Level Control System by Excel Automation

System Overview

Excel Automation offers a custom-built pre-wired system, to sense the level of media in a bin, hopper, or stacked height of materials, and display that info in a digital readout. The digital display is programmable and scalable, enabling readout in desired units (e.g., feet, meters, percentage). Standard system includes sensor, digital level control system readout/display, power supply, enclosure, and intra-connecting cables.

Options include

Four (4) programmable set-points, each with a dedicated, Form A SPST relay output.
Three-tier LED visual indication representative of the degree of fill or set-point achievement, as well as an audible alarm corresponding to the fourth set-point.
Wireless remote signaling (stand-alone, no software required)
Wireless MDC / Machine Data Collection System; software-based (free software); data-log operational status of up to 50 machines; optional counting and wireless remote control capabilities; e- mail / smartphone notification of events.

Specs

Technical specifications for the standard model
Input power (system)	110 vac @ 0.040 amps (nominal)
Media sensed	Liquids, solids, slurries; discrete parts/td>
Sensor	0-10 vdc or 4-20 ma analog output (user-specified); analog span selectable, GE Ultem Nema 4X/IP67
Housing	Quick-disconnect type with mating cable (price length dependent)
Sensor ranges	Max range 10 inches; 1 meter; 2 meter; or 8 meters (price: range dependent)
Digital Readout	5-digit; red LED; 0.56 inches height; variable intensity; scalable; panel mount sealed bezel (NEMA 4X/IP65); 4 programmable set-points with dedicated relay outputs; each relay: s.p.s.t; contacts rated 250vac @ 3 amps
Power supply (for sensor & signaling device)	24 vdc @ 0.6 amps; regulated
Enclosure	Non-metallic (FRP); hinged; stainless hinge & latches; Nema 4/4X; IP67; 9 inches wide x 11 inches high x 7 inches deep (external dimensions); with integral through-hole flanges for wall mounting.
Signaling option	LED flat sign signaling device, integral visual & audible, 220 mm high x 62 mm wide x 30.5 mm deep (90 mm at base only); 3-tier (R,Y,G; dip-switch selectable), 1 audible alarm, 85 db, IP65.

System Selection

Example Part #: LEV – 1 M – 2 – 0

System selection options
System function	Sensing ranges	System level	Wireless communications
LEV: Level Sensing CTG: Counting RAT: Rate/speed/RPM ROL: Roll Diameter	1F: up to 10 inches 1M: up to 1 meter (39 inches) 8M: up to 8 meters (26 feet)	1: Basic system, monitoring only; no outputs 2: Monitoring + [4] programmable set-points & [4] relay outputs 3: (Level 2) + 3-tier LED visual + [1] audible or visual alarm signaling	0: (none) 1: Wireless remote signaling; Reflect System modules 2: Wireless MDC/Machine Date Collection System*; software-based 3: (Level 2) + Counting module 4: (Level 2) + Control module 5. (Level 2) + Counting module + Control module

Sensing Solution

Alarms distinguishing level too high versus too low in a tank
Challenge:	Solution:	Net Value to our Customers:
It is common in industrial applications to need a sensor to sense and/or control the fill level in a tank. The refinement of this application request is to additionally provide an alarm output for stronger, positive action in the event the process is out-of-control The process being out-of-control may have nothing to do with the sensor; e.g., the sensor may correctly be telling the pump to stop, but the motor contactor for the pump may have welded contacts. In such a situation, the pump keeps filling the tank, even though the sensor correctly signaled the desired fill level was achieved. If this continues, the tank may overflow, with its consequences. Most sensors merely have either a discrete or analog output for controlling the level, and may, or may not, offer a single alarm output. Given that different courses of action may be necessary for alarming for being too high or too low a level, the challenge is to be able to distinguish the difference in alarm conditions, which a single alarm output can not provide.	1F: up to 10 iOur Hyde Park sensors are typically the optimal solution for nearly any type of level sensing and control. The advantage is the availability of various models with up to 8 meters (26 feet) sensing range. The sensors are ultrasonic, and essentially treat all reflective media the same, are independent of the color of the media, and are optimally suited for a wet, dirty, dusty environment. The Hyde Park analog models provide an output proportional to the distance to the media in the tank and would be used to control the level in the tank. One of these analog models also has two alarm outputs. One alarm output can be set for being too high, the other alarm output can be set for being too low. One of our discrete models is offered with either a pump-in latch or pump-out latching output to control the level in the tank, while also having two alarm outputs. One alarm output can be set for being too high, and the other for being too low. So either of these two different models, as a single sensor, will not only control the level in the tank, but also provide two separate alarm outputs, to distinguish one alarm event from the other alarm event, so the user can take the appropriate corrective action. inches 1M: up to 1 meter (39 inches) 8M: up to 8 meters (26 feet)	Whether you have an easy or more challenging type of application, give us a call. Chances are we may have either the sensor and/or the experience to solve it. Excel Automation, and Eagle Sensors & Controls, have years of experience, and are application-oriented Authorized Distributors of numerous products for Industrial Automation, and LED Lighting.

Alarms distinguishing level too high versus too low in a tank

Challenge:

Solution:

Net Value to our Customers:

It is common in industrial applications to need a sensor to sense and/or control the fill level in a tank. The refinement of this application request is to additionally provide an alarm output for stronger, positive action in the event the process is out-of-control

The process being out-of-control may have nothing to do with the sensor; e.g., the sensor may correctly be telling the pump to stop, but the motor contactor for the pump may have welded contacts. In such a situation, the pump keeps filling the tank, even though the sensor correctly signaled the desired fill level was achieved. If this continues, the tank may overflow, with its consequences.

Most sensors merely have either a discrete or analog output for controlling the level, and may, or may not, offer a single alarm output. Given that different courses of action may be necessary for alarming for being too high or too low a level, the challenge is to be able to distinguish the difference in alarm conditions, which a single alarm output can not provide.

1F: up to 10 iOur Hyde Park sensors are typically the optimal solution for nearly any type of level sensing and control. The advantage is the availability of various models with up to 8 meters (26 feet) sensing range. The sensors are ultrasonic, and essentially treat all reflective media the same, are independent of the color of the media, and are optimally suited for a wet, dirty, dusty environment.

The Hyde Park analog models provide an output proportional to the distance to the media in the tank and would be used to control the level in the tank. One of these analog models also has two alarm outputs. One alarm output can be set for being too high, the other alarm output can be set for being too low.

One of our discrete models is offered with either a pump-in latch or pump-out latching output to control the level in the tank, while also having two alarm outputs. One alarm output can be set for being too high, and the other for being too low.

So either of these two different models, as a single sensor, will not only control the level in the tank, but also provide two separate alarm outputs, to distinguish one alarm event from the other alarm event, so the user can take the appropriate corrective action.

inches
1M: up to 1 meter (39 inches)
8M: up to 8 meters (26 feet)

Whether you have an easy or more challenging type of application, give us a call. Chances are we may have either the sensor and/or the experience to solve it. Excel Automation, and Eagle Sensors & Controls, have years of experience, and are application-oriented Authorized Distributors of numerous products for Industrial Automation, and LED Lighting.

Additional Information

Excel Level Control System DataSheet

Ultrasonic Sensor Level Sensing

Excel Automation Level Control Video

Hyde Park Hold on Loss of Echo Feature

Sensing Solutions

CONFIGURE A PART NUMBER [click here]

MORE INFORMATION ON OUR CONTROL SYSTEMS [click here]

Contact Excel Automation for assistance selecting a custom system for your level control sensing application, level sensing application, liquid level sensing application, stack height control application, and other control systems.