OPERATION, INSTALLATION

& MAINTENANCE MANUAL

RF LEVEL SWITCH
Series RFLS10

LEVSEN CONTROLS & INSTRUMENTS

B-4, Aditya Complex, Block C-3, Yamuna Vihar,
DELHI – 110 053
 CONTENTS

INTRODUCTION

OPERATING PRINCIPLE

FEATURES

APPLICATION CONSIDERATIONS

SELECTION

MECHANICAL INSTALLATION

ELECTRICAL INSTALLATION
SPECIFICATIONS

OPERATION

CALIBRATION

TYPICAL APPLICATION

FACTORY ASSISTANCE

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 INTRODUCTION

RF Level Switch operates in the low MHz radio frequency range. Radio frequency (RF) principle is utlised to
monitor the level of material available in a vessel at a particular level. Relay contacts are used to provide
visual indication and also for interlocking purposes.
RF level switch provides reliable Relay outputs and its functioning is independent of moisture, material temperature,
Coating
be conductive, non conductive, solids, liquids, corrosive or even tend to coat on the sensing probe.

Design & Description

RF Level Switch comprises of an electronic controller, a

sensing probe and coaxial cable for the connection of the electronic controller to the probe. The Electronic Controller
provides RF signals to the probe and measures the changes in parameters provided by the sensing probe mounted in the
material (to be measured) container. The sensing probe does not contain any electronics.

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RF signal provided to the probe varies with the change of media (the application material having interparticle
cohesive contact) upto the vessel body as reference ground. The material in transit or the suspended particles which
do not have cohesive interparticle contact up to the vessel shell are not taken into account. The variation in RF
signal is utilized to activate a relay and the relay contacts are available as output for further use. To protect the
equipment from electrostatic charge developed in the vessel, an Electrostatic Charge Protector is provided in the
Probe Head.

The most common probe design is a stainless steel rod insulated from the housing and bin wall by a low-dielectric
insulator, such as PTFE/Teflon. These polymers have maximum operating temperatures of upto 250°C. Ceramics
can be used for higher temperature applications or if abrasion resistance is required. For applications where the
process material is conductive and corrosive, the probe is fully insulated with Teflon.
The point level sensors are provided with build-up immunity or coating rejection functionality by the use of a shield
section which is kept at the same potential and frequency as the measuring probe. Because current cannot flow
between equal potentials, the measuring probe does not sense material build-up between the sensing probe and
vessel wall.

The electronic circuitry of the probe performs the functions of:

1) Rectifying and filtering the incoming power,
2) Generating the radio frequency signal,
3) Measuring the changes in current flow, and
4) Driving and controlling interface devices such as relays and
Interlocks.
OPERATING PRINCIPLE

LEVSEN RF level switch Series RFLS 10 works on Radio Frequency Principle. Independent but identical low power
RF signals equal in frequency, phase, and amplitude and wave shape generated in Electronic Controller are
provided to active and shield sections of the Sensing Probe whereas , the reference ground of electronics is
connected to the vessel shell . The signal provided to the shield section is maintained constant by use of a
compensating circuit in the Electronic Controller while the signal applied to the active section varies with the change
of media between probe and the vessel shell. The suspended dust or material in transit do not have cohesive inter-
particle contact and have no role in this RF principle of Level Sensing. The variation in active signal is compared
with the constant shield signal. At a predetermined value of difference a relay is actuated to obtain potential free
relay change over.
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FEATURES

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 APPLICATION CONSIDERATIONS

Materials that are conductive (water-based liquids with a conductivity of 100 micromhos/cm or more) can cause a
short circuit between a bare stainless steel probe and the vessel wall. As the liquid level drops, the probe remains
wetted, providing a conductive path between the probe and the vessel wall. The faster the level changes, the more
likely this false indication is to occur. It is advisable to use Teflon insulation on the conductive probe surface when
the process fluid is conductive.

Temperature affects both the sensor components inside the vessel (active & shield sections and insulation) and the
electronic components and housing outside. An active probe is typically made from stainless steel and, as such
(unless it is coated), it is suitable for most applications. Probe insulators can be Teflon or ceramic, and should be
selected for the operating temperature of the application. The housing and the electronics are affected by both the
internal and external vessel temperatures.

Ambient temperature limits usually are specified by the manufacturer, but heat conduction from a high-temperature
process is more difficult to evaluate. Heat conduction can be reduced by using an extended mounting coupling or
one made of a low thermal conductivity material. If such methods are insufficient, the electronics may be mounted
up to 20 ft away and connected via PTFE insulated coaxial cable. Housings must also be compatible with the
equirements for hazardous, wash-down, wet, and/or dusty environments. Explosion-proof environments may
require the housing to be certified. In addition, the active probe might need to be intrinsically safe.

If the process material is corrosive to stainless steel, the probe should be fully coated with Teflon for protection.

