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Tank Level Applications

Tank Level Measurement

Senix ultrasonic sensors offer cost-effective, continuous level measurement for small and large tanks.

  • Non-contact measurement means nothing touches the liquid
  • Easy to install at the top of the tank into standard fittings
  • Rugged industrial sensors can be used indoors or out
  • Included interfaces connect to most industrial equipment
  • Measures a wide variety of liquids and liquid environments
  • Accessories to display, alarm and control liquid levels
  • Works with both metal and plastic tanks
  • Wireless option sends tank levels to a LAN or to the cloud
  • Software included for setup and duplication without re-calibrating

Applications

Inventory
Batch control
Low and high level alarms
Empty, fill or maintain level
Pump & valve control

Get a Quote Today.

Request a Quote

Tank Level Measurement

Senix non-contact ToughSonic® ultrasonic sensors offer cost-effective, continuous level measurement for small and large tanks. They install at the top of the tank, are not immersed in the liquid and can measure both benign and chemical liquids.

Tank Level Measurement

  • Non-contact – nothing touches the liquid
  • Easy to install at the top of the tank into standard fittings
  • Use indoors or outside, in metal or plastic tanks
  • Connects to other industrial equipment
  • Measures a wide variety of liquids and liquid environments
  • Accessories to display, alarm and control liquid levels
  • Wireless option sends tank levels to a LAN or the cloud
  • MRO & OEM tank setup duplication without re-calibration
Applications

Inventory
Batch control
Low and high level alarms
Empty, fill or maintain level
Pump & valve control

Get a Quote Today.

Request a Quote

Ultrasonic Tank Level Sensing Overview

Senix ultrasonic sensors offer cost-effective, continuous level measurement and support accessories.

Features

  1. Non-contacting measurement
  2. Rugged construction
  3. Multiple outputs (each sensor)
  4. Models for various distances
  5. Works in many environments
  6. Optional accessories
  7. Setup software included

Resulting Benefits

  1. Install at tank top, nothing touches the liquid
  2. Liquid tight, wide temperature range, used indoors or out
  3. Connect with most common equipment (PLCs, displays, PCs, etc.)
  4. Measure tanks from 6 in (15 cm) to 50 feet (15.2 m) tall
  5. Product lines for water/benign liquids, chemicals, and hazardous areas
  6. Easy to mount, connect, adjust, display and communicate level data
  7. Setup your application, save it, duplicate later without re-calibration

Ultrasonic Tank Level Measurement Overview

Our sensors mount at the top of the tank facing down toward the liquid, sending an ultrasonic pulse down toward the liquid that reflects back. The time of reflection determines the liquid distance, and therefore the liquid height from a predefined empty distance.

  • Measurements are a function of liquid height
  • Volume of non-linear tanks can be calculated and displayed
  • Works with metal or plastic tanks
  • Measurement filters can stabilize readings where mixers are used
  • Relays can be used to control fill or empty
  • Measurements can be displayed via wired or wireless connections
  • Local Area Network (LAN) and cloud-based displays optional

Applications

Inventory
Batch control
Low and high level alarms
Empty, fill or maintain level
Pump & valve control

Get a Quote Today.

Request a Quote

Tank Measurement Environments

Water & Mild Liquids Measurements

Water Level Sensing

ToughSonic General Purpose sensors easily handle these liquids. Rugged construction, corrosion resistant materials, a wide environmental operating range and a liquid-tight IP68 ingress rating make them ideal for indoor and outdoor use – even in salt water and hydrogen sulfide (H2S) environments.

Products are offered in a variety of distance ranges to accommodate tanks ranging from 6 in (15 cm) to 50 feet (15.2m), with various mounting threads and accessories available. All ToughSonic sensors include analog, switch and data interfaces and compatible setup software, included at no charge.

Chemical Level Measurement

ToughSonic CHEM sensors expand the range of environments in which our sensors operate. Some common chemicals can damage or corrode sensor materials, even 316 stainless steel. Transducer elements and bonding adhesives are also susceptible. Our CHEM sensors avoid these problems by using a continuous injection molded housing of Polyvinylidene fluoride (PVDF), a highly non-reactive thermoplastic that resists solvents, acids and hydrocarbons.

CHEM sensors have both top and bottom mounting threads and include a potted-in, PUR-jacketed, UV resistant cable. Verify your chemicals and operating temperatures with this compatibility chart. All ToughSonic sensors include analog, switch and data interfaces and compatible setup software, included at no charge.

Level Measurement in Hazardous Areas

Our SenixSAFE 25 is a two-wire, 4-20 mA, loop powered, intrinsically safe sensor CSA approved for use in Class I Division 1 and Class I Division 2 hazardous areas in the US and Canada. Pre-calibrated for a range of 1 to 25 feet (0.3 to 7.6 meters), it is user-configurable using SenixVIEWSAFE-01 software from the non-hazardous side of a safety barrier using our Remote Configuration Device. The 2-inch NPT threaded PVDF transducer maintains chemical compatibility with most liquids.

