A Minor Project Report On WIRELESS BIOMEDICAL MONITORING SYSTEM

Submitted in partial fulfilment for the award of the degree of

BACHELOR OF TECHNOLOGY In Electronics and Communication Engineering

2011-2012
Submitted to: Mr. ASHOK KAJLA Prof.&Head, Department of Electronics &Comm. Engg.

Submitted by: -

Pulkit Rawka(08EAIEC070) Vishal Kothari(08EAIEC116) B.Tech IV Yr. VII Sem

RAJASTHAN TECHNICAL UNIVERSITY, KOTA

DEPARTMENT OF ELECTRONICS ENGINEERING SP-40, RIICO INDUSTRIAL AREA, KUKAS, JAIPUR, RAJASTHAN DEPARTMENT OF ELECTRONICS ENGINEERING ARYA INSTITUTE OF ENGINEERING & TECHNOLOGY
SP-40, RIICO INDUSTRIAL AREA, JAIPUR (RAJASTHAN) 302 022 SP-40, RIIC

ARYA INSTITUTE OF ENGINEERING & TECHNOLOGY

CERTIFICATE
1

This is to certify that the Minor Project Report on WIRELESS BIOMEDICAL MONITORING SYSTEM at ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY, JAIPUR is submitted by Mr. Pulkit Rawka (08EAIEC070), Mr.Vishal Kothari in partial fulfilment for the award of degree of Bachelor of Technology in Electronics and Communication Engineering approved for submission. has been found satisfactory and is

Project Guide Mr. Manish Raverkar Associate Professor Deptt. of Electronics Engineering

Project Coordinator Mr. Manish Raverkar Associate Professor Deptt. of Electronics Engineering

ACKNOWLEDGEMENT
We cannot achieve anything worthwhile in the field of technical education unless or until the theoretical education acquired in the classroom is effectively wedded to its practical approach that we do live projects and seminars. It gives us a great pleasure to have an opportunity to acknowledge and to express gratitude to those who were associated with us. First of all we are thankful to Dr. Arvind Agrawal for providing us with an opportunity to undergo my engineering at AIET. We are grateful to our Principle Mr. M.L.Gupta and our Head of Department of Electronics and Communication Department Mr. Ashok Kajla.
2

We express our gratitude to AIET faculties for allowing us to undergo our project with many helping hands and no regrets. We are thankful to Mr. Manish Raverkar who guided us at every step & our discussion with them was truly enlightening. Their dedication & sincerity towards the project helped us a lot in the completion of this project report & gave it the present attractive look. I also owe a great deal to all my colleagues & persons who directly or indirectly were a source of constant help & suggestions for the project. PULKIT RAWKA VISHAL KOTHARI

ABSTRACT
SAPCON INSTRUMENTS PVT. LTD. was established in the year 1983 in the commercial capital of the state of Madhya Pradesh, the city of Indore. Today the company has almost 1300 customers in almost countries of the world. Today SAPCON continues to grow steadily to greater heights under stewardship of Mr. RAJENDRA PALSHIKAR (Director). It had been accredited to various accredit ion bodies such
3

as ISO 9001-2008, ISO 14000, D&B, CE, ANAB etc. The whole company has three sections Electronics production section, mechanical production section, research and development department. SAPCON produces Level Measuring Instruments and Speed Monitoring Instruments which are the requirements of a large number of organizations for the measurement of level and speed. SAPCON produces level measuring instruments on the principles of admittance, capacitance, conductivity, vibrating fork etc. These instruments are either electronically based or microprocessor or microcontroller based for the measurement of level. There is a phenomenal rise in the growth of company in recent decades and has a vision of covering almost 100 countries by the end of the year 2012.

FIGURE LIST S.No.

1. 2. 3. 4. 5. 4

Figure Name
Water Level Sensor. Liquid Level Switch. Level Transmitter. Fork Level Switch. Admittance Level Switch.

Page no.
(AIET/DOECE/2011-12/4) (AIET/DOECE/2011-12/5) (AIET/DOECE/2011-12/6) (AIET/DOECE/2011-12/7) (AIET/DOECE/2011-12/8)

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Ultrasonic Level Transmitter. (AIET/DOECE/2011-12/9) Admittance Level Switch. (AIET/DOECE/2011-12/11) System Diagram of Admittance Level Switch. (AIET/DOECE/2011-12/12) Capacitance Level Limit Switch. (AIET/DOECE/2011-12/18) System Diagram of Capacitance Level Limit Switch. (AIET/DOECE/2011-12/19) Conductivity Level Limit Switch. (AIET/DOECE/2011-12/23) System Diagram of Conductivity Level Limit Switch. (AIET/DOECE/2011-12/24) Vibrating Fork Level Switch.(SLM) (AIET/DOECE/2011-12/30) System Diagram of SLM Series. (AIET/DOECE/2011-12/31) Vibrating Fork Level Switch.(SLF) (AIET/DOECE/2011-12/34) System Diagram of SLF Series. (AIET/DOECE/2011-12/34) Elixir MPSLF. (AIET/DOECE/2011-12/37) MPILC. (AIET/DOECE/2011-12/43) System Diagram of MPILC. (AIET/DOECE/2011-12/44) Translite. (AIET/DOECE/2011-12/47) MP-SLA. (AIET/DOECE/2011-12/51) System Diagram of MP-SLA. (AIET/DOECE/2011-12/51)

TABLE LIST S.NO

1. 2. 3. 4. 5. 5

Table Name

Page no.
(AIET/DOECE/2011-12/2) (AIET/DOECE/2011-12/13) (AIET/DOECE/2011-12/15) (AIET/DOECE/2011-12/17) (AIET/DOECE/2011-12/27)

Level Measuring Instruments. Connection Diagram of Admittance level limit switch Calibration of Admittance level limit switch. Troubleshooting. Calibration of Conductivity level limit switch.

a). Single point operation i). For fail safe High. ii). For fail safe Low. b).Two point level limit switching with Pump control.(AIET/DOECE/2011-12/28) i). For fail safe High. ii). For fail safe Low. 6. Calibration of Translite. (AIET/DOECE/2011-12/49)

CONTENTS
I. II. III. IV. V.
6

SAPCON HISTORY WHERE ARE WE TODAY SAPCON ADVANTAGE LEVEL MEASURING INSTRUMENTS ELECTRONICALLY BASED LEVEL LIMIT SWITCHES

1. ADMITTANCE LEVEL SWITCH.

-INTRODUCTION -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -INSTALLATION -TECHNICAL SPECIFICATION -CALIBRATION -SALIENT FEATURES -APPLICATIONS -USAGE 2. CAPACITANCE LEVEL LIMIT SWITCH. -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -INSTALLATION -TECHNICAL SPECIFICATION -CALIBRATION -SALIENT FEATURES -APPLICATIONS -USAGE 3. CONDUCTIVITY LEVEL LIMIT SWITCH. -INTRODUCTION -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -INSTALLATION -TECHNICAL SPECIFICATION -CALIBRATION -SALIENT FEATURES -APPLICATIONS -USAGE 4. VIBRATING FORK LEVEL LIMIT SWITCH. -INTRODUCTION -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -INSTALLATION -TECHNICAL SPECIFICATION -CALIBRATION -SALIENT FEATURES -APPLICATIONS -USAGE

I.

MICROPROCESSOR/MICROCONTROLLER BASED LEVEL LIMIT SWITCHES

1. ELIXIR-MPSLF -INTRODUCTION -PRINCIPLE OF OPERATION

7

-SYSTEM DESCRIPTION -INSTALLATION -TECHNICAL SPECIFICATION -CALIBRATION -ERROR INDICATION -MAINTENANCE -FAULT FINDING PROCEDURE -SALIENT FEATURES -APPLICATIONS 2. MPILC -INTRODUCTION -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -TECHNICAL SPECIFICATION -SALIENT FEATURES -APPLICATIONS 3. TRANSLITE -INTRODUCTION -PRINCIPLE OF OPERATION -SYSTEM DESCRIPTION -TECHNICAL SPECIFICATION -CALIBRATION -SALIENT FEATURES -APPLICATION 4. MP-SLA -INTRODUCTION -SYSTEM DESCRIPTION -TECHNICAL SPECIFICATION -SALIENT FEATURES -APPLICATIONS

I. II.
III.

RESULT CONCLUSION REFERENCES

SAPCON HISTORY
Setting the clock back to year 1983, Sapcon Instruments found itself surfaced with a vision to help automate the measurement of industrial processes. Sapcon founders started the company in the commercial capital of the state of Madhya Pradesh; the city of Indore. The founders of Sapcon had a technical background with sound experience in engineering.
Without a fear of the unknown or the hitch of failure, the only thing our far sighted technocrats had in
8

mind was a clear focus and a vision to be a renowned brand in the process automation market. The start though small, nevertheless laid the foundation towards the establishment of the million dollar worth Sapcon Instruments. The first commercial success of the company came

when JK cement group and

Larsen & Turbo (L & T) India started

doling contracts to Sapcon in year 1984.

