LEVEL MEASUREMENT SYSTEMS
Flow Reference Section
INTRODUCTION is designed to provide high
repeatability, minimizing the effects
pulses and a transmit gate signal
that are routed through the analog
Level measurement is an integral of shock, vibration and pressure. signal processor to the sensor.
part of process control, and may be Float switches can be used in a The sensor transmits an ultrasonic
used in a wide variety of industries. variety of media, as they are beam to the surface level, and the
Level measurement may be divided available with various materials of returned echo from the surface is
into two categories, point level construction. Also, minimum detected by the sensor and routed
measurement and continuous level maintenance is required, and to the microprocessor, which
measurement. Point level sensors installation is simple. The processes the signal into a digital
are used to mark a single discrete reed switch incorporated in representation of the distance
liquid height, a preset level a float switch is a hermetically between the sensor and the surface
condition. Generally, this type of sealed, magnetically actuated, level. The microprocessor stores
sensor is used as a high alarm, make-and-break type. For various the distance value and, by means
to signal the existence of an overfill models, the switches may be either of a moving average technique built
condition, or as a marker for a low single pole-single throw (SPST), into the software program,
alarm condition. The more or single pole-double throw (SPDT). compares it to the value of others
sophisticated continuous level stored in memory. If the value does
sensors can provide complete
level monitoring of a system.
NON-CONTACT not correspond to prior signals or
new signals being received, it is
A continuous level sensor, as the
name implies, measures the fluid
ULTRASONIC SENSORS rejected. Incorporation of a moving
average technique and a non-linear
level within a measurement range, The non-contact ultrasonic level digital filter ensures rejection of
rather than at a specific, single sensors consist of the following spurious signals and noise. The
point. The continuous level sensor elements: sensor, analog signal microprocessor constantly updates
provides an analog output that processor, microprocessor, and reviews the signals received,
directly correlates to the level within binary coded decimal (BCD) creating new averaged values which
the containing vessel. This analog range switches, and an output are indications of the actual fluid
signal from the sensor may be driver circuit. The microprocessor level in the tank.
directly linked to a visual indicator generates a series of transmit
or to a process control loop, forming Continuous Sensors
a level management system. For continuous sensors, the
averaged value from the
FLOAT SWITCHES microprocessor is converted into
an analog 4 to 20 mA signal which
The basic float switch is a is linear with the liquid level. In an
simple point level sensor. empty pipe or low level condition,
A magnet-equipped float, which when the echo from the level does
moves directly with the liquid not return to the sensor for more
surface, actuates a hermetically than 8 seconds, the output signal
sealed switch within the stem. The from the system drops below the
rugged construction of the reed minimum 4 mA.
switch design provides long, trouble
free service. The float switch Point Sensors
When the averaged value from
the microprocessor coincides
with the BCD switch setting, the
microcomputer energizes an output
relay, for either high or low level
indication. A momentary loss of
PERMANENT
signal from the sensor will not
FLOAT change the output status; the
MAGNET
microprocessor’s memory retains
the last valid value. However,
a signal loss for more than 8
seconds will cause the relays to
HERMETICALLY de-energize and return to original
SEALED state. A fixed half-second time
MAGNETIC
REED SWITCH delay is incorporated into the
electronics to minimize the
Non-contact ultrasonic sensor effects of surface turbulence
Reed-relay float switch and agitation on the unit’s output.
K-3
CONTACT droplets, foam or vapor. Liquids
which are highly aerated, or so
the material level changes.
These changes are electronically
ULTRASONIC SENSORS highly viscous as to cling in the
sensor gap, however, may present
conditioned into retrospective
capacitive and resistive values, and
The contact ultrasonic liquid level operating difficulties. are further processed and converted
switch detects and controls the into an analog signal. The probe
level of liquids, at a point, by means
of a low energy ultrasonic device CAPACITANCE and the vessel wall form the two
plates of a capacitor, with the liquid
having no moving parts. The
system consists of a field-mounted
LEVEL SENSORS medium serving as the dielectric.
The signal is generated only from
sensor with an integral solid state As with ultrasonic sensors, this level true level changes, thus rejecting
amplifier. Terminal blocks are measurement technology can be the unwanted effects of material
provided for connecting the system used for either point or continuous built-up on the probe. Note that for
to a power source and to external level measurement. A probe a non-conductive fluid vessel,
control devices. No calibration or inserted into the fluid tank senses special systems utilizing either
adjustment is required for dual probes or an external
automatic, trouble-free operation. conducting strip may be required.
The sensing probe may be
The sensor contains a 1⁄2" gap constructed from different materials,
across which an inaudible, high LVU-230S,
$489, shown with either a rigid or flexible design.
frequency ultrasonic signal is smaller than The most common design is a
generated. When liquid is in the actual size, conducting wire insulated with
gap, the ultrasonic signal easily see page K-34. PTFE A stainless steel probe
travels across the gap, and the is also available for applications
control relay switches. The sensing where greater probe sensitivity
level is approximately midway in the is necessary. For example, low
gap for horizontally mounted dielectric or non-conductive
sensors, and is at the top face of fluids (dielectric constant under 4)
the gap for vertically mounted or granular fluids require the
sensors. As the liquid falls below stainless steel probe. The flexible
this level, the ultrasonic signal is probes are used when there is not
attenuated and the relay switches enough overhead clearance for the
back to its previous state. This type rigid probe, or in applications
of level switch can be used in requiring the longer length. The
vessels or pipes to automatically rigid probe provides higher stability,
operate pumps, solenoid valves especially in turbulent systems.
and/or audible or visual high and If the probe sways to and from the
low alarms. Two units can control Contact ultrasonic sensor
vessel wall, the signal from the
tank filling (or emptying), or probe may fluctuate.
metering of a specific volume of
liquid. The switch will perform
satisfactorily in most liquids, and is
unaffected by coatings, clinging
K
Switch Ratings Max Resistive Load
VA Volts Amps ac Amps dc
0-50 0.2 0.13
10 120 0.08 0.05
240 0.04 0.02
0-30 0.4 0.3
20 120 0.17 0.13
240 0.08 0.06
0-50 0.5 0.5
50 120 0.4 0.4
240 0.2 0.2
120 0.8 N.A.
100
240 0.4 N.A. Ultrasonic interface detector
K-4
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