Float Switch Technology Replacement With Electronic Sensor For Cost Reduction

Our customer was using a stainless steel electro mechanical float switch to measure high levels of oil in a tank. The float switch had an M18 stainless steel thread and was electrically specified at 240v AC or 24v DC (The customer was using the 24v DC option) and the customer stipulated that the M18 mounting thread and the electrical configuration could not change. There were an number of issues –

  • Space Constraints – The float switch length was 25mm and therefore could only be used in the larger tanks provided by this   customer.
  • Reliability – As the float is a moving product, there were occasions where the switch stuck due to the build up of residue or particulate, this caused false readings.
  • Cost – Product cost reduction was desirable – Float switch cost €52.20

By taking one of our LLC liquid level sensors as a building block, SST selected an M18 threaded stainless housing and mounted the required electronics into the housing. We were then able to offer the customer the same mounting and electrical configuration.

The space intrusion into the tank reduced to 7mm, there are no moving parts with the SST Electronic Sensors and therefore the reliability issue was solved and the price reduced by over 40%.

For more information on this type of application, please Ask Our Experts!

Sick Building Syndrome and indoor climate control

The problem of high levels of CO2 in ambient air appears to be a modern one. Yet, this is not one of the new fads that crop up from time to time and then disappear again, never to be mentioned again. It is, indeed, a modern problem, caused by the improvements in building standards and especially window manufacture. These improvements, hailed as a triumph over the age-old problem of draughty buildings, have nevertheless created a new negative effect. Ventilation was never a matter for discussion in most cases, it happened naturally as the wind blew and the air in rooms was replaced on a regular basis. With the new, draught-proof buildings this no longer happened, particularly since central heating made it unnecessary to have an air flow for any reason. This has given birth to the concept of indoor climate control.
The result was stale air. Air that has been used and breathed and not replaced, seen as a rising concentration of carbon dioxide, not to mention humidity. These effects had a detrimental influence on the buildings, promoting the growth of mould and other unwanted plant life. This was not the only effect. Slowly, the level of days off for sickness rose and the quality of work sank in these newer or refurbished buildings, leading to something referred to as Sick

Building Syndrome, since it appeared to affect everybody in one building. The causes were not known for a long time, but now it is recognised that this is a result of breathing stale air with a high concentration of carbon dioxide over an extended period. Studies have shown that a level of 1000 ppm carbon dioxide will reduce the ability to concentrate by about 30 %, a significant drop by any means.
The obvious solution to this problem of indoor climate control was ventilation, and ventilation or air-conditioning systems were installed in all of these buildings leading only to the next problem: the heating bills in winter rocketed and staff complained of stiff necks and other maladies. Sick Building Syndrome was still here, but in a different form. How to provide adequate ventilation without simply heating the environment in winter? The only viable solution is control of the ventilation to reduce the exchange of air to the minimum required to keep a healthy atmosphere in the rooms, which is where indoor climate control becomes an active instead of just a passive discipline.

The real problem is the carbon dioxide, which is best measured with a NDIR infrared sensor. These are available in one or two cha nnel technology for CO2, but the single channel version
is quite accurate and stable enough for this purpose today. Older types of sensor used to drift, as do cheaply manufactured ones, but a good-quality single channel sensor today will remain stable over years, only requiring a reference point occasionally to set a relative zero point.

Such infrared sensors for CO2 are now available from a number of manufacturers such as Madur Electronics in Austria. These come complete with an appropriate analogue output to allow the CO2 level to control the function of the ventilation system. Industry standard for these control functions is the 0…10 V output, but there are other varieties in use. These can be readily accommodated in the construction or calibration of the system to ensure a high quality of indoor climate control. Perhaps we have finally seen the end to Sick Building Syndrome
and can now enjoy the benefits of a controlled climate indoors, if not outdoors. Further details are to be found under http://www.habmigern2003.info/

Simon Fowler madur electronics Voitgasse 4
1220 Vienna
Austria
Phone +43 1 258 45 02
Fax +43 1 258 45 02 22 E-Mail: sales@madur.at

Emergency Cut-off Switch Solves Shearing Health & Safety Issue

Our customer, a leading supplier of shearing equipment, found an inherent health & safety issue with their sheep shearing units. It was found that when the shearing blades became blocked with excess wool, the blades stopped cutting but the motor continued to run, when the blockage was cleared, the blades immediately began to cut again. This presented a serious problem as the operator was required to manually isolate the unit in order make it safe. This was an unacceptable situation and presented a risk for serious injury.