WHERE ARE WE TODAY

Today, Sapcon Instruments has shifted to a plush office in the heart of the Indore city. Sapcon grew and grew worldwide. Today, the company has a strong presence and exports process
automation instruments to more than 30 companies including USA, Australia, China, Thailand, Russia, Baltic States, Abu Dhabi, Dubai, Greece, Turkey, Malaysia, Thailand... just to name a few. The company has over 1300 satisfied customers across four continents.

THE SAPCON ADVANTAGE

Today, Sapcon designs and manufactures a broad portfolio of level instruments
and speed monitoring systems. Sapcon has the resources to support your design and

manufacturing requirements. Sapcon delivers personal attention from engineering experts and technical support to reduce the risks associated with developing a process automation system, improve the understanding of design issues based upon your requirements and quickly identify the right solutions. Decades of application engineering expertise provides the perspective quickly to prototype, build, and deliver systems exactly to your critical requirements. The R & D team at Sapcon simulates actual application environments and performs rigorous environmental testing. Experience has taught us which technology and product characteristics provide effective solutions to customers' problems. There's a good chance we've already dealt with design issues intriguing you and will probably have a solution in form of a product. Applications requiring a customized product solution will be thoroughly taken care of and we will try to modify an existing product or design something completely new. Our flexible manufacturing system reduces lead time and costs involved in made-to-order systems.
Sapcon Instruments is a leading manufacturer of process control and automation instruments like level sensors, level switches, level transmitters and level indicators. With over 25 years of experience and commitment to quality, for us its always Customer

First.
9

LEVEL MEASURING INSTRUMENTS

APPLICATION LEVEL LIQUID. INSTRUMENT LEVEL SWITCH for LEVEL SWITCH SLURRIES. LEVEL for TRANSMITTERS for LIQUIDS & SOLIDS. SWITCH for SOLIDS.

VIBRATING FORK VIBRATING ROD RF-ADMITTANCE

SLF X SLA

SLM/Humming Bird. SLP SLA...M/MPSLA/ PLATYPUS

SLF X SLA/ MPSLA

X X X

RFCAPACITANCE CONDUCTIVITY ULTRASONIC

SLC/ MPSLC

SLC/ MPSLC/ SLS

ILC/ MPILC

SLW HAWK sr...

X AW HAWK AW sr...

X HAWK sr...

X AW HAWK AW sr...

SLM: Vibrating Fork Level Switch

for solids up to 10mm size, high temperature up to

2000C, no calibration, no maintenance.

SLF: Vibrating Fork Level Switch

for liquids & slurries up to viscosity 10000cP, high

temperature up to 2000C, no calibration, and no maintenance.

Humming Bird:

Compact Vibrating Fork Level Switch for solids < 10mm size,

open collector/ relay output

SLP: Vibrating Rod Level Switch for light solids, ideal for packing industry. SLA: 3-element immune coat RF-Admittance Level switch for viscous liquids & slurries. SLA....M: 3-element immune coat RF-Admittance Level switch for low dielectric solids like fly
ash having tendency to form build-up on sensing probe, suitable for high temperature up to 6000C.

MPSLA: Microprocessor based RF-Admittance Level Switch with coating

& liquids. 10

immunity for solids

PLATYPUS:

Compact Microprocessor based Admittance Level Switch with open

collector output for light solids.

SLC: Capacitance Level Switch

6000C.

for free flowing liquids and solids upto maximum

MPSLC: Microprocessor based Capacitance Level Switch with PFM technology

liquids.

for solids and

SLS:

Compact Capacitance Level Switch (probe & electronics integrated as one

unit) for low dielectric service material.

ILC:

Capacitance Continuous Level indicator & transmitter for all liquids and

homogeneous solids with stable dielectric constant.

MPILC: Microprocessor based Capacitance Continuous

solids & liquids.

Level indicator & transmitter for

SLW:

Low cost Conductivity type Level switch for conductive liquids, pump

control, customized solution.

HAWK AW sr......: EX- M/S Hawk Measurement Systems, Australia, measuring range up to 60m in
solids & liquids, Remote & Integral Models. ** Universal Power Supply (90 to 260 VAC) also available in all entire models.

11

Water level Sensor

Conductivity based level sensor for water & liquids having conductivity of more than or equal to 25m Siemens

12

Liquid Level Switch

Vibrating fork based level switch for measuring level of a variety of liquids

13

Level Transmitter
Capacitance based continuous level control & indicator for acute plant conditions

14

Fork Level Switch

Vibrating Fork level switch for solids including granular service materials, free flowing powders and solids submerged in less viscous liquids (suspensions)

15

Admittance Level Switch

Reliable level switch with accurate signal transmission between the level probe and the evaluation electronics.

16

Ultrasonic Level Transmitter

Non contact type level transmitter with non invasive acoustic wave transmitter.

ELECTRONICALLY BASED LEVEL LIMIT SWITCHES

17

1. ADMITTANCE LEVEL LIMIT SWITCH

Levtester SLA.........M Series SLA.........B Series

INTRODUCTION
Sapcon Admittance level limit switch utilizing specially designed Immunocoat probe offers a reliable solution to level detection problem so far difficult to solve with capacitance type system utilizing conventional probes. The main advantage offered by admittance range of level
switches is their ability to ignore build up and coating of material on the probe. Purpose of adding a shield in between sensing element and ground is to avoid RF currents from reaching the container wall via the coating. Although there would be RF

current flowing between the shield and the container wall via the build up, it would not be considered by the measuring circuit and will not affect on the level instrument. This unique design enable the electronic circuitry to distinguish between significant process coating and the actual process material thereby gives reliable accurate switching.

18

Admittance measurement using Immunocoat probe gives satisfactory solution in tough environments where, Material has a tendency to coat. There is a bridging (build up) of material between probe and sidewall. Material particles with electrostatic charge and varying temperature float in the vicinity of the probe.

Admittance Level Switch

MEASURING PRINCIPLE

The sensing element and the container wall (or ground electrode) form a means to measure the admittance of the system with or without the intervening material. When all the parameters that affect the admittance value are kept constant then its value changes only due to the diff. in material level. The sensed signal is further amplified and used to actuate the relay. The relay contacts are used for alarm or control purpose.

MEASURING SYSTEM
A complete measuring system comprises:

19

Evaluation unit. Immunocoat probe. Interconnecting cable.

SYSTEM DESCRIPTION
Immunocoat probe is of a special construction with three concentrically positioned electrodes that are electrically insulated from each other. The innermost electrodes serve as the sense electrode whereas the one next to it is the shield & the outermost is ground. The sense electrode is connected to a radio frequency source and the shield is also connected to the same source but through an isolating amplifier.

They therefore have identical waveforms and the shield follows the sense, maintaining equivalent potential, frequency & phase relationship. Due to this there is no flow of RF current between the shield and sense electrode. The flow of RF currents via the shield to sidewalls does not affect the measurement due to isolation amplifier. The probe head is of cast Aluminium weather proof construction provided with suitable cable glands and fitted on to the probe mounting arrangement. A discharge device is provided with the system where there is a possibility of generation of static charge in the service material. The Immunocoat probe is connected to the evaluation unit with a special screened cable of pre-trimmed length. The evaluation unit is housed in a cast Aluminium weather proof housing that is stoving enamel
20

painted & provided with three nos. of cable entries of size. The electronics & interconnecting terminals are assembled on a glass epoxy PCB, which is heavily lacquered for rendering it immune to moisture, dust & fungus.

INSTALLATION
1. Instrument can be installed in almost any position. 2. Install probe in such a way that sense, shield & non active length must come in active zone. 3. The threaded mounting connection should be as short as possible to avoid deposit of material in the nozzle cavity. 4. When mounting is from side the cable entry should be pointing downwards, so that no moisture can enter. 5. Make sure that the probe insulation is not damaged when inserting the probe through the nozzle. 6. Probe should be installed away from the inlet. If it is not possible, fix baffle plate 300mm above from the probe.

INTERCONNECTION
1. Refer diagram before making interconnection. 2. One such diagram is also pasted inside the evaluation unit cover. 3. Connect the mains supply as mentioned inside the cover. 4. Verify the line voltage before switching on the instrument. 5. Interconnection between probe & evaluation unit is made by means of special PTFE co-axial cable of pre trimmed length. 6. Ensure controller unit is earthed properly.
7. Use three core cable of 1.5mm sq. diameters, in case of AC power supply & relay contacts.

