSHING
PACKING NUT

GAUGE GLASS

PACKING NUT

PACKING BUSHING
LOWER SPACER
PACKING

LOWER PACKING BOX

GAUGE VALVE

Figure 4 - Pipe Nipple Ended Gauge Installation

14
 Fossil Power Systems Inc.

10 Mosher Drive  Dartmouth, Nova Scotia  Canada B3B 1N5

Phone 902-468-4701 ext 720  Fax 902-468-2323
email enquiries: aquarian@fossil.ca
www.fossil.ca
Gauge Illuminator & Level Display Series 2
Installation, Operation
And Maintenance of

Aquarian 3000Visual

FOSSIL POWER SYSTEMS INC.

10 Mosher Drive
Dartmouth, NS
Canada B3B 1N5

PH# (902) 468-4701 ext 720

FAX# (902) 468-2323
www.fossil.ca
 Aquarian 3000Visual Illuminator Series 2
Instruction Manual
PN 9340-1019
Last Modified: January 8, 2010

Copyright  2007 Fossil Power Systems, Inc. All rights reserved.

All trademarks referenced herein are property of their respective corporation.
The information contained herein is subject to change without notice.

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About this Manual

This instruction manual describes the construction and operation of the Aquarian 3000V
Series 2 Gauge Illuminator & Level Display as supplied by Fossil Power Systems Inc.

Although care was exercised to make this Manual specific and complete, it is not intended that
it and its accompanying equipment manuals should provide for all potential operating and
maintenance conditions. It must be recognized that no amount of written instruction can
replace intelligent thinking and reasoning on the part of qualified personnel. It is the
responsibility of these personnel to become completely familiar with the mechanical,
electrical and control systems involved, including their characteristics and performance under
various operating conditions.

This knowledge can be obtained through the basic information provided in this manual,
supplemented by advice and recommendations from this Company’s field agents and by
actual experience.

Operation, maintenance and performance of any equipment not furnished by this Company
are the sole responsibility of others.

The nature of the electronics, the harsh operation environment and the potential
hazards associated with live steam require that only qualified personnel install and
maintain the equipment.

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Table of Contents
1 INTRODUCTION ................................................................................................................. 1

2 DESCRIPTION...................................................................................................................... 2

3 SAFETY INFORMATION ................................................................................................... 2

4 EQUIPMENT INSTALLATION ......................................................................................... 2

4.1 INSTALLATION PREPARATIONS ................................................................................................. 2
4.2 INSTALLATION .......................................................................................................................... 3
4.3 WIRING – STANDARD ILLUMINATOR......................................................................................... 3
4.4 PROTECTIVE GROUND WIRING ................................................................................................. 3
4.5 DISPLAY ADJUSTMENTS ........................................................................................................... 3
5 PRINCIPLE OF OPERATION ............................................................................................ 4

6 MAINTENANCE................................................................................................................... 4
6.1 LENS CLEANING ........................................................................................................................ 4
6.2 LED REPLACEMENT ................................................................................................................. 4
7 TROUBLESHOOTING ........................................................................................................ 5
7.1 NONE OF THE LIGHTS COME ON ................................................................................................ 5
7.2 ONLY SOME OF THE LIGHTS COME ON ....................................................................................... 5
7.3 RED/GREEN COLORS ARE REVERSED (STEAM IS GREEN, WATER IS RED) ............................ 5
7.4 IMAGE IS DIM ........................................................................................................................... 5
8 PACKING, STORAGE AND TRANSPORTATION ......................................................... 5

9 SPARE PARTS ...................................................................................................................... 5

10 SPECIFICATIONS ............................................................................................................... 6

11 AVAILABLE OPTIONS ....................................................................................................... 6

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List of Figures
Figure 1 – Gauge Hardware arrangement: Orientation A..................................................................7
Figure 2 – Gauge Hardware arrangement: Orientation B ..................................................................8
Figure 3 – Illuminator Assembly .......................................................................................................9
Figure 4 – Level Display Assembly ................................................................................................10
Figure 5 - Power Supply Assembly .................................................................................................11
Figure 6 - LED Orientation ............................................................................................................12
Figure 7 – LED Orientation Correction ..........................................................................................12

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

installation, operation and maintenance of

Aquarian 3000Visual Series 2
gauge illuminator & level display

1 INTRODUCTION
The Aquarian 3000Visual is a high-pressure
ported water level gauge used to measure the
water level in high-pressure boiler steam
drums. The ASME Boiler and Pressure Vessel
Code state, “ported gages or end-connected
strip gages, shall be equipped to afford obvious
visual discrimination between the appearance
of water or vapor in the individual sections.”