SST performed significant analysis into the conditions present during normal operation and how these differentiated from the conditions during blockage. It was identified that there were two clear conditions which occurred during a blockage, we performed trials using a variety of technologies including Optical, Hall Effect, Current and Magneto-resistive. The final solution provided fail-safe unit to protect the user and a very cost effective solution for the customer. Additionally we spent time with the customer to make sure our solution was designed to fit in with their existing manufacturing process

Glasgow Caledonian Researchers and SST Sensing to Develop New Industry Sensors

Glasgow Caledonian University (GCU) researchers are collaborating with SST Sensing, manufacturer of electronic fluid and gas sensors, to develop new sensors which measure levels of oxygen in the air for a wide range of industrial applications.

Funded by a two-year Knowledge Transfer Partnership (KTP), from which GCU will be awarded £140,000, the partners aim to develop the next generation of small, low-cost gaseous oxygen sensors.

Coatbridge-based SST Sensing has aimed to mark itself out from competitors with the development of innovative, low cost, small optical oxygen sensors for industrial applications.

The company has identified opportunities to improve the performance of their sensors, thereby opening up a significantly larger market for the product. For example, making the sensor react much faster to changes in oxygen would allow the sensor to be used in medical breath analysis and accurate measurement of parts per million (ppm) levels.

Having identified a number of potential improvements, but lacking the necessary skills in-house, the company decided that a KTP would be the best way to tackle these challenges. KTP is a part government-funded programme to encourage collaboration between businesses and universities.

SST Sensing also aims to develop new sensors which work effectively at high concentrations of oxygen to supply a growing international market for oxygen concentrators. Another possibility is extending the product family to measure other gases using the same principle of fluorescence quenching.

The project will recruit a PhD graduate to work within SST at Coatbridge and focus on embedding chemistry expertise into the company, with the specific aim of improving the performance of the current oxygen sensor and developing a new oxygen sensor.

GCU has specialised instruments for characterising the sensing polymer, fluorescence spectrometers for calibration, and high resolution microscopes to examine the structural make-up of the polymers.

Patrick Shannon, Technical Director at SST Sensing, said: “We are very much looking forward to working with our chosen KTP Associate and with GCU. Our dealings with GCU so far have been very encouraging.”

The partnership will be led by GCU’s Dr Sheila Smith, Assistant Head of Department with responsibility for Instrumentation, Control and Chemical Sciences within the School of Engineering and Built Environment. She has research interests in optical chemical sensor development with a particular emphasis on fluorescence-based sensing technologies.

Dr Smith said: “SST manufactures all of its instruments in-house, including calibration and testing facilities, where sensors are exposed to thermal cycling. It is a great opportunity for the KTP Associate to be part of an enthusiastic team of engineers, be involved in instrument development and be part of the product journey from prototype right through to an end product.”

A Breath of Fresh Air is Easier Said than Done

Deprived Indoor Air Quality can shrink a person’s ability to execute specific mental activities requiring concentration and memory. Dry itchy eyes, fatigue, headache, shortness of breath, dizziness and nausea are all symptoms an individual can experience when in an environment where the air quality is poor. Carbon Dioxide is taken to be the main indicator resulting in inadequate conditions for teaching, learning and overall performance in places of work. Ventilation systems incorpating carbon dioxide monitors can be designed to provide optimum indoor air quality to keep individuals alert in any environment where the air quality is poor and causing concern.

Stand Out From the Crowd

SST’s AQ-Alert+ Environmental Monitoring System was designed for the surveillance of air quality in any building in order to combat these wide spread issues resulting in benefits such as improved comfort and health. Stand out from the crowd in your tender submissions by offering air quality solutions that can improve environmental conditions, creating a comfortable environment to teach, learn, work and play. While most customers choose a monitor from our range of standard products, the configuration of the AQ-Alert+ may be defined by the user, making it ideally suited for use in a wide range of applications with varying requirements.