CONNECTION DIAGRAM
1. L 2. N 3. E 4. C 5. N/O 6. N/C 7. 8. 9. 10. R 11. B 12. W

21

110/230 VAC 50Hz

TECHNICAL SPECIFICATION
Model BAR DOT SLA 122M/222M/322M/622M SLA3-122B/222B/322/622B

EVALUATION UNIT Housing Cast Aluminium Weather Proof stoving enamel painted / Siemens grey powder coated / Epoxy coated suitable for back panel / Wall mounting. Cable Entry Cable Gland ET-2 nos. & 1no. for jack connector. Single/Double Compression Size / BSP/NPT/Brass/Stainless Steel/NG 20
Tolerable Ambient Temp. Power Consumption 00 C to 600 C 5VA Approx

Mains Supply

90 to 265 VAC, 50 Hz (Universal Power Supply), 110/230 VAC50Hz Optional 24 VDC

Fail Safe Mode Output

Max/Min Field selectable. One/Two set of potential free c/o contacts rated at 6 Amps 230 VAC for non inductive loads.

Indication RED LED for Alarm & GREEN LED for Normal Condition.

Sensitivity Indicator

Ten Dot display for sensitivity calibration also for showing the material trend in the vicinity of the probe.

Calibration

Through Multi Turn Potentiometer.

Measuring Frequency 100 KHz Response Time Less than 1 second

Switching Delay

Adjustable from 5 to 20 seconds (Covered & Uncovered) applicable for Model SLA 322M & 622M

22

Inter Connection

Between Probe & Evaluation Unit, by special coaxial cable with drain wire.

Weight IMMUNO COAT PROBE Housing Cable Entry Cable Grand Mounting Connection

2.25Kgs

Cast Aluminium Weather Proof. One no. BSP/NPT/Brass/Plastic/Stainless Steel Single/Double Compression Screw-1/1/BSP/NPT Flange-As per requirement

Insulation Insulating Material Process Temp. Extension

Part/Full PTFE/Ceramic Probes types available for 800 C/1200 C/2500 C/ 4000 C/6000 C Red-Stainless Steel/Metal Steel (Plated) Rope-Galvanized Steel/Stainless Steel

Sensing Part Grounding Pipe Stand Off Discharge Device

Harmless Steel/Metal Steel (Plated) Galvanized Steel/Stainless Steel/Metal Steel (Plated) Galvanized Steel/Stainless Steel/Aluminium In Case of Static Charge

CALIBRATION
A DOT LED display serves as a sensitivity indicator. The (for DOT display) indicator range is divided into ten parts. The divisions are as follows:DOT Region 1 to 6 7 to 9 10 23 Colour Green Yellow Red Sensitivity Low Medium High Relay switching Remarks

region

The following standard procedure should be carried out when tank is empty. 1. Switch on the mains supply voltage. 2. Select the desired fail safe by using FSS toggle switch. 3. For versions provided with adjustable time delay, turn the pot fully counter clockwise to the minimum delay condition. 4. Now rotate the sensitivity adjustment potentiometer fully counter clockwise. In this condition dot display will be green. 5. Fill the level up to the probe, so that it covers the probe sufficiently. 6. Rotate the sensitivity potentiometer gradually clockwise observing the DOT display to move through the green and yellow region to red region. Continue the turning of potentiometer until the relay just operates. This should occur close to red region. 7. Without disturbing the sensitivity pot reduce the level of the material. As the probe gets uncovered the dot display will move from red through yellow to green. Record this display indication for future calibration. 8. The calibration is now completed. CALIBRATION(FOR BAR DISPLAY) The following standard procedure should be carried out when tank is empty:1. Switch on the mains supply voltage. 2. Select the desired fail safe by using FSS toggle switch. 3. For versions provided with adjustable time delay, turn the pot fully counter clockwise to the minimum delay condition. 4. Ensure all the four DIP switches just below SENS Trimmer are in off position. 5. Note the display in SENS/DEV indicator. (i) (ii) If all the red LEDs are glowing along with the alarm red LED, than turn the SENS trimmer slowly towards anticlockwise. If alarm condition does not change, than put DIP switch 1 to on condition. If the red LED alarm still glows than put DIP switch 1 to off condition & turn the DIP switch 2,3,4 to on condition till green LED glows & note if SENS/DEV indicator shows any LED glowing. 1. Rotate the SENS trimmer slowly towards clockwise direction till display is on. SENS/DEV indicator shows 4 LEDs glowing. 2. Fill the level up to the probe, so that it covers the probe tip sufficiently. 3. If the red alarm LED glows along with the relay change over, than the calibration is complete.
24

4. If the green LED still glows, than further rotate the SENS trimmer clockwise till the red alarm LED glows.

SALIENT FEATURES
1. High Durability and System Reliability No moving parts, no mechanical wear and tear, interference-free signal transmission from electronic insert to evaluation unit, system fault indication for added reliability. 2. Calibration Possible from Remote Location Evaluation unit can be installed far away from the probe. Calibration controls available in the evaluation unit. 3. Fail-Safe High/Low Selection Feature Available as Standard Reduces inventory, since the same evaluation unit can be field-configured either for high or low level fail-safe detection. 4. Ignores Build-Up of Sticky and Conductive Material between Probe and Vessel Walls Uses 3-Electrode technique with coat-immunizing circuitry to create inactive region. 5. Economical to Install Uses ordinary 3-Core cable for interconnecting the electronic insert with the evaluation unit.

TROUBLESHOOTING
S. No. 1. No change in bar display No change in the evaluation Check level or evaluation unit unit is faulty. 2. LED indication does not LED driving circuit is faulty. with other probe. Diagnose remove component. 3. Relay not actuating but LED Relay or its associated circuit As above. changes. 4. is faulty. the the fault and Problem Probable cause Remedy

change.

defective

Evaluating unit ok but no Probe or interconnection wire Check cable connectivity and change occurs when probe is is disconnected. connected. probe.

5.

Relay actuating but no output. Relay contact worn out /track Replace relay or check tracks. discontinuity.

25

APPLICATION
Level limit detection of fine, coarse, solids, liquids and slurries, conductive or non-conductive, corrosive or non- corrosive that have a tendency to stick and coat. For switching off conveyors when the vessel is full to avoid overflow. For indicating an empty tank well in time to avoid production stoppage and for pump control.

USAGE
Levtester SLA series of level switches are successfully used in processing plants for Cement, Food, Chemicals, Fertilizer, Sugar, Cosmetics, and Detergents etc.

1. CAPACITANCE LEVEL LIMIT SWITCH

PRINCIPLE OF OPERATION
The probe and the container wall (or ground probe) form electrodes of capacitor. When the probe is not covered the dielectric is air and when covered, the dielectric is that of the material. The difference in the dielectric is sense as the difference in the capacitances and use to operate a relay. The relay contact in turn are used for annunciation or control.

SYSTEM DESCRIPTION
The electronics is housed in a weather and flame proof cast aluminium probe had provided with two cable entries of NPT/BSP, NPT/BSP. The probe can be mounted on to the vessel by means of the
26

Mounting Bush for probes provided with screwed connection or by means of the flange for probes provided with flanged connection. The electronic is assembled on glass epoxy cards that fit into the probe housing as a module. The
module comprises of a step down transformer, DC power supplier and regulator, capacitance to voltage converter, comparator, relay driver and relays. The upper card is provided with indications, calibration controls and PCB mounted terminal for making connection.

INSTALLATION
Probe construction differs from application to application. Probes can be install either from
the top or side of the vessel. They are provided with either a screwed or flanged connection. Top mounted probe are easy to service and maintain and experience only longitudinal stresses during the extraction of the material. Side mounted probe experience lateral stresses due to the column of material above them and often need a baffle over them to reduce the stress especially for low level application. They are prone to suffer from problems arising out of build-up of material from side walls to the vessel and due to coating. They must preferably be mounted at a lightly downward angle in application where in the liquid is viscous there by allowing the liquid to drip off. They should be mounted such that the cable

inlet glands point downwards to avoid water seepage. The insertion length of the probe should be carefully chosen so that the sense electrode is in the active zone of the vessel i.e. where material
27

movement due to level change always occurs. For turbulent liquids a still well becomes necessary spurious switching due to ripples on the surface of the liquid can be eliminated by the adjustable switching delay feature. Since the probe contains electronic components it should not be mounted at places where high ambient temperature are expected or where the sun rays fall directly on the probe head. Top mounted rigid probes (rod probes) should have sufficient clearance between the vessel top and the roof facilitates hoisting of the probe over the tank top during the installation. Wherein sufficient clearance is not available, flexible rope probes may be used. Certain applications wherein there is likelihood of the probe swaying excessively due to the material movement, an anchor from the vessel wall could be provided. Accurate length adjustments at site are possible for part insulated probes by swaying off the additional length from the bottom. This is not possible with fully insulated probes.

