History of Water Level Sensors
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How To Install A Water Level Indicator

Installing a water level indicator can be a straightforward DIY project or a more technical job, depending on the type of system (mechanical, float-based, sensor-based, or electronic). Below is a general step-by-step guide for installing a basic electronic water level indicator system for a standard overhead tank.

🧰 What You’ll Need:

  • Water level indicator kit (includes sensors, control unit, wires, and possibly a display)

  • Power drill

  • Waterproof silicone or sealant

  • Electrical tape

  • Screwdriver

  • Cable clips or zip ties

  • Ladder (if the tank is elevated)

🪜 Step-by-Step Installation Guide

✅ 1. Turn Off Power

Always start by turning off the main power supply if you’re working with electrical devices.

✅ 2. Mount the Control Unit

  • Choose a dry, accessible location near the tank or inside your house (depending on the model).

  • Mount the control/display unit on a wall using screws.

✅ 3. Install Sensor Probes in the Tank

You typically need 3 to 5 probes (depending on your system), which measure:

  • Empty/Low level

  • Middle level

  • Full/High level

  • (Optional) Overflow or critical low

How to install:

  • Drill small holes on the tank lid or side wall near the top.

  • Insert the probes or float sensors to the corresponding depths (use the manual to know the exact position).

  • Seal around the holes using waterproof silicone to prevent leakage.

  • Secure the sensor wires with cable clips inside or along the tank body.

✅ 4. Connect Wires to the Control Unit

  • Use the labeled diagram in your kit’s manual to match each sensor wire to its terminal.

  • Typically, wires run from each sensor to a central controller unit via color-coded terminals (e.g., red = full, yellow = mid, green = low).

  • Use electrical tape to secure connections and prevent short-circuits.

✅ 5. Test the System

  • Turn the power back on.

  • Slowly fill the tank and monitor the display or indicator lights.

  • The control unit should light up or beep as water reaches each sensor level.

✅ 6. Optional: Connect to Pump

If your indicator supports pump automation:

  • Connect the pump’s power relay to the controller as instructed.

  • The system will automatically turn the pump on when water is low and off when full.

🔒 Safety Tips:

  • Always use waterproof-rated wires and connectors.

  • Keep control units protected from rain and moisture.

  • Don’t overtighten sensors; water tanks expand slightly when filled.

🛠️ Types of Systems You Can Install:

Type Difficulty Features
Float-based Easy No electricity needed; mechanical
Electrode/probe Moderate Common in homes; needs wiring
Ultrasonic sensor Moderate No contact with water; more accurate
Smart IoT systems Hard Remote monitoring via smartphone

Our level sensors and controls aren’t just for use in residential potable water holding tanks; some of the other applications include cooling towers, sump pumps, wastewater, boilers, water storage tanks, and building fire protection water tanks.

Cooling Towers, Fire Protection, Pumping Stations, Sump Pump Float, Water Level Controls, Water Tanks
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Cooling Tower Vs Chiller
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Cooling Tower Vs Chiller

Cooling towers and chillers are both used in HVAC systems to remove heat, but they operate differently and are suited for different applications. Here’s a comparison to help understand their functions, advantages, and disadvantages:

Cooling Tower

Function: A cooling tower is a heat rejection device that extracts waste heat to the atmosphere by cooling a water stream to a lower temperature.

Working Principle:

  • Evaporative Cooling: Water is pumped to the top of the cooling tower and sprayed over a heat exchange surface. As the water flows down, air is drawn through the tower, causing some of the water to evaporate. This evaporation cools the remaining water, which is then recirculated through the system.

Applications:

  • Used in industrial processes, large commercial buildings, and power plants where large amounts of heat need to be removed.
  • Common in HVAC systems for cooling buildings.

Advantages:

  • Energy Efficient: Uses less energy compared to chillers for the same cooling capacity.
  • Cost Effective: Lower operating costs due to lower energy consumption.
  • Effective for Large Systems: Suitable for large-scale cooling applications.

Disadvantages:

  • Water Consumption: Requires a constant supply of water, which can be a concern in water-scarce regions.
  • Maintenance: Needs regular maintenance to prevent issues like scaling, biological growth, and corrosion.
  • Climate Dependency: Efficiency can be affected by ambient temperature and humidity.

Chiller

Function: A chiller removes heat from a liquid via a vapor-compression or absorption refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool air or equipment.