Level Measurement in Hazardous Areas

Our SenixSAFE 25 is a two-wire, 4-20 mA, loop powered, intrinsically safe sensor CSA approved for use in Class I Division 1 and Class I Division 2 hazardous areas in the US and Canada. Pre-calibrated for a range of 1 to 25 feet (0.3 to 7.6 meters), it is user-configurable using SenixVIEWSAFE-01 software from the non-hazardous side of a safety barrier using our Remote Configuration Device. The 2-inch NPT threaded PVDF transducer maintains chemical compatibility with most liquids.

Hazardous-Area-Sensors-16x9-a.pngSee our SenixSAFE sensors.

Sensor Outputs & Interfaces

SenixVIEW Software

The ToughSonic General Purpose and ToughSonic CHEM product lines all have multiple analog and switch outputs compatible with most industrial equipment, plus a serial data communications interface for SenixVIEW software setup or user applications.

Analog outputs can be proportional to tank level or volume. Switch outputs can control pumps and valves, or indicate low or high alarm conditions. Simple level controls can be created with only a sensor and an external relay option. Outputs are user-configured with SenixVIEW setup software. Setups are permanently stored in the sensor, and can be saved and duplicated in other sensors without re-calibrating. Some models have 5 simultaneous outputs while others have 2 SenixVIEW selected outputs. All sensors have a serial data interface, and all outputs operate concurrently.

Outputs, ToughSonic 30, 50 and CHEM products

Accessories & Options

Displays, Alarms and Packaged Systems

Digital controller accessories display level measurements and/or provide outputs to control other equipment. Tank levels can be displayed as level or volume in any units. Relay output options control pumps, valves or level alarms. Measurements can also be re-transmitted to additional displays or equipment at other locations. Other features include:

  • Sunlight readable outdoor displays with large digits
  • Pump control sequencing for multi-pump systems
  • Volume calculations for horizontal cylindrical tanks or other shapes

Displays are sold individually, with or without housings, or Senix can custom build a packaged system according to customer requirements.

See our Display Accessories.

Wireless Connectivity to LAN or Cloud

AirWire Level Transmitter

With Senix AirWire® Local, tank level measurements are sent wirelessly from the tank to a receiver-gateway on your Local Area Network (LAN) and/or transferred to the cloud for worldwide access.

  • Transmit tank levels inside buildings without installing conduit or wiring
  • Collect nearby tank levels up to miles away
  • No recurring cellular charges
  • No wiring is required at the tank site
  • Ideal for measurement rates as fast as a few times per hour
  • Connects with any Senix ToughSonic sensor with an RS-485 interface

Wireless Connectivity to LAN or Cloud

Test

See our Display Accessories.

Environmental Considerations

Test

Warnings for high pressure, temperature, vacuum, gradients, etc. PUT THIS IN THE SENSOR SPECIFICATIONS AREA?

 

Known incompatibilities include acetone, ketones, caustics, #6 crude oil, hydrochloric acid (vapors OK), MEK,

Ultrasonic Tank level sensor display in liters

Tank Level Display

In the most basic application, a tank level sensor may simply transmit continuous liquid level data to a process meter or to your PC running SenixVIEW software. A simple display will provide tank level in feet or meters. With more advanced displays, you can convert simple level measurements to engineering units like gallons, liters, pounds or kilograms. ToughSonic sensors, with simultaneous outputs, allow you to select digital or analog output for display while other output(s) provide control input. Display versatility is just one of the many ways that non-contact tank level sensors out perform traditional mechanical level indicators.

Ultrasonic tank level sensor and display

ultrasonic tank level sensor alarm

Tank Level Alarms

Many tank level applications require alarms to be sounded when levels get above or below a certain point. All ToughSonic and ToughSonic CHEM sensors include 2 solid state switches that can be configured to activate alarms at pre-determined levels. Sensor switch outputs are independent of other outputs so, for example, you can maintain a continuous tank level display and alarm settings using the same level sensor.

Ultrasonic tank level sensors configured using SenixVIEW

SenixVIEW software includes built-in hysteresis and time delay capabilities to manage level alarms, pumps and valves.

Tank level control computer

Ultrasonic level sensors may send measurements to a tank level controller or ToughSonic sensors may control tanks directly using switches and relays.

Tank Level Control

Liquid level data is commonly transmitted to control devices such as Programmable Logic Controllers (PLCs), Remote Terminal Units (RTUs) or other computers as part of more complex process control systems. To meet the full range of system requirements, ToughSonic liquid level sensors can send measurement and control data using industry-standard serial digital, analog or switch outputsor all three simultaneously. For example, a ToughSonic or ToughSonic CHEM sensor might provide serial data to a digital display, use switches to activate high and low level alarms and send 4-20 mA analog output to a PLC that manages the pumps or valves controlling tank level.