The Solid State Bi-Colour Gauge Illuminator

and Display attach to the 3000 psi (207 BAR)
ported gauge to produce a red or green image
on the display. A red image indicates that
steam is present and a green image indicates
that water is present. The red/green image is
produced by an array of solid-state light
emitting diodes (LED’s) and precision lenses
that focus the image through the gauge body
onto the display. The LED’s replace the
unfocused incandescent light bulb and colored
glass that are currently used in conventional bi-
colour illuminators.

The LED arrays and precision Plano-convex

lens provide a bright, clear and unmistakable
image in the presence of steam and water. The
high intensity narrow beam LED’s are
mounted on an electronic printed circuit board
with current limiting resistors. A 24VDC
power supply provides the Illuminator with the
current required for a constant clean image.

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Aquarian 3000Visual Illuminator Series 2
Instruction Manual
PN 9340-1019
2 DESCRIPTION
Reference:
• Figure 1 – Gauge Hardware arrangement:
Orientation A
• Figure 2 – Gauge Hardware arrangement:
Orientation B
• Figure 3 – Illuminator Assembly
• Figure 4 – Level Display Assembly
• Figure 5 - Power Supply Assembly
The Aquarian 3000V Gauge Illuminator and
Display are designed for use in conjunction
with the Aquarian 3000V to indicate boiler
water level. A clear Red or Green image is
displayed to indicate water or steam in the
gauge. The Illuminator houses an array of
solid-state light emitting diodes (LED's) and
precision lenses that focus the image through
the gauge body and onto the display. The
Display houses a translucent view screen and
adjustable windows for viewing the image. A
24VDC transformer that uses a 120 or 240
VAC input powers the Illuminator. The
Illuminator and Display can be installed on
either side of the gauge to give the best
viewing.
3 SAFETY INFORMATION
It is the user's responsibility to ensure that all
connections and wiring comply with all
applicable codes, specifications, sales
contracts or public laws. Qualified personnel
should perform all wiring.
The Illuminator must be operated at 24VDC
using the 120 VAC or 240 VAC power supply
transformer provided with the equipment.
Operation at any other voltage or with any
other power supply will cause equipment
damage.
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Fossil Power Systems Inc.
The Aquarian 3000V gauge operates at the
boiler saturated steam temperature. High
surface temperatures can be expected where
this equipment connects to the gauge.
The Illuminator and Level Display are
designed for indoor or outdoor service.
Shut off the Illuminator before doing any
maintenance or repairs.
4 EQUIPMENT INSTALLATION
Tools Required:
• 1/2" Socket, closed or open ended Wrench
• 1/8" Allen wrench
4.1 Installation Preparations
Reference:
• Figure 6 - LED Orientation
Note: The illuminator must be oriented
properly or the RED and GREEN colors
will be reversed (STEAM/WATER
indication)
1. Inspect the equipment to ensure no
damage has occurred.
2. Determine on which side of the
gauge the Illuminator and Display
will be installed.
3. Look at the illuminator top plate.
The “Wide Side” should match the
wide side of the visual gauge.
(figure 6). Also, the tag on the
Illuminator side identifies the
proper orientation.
4. If the orientation is incorrect,
remove the illuminator mounting
brackets (figure 7), rotate the
illuminator 180 degrees (top to
bottom), re-attach the mounting
brackets.
Aquarian 3000Visual Illuminator Series 2
Instruction Manual
PN 9340-1019
5. Confirm that the illuminator top
plate “Wide Side” marking is
toward the visual gauge wide side,
and the tag on the side is orientated
properly.
4.2 Installation
1. Loosen the 1/2" flange washers on
the gauge body.
2. First, hang the Illuminator on the
gauge body 5/16-18 studs. Then,
hang the Level Display on the
gauge body studs.
3. Snug up the 1/2" flange washers.
4.3 Wiring – Standard Illuminator
Reference:
• Figure 5 - Power Supply Assembly
CAUTION Before making any connections,
make sure that the power source to be used is
isolated by use of the appropriate circuit
breakers and switches so that no work is being
performed with "live wires".
For reliable operation, a power source with the
following requirements is necessary.
120 VAC ¼ Amp or 240 VAC ⅛ Amp
Single Phase, 50/60 Hz
The input power configuration is factory set to
either 120 VAC or 240 VAC before shipment.
This setting is shown on the power supply
name tag. It is recommended to use 18 AWG
or heavier wire for power connections.
1. Follow applicable wiring codes.
2. Attach input power to terminal
TB1. Power is connected to the
terminals designated "L" (line) and
"N" (neutral).
Fossil Power Systems Inc.
3. Connect the protective ground as
described in Section 4.4 below
4. Energize the Illuminator and check
for proper light on the display.
4.4 Protective Ground Wiring
Reference:
• Figure 5 - Power Supply Assembly
1. Locate the Protective Ground
screw inside the
enclosure below the
ground symbol. This
screw is close to the power supply
terminal TB1.
2. A green/yellow wire, having
minimum AWG size as the supply
cable, and fitted with a ring type
connector is to be secured to the
ground screw as shown below.
GROUND SCREW &
LOCK WASHER
GROUND WIRE & LUG
STAR WASHER
3. Ensure that the placement of the
