Level Sensing Is Not One Size Fits All
Because BinMaster carries a complete
selection of level sensors, we can outfit your facility with the type of sensor
that best suits your application. Call BinMaster and one of our sales
specialists will consult with you on your application, determine what devices
are best suited, provide you with price quotes, and place your order for you.
If we don’t have the right solution to meet your objectives, we’ll let you know.
Selecting the right product for your level sensing application can be
determined by a wide range of factors.
Some or all of these may influence sensor selection.
·
The material being measured
·
The material’s bulk density
·
The material’s propensity to buildup
·
How corrosive the material may be
·
How much moisture is present
·
The temperature and pressure in the
silo
·
If there is a lot of vibration
·
If there is dust, steam or vapor
present
·
The size and shape of the silo
·
Excessive noise
·
Where the sensor is mounted on the
silo
In addition to the physical factors,
there may also be specific business or data needs for the sensor.
·
Is a simple high, mid or low level
point indicator adequate?
·
What type of alert is needed?
·
Is it important to know the status of
the device?
·
Is continuous level measurement a
requirement?
·
How often do I need to measure?
·
How precise does the level measurement
need to be?
·
Is level, volume, or weight needed?
·
Is the sensor tied to a process?
·
How many people need access to the
data? How will the information be shared?
·
What are the budgetary requirements
for equipment?
Point Level Indicators
This variety of devices simply detects when material in the bin has
reached a certain point in the vessel. Most commonly used to prevent
overfilling or running out of material, most can be mounted for high, mid or
low level detection and indicate when material reaches the level of the
indicator or falls below it.
Rotaries
The rotary is the most common workhorse of all point level indicators.
What’s different about BinMaster is how we’ve made it easy to tailor a rotary
to an application. Start with choosing either the standard BMRX or the advanced
MAXIMA+ with genuine fail-safe protection and LED
indicator light to provide an immediate alert when continuous operation of the
rotary is critical. Mounting plates come in a variety of angles to fit bin
roofs to make rotaries easy to install.
There are 16 different paddles to choose from including insertable,
collapsible paddles that install without entering the bin. A horizontal rotary
extension can be used when bin walls are thick, such as in cement silos.
Optional heat tubes can be added to distance electronics from a heat source in
higher temperature environments. A stainless steel process connection offers
durability in caustic environments or in food processing applications where all
components that come into contact with material must be stainless steel.
Vertical rotary extensions up to 12 feet can be used on top-mounted rotaries
used for high level indication.
Capacitance
Probes
BinMaster offers thousands of capacitance probe configurations, all
featuring interference-free operation. Unlike many other probes, BinMaster
probes do not use RF signals, so they are not affected by RF present in the
facility and won’t interfere with other devices using RF in the plant. Pro-shield technology protects against false
readings due to buildup. A flexible extended probe (up to 35’) can be used in
aggregates and lump material that might damage a rigid probe. Flush mounted
probes can be installed when there are space constraints. Remote electronics
enable use in hostile environments, such as when high temperatures and
vibration are present. A bendable probe can be used when there are obstructions in the vessel. Explosion proof models can be
used in hazardous locations. For the food and pharmaceutical industries, a
clean-in-place configuration is 3-A and USDA compliant.
Vibrating Rods
BinMaster’s single-rod design with a sword-shaped blade has been updated
in a new enclosure with dual conduit entries,
an LED indicator light, two conduit entries and double-pole, double-throw
relays are now standard. When it comes to vibrating rods, BinMaster offers more
configurations to meet top, mid and low-level mounting requirements. For
top-mounted applications as a high level detector, BinMaster vibrating rods are
available with flexible or rigid extensions. Remote electronics can be used
when the electronics need to be distanced from sensor. For super high
temperatures up to 482°F (250°C) , there are standard and extended length
vibrating rods that can be customized in lengths from 13 inches to 13 feet. A mini vibrating rod is ideal for small bins and
hoppers and tight spaces.
Diaphragm
Switch
The most basic of level indicators, the diaphragm or pressure switch
works by sending an alert to a horn or light panel when the material in the
vessel presses against the switch. Depending on the model selected, the
diaphragm switch is mounted either inside or from the outside of the bin.
Mounting from the outside of the bin requires a hole to be cut in the bin.
Mounting on the inside involves getting into the bin to install it. BinMaster
offers models for both non-hazardous and explosion proof applications.
Diaphragm materials include neoprene which is suitable for most applications,
silicone which is more resilient and sensitive in extreme temperatures, or
neoprene with mesh which is thicker and more durable for extremely abrasive
materials.