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 LEVSEN MODELS
LEVSEN provides various models of sensing probes to suit customer requirements. Since the sensing probe do not contain any
electronics the electronic controller is identical for all the sensing probe

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 MECHANICAL INSTALLATION

The sensing probe should be mounted in such a way that its operation is unaffected by incoming or outgoing material
flow. Material impacts can cause false readings or damage to the sensing probe.
Install the probe so that it does not contact the vessel wall or any structural elements of the vessel.

LOCATION & INSTALLATION

The Following should be considered while mounting sensing probes.

1) Verify that material will cover the active section of the probe at the proposed mounting location consider the probe
length.

SHIELD SECTION OF THE PROBE MUST
PROJECT INSIDE THE VESSEL FREELY
AT ALEAST 50 MM (2”) NO MECHANICAL
PROTECTION IS REQUIRED FOR
LEVSEN PROBES. FOR LARGE SIZE
PARTICALS & TALL BINS USE FLUSH PROBES.
ACTIVE SECTION OOF PROBE MUST
NOT BE TOO CLOSE TO THE VESSEL
SHELL OR ANY OTHER METALLIC -
GROUNTED PARTS
ASK LEVSEN FOR A SUITABLE PROBE

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2) Be certain there is a sufficient clearance outside the hopper for insertion and writing. For thermal insulated vessel use
lagging extension of length equal to thickness of insertion, for easy access to terminals.

IF LONG EXTENTIN REQUIRED MOUNT THE PROBE PERPENDICULAR

INSIDE THE VESSEL (90± 15º) TO THE VESSEL SHELL
ASK LEVSEN FOR A SUITABLE PROBE FOR SPECIAL REQUIREMENTS ASK LEVSEN

DO NOT INSTALL THE PROBE VERY CLOSE TO THE OTHER SIDE WALL PLATE PREFFERED LOCATION NEAR
CENTER LINE OF THE WALL / PLATE OF MOUNTING

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 FLEXIBLE TOP MOUNTED PROBE AWAY FROMSIDE WALLS & NEAREST TO THE FILL POINT PROBE INSERTION LENGTH TO
BE SELECTED CONSIDERING ANGLE OF REPOSE OF MATERIAL DISTANCE FROM FILL POINT UPTO NOZZEL HEIGHT
SAFETY LEVEL ( ETC. +150 MM FOR SENSING RULE ) OF THUMB THE INSERTION LENGTH OF PROBE SHOULD NOT BE
LESS THAN HORIZONTAL DISTANCE FROM FILL POINT TO PROBE MOUNTING

FLUSHED PROBE MUST FLUSH WITH PROTECT ELECTRONICS FROM

THE INNER SURFACE OF THE VESSEL DIRECT SUN, RAIN & SNOW
WALL / PLATE OR MAY PROTECT INSIDE AND DO NOT SELECT VERY HOT
THE VESSEL UPTO 5MM BUT MUST NOT OR HEAVY VIBRATION AREA FOR LOCATION
REMAIN BEHIND. THE INNER OR ANY
METALLIC LINERS ETC.

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 ELECTRICAL INSTALLATION

ELECTRONIC CONTROLLER LOCATION & INSTALLATION

The following should be considered while mounting the electronic controller:

• Location Mount on convenient structure (near probe location) free from obstruction
• Temperature Be sure ambient temperature is not more than specified temperature
• Environment Install unit at a location so that there is no exposure to direct sunlight,
rain or snow
• Vibration If there is excess vibration in the area, use alternate mounting area or
provide vibration absorbing material under the enclosure base.
• Distance Make sure that cable distance from the Sensing probe to electronic controller
is minimum possible .

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PROBE LOCATION & INSTALLATION
The following should be taken care of while mounting sensing probes:
i. Verify that material will cover the active section of the probe at the proposed mounting location.
ii. Be certain that shield section of the probe must project freely inside the vessel (at least 2 inch or 50mm)
for Rod type/Flexible probes.
iii. Be certain there is a sufficient clearance outside the hopper for inserting and wiring. For thermal insulated
vessel use lagging extension (of length equal to thickness of insulation) for easy access to terminals.
iv. Disc type probe must be either flushed with inner surface of hopper wall or may project inside (up to 5mm)
but not remain behind the inner surface of the vessel.
v. Probe must be almost perpendicular (90 + 15°) to the vessel wall on which it is to be mounted.
vi. Active section must not be too close to any other grounded metal part of the hopper/Vessel maximum
possible gap must be maintained. Prefer location along the centre line of the wall/plate of the vessel.
vii. Termination must be done with proper lugs & gland and each conductor must be totally isolated from each
other.
viii. Probe length is selected considering angle of repose (for solids), roof thickness, mounting nozzle height
etc., as rule of thumb for solid materials, Horizontal distance from fill point/points must be less than the
insertion length of the probe.
ix. Select location for flexible top mounted sensing probe nearest (possible) to the vertical centre axis of the
filling point /points & maximum possible distance from side walls.
x. Probe grounding of hopper/vessel body with electronic controller must be ensured.
xi. Do not provide additional metallic protection like pipe/channel/plate inside the vessel covering the sensing
probe, if provided must be removed, as this can result malfunctioning. For large size particles use disc
type flush mounted Probes.

