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Component tank level monitoring at a thermal insulation plant

Non-contact radar level measurement with 4-20 mA output and IO-Link
October 15, 2026 by
Ričards Sleņģis

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Automated level and pressure monitoring for four component tanks at a thermal insulation plant - with Banner T30R radar sensors, BD Sensors pressure sensors and data sent to the PLC.




4

tanks with radar level sensor

1 week.

sensor installation and configuration

4-20 mA

signal to PLC and IO-Link configuration

The problem

Production depends on the component level in four tanks

The insulation material is made by mixing components from four tanks. If one tank runs out, the mix cannot be made.

 An empty tank stops production

Without one component the line stands still until the tank is refilled.

 Raw material planning without an exact level

Without the exact level in each tank, component deliveries are hard to order on time.

 Level control depends on the operator

Watching four tanks takes staff time, and every missed reading can stop production.

 Aggressive vapours damage sensors

Component vapours wear out sensor seals over time if the material is not matched to the medium.

Solution

Level and pressure measurement with a signal to the PLC

Non-contact level measurement

Each of the four tanks has a Banner T30R radar sensor. It measures the distance to the liquid surface without touching the component.

4-20 mA signal to PLC

The sensor sends the level to the PLC as a 4-20 mA signal. The PLC sees the level in every tank and starts filling when a level drops to the minimum.

Remote setup via IO-Link

The radar sensors also have IO-Link, so their parameters can be changed remotely through the PLC without climbing onto the tank.

Pressure - to the PLC and on site for the operator

BD Sensors DS 200 pressure sensors send a 4-20 mA signal to the PLC and show the pressure on a display the operator reads at the pipe.


Komponenšu tvertņu līmeņa uzraudzība Četras tvertnes ar radara līmeņa sensoriem, kas nodod līmeni PLK. Kad līmenis nokrīt līdz minimumam, PLK ieslēdz iepildi. iepilde uz maisīšanu 0.13 BD Sensors DS 200 spiediens: PLK + displejs PLK 4-20 mA · IO-Link attālināta piekļuve Banner T30R radara līmeņa sensors
Gatavs

System components

Radar level sensors, pressure sensors, and installation on site

Banner T30R-1515-CKIQP

  • Radar level sensor - measures the level of the component in each tank without contact with the environment.

    Measuring range: 0.1-6 m

  • Frequency: 122 GHz, 15° beam
  • Outputs: 4-20 mA, 1 discrete NPN/PNP, IO-Link
  • Housing: M30, IP67

    View product
 

BD Sensors DS 200

  • Pressure sensor with display - 4-20 mA signal to the PLC and a reading for the operator right at the pipe.

    Display: 4 digit LED

  • Outputs: 4-20 mA, PNP switching output
  • Accuracy: 0.35 % FSO
  • Seals: FKM or NBR

    View products
 

BD Sensors DMP 331 and 18.601 G

  • Industrial pressure sensors - 4-20 mA signal to PLC from additional pressure measurement points.

    Diaphragm: stainless steel 316L

  • Output: 4-20 mA, 2 wire
  • 18.601 G accuracy: 0.5 % FSO, FKM seal
  • DMP 331 protection: up to IP68

    View DMP 331   View 18.601 G
 

What it changes day to day

Automatic level control and remote monitoring

Filling starts before a tank runs empty
The PLC keeps each tank level from the radar signal, so production does not stop for lack of a component.

Exact levels for raw material planning
The level in every tank is known at any time, so component deliveries can be ordered on time.

Less manual work and fewer errors
The PLC decides when to fill based on the sensor signal, not the operator based on a visual check.

Remote monitoring and setup
Connecting to the PLC shows levels and pressures remotely, and radar parameters can be changed via IO-Link.

Questions and answers

Cost, installation and operation in an aggressive environment

In this project, sensors and accessories for four tanks cost about €9,500. The final price depends on the number of tanks, the measuring range and the number of pressure points.

Installing and setting up the sensors takes about one week. PLC programming is not included in that time.

Component levels are maintained automatically and reliably, without depending on operator attention.
Yes. Connecting to the PLC shows levels and pressures remotely, and radar settings can be changed via IO-Link.
The radar sensor does not touch the component, so it does not get coated and is not exposed directly to the liquid.
Yes. The sensors use a standard 4-20 mA signal accepted by PLC analog inputs. Remote setup via IO-Link requires an IO-Link master.

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