ground ring connector is between
the lock washer and star washer.
4.5 Display Adjustments
1. The adjustable end plate (Display
Item 3) must be adjusted to give
the best RED/GREEN color
image. Adjustments are made by
loosening the two 10-32 button
head screws (Display Item 4) and
sliding the adjustable end plate
left/right as required.
2. If the Level Gauge is isolated and
drained, the display should show
all RED (steam). Adjust the
adjustable end plate as required.
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Aquarian 3000Visual Illuminator Series 2
Instruction Manual
PN 9340-1019
3. If the Level Gauge is in service and
the water level is intermediate,
adjust the adjustable end plate to
produce the best RED/GREEN
image.
4. If the gauge is isolated and full of
water, adjust the display to show
“GREEN”.
5. When adjustments are complete, the
10-32 screws should be snug. Do
not over tighten.
6. Fine adjustments should be made
with the gauge in service at
normal operating conditions
5 PRINCIPLE OF OPERATION
The AQ3000V Bi-colour Level Gauge, Gauge
Illuminator and Level Display utilize the
principle of the refraction of light. The
principle of refraction states that light will
bend (refract) as it passes through materials
with different densities (or indexes of
refraction). This principle is utilized to produce
a RED/GREEN color change that indicates if
WATER or STEAM is present in the Level
Gauge. The gauge body is a trapezoidal shape
because the light must contact the surface at an
angle in order for refraction to occur.
The Fossil AQ3000V Illuminator System uses
the following components:
1. AQ3000V Illuminator: Contains
the high intensity red and green
LED arrays and focusing lens.
2. AQ3000V Level Display: Contains
the view screen and adjustable
viewing windows.
3. AQ3000V Level Display Hood
and Hooded Mirror: These are
optional accessories used to
enhance the image for outdoor
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Fossil Power Systems Inc.
installations, or redirect the image
for viewing below the gauge.
Red and Green light from the LED's is
projected through a focusing lens and into the
individual gauge ports. If the gauge port
contains steam, the light passes straight
through the gauge with no refraction. A RED
image is displayed on the viewing screen. If
the gauge port contains water, the light is
refracted and a GREEN image is displayed on
the viewing screen.
6 MAINTENANCE
There is no routine maintenance required for
this product. The LED's have a rated nominal
life of 11 years.
6.1 Lens cleaning
Over a long period of time the light intensity
could decrease as the lens become dirty. The
lens assembly can be removed for cleaning as
follows:
1. De-energize the Illuminator.
2. Loosen the 1/2" flange nuts and
remove the Illuminator from the
gauge.
3. Remove the Cover and heat
divider
4. Carefully clean the lenses with
water and a soft cloth.
5. Re-assemble in the reverse order.
6.2 LED replacement
The LED's are installed on a printed circuit
board (PCB). These are replaced as follows:
1. De-energize the Illuminator.
2. Remove the 10-32 screws and
remove the cover.
Aquarian 3000Visual Illuminator Series 2
Instruction Manual
PN 9340-1019
3. Replace the defective PCB.
4. Re-assemble in the reverse order.
7 TROUBLESHOOTING
Ensure that proper electrical precautions are
taken when working on this equipment.
7.1 None of the Lights come on
1. Check for 120 or 240 VAC input
power to the power transformer.
2. Check for 24VDC power Pak
output.
3. Check for a blown fuse. For 120
VAC systems replace with ¼ Amp
250V 2AG fast acting
subminiature fuse, similar to
Littelfuse 225.250. For 240 VAC
systems replace with ⅛ Amp 250V
2AG fast acting subminiature fuse,
similar to Littelfuse 225.125.
4. Check for 24VDC at circuit board.
7.2 Only some of the lights come on
1. Remove the electronics divider
from the Illuminator housing.
2. Check that the power supply wire
is not blocking any of the LED's.
7.3 RED/GREEN colors are reversed
(steam is GREEN, water is RED)
1. The Illuminator must be properly
oriented toward the wide side of
the gauge.(see figure 5,6,7, and
section 4.1).
2. Remove the mounting ears and
reverse the orientation
. manual.
7.4 Image is Dim
1. Isolate and depressurize the Level
Gauge.
Fossil Power Systems Inc.
2. Remove the Illuminator and
display.
3. Check each gauge port for clarity.
If any port is starting to turn white
or opaque, this indicates mica
failure and the gauge port should
be replaced immediately. If the
ports appear dirty, the gauge
should be blown down more
frequently. See the AQ3000V
Level Gauge manual for detailed
instructions.
4. If the gauge ports are clear, check
the Illuminator Lenses and clean if
required.
8 Packing, Storage and Transportation
Although neither the Illuminator nor the Level
Display contain any fragile components,
reasonable care should be taken when handling
these precision engineered and manufactured
devices.
9 SPARE PARTS
There are no spare parts required or
recommended for this equipment. Any parts
that break or are damaged should be purchased
and replaced on an as needed basis.
To order replacement parts:
1. Provide Level Gauge serial number
and visibility.
2. Provide description and item
number from the parts lists in this
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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