Working Principle:

  • Vapor-Compression Cycle: Uses a refrigerant to absorb heat from the water in the evaporator. The refrigerant is then compressed, which increases its temperature, and the heat is rejected in the condenser. The cooled refrigerant is then expanded and circulated back to the evaporator.
  • Absorption Cycle: Uses heat energy (from steam or hot water) to drive the refrigeration process, which is more common in specific industrial applications.

Applications:

  • Used in smaller commercial and residential buildings.
  • Common in HVAC systems for precise temperature control.
  • Suitable for applications where water is not readily available or where water conservation is important.

Advantages:

  • Versatility: Can be used in a wide range of applications, including precise cooling for manufacturing processes.
  • Water Conservation: Does not require a continuous water supply like cooling towers.
  • Climate Independence: Less affected by ambient weather conditions compared to cooling towers.

Disadvantages:

  • Energy Consumption: Generally uses more electricity compared to cooling towers, leading to higher operating costs.
  • Initial Cost: Higher upfront costs due to the complexity of the system.
  • Maintenance: Requires regular maintenance, especially for the refrigeration components.

Comparison Summary

  • Energy Efficiency: Cooling towers are generally more energy-efficient than chillers.
  • Water Use: Cooling towers consume more water, while chillers are more water-efficient.
  • Application Size: Cooling towers are suitable for large-scale applications, whereas chillers are better for smaller, precise cooling needs.
  • Climate: Cooling towers are more effective in dry climates, whereas chillers can operate effectively regardless of the climate.
  • Cost: Cooling towers typically have lower operating costs but may have higher water costs. Chillers have higher energy costs but are more versatile in applications.

Choosing between a cooling tower and a chiller depends on the specific cooling needs, available resources, and environmental considerations of the application.

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History of Water Level Sensors
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History of Water Level Sensors

Water level sensors have a long history dating back to ancient times when simple devices were used to measure water levels for irrigation and flood control. Over the centuries, advancements in technology have led to the development of more sophisticated water level sensing devices for various applications. Here’s a brief overview of the history of water level sensors:

  1. Ancient Water Level Measurement: The earliest water level measurement devices were simple float-based mechanisms used by ancient civilizations for irrigation and flood control. These devices typically consisted of a float attached to a lever or rod, which would rise and fall with the water level, indicating the depth.
  2. Early Mechanical Water Level Gauges: In the 17th and 18th centuries, mechanical water level gauges were developed for use in wells, reservoirs, and other water storage systems. These gauges often used a float connected to a chain or pulley system to measure the water level.
  3. Development of Electrical Sensors: The invention of electrical conductivity and capacitance sensors in the 19th century paved the way for more accurate and reliable water level measurement devices. These sensors could detect changes in water level by measuring changes in electrical properties such as conductivity or capacitance.
  4. Ultrasonic and Radar Sensors: In the mid-20th century, ultrasonic and radar-based water level sensors were developed, offering non-contact measurement capabilities. These sensors emit sound or radio waves that bounce off the water surface and are then detected to determine the water level.
  5. Pressure Transducers: Pressure transducers, which measure water level based on the pressure exerted by the water column, were also developed in the 20th century. These sensors are commonly used in applications such as groundwater monitoring, sewage systems, and industrial tanks.
  6. Modern Sensor Technologies: In recent decades, advancements in microelectronics and sensor technologies have led to the development of highly accurate and versatile water level sensors. These sensors often use a combination of different measurement principles, such as ultrasonic, pressure, capacitance, or optical sensing, to provide precise and reliable water level measurements in various environments.
  7. Wireless and IoT Integration: With the rise of wireless communication and Internet of Things (IoT) technologies, water level sensors can now be easily integrated into remote monitoring and control systems. These systems allow for real-time monitoring of water levels and automated alerts or actions based on predefined thresholds.

Today, water level sensors are widely used in various applications, including environmental monitoring, flood warning systems, water resource management, wastewater treatment, agriculture, aquaculture, and industrial process control. Continued advancements in sensor technology are expected to further enhance the accuracy, reliability, and functionality of water level sensing devices in the future.

Our level sensors and controls aren’t just for use in residential potable water holding tanks; some of the other applications include cooling towers, sump pumps, wastewater, boilers, water storage tanks, and building fire protection water tanks.

Cooling Towers, Fire Protection, Pumping Stations, Sump Pump Float, Water Level Controls, Water Tanks
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Chillers In Winter Weather Conditions
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Chillers In Winter Weather Conditions

Chillers have to be able to work year round and in some cases it is a good idea to make sure your chiller can work at maximum capacity. Follow these tips to make sure your chillers work hard through the cold weather.