TECHNICAL SPECIFICATIONS
Housing Cast Aluminium Weather Proof IP55/IP65, integral with the probe and stoving enamel painted Cable Entry 2x3/4 NPT/BSP, 1 NPT/BSP, NPT/BSP, Flanged-2 ASA/ANSI/IS
Ambient Temperature Power Consumption -20 to +600C 5VA (approx)

Mains Fail Safe Mode Output

220/230/240/110V AC (+10%, -15%), 50 Hz, 24V DC High or Low (field selectable) One set/two sets of potential free c/o contacts rated at 6Amps/3Amps, 230/110V AC for non inductive loads

Indication of Operation

Red LED signals for ALARM condition and Green LED signals for NORMAL condition

Measuring Frequency Response Time

500KHz (approx) 0.1 to 0.3 seconds

Switching Delay

0 to 20/30 seconds adjustable for probe covered and/or uncovered condition, selected by toggle switch

Initial Capacitance Switching Hysteresis

Three overlapping ranges with overlap exceeding 10% 0.5pF typical continuously adjustable over the entire range for SLC 530F/730F

28

Weight

2kg (approx)

CALIBRATION
Calibration controls are accessible after opening the housing cover. After installation & wiring, ensure that the material does not cover the probe and is well below it(at least 100mm). Switch on the mains supply. a) SLC 130/230. 1. Select the fail safe mode to FSS HI position by means of the fail safe select switch FSS. 2. Select range I by means of the range selection switch. 3. Calibration Procedure for Fail Safe High
i)

Rotate sensitivity adjustment multi turn pot(CA),fully counter clockwise. This being a multi turn pot. It has to be rotated for a number of revolutions until the clutch slipping sound is heard. Red LED glows.

ii) iii) iv) v) vi)

Rotate CA clockwise until Green LED goes ON. If the Green LED does not glow for full clockwise rotation of the pot, select the next higher range until the Green LED glows. Rotate CA pot gradually counter clockwise until Red LED goes ON, again rotate CA pot clockwise slowly until the Green LED just goes ON. By gradually rotating the pot forward & backward the exact switch point can be determined. From this exact position rotate the pot to 1 revolution clockwise. Green LED remains ON.

1. Calibration Procedure for Fail Safe Low

a) After doing the same as per instructions 3(i) to (vi) changeover the FSS switch to LO

position. The instrument is now calibrated. The material level may now be varied in the vicinity of the point level to confirm the correctness of the calibration. N.B.: For materials that tend to deposit on the probe, check & re-calibrate periodically.

b) SLC 330/630
These models are provided with continuously adjustable switching delays both for covered & uncovered probe condition. Turn both the relay adjustment pots fully counter clockwise and proceed as per calibration instrument for SLC 130/230 (1 to 4). a) Turn the delay on covered pot clockwise to set the desired switching delay.
29

b) Turn the delay on uncovered pot clockwise to set the desired switching delay. c) Vary the level in the vicinity of the set point to check & confirm the switching delays on covered & uncovered probe condition.

SALIENT FEATURES
1. High Durability and System Reliability. No moving parts, no mechanical wear and tear. Interference-free signal transmission from electronic insert to evaluation unit, system fault indication for added reliability. 2. Calibration Possible from Remote Location Evaluation unit can be installed far away from the probe. Calibration controls available in the evaluation unit. 3. Fail-Safe High/Low Selection Feature Available as Standard Reduces inventory, since the same evaluation unit can be field configured either for High or Low Level fail-safe detection 4. Ignores Build UP of Material on Vessel Walls Uses extended ground technique to create inactive region. 5. Economical to Install. Use ordinary 3 core cable for interconnecting the electronic insert with the evaluation unit. A variety of built in multi-point evaluation units available to reduce the number of discrete controllers thereby reducing overall cost. 6. Also available in circular enclosures.
APPLICATIONS

Level limit detection of fine, coarse, bulk solids, liquids and non sticky slurries, conductive or non-conductive, corrosive or non-corrosive in nature. For switching off conveyors when the vessel is full, to avoid overflow. For indicating an empty tank well in time to avoid production stoppage. For protecting pumps from running dry thereby reducing wear and tear. For detecting separation layers accurately.

USAGE
Levtester SLC..... series of level switches are successfully used in processing plants for Cement, Plastic, Power, Food, Chemicals, Fertilizer, Sugar, Detergents and for material handling of coal, mineral ores etc.

1. CONDUCTIVITY LEVEL LIMIT SWITCH

30

INTRODUCTION
Levtester SLW series of instrument can be used for level limit switching applications for single/two point action for conductive liquids. They can be used for: Switching OFF pumps when the tanks are full, thereby avoiding spilling and wear & tear. For indicating empty tank in good time to avoid production stoppages. For maintaining a constant level to avoid material wastage.

They incorporate solid state circuits for better reliability. Low voltage on probes provided operational safety. AC on probes protects electrolytic deterioration of electrodes. Wide probe choice is available for aggressive materials, high pressures and high & low temperature operation. The instrument is easy to install and long cable connection is permissible between probe and evaluation unit.

PRINCIPLE OF OPERATION

31

A low AC voltage is applied between the probe electrode and the tank wall (or reference electrode in case of insulated tanks). When the liquid comes in contact with the electrode tip, a conductive path is established between the electrode and the tank wall (or reference electrodes). A current therefore flows between the two through liquid. This current is sensed, amplified and made to operate relay, whose contact in turn can be used for annunciation/control.

MEASURING SYSTEM
It comprises of a sensing probe and an evaluation unit. Single point control application needs
one probe for a metallic container whereas an additional probe that serves the purpose of a ground electrode is necessary for insulated containers. For two point action two probes are necessary, one for high level and other for low level.

SYSTEM DESCRIPTION
Level sensing is done by partly insulated rod or probes as per application demand. Rod probes are suitable for short lengths of a maximum 2 meter whereas wire ropes are suitable for longer lengths. The sensing terminals are housed in a weather proof cast Aluminium housing provided with a 3/8

MAINS

OUTPUT

BSP cable entry gland and a BSP screwed connection. The probe electrodes are connected to the evaluation unit via 2-core cable for single point switching and 3-core cable for two point pump control. The evaluation unit comprises of power supply, amplifier and a relay housed in a cast Aluminium weather proof housing suitable for wall/back panel mounting. The cast Aluminium housing is provided with three numbers of BSP cable entries for wiring. The electrode is assembled on a glass epoxy PCB duly
32

lacquered for resisting moisture and fungus. One set of potential free change over contacts are available at the output terminals for annunciation/control.

INSTALLATION
1. PROBE The mechanical construction of the probe differs from application to application. Standard methods of mounting are screwed or flanged. The count, size and material of the mounting bush / flange depends on the application. Depending on the application Rod Probes can be either mounted from the top of the container or from the side of the top only. For installing Rod Probe from the top of the containers, sufficient clearance between the roof and tank top is necessary as the Probe has to be hoisted up over the tank top during installation. 2. EVALUATION UNIT The evaluation unit is suitable for back panel mounting. In case of weather proof housing, remove instrument cover, box fixing holes will be clearly visible on the box bottom, above and below card. Mount with supplied network consisting of 4 numbers of M4 Cheese Head Screws. The housing is suitable for outdoor installation. However, in no case should the instrument be subjected to temperature exceeding 600C. Through the instrument can be installed outdoors, it should never be subjected to direct sun rays and the rain fall. Preferably a sun shade is provided.

TECHNICAL SPECIFICATIONS
a) EVALUATION UNIT (STANDARD)

Housing Cable Entry Cable Gland Type Mains Voltage

Ambient Temp. Power Consumption

Cast Aluminium Weather Proof suitable for back panel/wall mounting 3x/1/2/3/4 BSP/NPT Brass on NG20 (plastic) Single/Double Compression Gland 110/220/230/240V AC (+10%, -15%), 50 Hz
-200C to +600C 5 VA (approx)

Fail Safe Mode Output

Maximum or Minimum (field selectable) One set/Two sets of potential free c/o contacts rated at 6 Amps, for non inductive loads 230V AC

Indication
33

Red LED signals for ALARM condition and Green LED signals for NORMAL condition

Response time

0.1to 0.3 seconds

Switching Delay Calibration Weight Overall Dimensions

0.5 to 10/20 second (adjustable) for Probe covered or uncovered condition By means of single continuously adjustable set point control 2.25kg (approx) L-180xB-180xH-85(mm) (approx)

B) PROBE
Housing Cable Entry Cable Gland Type Mounting Cast Aluminium Weather proof 1x3/8 /1/2 BSP/NPT, Brass/SS Single/Double Compression Gland Screwed-1/2/1/1-1/2 BSP/NPT Flange-as per order Material-MS(plated)/SS Insulation Working temp. Voltage Current Extension Sensing PART/PVC/NYLON/PTFE (Max.): 800C/1200C/2500C/3000C/____0C 12 volts AC (across probe or tank wall) 1mA maximum(between probe and tank wall) Rod-SS; Rope-GI/SS Rod/Weight, SS

CALIBRATION
After installing probes and making connections above check continuity between container and wall probe housing (for metallic containers). This should show low resistance. If possible, vary the liquid level in the vicinity of the set point & observe the LED indicators and relay switching. a) SINGLE POINT OPERATION 1). For Fail Safe High. Material container
34

in High Probe

level Relay

Indicator

Green(Normal) Red (Normal) Rising Rising Falling Falling Not covered Covered Covered Not covered Energized De-energized De-energized Energized ON OFF OFF ON OFF ON ON OFF

2). For Fail Safe Low.