10 SPECIFICATIONS

Supply Voltage 120 (108-132) VAC

240 (216-264) VAC

Supply Frequency 50-60 Hz

Supply Current ¼ Amp at 120VAC

⅛ Amp at 240VAC

Operating Conditions
This equipment is designed to be operated under normal environmental conditions for altitudes up to 2000 m.
Electronics: -20 °C to 60 °C (-4 °F to 140 °F)
Maximum relative humidity 80% at 30°C (86 °F)
Output
Voltage: 24 VDC
Power: 0.5 Watts/port, 0.02 Amps/port

LED life
Typical: average life is 11 years

Illuminator
Enclosure: Meets NEMA 4x requirements

Standards: Fossil is an ISO 9002 Registered Company

Manufactured under U.S. Patent Nos. 6,938,477; 7,197,926;
and 7,213,457
Canada Patent No. 2,465,601
A Patent is Pending for: Europe, Japan and China

Specifications and descriptions are subject to change without notice.

11 AVAILABLE OPTIONS
Additional options can be purchased to
customize the Aquarian 3000 Visual System to
individual applications:

• Display hood, for increased visibility

of display in bright sunlight
• Mirror or closed circuit TV camera
(CCTV) for remote viewing

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Figure 1 – Gauge Hardware arrangement: Orientation A

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Figure 2 – Gauge Hardware arrangement: Orientation B

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Figure 3 – Illuminator Assembly

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Figure 4 – Level Display Assembly

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

120 VAC Power Supply Assembly: PN 9310-9368

240 VAC Power Supply Assembly: PN 9310-9369

AC POWER
INPUT

CUSTOMER
CONNECTION
(SCREW TERMINALS)

Figure 5 - Power Supply Assembly

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Figure 6 - LED Orientation

Figure 7 – LED Orientation Correction

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Aquarian 3000Visual Illuminator Series 2 Fossil Power Systems Inc.
Instruction Manual
PN 9340-1019

Fossil Power Systems Inc.

10 Mosher Drive • Dartmouth, Nova Scotia • Canada B3B 1N5

Phone 902-468-4701 ext 720 • Fax 902-468-2323
email enquiries: aquarian@fossil.ca
www.fossil.ca

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