 

  • Glycol charts will display the ambient temperature and give you an indication of the total amount of glycol you will need. To do this you will have to utilize a refractometer, specifically inhibited propylene glycol that is especially made for HVAC systems, especially for high and medium temperature chiller applications.
  • Snow and ice must be kept off the chiller condenser coils as they can damage fan blades and restrict the air flow through the condenser and this will reduce the potential of the cooling abilities of the chiller.
  • Use the manual controls for your head pressures. Head pressures drop during very cold weather and if the chiller is not one that has ambient control equipment such as a flooded condenser or fan cycling, the chiller may not operate correctly. One way of solving this is to block the flow of air through the condenser by wrapping it with plastic or using some card board to block the condenser. it is not a perfect fix, nor a permanent one but will work on a temporary basis.
  • By allowing the pump to run, it should provide sufficent warm water to keep the fluid above the freezing level or above the freeeze levels of the glycol. But at night, the ambient temperature of the air will cool down the fluid rapidly. When the pump is allowed to run, heat will be added from the pumps and from inside the buildings.
  • By planning ahead, you can ensure your chiller is equipped to handle the cold weather conditions in your environment. If you perform a maintenance check in Spetember, it will give you ample time to make any needed alternations.
  • Make sure everything in the system is correctly and completely installed including pumps, piping, safeties and controls.
  • Make sure the cooler evaporator is connected to its separate electrical service and checked for the correct voltage.
  • Perform an inspection for cracks and leaks before the onset of cold weather. This may be an action that saves you tens of thousands of dollars over the winter.
  • Develop a back up plan should your chiller lose power over the cold weather period of the year.
Cooling Towers
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Chillers In Winter Weather Conditions
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Written by webtechs

Chiller Tips For Cold Weather

Chillers have to be able to work year round and in some cases it is a good idea to make sure your chiller can work at maximum capacity. Follow these tips to make sure your chillers work hard through the cold weather.

 

  • Glycol charts will display the ambient temperature and give you an indication of the total amount of glycol you will need. To do this you will have to utilize a refractometer, specifically inhibited propylene glycol that is especially made for HVAC systems, especially for high and medium temperature chiller applications.
  • Snow and ice must be kept off the chiller condenser coils as they can damage fan blades and restrict the air flow through the condenser and this will reduce the potential of the cooling abilities of the chiller.
  • Use the manual controls for your head pressures. Head pressures drop during very cold weather and if the chiller is not one that has ambient control equipment such as a flooded condenser or fan cycling, the chiller may not operate correctly. One way of solving this is to block the flow of air through the condenser by wrapping it with plastic or using some card board to block the condenser. it is not a perfect fix, nor a permanent one but will work on a temporary basis.
  • By allowing the pump to run, it should provide sufficent warm water to keep the fluid above the freezing level or above the freeeze levels of the glycol. But at night, the ambient temperature of the air will cool down the fluid rapidly. When the pump is allowed to run, heat will be added from the pumps and from inside the buildings.
  • By planning ahead, you can ensure your chiller is equipped to handle the cold weather conditions in your environment. If you perform a maintenance check in Spetember, it will give you ample time to make any needed alternations.
  • Make sure everything in the system is correctly and completely installed including pumps, piping, safeties and controls.
  • Make sure the cooler evaporator is connected to its separate electrical service and checked for the correct voltage.
  • Perform an inspection for cracks and leaks before the onset of cold weather. This may be an action that saves you tens of thousands of dollars over the winter.
  • Develop a back up plan should your chiller lose power over the cold weather period of the year.
Cooling Towers
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New Tech: Water Reuse at Power Plants through Vapor Catching

At Waterline Controls, we understand the challenges faced in industry when it comes to the responsible use of water, especially when there are millions or billions of gallons involved. That’s why we were happy to see the innovative solution created by MIT researchers that deals with the problems of water reuse involving thermoelectric plants.

The Problem

Fossil fuel thermoelectric plants, which produce about 90% of our power here in the US, consume billions gallons of water per day. These plants depend on water to provide the steam to drive the electricity-generating turbines and to keep the plant cool. According to USGS, 99% of that water is surface water and most of that is freshwater extracted from rivers, lakes, and reservoirs. Reuse of that water is vital, but can be very difficult.

An Innovative Approach to Water Reuse

MIT researchers Dr. Maher Damak and Dr. Kripa Varanasi have developed an innovative way to use the water consumed by thermoelectric power plants more responsibly, as published in Science Advances. Their focus is on the water that escapes through the cooling towers. Keep in mind that the cooling towers are an integral part of keeping plant temperatures under control.