In simple tank control applications, you don’t even need a PLC. Simply connect the two ToughSonic solid state switches to a pump and/or valve using relays and a ToughSonic sensor will manage tank level for you. SenixVIEW software includes built-in hysteresis and time delay capabilities that allow precise control over liquid level measurement parameters.

This 3 minute VIDEO shows you how to set-up a ToughSonic sensor to control tank level without a PLC.

Ultrasonic tank level sensor pump control and display

ToughSonic and ToughSonic CHEM sensors provide digital, analog and/or switch output to multiple devices simultaneously.

Tank level control computer

Ultrasonic level sensors may send measurements to a tank level controller or ToughSonic sensors may control tanks directly using switches and relays.

Tank Level Control

Liquid level data is commonly transmitted to control devices such as Programmable Logic Controllers (PLCs), Remote Terminal Units (RTUs) or other computers as part of more complex process control systems. To meet the full range of system requirements, ToughSonic liquid level sensors can send measurement and control data using industry-standard serial digital, analog or switch outputsor all three simultaneously. For example, a ToughSonic or ToughSonic CHEM sensor might provide serial data to a digital display, use switches to activate high and low level alarms and send 4-20 mA analog output to a PLC that manages the pumps or valves controlling tank level.

In simple tank control applications, you don’t even need a PLC. Simply connect the two ToughSonic solid state switches to a pump and/or valve using relays and a ToughSonic sensor will manage tank level for you. SenixVIEW software includes built-in hysteresis and time delay capabilities that allow precise control over liquid level measurement parameters.

This 3 minute VIDEO shows you how to set-up a ToughSonic sensor to control tank level without a PLC.

Ultrasonic tank level sensor pump control and display

ToughSonic and ToughSonic CHEM sensors provide digital, analog and/or switch output to multiple devices simultaneously.

Advanced Tank Adjustments

Tank level measurements are sometimes complicated by conditions in the tank. ToughSonic sensors have adjustable features to accommodate many of these issues:

  • Tank obstacles and liquid foaming can be ignored with a stilling tube
  • Exposed mixer blades
  • Agitated liquid surfaces
  • Acoustic problems from poor process connections

Read more about SenixVIEW software.

Sensor Features

  • Scaling of output to tank size
  • Filters for agitated liquids
  • Filters to ignore visible mixers
  • Stilling tube sensitivity curves
  • Tank attachment adjustments
  • Temperature compensation
  • Converting level to volume

Ultrasonic tank level sensor stilling tube

Stilling tubes provide liquid level stability in complex tank level applications as well as outdoor water level applications such as streams, irrigation channels and wet wells.

Advanced Tank Level Measurements

Tank level measurements are sometimes complicated by conditions in the tank. Structural obstacles such as supports or mixing equipment might be in the sensor measurement path. Similarly, spray or foam can obscure the air-to-liquid interface that ultrasonic sensors detect. These applications require more advanced sensor capabilities.

One approach is to use a stilling tube. A stilling tube is a simple vented pipe that extends from the top of the tank to just short of the bottom. The sensor is placed at the top and the liquid level inside the tube follows the liquid level of the tank. The stilling tube protects the interior liquid from disturbances and provides a clear unobstructed path for the ultrasonic sound waves to follow. And since the liquid flows into the tube from the bottom where the liquid column exerts pressure, foaming is supressed.

Another approach to complicated tank level measuring environments is to use built-in sensor logic to process or filter measurements. You can use SenixVIEW to configure your ToughSonic sensor to reject certain measurements, average a series of measurement or limit the rate at which output values change. A running average of readings will smooth peaks and valleys and provide a consistent liquid level measurement. You can use the input filters in SenixVIEW to accept only maximum or minimum measurements or to negate the effect of waves or unintended objects in the measurement path. Read more about data filtering with SenixVIEW.

SenixVIEW ultrasonic liquid level sensor configuration display

ToughSonic sensors and SenixVIEW software provide advanced measurement compensation and filtering options to handle the most complex tank level applications.

Senix ultrasonic tank level sensors

Senix Tank Level Experience

Senix manufactures the most versatile and rugged ultrasonic sensors in the world. We’ve guided thousands of customers through successful tank level installations and we can help you.  Please contact us to see how.  We’re here to help.

Questions or assistance?

We’re here to help. Call us at 802 489 7300.

Water & Benign Liquids

General-Purpose-Sensors-16x9-a.pngSee our ToughSonic General Purpose sensors.

Chemicals

CHEM-Sensors-16x9-a.pngSee our ToughSonic CHEM sensors.

Hazardous Areas

Hazardous-Area-Sensors-16x9-a.pngSee our SenixSAFE sensors.

Questions?

Technical-Support.png

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