Capacitive Level Sensor

Forrest Long MECH 207 Fall 2009

Images courtesy of Omega corp, discovercircuits.com, and Magnetrol Corp.

Introduction
y Level Sensor, used for a variety of liquids or solids

(powder, granular, aggregate, etc) in a storage tank/vessel

y

Fuel levels, Water levels for process, waste, treatment, Raw materials (alcohols, oils, chemicals) y Plastics or solid powders for raw materials
y Can be integrated with electronics for continuous or

point (switch) level indications

Typical sensor and installation

Principle of Operation
y Basic principle is that of the capacitor
y

Capacitor is defined as follows:

Principle of Operation
Distance over which charge is stored is shown in diagrams below and depends on the medium measured
If the medium is non conductive then it provides a large change in the dielectric constant If the medium is conductive then an insulated probe is used and the capacitor is formed by the outer surface of the insulation (shorted to the wall) and the electrode

Operation
y For the insulative medium case, As level rises then the capacitance

changes approximately as follows y C =0.225 (Kair x Aair) +0.225 (Kmaterial x Amaterial ) Dair Dmaterial y C = (Kair x Aair) + (Kmaterial x Amaterial ) when Ds are the same
y For the conductive medium case, As level rises then the capacitance

changes approximately as follows y C =0.225 (Kmaterial x Amaterial ) Dmaterial y With Amaterial defined by the height of the substance and the air term eliminated since Dair>> Dmaterial without conductive medium to connect

y The capacitance is directly proportional to the

height of the medium

Dielectric constants

One typical implementation

Enhancements
y Measure the complex impedance of the circuit rather

than just the capacitance which can easily, as in the above implementation generate a 4-20 mA signal other analog transmittable signal y Impedance measurement is a standard analog signal processing method, easier to implement than high precision measurements of femto-, pico-, nano-, or micro-Farads

Typical installation concerns

Issues in use
y Coating or build-up of salts or other process chemicals y Wicking and un even coating of the electrode y Corrosion y Non-conductive tanks y High temperatures or pressures y Signal noise particularly in using RF near other

sources y Splashing or bubbles/foam y Incompatible with very low density or very low dielectric constant materials

Additional References
y www.discovercircuits.com/PDF-FILES/capgage.pdf y www.omega.com/GREEN/pdf/CAP_LEV_MEAS.pdf y www.sensorsmag.com/articles/1000/55/main.shtm y http://us.magnetrol.com/products.aspx?menu=184

Pricing Synopsis
y Per Omega:
y

$850 - $1200 for probe and signal processing head (starting) y Up to $1200 for remote (if required) signal processing and control box y $150 - $300 for isolation and power supply and other interface eletronics
y Per Magnetrol
y

Ca. $1500 for integral mount continuous level transmitter with 4 relays and 4-20 mA ouput (4-wire or 2-wire) y Ca. $800 for remote probe with ca. $1200 additional for display, calibration, control, and transmitter electronics

F L E X I B L E

P R O B E S

C A P A C I T A N C E
G A I N G R A P H S

P I C O F A R A D
pF per inch cm 20 8.0 18 7.2

( P F )

Insulated flexible and bare flexible probes Rigid probes longer than 10 feet (3 m) are difficult to install and to physically move in the field. Flexible probes are the ideal solution for measuring ranges from 10 feet (3 m) up to 150 feet (45 m). Insulated flexible probes can be used with either conductive or non-conductive media. Bare flexible probes can only be used with non-conductive media. Always verify that the selected electronics is powerful enough to operate at these longer distances. The following pages contain capacitance gain graphs which can be used to determine the proper probe/electronics choice for any given application. To use the graphs, follow the steps below. 1. Determine the dielectric of the process medium being measured. If the dielectric is unknown, use a dielectric of 2 for non-conductive media such as hydrocarbons or dry media, and a dielectric value of 80 for water based, conductive liquids (dielectric values are along the X axis). 2. Choose a probe. Because more than one probe will usually work, consider the other application parameters such as temperature, pressure, material compatibility, etc.

Stillwell

16 6.4 14 5.6 12 4.8 10 8 6 4 2 0 4.0 3.2 2.4 1.6 0.8 0 1 2 3 4 5 6 7 Dielectric value of media 8 9 10 Tank diameter inches (cm) 4 (10) 12 24 48 96 (30) (60) (120) (240)

H E A T

E X T E N S I O N
The heat dissipation graph, at left, depicts the maximum temperatures at which the extension can be used effectively. 1. Determine the maximum process temperature in the application and locate on X axis. 2. Determine the maximum ambient temperature surrounding the heat extension and locate on the Y axis. 3. If the intersecting point on the graph is within the shaded area the heat extension will dissipate enough heat to keep the electronics temperature below +160 F (+70 C). NOTE: The heat extension may be used with all rigid probe configurations and flexible probe configuration 8A2-AA1A-0XX. The heat extension can not be used with guarded probes.
10" (254 mm)

HEAT DISSIPATION GRAPH

For use with Heat extension (89-6593-001)
160

3. Find the graph which covers the chosen probe. Choose the curve on the graph which most closely relates to your particular application. 4. Using the chosen curve, determine the amount of pF/inch or pF/centimeter your application will develop (values are on Y axis). 5. Multiply the pF/inch value by the transmitter span needed in the application. 6. Compare total capacitance generated by the probe against the needed zero and span of the Kotron electronics to be used.