How it Works

As water vapor leaves the massive cooling towers, a beam of ions (electronically charged particles) passes through the vapor cloud. These ions cause the water droplets within the vapor to become charged. Those droplets are then attracted to a metal mesh placed over the top of the cooling tower. The mesh traps the droplets. After the trapped droplets are collected, the water can be reused. The power plant can reuse the reclaimed water, or it can be a source of potable fresh water for coastal cities (many of which use seawater to cool their thermoelectric power plants).

How it is Different

This isn’t the first time that an attempt has been made to use a mesh to capture water exiting as vapor from the cooling towers. However, previous designs have been incredibly inefficient, capturing maybe 3% of the potential water vapor escaping. Strange as it may seem, the problem with these previous mesh designs was an aerodynamic one. The mesh acts as a flow barrier, and the water vapor flows around it. Damak and Varanasi’s solution, however, attracts the flow of vapor to the mesh by electrically charging the droplets, so they are drawn to the mesh, which has a small voltage applied to it. Also, the droplets are attracted to the wire itself, and not the holes.

Testing

A full-scale test version of the device will be installed on the cooling tower of MIT’s Central Utility Plant before fall of this year. It is easy to integrate into existing equipment and does not require any significant modifications. The purpose of this test is to “de-risk” the technology so that power companies, which tend to be quite conservative when it comes to new technology, will be more comfortable considering it.

Working With Water Responsibly

Here at Waterline Controls, we are committed to the responsible use of water, one of our most precious natural resources. Because of that, we remain committed to providing technology that supports water conservation. For example, our cooling tower water level sensors and controls prevent the loss of water by providing reliable solutions to the failure/overflowing of the float valves. Our controllers are designed for 99% reliability at a 15-year life cycle. They are modularly designed so that if one component fails, only that module needs to be replaced — not the entire unit. And our electronic sensor design uses just a small amount of power, is far more dependable than float switches, and will not degrade, foul, or plate. The characteristics make our controllers an environmentally friendly, reliable solution to water conservation problems.

Cooling Towers
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Cooling Towers & Water Conservation

At Waterline Controls we are always pleased to hear about progress being made in green technology and environmental conservation. That’s why we wanted to share the great news about Infinite Cooling’s first-place win at the Houston-based Rice Business Plan Competition. Their victory is a major win in one of our nation’s largest startup competitions. Infinite Cooling’s eco-friendly design was voted number one out of a total of 42 very competitive entries. Their innovative design would enable power plants to capture and reuse water that is usually lost through their cooling towers.

Combining Water Conservation and Power Generation

Infinite Cooling is an alum of MIT’s delta ν startup accelerator and was co-founded by Karim Khalil, Kripa Varanasi, and Maher Damak. Their mission, according to the Infinite Cooling website, is to “provide novel technology to enable water-sustainable thermoelectric power.” In layman’s language, they want to help power companies use less water while still producing the same amount of power. Their recent win at the Rice Business Plan Competition was based on the presentation of an innovative solution to water consumption at power plants: a way to capture the enormous water vapor plumes as they exit power plant cooling towers.
As the name implies, the purpose of a cooling tower is to provide evaporative cooling. Part of the water is evaporated to cool the rest of the water. As a result of the evaporation, water vapor escapes the towers in a massive plume, and the cooling water must be replenished to make up for this loss. That’s where Infinite Cooling and their state-of-the-art solution comes in.
Their dome-shaped device made out of what looks like a mesh material and is retrofitted onto existing cooling towers. The device uses electric fields to charge water and then use that charge to redirect the exiting water to a collector rather than allowing it to escape into the atmosphere. This allows a significant amount of water to be captured for reuse, thereby reducing the water consumption requirements of the power plant by 20% to 30% and can capture 100% of the vapor plume. The water savings from implementing this technology could prove crucial in areas prone to drought and water shortages, such as certain parts of California.

Conclusion

We know that our environmental resources are critical. Because of that we aim to provide technology that supports water conservation and greener alternatives to traditional water level control technology. For example, our cooling tower water level sensors and controls prevent the loss of water by providing reliable solutions to the failure/overflowing of the float valves. The electronic sensor design is far more dependable than the traditional mechanical float switches and will not plate, degrade, or foul. Our controllers have a modular design, so that if a component should fail the entire unit does not need to be replaced. In addition, WLC controllers are designed for a 15-year life cycle at 99% reliability. All of these features combined provide a green solution to your water level control needs.