Material container Rising Rising Falling Falling in High Probe Not covered Covered Covered Not covered De-energized Energized Energized De-energized level Relay Indicator Green(Normal) Red (Normal) OFF ON ON OFF ON OFF OFF ON

b). TWO POINT LEVEL LIMIT SWITCHING WITH PUMP CONTROL LOGIC 1).For Fail Safe High. Material Container Rising in High Probe Not Covered Not Covered Deenergized Rising Not Covered Covered Deenergized Rising Falling Falling Covered Not Covered Not Covered Covered Covered Not Covered Energized Energized Deenergized OFF OFF ON ON ON OFF ON OFF Level Low Level Probe Relay Indicator Green ON Red OFF

2).For Fail Safe Low.

Material Container Rising Rising Rising
35

in High Probe

Level Low Probe

Level Relay

Indicator Green Red ON ON OFF

Not Covered Not Covered Covered

Not Covered Covered Covered

Energized Energized De-

OFF OFF ON

energized Falling Not Covered Covered Deenergized Falling Not Covered Not Covered Energized OFF ON ON OFF

N.B: For two point logic the relay changes state when1. Material level is rising and rises above the maximum level probe. 2. Material level is falling and falls below the minimum level probe. The aforesaid control action maintains the level in the tank between maximum & minimum level as set by the respective probe lengths. The switch differential obtained by the control action can also be used to reduce frequent switch of pumps due to ripples on the liquid surface & turbulence.

SALIENT FEATURES
No moving parts, so free from maintenance. No special cable required for signal transmission, so Economical to Install. Long cable connections permissible between probe and evaluation unit. AC on probes for prevention of electrolytic deterioration of electrodes. Low voltage on probe for operational safety. Variety of control functions and installation systems available. Two -point action for automatic pump control. Two-point independent switching.

- Three-point switching, two points with pump control logic and one independent point with or without settable delay for probe covered or uncovered condition. Four-point switching with two pump control logic. Variety of probes available for various process conditions.

APPLICATIONS
Switching off pumps when tank is full, to avoid overflow. For maintaining a constant level to avoid material wastage. For switching off pumps when running dry and indicating an empty tank to avoid wear and tear and production stoppage.

36

USAGE
Levtester SLW..... series of level switches are successfully used in processing plants for conductive liquids of conductivity not less than 25 Siemens in Food, Power, Chemicals, Sugar, Detergents, Steel, Minerals, Textiles etc.

1. VIBRATING FORK LEVEL SWITCH

a) SLM SERIES
This tuning fork level switch from SAPCON Instruments, known as the SLM series, is best suited for level limit detection of
Fine grained free flowing solids including very low density and pneumatically conveyed media, powders, plastic chips, cement, sand, sugar, food grains. For detecting level of granular solid material submerged in liquids of low viscosity, like sand, gravel, plastic chips under water. For applications requiring the processing of different type of material in the same vessel.

SLM series (vibrating fork switch) can indicate a full tank to switch conveyers off and can indicate an empty tank to avoid stoppage of production. Many of our customers in the cement, power, chemical, man-made fibre and food industries uses this fork.

have used this fork based level switch successfully and have been happy with the rugged performance.

37

The SLM series tuning fork level switch/level detector has no moving parts and requires no calibration. The High/Low selection feature is available as a standard feature unlike the instruments from other manufactures. The level switch is insensitive to material build-up and isnt affected by the electrical properties of the service material. You can choose an enclosure depending on process plant conditions. We have housing that prevents and protects the fork level switch from explosive conditions, dusty areas and unpredictable weather conditions. What else, we also have a circular enclosure available if needed.

PRINCIPLE OF OPERATION
A top or side mounted, stainless steel made tuning fork is kept in mechanical vibration at the resonance frequency by piezo ceramic elements. When the service material covers the tines of the tuning fork, vibrations are damped. This is sensed electronically and processed signal is used to energize a relay whose contacts in turn are used for annunciation or control. Two basic type of constructional arrangements are available. One, where the electronics is separated from the fork, the other has them integrated. You can choose from:

1. Mounting arrangement of your choice (screwed or flanged type). 2. Various standards of the mounting according to plant conditions.
3. High temperature versions up to 2000C without the necessity of elaborate cooling arrangements.

4. Flame proof versions for hazardous areas. Longer probe length use pipe extension made of GI or SS as required. Integral versions meant for high temperature operation are provided with a stand-off arrangement for keeping the electronics in a relatively cooler environment. Adjustable probe length types are provided with the gland arrangement for making length adjustments.

MEASURING SYSTEM
A Tuning Fork made of Stainless Steel is kept in Mechanical Vibration at the Resonance Frequency by Piezo Ceramic elements. The fork is either side or top mounted on the vessel.

38

When the Service Material covers the tines of the fork, vibrations are damped. This is sensed electronically and processed signal is used to energize a Relay whose contacts in turn are used for annunciation or control. Two basic types of constructional arrangements are available. In one, the electronics is separated from the fork, whereas in the other, it is integrated. Mounting arrangements of the screwed or flanged type conforming to various standards, High Temperature versions up to 2000Cwithout the necessity of elaborate cooling arrangements and Flame Proof versions for hazardous

area are available.

TECHNICAL SPECIFICATION
EVALUATION UNIT Housing Cast Aluminium, Weather proof, back panel (wall mounting) / Integral. Cable Entry
Max. Amb. Temp. Power Consumption

3 Nos. / 2 Nos.
-20 C to +60 C 5 VA approx

Mains Voltage

230/110 V AC (-15% to +10%), 50 Hz; 24 V AC/DC on request 90 to 260 universal power supply

Relay Output

One/two set(s) of potential free change over contacts rated at 230V AC 6A, 50 Hz for non-inductive load.

Fail Safe Mode Indication

39

Max. or Min. Field selectable. Red LED for alarm, Green LED for normal.

Response Time

2 to 5 Sec

Switching Delay

Adjustable from 2 to 20 Sec. for probe covered and condition

un-covered

Inter connection cable a) Remote version b) Split version Overall Dim. Weight PROBE (for standard model) Tuning Fork Mounting Frequency Vessel Temp. Length Extension
0

2-core Independent screen 3-core unscreened. 180 x 180 x 85 mm ~ 2.5 Kg. Stainless Steel 1/1/2 Screwed or 2 Flanged. 85 Hz Std. (approximately)
0 200C to 800C

250 to 3000 mm Pipe (GI or SS)

SALIENT FEATURES
1. High Durability

No moving parts, no mechanical wear and tear, no maintenance.

2. Fast and Easy Installation

Requires no Calibration.
3. Fail-safe High/Low Selection Feature Available as Standard

Reduces inventory, since the same evaluation unit can be field configured either for High or Low Level fail-safe detection.
4. Insensitive to Mechanical Vibrations and build up of Material from Vessel Walls

Inherent property of our fork.

5. Not affected by Electrical Properties of the Service Material

Mechanical principle used for level detection.

6. Suitable for Dusty and Hazardous Area

Weather-proof and Explosion-proof versions available.

7. Also available in circular enclosures. 40

APPLICATION
Level limit detection of fine grained free flowing solid including very low density and pneumatically conveyed medium, powders, plastic chips, cement, sand, sugar, food grains etc. For switching conveyors off to avoid overflow. For indicating an empty tank well in time to avoid production stoppage For applications requiring the processing of different types of material in the same vessel For detecting level of granular material submerged in liquids of low viscosity, like sand, gravel, plastic chips under water. Satisfactory working in numerous applications in cement, power, chemical, manmade fiber food industries

b). SLF SERIES

The Sapcon Fluidofork (SLF Series) is a tuning fork based liquid level indicator for single point control. The instrument has an adjustable switching delay for covered and

uncovered conditions. The electronics is integral with the fork and can be mounted in different ways such as wall/back panel mounting or remote mounting. If the use is in hazardous area, you could choose the flame proof version. You also have the flexibility of choosing the insertion length. The Fluidofork (SLF... Series) has no moving parts and is not affected by the turbulence in the tank, floating particles, suspensions or gas bubbles. If you are using any viscous liquids, Fluidofork can be your best bargain. The instrument neither requires adjustments nor is dependent on the position, thus making it the best choice for liquid level indication in small tanks, pipes and mixing tanks.