Did You Know?

The AQ-Alert+ offers benefits including:

  • 5 sensor options available –  CO₂, O₂, Temperature, Relative Humidity and Atmospheric Pressure
  • Maintenance free
  • Stand alone or integrated into YOUR building management systems
  • Customer specified outputs (voltage, current, relays, RS232, RS485, MODBUS, LEDs, Buzzer)
  • Standard or customer specific alarm levels
  • Self-calibrating

Maximise Efficiency, Minimise Your Costs & Emissions with SST’s Zirconia Oxygen Sensors

The amount of oxygen in the flue gas of a boiler indicates how much excess air is in the flue gas mixture. The lower the amount of excess air, the higher the boiler efficiency. In other words, the higher the amount of oxygen, your boiler becomes less efficient and more expensive to operate. According to Carbon Trust, the air to fuel ratio is one of the main factors affecting boiler efficiency. The technology of air to fuel ratio is set during commissioning and over time this tends to drift due to the changes in the fuels calorific value, combustion air temperature and control electronics. As a result of this, the boiler uses more energy to burn more fuel, causing increased emissions and increased costs.

Oxygen trim systems overcome these issues. If you have a large, continuously operating boiler plant, you are likely to save at least 5% and recoup your costs within 2 years. The oxygen sensor is inserted directly into the boiler flue which is connected to a control panel that continuously monitors the oxygen concentration enabling complete control over the boilers air to fuel ratio. Meaning that factors influencing drift within the boilers environment such as barometric pressure and high temperature do not force the boiler to run less efficiently that it is capable of. 

 

Zirconium Dioxide Oxygen Sensors are the most common type of sensor used in this field and the sensors from SST have been used reliably in boiler exhaust gases for over 25 years. The full pourus stainless steel cap allows free flow of the flue gases to reach the sensor while trapping any soot or debris which might otherwise lead to sensor malfunction. SST’s sensors will last for years even in badly regulated combustion processes before the dirt and pollution has any effect.

Why Use SST’s Zirconia Oxygen Trim Systems

  • Proven track record, very robust sensor with many years of operation in boiler exhaust gas
  • Highly accurate in aggressive, high temperature environment
  • Single point calibration with no reference gas required
  • Supplied with or without control electronics

The oxygen sensor can be supplied with the control electronics separately or as an integrated solution, both of which use the same technology, the only difference being is the mounting options.

To be cost effective, oxygen trim control systems are really designed for large boilers of over 500kW of output. They can work with natural gas, LPG, oil-fired and dual fuel bruners.

For more information on SST’s Zirconia Oxygen Sensor Systems, please Ask Our Sensor Experts Today!for their advice.

SST Sensing Launch Next Generation of Multi Gas Analysers

Gas Analysers, Gas Instruments, Gas Monitors
Leading gas sensor specialist SST Sensing announce the launch of their next generation gas analysers. The analysers will be seen for the first time at the World of Technology and Science exhibition in Holland later this month. The new additions to the SST range will include exciting new single gas sensors, dual gas and multi-gas analysers. SST Sensing would be delighted to welcome anyone on to their stand who is interested in learning more about these products. The exhibition runs from 30th September to 3rd October. Come and visit us at World of Technology and Science and see the next generation of gas sensors for yourself. SST Sensing will be on Stand 9D001, Jaarbeurs Utrecht, Hal 7 t/m 11, Jaarbeursplein, 3521 AL Utrecht.

SST Report Strong Start to Their Financial Year

As the demand to measure greater amounts of information within our environments as does the demand for electronic sensors. To remain competitive, small to medium size enterprises (SME’s) sensor manufacturers must continually review their product and service offerings in order to remain key partners to their customers. A distinctive advantage that SME manufacturers have over larger companies is their ability to be flexible and respond to variations in product specifications and customer requirements. Decision making in large multinational companies is often a slow and regulated process whereas SME’s can make decisions within hours rather than weeks.