Cooling Towers
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Commercial Cooling Tower Water Level Control
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Additional Measure Continue to be Looked at to Combat Legionnaires’ Disease

Additional Measure Continue to be Looked at to Combat Legionnaires’ Disease

Under typical operating conditions, cooling towers can propagate Legionella. Combining chillers and plastic surface cooling towers with added anti-microbial options can significantly reduce the infection risk.

NSF P453: Cooling Towers – Treatment, Operation, and Maintenance to Prevent Legionellosis

This protocol outlines proper maintenance and safety practices associated with evaporative cooling systems. It’s a simple plan with specific means and procedures to manage risks of Legionnaires’ disease. Also addressed are several health concerns associated with commercial buildings and health care facilities. NSF P453 gives the rest of the U.S. rules similar to the New York City and state regulations for cooling towers.

Disneyland, the ‘happiest place on earth’ was required to shut down two water-cooling towers after some visitors to the Anaheim, Calif., theme park contracted Legionnaires’ disease.

12 cases were discovered ‘about’ three weeks ago by the Orange County Health Care Agency.

Disneyland was informed of the cases Oct. 27. After testing found two cooling towers had high levels of Legionella bacteria, the towers were taken out of service and disinfected. They were put back in operation Nov. 5 but, but were shut down again 2 days later. At this point, tests will be required to confirm they are free from contamination, according to the park and the county health agency, before they will be put back in service.

The New York City Department of Health, while investigating an outbreak of Legionnaires’ disease in the middle of October that infected 15 people, took samples from 55 cooling towers in the area of the reported outbreak. Preliminary results determined that 10 cooling towers contained Legionella DNA. The Department has issued orders to increase or change the biocide used to the kill bacteria.

Cooling Towers
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Austin, Texas Cooling Tower Registration and Update Deadline Nearing

Austin, Texas Cooling Tower Registration and Update Deadline Nearing

The 2015 Uniform Mechanical Code and 2015 Uniform Plumbing Code (UPC) for the city of Austin, Texas includes a deadline of December 31, 2017 for registration of all Cooling Towers in the city. There are several specific rules that require upgrades to most older towers.

Section 1126.0 of the city’s UPC requires all properties with cooling towers to register them with Austin Water.

The City ordinance requirements include:

  1. Make-up and Blow-Down meters.
  2. Conductivity Controller.
  3. Drift Eliminators with a drift rate of not more than 0.005% of the tower circulating rate.
  4. Cold water basin high level alarm.
  5. Must operate at a minimum of 5 cycles of concentration.

The City ordinance requires that cooling towers must have a cold water basin high level/overflow alarm. For cooling towers of 100 tons or more, the make-up and overflow meters, and the over flow alarm shall be connected to the building’s Central energy Management System or Utility Monitoring Dashboard.

WLC 6000 SeriesWhat this means is that all towers need a modern system with alarms and sensors that can connect to a BMS. Waterline Controls model WLC-6000 Cooling Tower Water Level Controller is our most popular model for providing a high level alarm, make-up water control, low alarm and a low water level cutout.

Waterline Controls has the system to retrofit and get you compliant fast. Our Stainless Steel Electronic sensors and solid state software driven controllers offer the connectivity, accuracy and reliability you need. With a multi-wire connection for you BMS or Building Automation, we have you covered.

Cooling Towers
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Commercial Cooling Tower Water Level Control
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Cooling Tower News Updates

Cooling Tower News Updates

100s Of Cooling Towers Examined After Melbourne Legionnaire’s Disease Outbreak In March That Had Six Confirmed Cases

Cleaning of large amounts of cooling towers in Melbourne Australia were undertaken after Victoria’s Department of Health and Human Services confirmed the outbreak in the Central Business District.

Just a few months ago there was discussion about many of Melbourne’s new apartment buildings posing a legionella bacteria risk due to their energy-efficient “warm water” systems.

$42 Million Cooling Tower Replacement At Nuclear Plant Being Proposed For Closure

Palisades Nuclear Power Plant

Palisades Nuclear Power Plant, which according to WBFO has divided some residents in the area of Van Buren County in Michigan over its proposed closure, is replacing a cooling tower over the next 3-4 months. While the plant may be closing down, maintenance and upkeep will continue to be an ongoing job for quite some time.

Decommissioning and cleaning up a nuclear plant can take over 50 years. The Michigan Public Services Commission will host several public meetings in May before deciding on the final outcome of the plant. Economic impacts may be hard on some of the surrounding communities as the plant employs over 130 people.

Cooling Towers
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