Battery operated ultrasonic level sensor

A battery operated ultrasonic level sensor is the perfect solution for remote tank monitoring. Some locations do not have 24DC power available which makes it very difficult to install an ultrasonic level sensor to monitor your current tank level. The only solutions are either mechanical sight glasses or a battery operated ultrasonic level sensor. The issue is that not very many companies manufacture a battery operated ultrasonic level sensor, this is a market that is huge but for some reason companies are not exploring this opportunity.

The largest requirement for a battery operated ultrasonic level sensor would have to be on small tanks, drums and totes. The operators that are purchasing liquids in small quantities such as these generally do not have that large of a budget for a ultrasonic level sensor. Also it may not be as important to know the level in the small vessel than it would be in a large holding tank. The small tank market is very large and they have been looking for a solution such as a battery operated ultrasonic level sensor. The battery operated ultrasonic level sensor has several different features which really make them appealing to the small tank operators. The local LCD display will provide a bar graph for continuously monitoring the level in these small tanks. The battery operated ultrasonic level sensor will also provide a low level indication decal which will alert the operator when they are in a low level condition. With several mounting options the battery operated ultrasonic level sensor can be mounted directly into a drum through the fine or coarse threaded bung. The battery operated ultrasonic level sensor will actually be provided with the mounting kit to install into NPT or straight thread connections making retrofitting very simplistic.

The battery operated ultrasonic level sensor is constructed with polyethylene due to the fact that many chemicals are stored in these drums and totes. They would not want to have to specify a material of construction for each application so they provided the battery operated ultrasonic level sensor with one of the most chemically inert materials so it does not take an expert to choose the right product.

 

The battery operated ultrasonic level sensor also has the ability to communicate wirelessly to a remote wall mounted display that will display gallons, inches, and even temperature. The way that the battery operated ultrasonic level sensor communicates to the remote display is through radio frequency technology. The concern many have with wireless communication is noise from other products interfering with others and then you will not get a good communication. This is not true with the battery operated ultrasonic level sensor and remote display provided by level pro. This is because the RF signal is unique and independent for each lbattery operated ultrasonic level sensor making it impossible to cross signals. The easiest way to put it, is to picture two walkie talkie’s and how they communicate via their own signal and nothing can interfere. The battery operated ultrasonic level sensor would be one walkie talkie and the display would be the other. Your customer will never have to worry about noise with the level pro battery operated ultrasonic level sensor.

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Ultrasonic level sensor

As previously mentioned you have many options for level transmitters, one of the most prominent is an ultrasonic level sensor. The ultrasonic level sensor is mounted on the top of a holding tank, side mounted into a pit or sump, or even used for small tank monitoring as they are becoming more and more affordable. The issue with submersible level sensors is that the operator must be aware of the media’s specific gravity. This is because submersible level sensors are continuously monitoring the weight on a diaphragm. If the operator is unaware of the specific gravity or if it changes due to temperature, then he will often look at installing aultrasonic level sensor. The ultrasonic level sensordetects the current level and monitors it continuously by transmitter a sound, the sound then travels and bounces off of a reflective surface and the ultrasonic level sensor measures the time of flight. 

The ultrasonic level sensor will then transmit a 4-20mA signal or 0-10V to a remote display / controller or PLC unit. It is often found that in large facilities the ultrasonic level sensor will be directly wired into a SCADA system so that the operator can monitor the reading from the ultrasonic level sensor on a PC or television. The operator can zoom in and highlight each independent ultrasonic level sensor and view the current readings remotely making it very simplistic to determine which condition his tanks are in. Some ultrasonic level sensors will actually have relay outputs often used for pump or valve control. For example, if the ultrasonic level sensor were to read a low level input that the operator entered it will activate the relay output and close a valve to prevent more liquid from leaving that holding tank. Alternatively, once the ultrasonic level sensor could continuously monitor the tank level and once the ultrasonic level sensor detects a high level it could activate a pump. The ultrasonic level sensor would let the pump know that it is time to pump down the liquid level to the operators desired level and then turn off.

There are several applications where an ultrasonic level sensor should not be recommended and those involve factors such as foam, vapor, turbulence and condensation. These factors will not be ideal for the ultrasonic level sensor and you can expect inaccurate readings which will mislead the operator or equipment that is connected to the ultrasonic level sensor. Having a sensor such as an ultrasonic level sensor that requires a return signal from the emitted noise you need to ensure that the sensor does not go lost or you will lose your reading. There are ways to install an ultrasonic level sensor and prevent some of the factors in the tank from misleading it. One of which is to install a standpipe around the ultrasonic level sensor, this liquid level will travel up the standpipe and the foam and vapor will remain on the outside of the standpipe. So if you are installing aultrasonic level sensor in an application where these factors are present that you will want to take precautions and install a standpipe.

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Chemical level sensor

Many applications will require a chemical level sensor over your generic level sensor designed for water or non-corrosive applications. Many do not realize what sets aside these two different level sensors and why they should select a chemical level sensor regardless of how corrosive the chemical is.

What sets aside a chemical level sensor from the generic level sensor is mainly the materials of construction and functionality of the level sensor itself. The chemical level sensor will generally be constructed of PVDF Kynar or another chemically inert material. Even if the chemical level sensor is never in contact with the media, there may be fumes or vapors present that would attack even the non-wetted materials on the chemical level sensor. Many operators overlook the fact that the chemical level sensor should be corrosion resistant even if the chemical level sensor is never in contact with the media. The level sensor manufactured for water and non-corrosive medias will generally be manufactured in metal. The metal will corrode and this is why you must be careful when selecting a chemical level sensor.