41

PRINCIPLE OF OPERATIONA

specially shaped tuning fork is kept vibrating by

piezo-electric elements. The frequency of the fork changes when the tines are immersed in the liquid. The change in the frequency is detected and used for switching a relay. The output contacts of the relay can in turn be used for annunciation or control.

TECHNICALSPECIFICATION
EVALUATION UNIT Housin g Cabl e Entrie s Mains Relay Output Cast aluminium, Weathe r- proo f (IP-67) Stoving enamel suitable for back panel/wall mounting. 3 Nos. of BSP 110 or 230 V AC (15% to +10% ) 50 Hz (as specified in order) One set of potential free change over contacts rated at 6A 230V AC, 50Hz for non-inductive load.
Power Consum ption Re o se sp n O e tin p ra g Time Tem p. 5 VA approx 0.5 sec. approx. _ 20C to +60C

painted,

Fail -Safe Mode PROBE

42

High or Low (Field Selectable)

Tuning Fork Mounting Extension Probe Length O perating Tem perature Viscosity Density

Stainless steel-316 1" or 1" BSP screwed (Flanged mounting on request). 1" BSP for High Temperature version. Stainless Steel pipe. Min. 128 mm, max. 3000 mm. -20 C to + 80 C

Standard models (high Temp. models upto 200C are also available.) Up to 10000 cP Greater than 0.7gm/cc

SALIENT FEATURES
No moving parts, no wear and tear. Operates reliably in viscous liquids Not affected by streams, turbulence, floating particles and gas bubbles Operation is independent of electrical properties of the material Can be installed quickly in small entries, pipes and mixing tanks Installation is independent of position No adjustment required, therefore fast commissioning

VARIETY OFCONTROL FUNCTIONS AND VERSIONS AVAILABLE

43

Single-point control. Adjustable switching delay for fork covered/uncovered. Electronics integral with fork. Electronics remote, wall/ back panel mounting. Flame-proof version for hazardous areas. Adjustable insertion length version.

APPLICATION
Fluidofork can be used for all types of liquids in storage tanks, mixing tanks and pipe lines having Temperature between _20C and +80C (Standard Version), Viscosity up to 10,000cP, Density greater than 0.7 gm/c.c. Fluidofork is suitable for most of the applications, where float switches were previously used and for liquids, which are sticky, corrosive, agitated, splashing and foaming.

USAGE
Levtester SLF series of level switches are successfully used in processing plants for liquids having viscosity up to 10,000cP in Food, Power, Chemicals, Sugar, Detergents, Steel, Minerals, Textiles etc. It has also replaced the float operated switches in some of the applications. It is also not affected by electrical properties of the service material.

MICROPROCESSOR/MICROCONTROLLER BASED LEVEL LIMIT SWITCHES 1. ELIXIR MPSLF:

INTRODUCTION
ELIXIR instrument is a vibrating fork liquid level limit switch. It is suitable for level detection in storage tanks, mixing container and pipelines, for liquids that do not react with SS whose viscosity does not exceed 10000 CP and whose temperature lies within 00 to +800 C. It is suitable for most of the application where float

switches were previously employed, as well as in such places where float switches were not appropriate (Due to deposit formation, turbulence, stresses and air bubble)

44

OPERATING PRINCIPLE
A specially shaped tuning fork is kept, vibrating by piezo electric elements. The resonant frequency of the fork changes when the lines are immersed in a fluid. The change in frequency is detected and used for switching a relay. The output contacts of the relay are in turn used for annunciation and/or control.

SYSTEM DESCRIPTION
The ELIXIR Level detecting system consists of a Microcontroller based Electronic Insert
with Fork Probe. The instrument comprises of an Electronics & SS 316 Tuning Fork

housed in a cast Aluminium housing & provided with 02 nos. suitable cable entries. The Fork is of a special shape suitable for operating in liquids of specified range of viscosities. This is provided with either Screwed Mounting or Flanged Mounting suitable for installation on to a container or pipeline. Piezo ceramic elements are mounted inside the fork capsule and potted with epoxy compound for rendering them immune to dust, moisture and inflammable gases.

INSTALLATION
The ELIXIR MPSLF series probe can be installed in the vessel in almost any position. Previously existing bosses welded in any direction can be used. Since the probe can be screwed into a mounting socket suitable for supplied threads and the fork length is comparatively short, it can be installed directly on pipes too. For liquids with higher viscosities, top mounting or side mounting with tines slanting downward is preferred as then the viscous liquid can drip off faster when the level goes below set point. While installation of Probe, please take care of the following points:
45

1. The tine should not be bent nor should their dimensions be altered. 2. To prevent ingress of moisture and water seepage inside mounting position, the cable entries should always point downwards.
3. Weather proofness of enclosure is guaranteed only if the cover is in place & glands adequately

tightened. Damage due to accidental entry of water can be avoided if the instrument is installed in a rain shade.
4. If the ambient temperature is high, the instrument should not be installed to receive direct sunlight.

In case such a position of shade is not available, a heat shield should be fitted above the instrument especially if the operating temperature lies between +600 C & 800C.
5. While screwing the ELIXIR: MPSLF series instrument, the hexagonal mounting bush should be

turned and not the housing.

TECHNICAL SPECIFICATIONS
Housing Last Aluminium Weather & Flame Proof suitable for Mounting in hazardous area gas group 11A & 11B as per IS-2148 Mounting Cable Entry Gland Type Mains Relay Output Integral with Fork 2x / BSP/NPT, Brass Double Compression Gland 20 to 260 VAC, 50/60 Hz, 11 to 55 VDC One Set of potential free c/o contact rated at 6 Amps, 230 AC for noninductive loads Time Delay Setting Mounting Digital 1 to 20 seconds, covered and uncovered both Screwed- 1/1 BSP/NPT (M) Flanged- as per order Material- MS( Plated)/SS Sensing Extension Fork, SS 316 Pipe GI/SS

46

Material Temp. in Vessel Response Time Switching Indication

-200 to 800 C/1200 C /1500 C

0.5 Seconds Bicolour LED, Red: Alarm, Green: Normal

Fail Safe Feature

Power Consumption Tolerable Ambient Temp. Frequency Change Minimum Liquid Density Maximum Viscosity of Liquid

Field Selectable (Min: Fail Safe low, Max: Fail Safe high)
0.5 watt maximum 00 to +600 C

Frequency in air : <500 Hz (Approx.) 0.7 gm/cm3 10000 CP

Switching Hysteresis

5mm Approx

CALIBRATION
ELIXIRs are factory calibrated for the water medium. The switching point is at the notch for vertical mounting. To modify the factory supplied calibration, open the Aluminium cover, connect the supply connection in supplied connection diagram. (Earthing on green terminal should not be connected.)Turn the supply on. The vibration should be felt on the fork tines. These are very mild vibrations. ELIXIR at the notch point for a given liquid:
1. To start calibration, set calibration switch to Close position.(opposite to open switch.)

2. Make sure that STATUS LED is not blinking for error. 3. Dip the fork till the notch point. 4. Then press Enter. 5. The STATUS LED will blink in Red colour. Blinking indicates that ELIXIR is registering the switch point position. Keep Enter key pressed for 4 to 5 blinks. Then release Enter key. 6. On release, the STATUS LED should: Turn RED for Maximum Failsafe Selection. Turn GREEN for Minimum Failsafe Selection. Which indicates that calibration is correct.
47

Now test the calibration by dipping & removing the tines from liquid. During calibration, delays are automatically bypassed switching should occur as explained. If the calibration is correct put the calibration switch back to Open position. Else ELIXIR will indicate error after 2 min of pressing the Enter key for the last time. If calibration is incorrect, repeat the above stated steps once again.

SALIENT FEATURES
Very compact Fork is single piece in cast stainless steel Universal Power Supply Multi-function bi-coloured LED. Low Power consumption. On & Off Time Delay, Fail-Safe mode programmable via DIP switches and one push button switch. Self-checking System fault alarm, Fork erosion alarm. EMC & RFI protected using Noise Filters.

ERROR INDICATION
In ELIXIR, errors are indicated for operators mis-handling of the instrument in the view of instrument protection and proper setting of the instrument.