Example: Parameters: a. b. c. d. e. f.

Dielectric = 2.0 Probe = Part No. 8AB-AA2B-072 (with stillwell) pF/inch = 2.00 Electronics = Kotron Two-Wire Transmitter Required application span = 72 in. Electronics span = 50 pF min. to 4000 pF maximum (See chart below)

2.00 pF/inch 72 in = 144 pF The total capacitance is enough to meet the 50 pF minimum span of the electronics.

Ambient air temperature at heat extension F

150 140 130 120 110 100 90 80 70 60 50 0 200 400 600 800 1000

These charts are meant as an application aid; actual values may differ slightly. Always provide a 10% margin of error to ensure satisfactory performance. These curves represent the probe located in the center of the vessel. If the probe is near one wall of a large vessel, multiply the distance from the vessel wall by 2 (to develop a diameter), choose the closest curve in the chart to your application, and then multiply the resultant pF value 78%. This will account for the probe not being totally surrounded by the ground reference.

RANGE OF CAPACITANCE ADJUSTMENT

Level Kotron Electronics Model 80-8032 Model 810 Model 811 Point Models 80/81 Narrow Wide High Range Wide Low Range Models 822/832/842 Model 82CE Continuous Model 804 Model 801 Model 805 Zero set point 0 to 350 pF 0 to 500 pF 0 to 1000 pF 0 to 3000 pF 0 to 3000 pF 0 to 3000 pF 0 to 50,000 pF 0 to 1000 pF 0 to 50,000 pF 0 to 50,000 pF 0 to 10,000 pF Span/Differential 0.5 pF, fixed 0.5 pF, fixed 0.5 pF to 700 pF 0.5 pF, fixed 4 to 1500 pF 2 to 1500 pF 0.5 to 50,000 pF 50 to 4000 pF 5 to 50,000 pF, 0.5 pF (setpoint min.) 5 to 50,000 pF, 0.5 pF (setpoint min.) 5 pF to 10,000 pF

Process temperature F

C A P A C I T A N C E
G A I N G R A P H S

P I C O F A R A D
8XA-1AXX-XXX or 8XA-4AXX-XXX 8XA-2AXX-XXX or 8XA-5AXX-XXX pF per inch cm 10 4.0
9 8 7 6 5 4 3 2 1 0 3.6 3.2 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0 10 20 30

( P F )

C O N T I N U E D

C A P A C I T A N C E
G A I N G R A P H S

P I C O F A R A D

( P F )

C O N T I N U E D

Capacitance gain for Teflon and Halar coated probes

Tank diameter inches (cm) 4 12 24 48 96 (10) (30) (60) (120) (240) Stillwell

Capacitance gain chart for bare flexible probe

8X2-AA1A-XXX 0.19" (5 mm) probe diameter
pF per inch cm 4 1.6

Tank diameter inches (cm) 4 (10) 12 (30)

1.2

0.8

24 (60) 48 (120) 96 (240)

0.4

0 1 2 3 4 5 6 Dielectric value of media 7 8

Capacitance gain for Kynar coated probes

8XA-3XXX-XXX or 8XA-6XXX-XXX
pF per inch cm 40 16.0 40 50 60 70 80 Dielectric value of media

Stillwell Tank diameter inches (cm)

30 12.0

20

8.0

4 12 24 48 96

(10) (30) (60) (120) (240)

Capacitance gain chart for standard flexible probe

8X1-5A1A-XXX 0.19" (5 mm) probe diameter
pF per inch cm 7 2.8 6 5 2.4 2.0 1.6 1.2 0.8 0.4 0 10 20 30 40 50 60 Dielectric value of media 70 80 Tank diameter inches (cm) 4 (10) 12 (30) 24 (60) 48 (120) 96 (240)

10

4.0

0 0 10 20 30 40 50 60 Dielectric value of media 70 80

4 3 2 1

Capacitance gain chart for bare probes

8XB-XXXX-XXX or 8XC-XXXX-XXX
pF per inch cm 20 8.0 18 7.2 Stillwell

16 6.4 14 5.6 12 4.8 10 8 6 4 2 0 4.0 3.2 2.4 1.6 0.8 0 1 2 3 4 5 6 7 Dielectric value of media 8 9 10 Tank diameter inches (cm) 4 (10) 12 (30) 24 (60) 48 (120) 96 (240)