Next up is selecting the correct output signal for the chemical level sensor, this is dependent on if it is a new or existing application. For existing chemical level sensor applications, you will have to look at the communication input on the PLC, remote display, or VFD / valve. This will dictate which chemical level sensor output you will have to choose. For example, if the PLC has a 4-20mA input, then you must choose a chemical level sensor with a 4-20mA output. This is the only way the chemical level sensor will be able to communicate with the PLC. Now when you have a new installation for a chemical level sensor you can choose from any output as long as you select a PLC or display with the same input. The most common outputs for a chemical level sensor are 4-20mA, 0-5V or 0-10V. It is very rare that a chemical level sensor would have an output that varies from one of these options. 

Another very important feature to pay attention to when selecting a chemical level sensor is the IP rating on the enclosure or housing. The IP rating allows the operator to know what environment the chemical level sensor will hold up in. For example, if your chemical level sensor carries an IP65 rating or NEMA 4X enclosure, he will have the ability to install in an outdoor application. The IP65 housing will prevent any moisture or liquid from entering the electronics and damaging the internals of your chemical level sensor. Also you will want to ensure that your chemical level sensor carries the electrical approvals that you require to sell into your market. Whether that is Class 1 Division 1 explosion proof rating, or a CSA Canadian standards rating. If an inspector were to stop by your plant and you have a product that is not certified than you will have to remove it and you may receive a fine.

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Level Sensor

When choosing a level sensor for a specific application there are many factors that an operator will have to consider to ensure they select the best level sensor for the job. The level sensor must be compatible with the chemistry in the application, this is important even if they decide to install a non-contact level sensor. Next the operator will have to look at the different factors within the application for the level sensor, for example, they may have an open or closed top tank or sump and they must have a means to mount the level sensor. 

In a closed top tank, they can mount the level sensor in a bulkhead fitting or threaded flange. If they have an open top tank or a sump, then they may have to get creative. The level sensor in a open top tank or sump can be mounted in a side mount bracket the level sensor will have a threaded process connection. Once they have decided how they intend to mount the level sensor they now have to look at different factors that may influence the reading of the level sensor. These factors can include vapor, foam, turbulence, and condensation. All of which will impact the selection of the level sensor and it is very important that the operator has the ability to make an educated selection for the right level sensor. 

Now, I will break down each factor and advise you on how it will influence the level sensor selection process based on functionality. First we will discuss how vapor will influence your selection for the level sensor. Vapor will heavily effect the readings on ultrasonic level sensors, the ultrasonic level sensor emits a noise and waits for a return signal. The vapor has the ability to bounce the signal from the level sensor causing it to go lost or get deflected off of the tank walls or obstructions in the application. For applications that have vapor present you should select a submersible level sensor. Foam has a very similar impact on a non-contact level sensor, the level sensor will emit that sound signal and it will become absorbed into the foam and since the level sensor is not getting a return signal it will go lost. For applications with foam present it is in your best interest to select a submersible level sensor as well.

 Turbulence is also very difficult factor internal to your tank or pit making it a tough one for a level sensor. The turbulence will cause the level sensor to jump as the liquid level is constantly fluctuating. The level sensor should also not be a contact switch style, as you may have chatter occurring. The level sensor the operator should choose remains submersible for this application as well. Lastly we have arrived at condensation, the condensation builds up in a tank and hoovers around the top portion and causing ultrasonic level sensors to detect the level of the condensation. It is also possible that the level sensor will build up a lot of condensation on the transducer and then it will go lost. Again, the best level sensor for this application is submersible. 

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Liquid Level Probe

There are several reasons why an operator would install a liquid level probe, the most common is to determine the current level in a tank without incorporating any electrical equipment. Many companies either do not have access to electricity where the tanks are located or they simply do not want anything complicated. Other applications for a liquid level probe include but are not limited to sump level, drum level, and open tank level control. 

Most liquid level probes are inserted into the top of the tank through a threaded bulkhead fitting or flanged connection, this is the most common way to install a liquid level probe. Essentially a liquid level probe will either be used for continuous level measurement with a 4-20mA output that would be ran from the liquid level probe to a PLC or local LED display. Alternatively, a liquid level probe would be used from a high or low level switch. The liquid level probe would have a relay output and once the liquid level hits the liquid level probe it would switch and communicate to a local audible or visual alarm. The liquid level probe would alert the operator that their tank is in an upset condition, whether it is low or high level the liquid level probe can work in either application. It all depends on how the liquid level probe is connected to the alarm, normally open or normally closed are the standard options for a liquid level probe.   

The most common mistake that operators make when choosing a liquid level probe is that they will not take into consideration the wetted materials. Especially when they use one that should never really see the application, such as a high level liquid level probe. Many companies will make stainless steel liquid level probes and this will not be suitable in any aggressive chemical applications. It is highly recommended that the operator select the Level Pro CSS liquid level probe which is constructed of polyethylene material and suitable for most chemical applications. The simplistic is also a reason that operators lean towards the Level Pro CSS liquid level probe. Complete with a NEMA 4X junction box with an internal terminal strip so the operator can run his own cable into the switch to connect it to his alarm is very important to most companies. 

The Level Pro CSS liquid level probe is one of the only liquid level probes that have this as a standard feature. A market leading water treatment chemical skid manufacturer was looking for a corrosion resistant liquid level probe that would replace the floats that they were currently using, the issue was that the floats on the current liquid level probe would eventually stick and fail causing amisreading and a lot of overfills within the plant that purchased the units. The solution was to incorporate the Level Pro CSS liquid level probe, with no moving parts the capacitance liquid level probe would detect the high or low level and never become subject to failure due to sticking. 

Our more products: Liquid Level Sensor, Level Sensor