Error Indication
On error STATUS LED starts blinking in RED and GREEN alternately at a faster rate. Normal LED blinks are always 1 blink per second in either RED or GREEN colour. Nature of the errors are: 1. Incomplete calibration. 2. Incomplete delay settings. 3. Two or more than two commands are asked at once. To avoid errors:
1. Always complete the calibration by putting the Calibration switch back to open position. This can

be done within 2minute of releasing Enter for last time for calibration purpose.
48

2. Always complete the delay settings by putting the Delay switch back to open position. This can be

done within 2minute of releasing Enter for Delay setting purpose.

3. Make sure that only one switch is at the close position among calibrate, cover & uncover. Failsafe

switch can be Open or Close and is not a source of error.

RESETTING ERROR
1. Bring the CALIBRATE, COVER & UNCOVER switches to OPEN position. 2. Press ENTER key. 3. LED alternate colour blinking will STOP. 4. Is recalibration is needed: 5. Only if the cause of error was incomplete calibration.

MAINTENANCE
The electronics of ELIXIR MPSLF series instrument needs no maintenance. When cleaning and checking the vessel, free the tuning fork from deposits. If the material has the tendency to form a hard sticky deposit the instrument must be checked more often. Make sure that the cable ducts & the lid are tightly sealed so that no moisture seeps into the instrument.

FAULT FINDING PROCEDURE

If the instrument fails, check
1. That the ELIXIR SLF Series Instrument is correctly connected.

2. That the connections for low/high alarm and the tuning fork are correct. 3. That the tines vibrate when free from material. 4. That the indicating devices connected to the output are functioning correctly.

APPLICATIONS
Pharmaceuticals, Bulk Drugs, Chemicals, Petrochemicals, Pesticides, Textile, Food, Cosmetics, Confectionery, Edible Oil, Brewery, Distillery, Dairy, FMCG, Packaging, Utility, Paper, Sugar, Power.

MPILC
INTRODUCTION
MPILC series instrument are RISC Processor based Capacitance type Continuous Level Indicators with built in three point switching. The instrument is suitable for 49

measuring the level of conductive or non conductive liquids, slurries and powdered or fine grained solids homogeneous composition having a stable dielectric constant. Apart from level indication, the built in three point electronic level limit switch offers the switching functions for alarm annunciation and/or control application at the set levels. The set points are independent of each other and are continuously configurable over the entire range.

PRINCIPLE OF OPERATION
In an application, the measuring electrodes (sense probe) and the container wall (ground or reference probe) form a capacitor. The amount of capacitance of this capacitor is governed by the dielectric constant of the material between the electrodes (sense probe & metallic container wall or reference probe or ground). The value of this capacitor is dependent on the level of material, therefore the dielectric of the material is effective only to the level to which the material is filled. MPILC measures change of capacitance to measure the change of level of material since this is a relative measurement a proper calibration is thus always necessary.

MEASURING SYSTEM
It consists of an evaluation unit, an electronic insert and a probe. The probe is mounted from the top of the vessel and it comprises a sense electrode, electrically isolated from the metallic tank by means of a suitable insulator. The sense electrode and the vessel wall serve as the two electrodes of a capacitor with the service material as the dielectric. A change in material level causes a change in the dielectric, which in turn causes the value of this tank capacitor to change. An accurate measurement of this change
50

affords an indirect measure of level of the material in the tank.

TECHNICAL SPECIFICATION
EVALUATION UNIT Housing Cast Aluminium Weather Proof Stoving enamel painted. Suitable for Back Panel / Water Mounting Cable Entries
Operating Ambient Temp.

Three Numbers of / BSP/NPT/Double Compression

-200 to 600 C

Power Supply Sensor to E.U. Cable

Universal Mains 90 to 265VAC, 50/60 Hz & 24 VDC (@ 3Watt) 2-Core, Resistance per core not to exceed 30 ohms. Use of shielded twisted pair cable is recommended for long runs of cable. Cable Length of 1000 Meters are thus supported with grounded cable Shields

Zero % Range 100% Range

30pf to 250pf 10pf to 4500pf (difference from zero %). Current 4 to 20mA.RL max=700 ohm using internal isolated supply. RL max=1k ohm for external loop supply of 24VDC

Outputs

3 potential free relays with one set of potential free change over contact per relay

51

Contact ratings Indication

6Amp @ 230VAC 50/60 Hz for non inductive loads continuous: 50% to 150% digitally on /seven segment display. Switching: 5mm Red LEDs for alarm indication

Switching Hysteresis Fail Safe Select Weight

1% in Single point switching, 1 to 98% selectable in Pump Control Field selectable three interactive relay configuration menu 2.3kgs

ELECTRONIC INSERT LDC 117, LCDM 111 Housing Power Supply Plastic, potted with epoxy resin 16VDC @ 5mA derived from sensor Communication Interface of Evaluation Unit
Measuring Frequency 250 KHz to 20 KHz, Reverse Frequency Measurement Operating Ambient Temp. -200 to +600 C

Sensitivity Output

10 Counts Per Pf Digitally encoded current (5mA-8mA) pulse

SALIENT FEATURES
Microprocessor based system for higher degree of reliability and stable operation in noisy environment due to intelligent digital communication between the electronic insert and the evaluation unit. All parameters programmable via Five keys and Five multipurpose LED displays. Calibration possible without completely filling and emptying the vessel. Galvanically isolated 4 to 20mA output available for connecting to PLC. Three relays for programming three levels independently or as pump control logic. Three potential free change over relay output contacts. Built-in universal power supply for 90 to 260 VAC or 24V DC operation.

APPLICATION

52

Suitable for continuous level measurement in conductive or non-conductive liquids, powdered or granular materials of homogeneous composition having stable dielectric constant Successfully used for monitoring and controlling the level in vessels containing water, oil, chemicals and foodstuffs in processing plants.

3. GALVANICALLY ISOLATED LIQUID LEVEL TRANSMITTER TRANSLITE

INTRODUCTION
Sapcon Instruments offers the TRANSlite family of fuel level sensor instruments which use the capacitance technology for accurate fuel and oil level measurement in process plants. The TRANSlite family of fuel level sensors has no moving parts and can be ideally used in extreme plant conditions of high temperature and pressure.

The TRANSlite instrument range supports a power supply within DC automation is available from 11 to 55 VDC, addressing the need for 12V, 24V and 48V industrial supply options.4-20mA Current Loop is galvanic ally isolated (4 Wire) and PLC, SCADA compatible. 4-20mA Current Loop can supply up to 1000 Ohm series load with 24VDC supply. This means 4-20mA signal can be carried to longer distance. The ease of calibration ensures user friendliness: Just let it know the fuel level for 4mA and 20mA, rest it will take care of. Following are the options for to choose from:

TRANSlite Fuel Level Sensor TRANS~lite Fuel Level Sensor TRANS2lite Fuel Level Sensor
TRANSlite Fuel Level Sensor It is composed of the specially developed Capacitance change gauging circuit. TRANSlite uses a fast RISC based processor which is the best in its class for evaluating fuel level using capacitance. The capacitance is formed by the sense rod and the metallic container wall. For non-metallic and/or nonuniform shaped containers, a metallic stilling well is provided. The amount of capacitance is proportional to the level of material between the sense rod and metallic wall of stilling container. TRANS~lite Fuel Level Sensor It is the best affordable liquid fuel level measuring solution for high temperature conditions. Its key feature is the ease of calibration which is not commonly available in this range of fuel level transmitters. TRANS~lite allows electronic-less measurement of level up-to 5 meters distance between the probe and the electronics. TRANS2lite Fuel Level Sensor
53

It is a microcontroller based 2 wire capacitance fuel level sensor. TRANS2lite has temperature compensated electronics that provide a stable output. This fuel level sensor allows calibration in steps of 10% from 0 to 100% eliminating the need for rigorous emptying filling calibration. Best Fuel Level Sensor

Fast delivery on request, cost effectiveness and low power consumption make this device cut above the rest. All in all, TRANSlite is a complete value for your money device and if your system has a SCADA or PLC interface, TRANSlite is your best buy. Custom Fuel Level Sensors - Capacitance TRANSlite family fuel level sensors can be custom designed to your specification requirements. The sensors have no moving parts and are extremely accurate. They can be designed to fit within the tightest of space envelopes and withstand the most acute work environments.

OPERATING PRINCIPLE
TRANSlite is composed of specially developed Capacitance Change Gauging circuit. It uses fast RISC based processor to perform all the complicated jobs of evaluating the level out of the capacitance. This capacitance is formed by the sense rod and the metallic container wall. Where containers are non metallic or not uniformly wide or having turbulent fluid, a metallic stilling well is provided. The amount of capacitance is proportional to the level of material between the sense rod and the metallic wall of the stilling tube or container.