SST Sensing Ltd has identified this as a very desirable service to their customers and was very much so the focus of their business strategy for growth over the last few years. They invest heavily to ensure they offer high specification and reliable products but have combined this with comprehensive technical, customer service and logistical support. SST can see the encouraging influence this business approach has had on sales revenues over the years, with 2011 seeing a whopping 92% increase compared to 2010. 2012/13 seen only a slight decrease despite the destructive effect of the economic recession in the UK manufacturing industry.  And at the end of our 2013/14 financial year, SST Sensing Ltd reported they were at the top of their game again with a turnover of £3.67 million, resulting in a 22% increase on the previous financial year.

SST witnessed a steady and continuous growth over the years in the number of customers buying their products and their end of 2013/14 year report supports this by confirming a 22% increase.

The future for SST is to execute their business strategy in markets where they have little presence but where there is countless opportunity. With this in mind, the US Sensor Industry is one market SST have yet to embrace with masses of potential for substantial growth. Market research analysts within the Freedonia Group report that US sales of sensors are forecast to climb at a 6.1% annual rate through to 2016 to $14.9 billion in industrial, military/aerospace, automotive, electronics and information technology markets. Having knowing this, gives SST the encouragement to source an established US sales partner capable to implement their business strategy within the US Sensor Industry, and the confidence to know that if all can be achieved there is potential for enormous growth.

SST Develop Cost Effective Solution to Carbon Dioxide Danger

As building design increasingly embraces low energy solutions so the concern over internal air quality increases. Monitoring the levels of carbon dioxide found in homes and businesses has become increasingly important and in response to the increased demand from local authorities, architects and builders for accurate, reliable, maintenance free carbon dioxide detectors we have developed the AQ-Alert+.

The AQ-Alert+ System is the latest addition to the range of Carbon Dioxide Air Quality Monitors. The system measures the concentration of carbon dioxide with options to also measure oxygen concentration, temperature, atmospheric pressure and relative humidity allowing effective control and management of air quality. An additional benefit is the detection of leaks from refrigeration, HCFC and CO2 that will send an alarm signal if the air quality is deteriorating.

What’s most interesting about the AQ-Alert+ though is its price. Our Lanarkshire-based research and development unit have developed a carbon dioxide sensor that has the highest specification, innovative design and build quality but is half the cost of its competitors.

Already the AQ-Alert+ has been placed on a number of tender lists and initial enquiries have been high. SST Sensing will showcase the AQ-Alert+ and a number of other sensing products at the World of Technology & Science Trade Show in Amsterdam at the end of September.

Please contact us for further information.

SST Introduce First New Product To Their Instrumentation Range

AQ-Alert+ Air Quality Monitor

SST Sensing Ltd recently launched their first multi-gas sensor system into the instrumentation market. The AQ-Alert+ Environmental Monitoring System was designed for the surveillance of air quality in schools, offices, homes, public buildings and hotel rooms. Being a new and exciting direction for SST, their overwhelming knowledge and experience in the sensing and control industry makes the decision in moving higher up the value chain in developing sensor systems opposed to sensor components an easy one to make.

The affordable AQ-Alert+ System measures the concentration of carbon dioxide in the air with options to also measure oxygen concentration, temperature, atmospheric pressure and relative humidity. Marketing Manager at SST, Siobhan Dalziel explains that, “As well as offering standard versions of the AQ-Alert+, which suit most customers’ application requirements, the AQ-Alert+ is completely configurable, meaning that you can customise the system to exactly meet your specific application needs. We feel that this flexibility to customise exactly what the customer wants, as well as offering a basic standard unit, gives us competitive edge from anything else that is on the market today”.

Any combination of output is available and the traffic light LED indicators can be set to illuminate at your chosen CO2 levels. The compact and maintenance free design assures long term stability in any ambient environment.

Part of SST’s marketing strategy is to target the construction industry, particularly in the public, private and commercial sectors with the Air Quality Environmental System. Dalziel states that “our market research team gathered information on the UK construction market and reported that the number of UK construction projects has increased by 15% compared to last year’s figures. The key driver being private housing, followed by commercial sectors, office projects, retail, hotel and leisure.

The healthy growth especially in the private and commercial sectors give us as a company increased confidence in our marketing strategy to boost sales revenue for this particular product range and we are very excited to see where this new direction takes us.”