In industries where numerous tanks hold either liquids or solids, accurate level measurement is crucial for ensuring operational efficiency and safety.
Equally important is the ability to monitor sensor signal wire break faults, ensuring continuous system monitoring.
This article presents a device system designed to meet these objectives.
System Overview
The system includes three identical tanks, each equipped with an NR4100 radar level sensor. The PR Electronics 4116 device (referred to as PR4116) reads the level signals from the sensors. The PR Electronics 4184 (referred to as PR4184) then sums up the signals from the PR4116 units to output the total liquid level across all three tanks.
This configuration provides individual tank level data and the total liquid level, while also incorporating a mechanism to detect sensor wire break faults in each tank. It can send alerts to operators via warning lights or relay signals to a central control system.
Technical Configuration
Each PR4116 is configured to receive 4–20 mA signals from the sensors and features galvanic isolation up to 2.3 kVAC, ensuring stable signals and excellent electromagnetic interference immunity. If a sensor fails or the wire is broken (resulting in 0 mA or abnormally low/high signals), the PR4116 will detect it and trigger an alert via its relay output.
The outputs of the PR4116 units are configured to provide 0–10 V signals, which are then connected in series to the PR4184’s input, utilizing its capability to handle high-voltage inputs (up to 300 VDC).
Applications and Benefits
This level measurement and sensor wire break monitoring system is flexible and suitable for any application involving multiple tanks. A single PR4184 device can sum signals from up to 30 tanks. It is especially beneficial for industries that prioritize high accuracy and comprehensive monitoring of sensor and wiring conditions.
Explore Products in This Application
NR 4100 (UWT)
- NR 4100 (UWT)
- Non-contact radar level measurement
- Suitable for liquids and solids
- Minimum dielectric constant: DK ≥ 1.1
- Material: PVDF
- Accuracy: ±2 mm
- Process and ambient temperature: -40°C to +80°C
- Max operating pressure: -1 bar to 3 bar
- Output: 2-wire 4–20 mA, HART
- Process connection: G 1″ DIN ISO 228-1 / NPT 1″ ANSI B 1.20.1 / R 1″ EN 10226 or 3” flange, DN80
- Measuring range: up to 30 m (recommended up to 20 m for solids)
- Cable lengths: 5 m / 10 m / 25 m
- Protection rating: IP66/68 (3 bar), Type 6P
- Food/Pharma certifications: FDA, NSF/ANSI/CAN 61, or EG 1935/2004
PR 4116
- Input: RTD, TC, resistance, potentiometer, current (mA), and voltage (V)
- Provides >16 V loop power
- Output: current, voltage, and two relays
- Universal power supply: 21.6–253 VAC / 19.2–300 VDC
- Complies with NAMUR NE21
- Isolation voltage: 2.3 kVAC
- Easy programming and monitoring with PR 4500 display
PR 4184
- Measures DC signals up to ±300 V / ±100 mA with resolution down to 25 mV / 0.5 mA
- Output: passive/active current and buffered voltage
- Fast response time < 20 ms, high accuracy 0.05%
- Universal power supply: 21.6–253 VAC / 19.2–300 VDC
- Complies with NAMUR NE21
- Isolation voltage: 2.3 kVAC
PR 4500
- Programming display for all devices in the 4000 / 9000 series and compatible 3000 series or ConfigMate 4590
- Displays values and device status
- User-friendly interface with 7 languages
- Backup memory for saving and transferring configurations
- Optional Bluetooth communication (with 4512) for data logging and iOS/Android app support
- Optional Modbus RTU communication via RS-485 (with 4511)
Conclusion
The integrated level measurement and sensor wire break monitoring solution using PR 4116, 4184, and 4500 devices offers optimal performance, enabling businesses to maintain stable operations, reduce costs, and enhance system reliability.
For more detailed information, please refer to the technical documentation available on the PR electronics website or contact the official distributor.
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