SYSTEM DESCRIPTION

54

TRANSlite is composed of cast Aluminium housing, supplied with suitable mounting arrangement viz. NPT, BSP or Flanges and two metallic cable entries. An External Ear thing/Grounding Terminal is also provided. The sensing rod which is mostly Teflon coated. This sensing rod can be replaced by flexible probe for some applications. The stilling tube is also provided for turbulent fluids, irregular width tanks, non metallic tanks or fluids with low dielectric (diesel) Opening the threaded Aluminium cover, an electronic insert could be found. This is the electronic unit which converts the level into 4-20mA signals depending on the calibration. The STATUS LED is a bicolour LED that blinks alternately in Red and Green to indicate instrument is in process of converting the level to 4-20mA signal. Two DIP switches are provided to calibrate the 4mA and 20mA points. The calibration is easy and a complete procedure is given in Calibration page. The two wires connected at the back are pre-connected sensor wires and should not be disturbed. Also while calibration try to keep hands away from the wires of terminal #6 and 7. TRANSlite can be wired in two possible combinations. Preferred one is galvanic ally isolated, 4-wire combination, where only one source of power is available, 3-wire non isolated combination can also be used. The converted level signal can be sensed using a 4-20mA indicator or PLC 4-20mA input or Multimeter in 40mA range or any other device that takes 4-20mA signal as input.

TECHNICAL SPECIFICATIONS
Housing Cast Aluminium Weather proof & Flame proof suitable for mounting in hazardous area Gas Group IIA & IIB as per standard IS-2148 Mounting Cable Entry Gland Type
Mains

Integral with same sense rod or probe 2x1/2 /3/4 BSP/NPT, Brass Double Compression Gland
11 to 55V DC

Output Mounting

4-20mA, Galvanic ally Isolated (in 4-wire combination) Screwed- 1/1-1/2 BSP/NPT (M) Flanged- as per order Material- MS(plated)/SS

Sensing Stilling Tube

55

Fully or partially TEFLON Coated Rod, Flexible Probe SS316 Pipe GI/SS

Response Time

0.5 to 5 seconds (depending on turbulence)

Measurement Span Switching Indication Fail Safe Feature

Power Consumption

15 to 5000pF above zero Two LED, displaying RUN & CALIBRATE Modes. Reverse Calibratable. (Low level: 20mA, High level: 4mA)
mA: 0.5Watt (Maximum)

RS485:0.4Watt (Maximum) DUAL:0.6Watt (Maximum) Ambient Temperature 00 to +600 C Frequency Change 125KHz to 12.5KHz (inverse frequency operation)

CALIBRATION
STATUS RUN Mode 4mA Mode 20mA Mode ERROR Calibrating 4mA/0% 1. Set the required level at 4mA/0% level.
2. Press once the 4mA micro switch. Now the RED LED will start blinking.

LED RED or GREEN Only RED Only Green RED and GREEN

STYLE BLINKING ON ON ON

3. Wait till blinking stops. Now the RED LED will glow continuously.
4. Press again the 4mA micro switch.

Calibrating 20mA/100% 1. Set the required level at 20mA/100% level. 2. Press once the 20mA micro switch. Now the GREEN LED will start blinking. 3. Wait till blinking stops. Now the GREEN LED will glow continuously. 4. Press again the 20mA micro switch.

SALIENT FEATURES

56

TRANSlite is a microcontroller based 2 Wire, capacitance type level transmitter. Equipped with a fast RISC processor, it combines 'ease of use' within a convenient size. Temperature compensated electronics provides stable output. It allows calibration in steps of 10% from 0 to 100% eliminating rigorous emptying filling needs for calibration. Power supply within DC automation is available from 11 to 55 VDC, addressing the need for 12V, 24V and 48V industrial supply options. 4-20mA Current Loop can supply up to 600 Ohm series load with supply. 24VDC

Total power consumption @ 24V is less than 240millivolt when signal is 20mA. This means 4-20mA signal can be carried to longer distance in terms of two wires Easiest Calibration: Just let it know the level for 0% to 100% in steps of 10%, rest it will take care off. Supports complete measurement range of Sapcons MPILC.

APPLICATION

Suitable for continuous level measurement in conductive or nonconductive liquids, powdered or granular material of homogeneous composition that have stable dielectric constant. Successfully used for monitoring and controlling the level in vessels containing water, oil, chemicals and foodstuff in processing plants

4. INTELLIGENT ADMITTANCE LEVEL LIMIT SWITCH MP-SLA INTRODUCTION

57

SYSTEM DESCRIPTION

TECHNICAL SPECIFICATION
Housing Cable Entries Cast Aluminium, Weather-proof, stoving enamel painted, suitable for back panel/wall mounting 3 Nos. of BSP/NPT/NG20

Ambient Temperature -200C to +600C

Mains

110/230V AC (-10 to +10%), 50Hz (as specified in order).

58

Power Consumption

5VA approx

Indication (Switching)

Red LED for each level alarm, red LED for fault alarm, flashing green LED as heart-beat for healthy condition.

Response time

0.2second typical

Switching Delay Connection to E.I. Initial Capacitance Switching Hysteresis Switching Hysteresis Relay Output Fail Safe Mode Weight Overall Dimensions ELECTRONIC INSERT Housing Operating Temp. Supply PROBES Housing Mounting Electrode Element Length Insulation

Programmable up to 99 second. For probe covered/uncovered condition for each set point. 2-core ordinary cable, having maximum resistance of 25 ohm per core 20 to 1200pF Approx 0.5pF at initial capacitance of 30pF (single point operation) Programmable over entire setting range one set of potential free change over contacts per channel rated at 6A 230V AC, 50Hz for non inductive load. High or Low field programmable for both channels. 2.5Kgs approx 180x180x85cm Plastic with electronics potted in epoxy resin -200C to +800C 12V at 17mA maximum derived from evaluation unit only Cast Aluminium, SS, FRP-coated, HDPE Flanged or Screwed as per requirement Special 3-element Probe Sense, Shield and Ground 150mm to 3000mm in Rod, Greater than 3000mm in Rope Part or full PVC, PTFE, Ceramic (part only) depending on service temperature of 800C, 2000C, 4000C respectively

Reference probe is required when the tank is non-metallic Grounding tube is required, when the liquid is turbulent or tank shape is curved.

SALIENT FEATURES
Intelligent and Self Checking A microprocessor checks the complete system and itself before validating the signal. A flashing green LED serves as a heartbeat to indicate a healthy system In the event of occurrence of a system fault such as
59

incorrect wiring, open or short sensor connection, failure of probe insulation, improper grounding or electronic insert failure, the heartbeat stops, fault LED glows, display indicates "E---" and the relay contacts revert to their fault conditions. Highly Reliable Two-wire Pulse Frequency Modulation (PFM) is used for interference-free signal transmission between probe and evaluation unit. Complete system is checked before each measurement. Auto compensation for temperature drift in the vicinity of pre-amplifier. High Degree of Programmability Features such as operating mode (independent/pump control), delayed switching in seconds for probe covered or uncovered condition, fail-safe high or low, switching sensitivity and set point calibration are programmable via key pad. The programmed parameters are stored in a non-volatile memory indefinitely requiring no battery back-up. Ignores Build-Up Special three-element probe and immune coat circuitry enables the system to ignore coating on the probe, build-up from wall and suspended dust particles, but reacts only to a true level. Easy Calibration and User-Friendly All parameters are programmed via four keys and an interactive menu-driven display leaving no chance for incorrect entry. If recalibration is required, the old data is displayed in the program mode, which can be edited as desired. Automatic Switch Point Optimization

APPLICATION
Level control of solids, liquids and slurries of conductive/Non-conductive, sticky/non-sticky material requiring extreme safety and high degree of reliability in industries such as cement, food, chemical and petrochemical, effluent treatment, cosmetics, power, plastic, material handling, fly ash etc.

60

RESULT
I have completed my training successfully as per the given duration of the university. I have also completed my project report on SAPCONs LEVEL MEASURING INSTRUMENTS.

61

CONCLUSION
To do training in such an esteemed organization like SAPCON INSTRUMENTS PVT. LTD. has been a phenomenal learning experience for me. It was a joy ride for me in the field of Electronics and now on completion of training I have gained a very good knowledge in the field of Electronics. The Electronics department in the company is well equipped with the latest technology. All the working of various departments of the company is both humanly and computerized. I have studied about the various instruments which play a very important role in measuring Level and Speed. So this is all about the learnings at SAPCON INSTRUMENTS PVT. LTD. within one month. I am thankful to all those people at SAPCON who directly or indirectly helped me in completing my one successful month in this company. I would be really obliged if I get to serve for this company in future to advance my learning more.

62

REFERENCES

1. 2.

www.sapcon instruments.com www.google.com

3. www.wikipedia.com

63