Adding an Illuminator to Existing Gages in the Field

If your facility has older gage glasses or level indicators installed in dark areas or locations with poor ambient lighting, you don't need to replace the entire gage. You can retrofit it with a modern LED illuminator to dramatically improve visibility. Here's what you need to know about adding illumination to existing equipment.

The Problem with Dark Gage Locations

Many facilities have gages installed in boiler rooms, control rooms, or outdoor areas where natural or ambient lighting is inadequate. Operators struggle to see water level clearly, especially at night or in overcast weather. This creates safety and operational issues:

• Difficult Reading: Operators must stand very close or use flashlights

• Operator Error: Poor visibility leads to misreading levels

• Safety Risk: Operators exposed to hot equipment trying to see better

• Equipment Wear: Operators tap or vibrate gages trying to confirm readings

Replacing the entire gage is expensive and time-consuming. Retrofitting with an LED illuminator is the practical solution.

LED Illuminators vs. Incandescent

Old Incandescent Style:

• Service life: 1,000-2,000 hours continuous use (about 3-6 months)

• Generates significant heat

• Requires frequent replacement

• High operating cost

• Unreliable in vibration-prone areas

Modern LED Illuminators:

• Service life: 100,000+ hours continuous use (10+ years)

• No heat generation

• Virtually maintenance-free

• Low operating cost

• Superior visibility regardless of ambient light

LED technology makes retrofitting practical because you won't be changing illuminators every few months.

The Jerguson EPL-100 LumaStar™ LED Illuminator

The EPL-100 LumaStar™ is specifically designed as a universal retrofit solution. Key features:

Universal Compatibility

• Fits Jerguson gages and most competitor models

• Accommodates gage cover widths up to 3-1/2 inches

• Universal bracket design adapts to most existing installations

• No gage modification required

Superior Light Output

• White LED cuts through process fluids (water, oil, chemicals)

• Exceptional visibility even in bright sunlight or dark areas

• Adjustable brightness on some models

• Consistent light output over entire service life

Low Maintenance

• 100,000+ hour service life (10-15 years typical)

• No replacement bulbs needed

• Sealed design withstands moisture and vibration

• Single power connection

Cost-Effective

• Fraction of gage replacement cost

• Quick installation (minimal downtime)

• Low power consumption (operates on standard AC voltage)

• Long service intervals reduce maintenance headaches

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Installation Overview

Adding an LED illuminator to an existing gage is straightforward:

Step 1: Mount Bracket The universal bracket attaches to the gage cover using existing mounting points. No drilling or gage modification required.

Step 2: Position Light Source The LED light source positions to illuminate the gage glass from behind or to the side, depending on gage type.

Step 3: Connect Power Electrical connection to site power (typically 120VAC or 240VAC). Most installations require standard electrical conduit.

Step 4: Test and Adjust Verify illumination and make minor brightness adjustments if available.

When to Retrofit vs. Replace

Retrofit with LED Illuminator if:

• Gage is functioning properly

• Main issue is visibility/lighting

• Existing gage is appropriate for the application

• Cost is a consideration

Replace the Entire Gage if:

• Gage glass is damaged or continuously fogging

• Seals are leaking

• Gage can't meet current safety standards

• Application requirements have changed

Applications Benefiting Most

LED retrofits are particularly valuable in:

• Outdoor boiler installations (weather exposure)

• Control rooms with variable lighting

• Dark boiler rooms

• 24/7 operations (night shift visibility)

• Remote locations where power is available

Next Steps

If you have existing gages that are difficult to read due to poor lighting, contact Clark-Reliance to discuss a retrofit with the EPL-100 LumaStar™ LED Illuminator. Our team can assess your installation and provide a quote and installation timeline.