Tilt
Switch
By activating an alarm when tilted more than 15° the tilt switch
features a simple mechanical design that operates reliably as a high level
indicator in bins, tanks and silos, detects plugged or clogged chutes, or can
be used as a high limit sensor on piles. The tilt switch is easy to install by
hanging it from a wire rope, chain or flexible hanger. A paddle can be attached
to a stainless steel shaft when the tilt switch is used in heavy materials such
as aggregates, rock, or coal. For lighter materials or powders, an optional
spherical float attached to a stainless shaft can be used.
Inventory Management Systems
When the level of material needs to be monitored on an ongoing basis and
the information needs to be accurate, continuous level measurement sensors may
output data to a console, use specialized software, or send the information to
a PLC. These systems can report the data from all of the bins on site, making
it easy to monitor inventory status for an entire operation.
SmartBob
BinMaster’s SmartBob system offers two different sensors – the SmartBob2
for bins up to 180’ tall and the SmartBob-TS1 for bins up to 60’ tall. What differentiates the SmartBob system from other types of
bob systems is the number of options that allow the system to be customized for
your operation. The advanced C-100 display console can report data for up to
128 bins from a single console to save money and eliminate walking from
bin-to-bin to get readings. A Modbus-compatible
model allows for integration into facilities utilizing the protocol, and the
C-50 analog expansion console provides multiple 4 -20 mA outputs to reduce
wiring costs associated with monitoring up to 120 bins.
Monitor all of the bins from a PC using eBob software, which now is
capable of integrating strapping table data to help with measuring the contents
of materials prone to compaction or adjust weight-to-distance readings for
cone-bottomed or other irregular shaped vessels. MultiBob – a configuration
that allows multiple sensors on a single bin – can average the level data,
providing better information such as indicating cone up or down and high or low
spots in the bin. The SmartBob SS for submersed solids can be used in interface
applications, such as measuring the level of solid material under liquid.
3DLevelScanner
BinMaster has more experience with the 3DLevelScanner non-contact,
dust-penetrating technology than any other US company. With a dedicated sales
and technical staff and more than 600 installations in place, BinMaster is the
best qualified company to assess your application and set up the scanners to
ensure they operate properly. With its multiple-point measurement and optional
3D mapping and visualization, the 3DLevelScanner also offers the ability to
calculate material volume with a high degree of accuracy. The MVL multiple
scanner system allows for two or more sensors mounted on a single bin, with a
processor that combines the data from multiple sensors to get better accuracy
in big bins. MultiVision software allows all of the bins
with the 3DLevelScanner to be monitored from a single screen and share
information easily among all departments in the facility. The model HE for
harsh environments can handle temperatures up to 250°F, making it suitable for
materials like clinker, fly ash and alumina or any other powder or solid that
may get heated in
the production process.
the production process.
SmartSonic
and SmartWave
BinMaster’s SmartSonic ultrasonic and SmartWave radar non-contact level
measurement devices eliminate the risk of contamination or interfering with the
internal bin structure. They are also ideal and highly accurate in liquid
applications, as liquid levels are even across the tank. Ultrasonic and radar-based
technologies use single-point, continuous measurement technology which can be
used for ongoing level measuring and monitoring of tanks that are up to 100
feet tall. They can be used in limited solids applications with a measuring
range of approximately half the distance for that of liquids. Ultrasonic and
radar may not perform consistently in high dust environments, where their
signals can become “confused” and provide inaccurate measurements or no data at
all. Since they only measure a single point in the tank, they may offer
compromised accuracy in materials like powders that are more prone to bridge or
have an irregular surface area which makes the tank more difficult to measure
accurately.
Custom Products at Stock Prices
Set on 30 acres, BinMaster’s 75,000 square foot facility also houses our
state-of-the-art machine shop. Not only does
BinMaster manufacture products in house, we can machine parts so
a product can be made precisely for an application. Custom configurations and built-to-order
equipment is at the core of our business. We are different from many companies
who manufacture or assemble overseas and are unable to customize equipment to
an application.
Made in the USA
BinMaster’s point level indicators and SmartBob systems were designed by
BinMaster engineers and are manufactured in Lincoln, Nebraska in our ISO
9001:2008 certified facility. Technical support is provided by a team of
seasoned professionals who work alongside our engineers and sales specialists.
You will always get a live person to answer your questions – whether you call or email BinMaster.
BinMaster Level Sensors Make Good
Sense Learn more at www.binmaster.com