CABLE CONNECTION
POWER CONNECTIONS:-
Power connections (as specified) are made directly to the terminal blocks located in the electronic controller.
Due to the low power consumption of the unit, (3VA) light gauge wiring of size 1.0mm sq. may be sufficient.
OUTPUT CONNECTIONS:-
Out put relay connections are made directly to the terminal blocks located inside the electronic
controller. These relay contacts (two numbers change over potential free contacts) are rated for
5amp at 220VAC non-in active or as specified. Output wiring should be compatible with the
intend output load (less than relay contact rating

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 SPECIFICATIONS
1) ELECTRONIC CONTROLLER
• Supply Voltage 220/110/24 VAC OR as specified
• Frequency 50 Hz ± 5% for AC supply
• Power Consumption 3 VA (Approx.)
• Ambient Temperature -10 to +50°C
• Output 2 sets of Change over potential free
Relay Contacts (DPDT) or as specified.
• Contact Rating 5 AMPS 220 VAC non-inductive
• Local LED Indications
Green Normal Level
Red Alarm Level
Yellow Probe Healthy: LED glows off in case of
the Probe or probe cable shorted
2) SENSING PROBES
• Probe Insertion Length/Range 0 to 10 mtrs.
• Process Temperature 250 / 600ºC
• Protection IP 65
• Mounting Side /Top
• Process Connection 40 NB Thread Or Flange (As required)
• Cable Entry “½ ET for connection of Coaxial Cable
• Insulation PTEF / Ceramic
• Compatible Electronics Electronic Controller Model RFLS10-EC
• Cable to Electronic Controller RF Coaxial cable.
3) COAXIAL CABLE
The special screened coaxial cable is used for connection of Sensing Probe and Electronic Controller
• CABLE Special coaxial cable
• Centre wire for Probe connection,
• Middle shield for Signal connection,
• Drain for Ground connection
• Conductor Copper
• Insulation PVC/PTFE

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 OPERATION START UP

ELECTRONIC UNIT:-

1. Verify that the ambient condition suitable (-10 to + 50° C. Max.).

2. Verify that the Electronic Controller is installed at convenient man height.
3. Verify that the Electronic Controller is not exposed to direct sunlight, rain or snow.
4. Verify that the mounting fasteners are tightened properly.
5. Verify that the Earthing grid is connected at both the earthing terminals of electronic unit
6. Verify that the Supply voltage is as specified on the terminals.
7.

PROBE:-

1. Verify that the Probe is mounted 90 (±) 15° to vessel wall/plate.

2. Verify that there is no Pipe cover Hood Canopy inside vessel over/near probe.
3. Verify that there is maximum gap from other walls/ any other metal parts.
4. Verify that the Shield section projection inside the vessel more than 50mm (2 ")
5. If flexible probe mounted from top only and distance from fill point is less than probe length.
6. If flushed probe: either flush with inner surface of the vessel or projects inside up to 5mm.
7. Verify probe ground terminal shows continuity with vessel/ earthing grid.
8. Switch on the appreciated supply voltage and yellow & either green or red Local LEDs glow.

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 CALIBRATION

The Instrument has been factory calibrated for use in the majority of applications; However, due to variations in
installations, for maximum accuracy, final adjustments should be made with the vessel/hopper at operating
conditions.
• Ensure the level of application material is below the probe.
• Select “Cal/Open” switch to “Cal”.
Check local indications LED. Greed LED should glow, if not turn adjustment clockwise so that Green LED
glows ON and Red LED glows off.
Turn the turning adjustments counter-clockwise until the Local Indication LED just glows Red.
• Turn adjustment clockwise till Green LED glows ON and add further half turn in same direction for preloading.
• Increase the material level above the desired level of operation and check that the local indication LED glows
“Red”.
• If unit does not respond, the preload setting must be reduced.
• Verify once again with material level for satisfaction of calibration.
• Select “Cal/Opn” switch “Opn.”

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 TYPICAL APPLICATION

Fly Ash, Cement, Urea,Lime,Coal Powder, Coal Lump, Soda Ash, Alumina, Talc,Polyster,Detergent Granules, PVC Resin,
Polyester, Glass Batch,Silicasand,Oils,Sugar,Salt,Coal Tar,Pigmrnts,Iron Ore, Sewage,
Slurries,Acids,Clay,Chemicals,Borax,Zinc Oxide, Tea Leaves,Glass,Bauxite and many more…………..

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 FACTORY ASSISTANCE

FOR ANY QUERIES, YOU MAY KINDLY CONTACT OUR TECHNICAL EXPERTS AT
THE FOLLOWING ADDRESS:

LEVSEN CONTROLS & INSTRUMENTS

B-4, ADITYA COMPLEX,
BLOCK C-3, YAMUNA VIHAR,
DELHI – 110 053

Ph.No. : 011-22914561 & 62

Fax No.: 011-22914562
E-mail : info@levsencontrols.com
levsencontrols@yahoo.co.in
levsencontrols@gmail.com

Website: www.levsencontrols.com

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