New Integral Level

New Integral Level


  • Analogue Electronics with discrete components.
  • Separated probe from the control unit (ECU).
  • Setup through potentiometer and dip-switches.
  • Multiwire to board connectors.
  • IP 55 Protection.
  • Visual alarm management via LED, with a single OR-ed output (cycle continuity).
  • Limited temperature range (0-60°C).
  • High dimensions and employed space.
  • A single type of compensation, fixed.


  • High costs of installation.OLD_INTEGRAL LEVEL_2
  • Possibility of alteration and/or loss of calibration.
  • Lockable external floater.
  • Fixed operation, non-configurable




A comprehensive and extensive range of new features


  • Micro-processor based digital electronic
  • Control unit and probe in a single device
  • Configurable set-up via remote PC
  • Unified IO-Link Connection
  • IP 67 Protection
  • Continuous measure of temperature and level
  • Security sensor using 2 redundancy channels
  • Single alarm management with integrated pump control
  • Extended temperature range (-40°C – +75°C)
  • Minimum employed space
  • Long-term compensation of the normal consumption and for rapid removals
  • Minimum costs of installation
  • No possibility of alteration and/or loss of calibration
  • Protected internal floater
  • Flexible operation, completely configurable






  • Up to 32 bit of data exchange (Cyclic Process Data and Parameters) with master.
  • Low inter-facing cost.
  • High transmission speed and 3ms typical refresh time.
  • Protocol with a high level immunity, solid, specific for automation and sensors, with 24V power source and signals.
  • Extended diagnostic, with a bit of “datavalid” which confirms or revokes received data.
  • If the transmission is garbled, it can operate anyway, in a downgraded way (SIO= Single I/O).



Operational security

No other probe, interconnected with PLC, guarantees these features


  • Synchronism preservation
  • Parity check
  • Check of the correct interpretation and response to master’s controls.
  • Check of the message length (dimension of string established and monitored).
  • Check of the correct reception of return string (checksum).
  • A bit of “datavalid” is integral part of every message.
  • Pumps do not start or are turned off if “Datavalid” is lacking.
  • The internal cyclic test verifies functionality (stability of features, lack of deviations) and the correspondence (connection) of level and temperature probes.
  • Check of floating, loss or extraction of magnet and/or of potential reduction of remanence.
  • If the probe has a malfunction, the approval to start pumps fails.
  • If there is overtemperature, thermostat won’t be calibrated and pumps wont’s work.



Functional Safety

Two redundant independent outputs


  1. In Standard procedure, output CQ sends data and controls to PLC via IO-Link.
  2. If communication is lacking, the output switches to SIO mode (single I/O) and goes to zero in the case of creepage alarm and other arrest causes at the end of the cycle.
  3. The redundant output DQ goes to zero for the same event: this output can be used for another safety contactor in series connected to the pump engine.

Threshold leakage- compensation


The purpose of fires prevention is to minimise the burden of fires, i.e. to minimise losses and maximise the sensitivity and the speed of reaction of the system detector of flammable liquids leakage.

The dispersion of 32 litres of oil is the limit value to tame the fire easily (water, fire extinguisher).

This feature requires reduced threshold leakages, with minimal gap of tank, leading to false alarms due to level cyclic oscillation, cylinder handling with huge section differences between breech and axis, etc.

In order to obtain the required purpose, the INTEGRAL LEVEL employs two compensation systems:

  • Physiological leaks: long term compensation of seepages and lubrification.
  • Rapid leaks: limited compensation both in time and leak rate on specific and determined events (initial charge of accumulators, fall of the press main cylinder).

Compensation does not work as total filter (any variation of the level is allowed during filtering), but it’s speed is limited (leak rate), assuring responsiveness and a high immunity level to unexpected changes.

The compensation of physiological leaks


The level of oil in hydraulic units lowers progressively over time due to physiological leaks: seepages, lubrification of axis, tightness of seals, etc.

This slow and progressive consumption of oil must be considered: if the overall loss registered by the INTEGRAL LEVEL exceeds the set threshold, it can bring to a warning signal of (uncontrolled) leak.

The INTEGRAL LEVEL cancels the effect of physiological leaks using a time compensation system over the long term: every XX minutes the accumulated leak decreases by one unit.

Compensation, with a time base of 6 minutes, can be set from 0 to 240, namely:

  • 1 x 6’= a pulse every 6 minutes (compensation for bigger leaks)
  • 240 x 6’= 1440’= a pulse every 24h (compensation for minimum leaks)
  • 0= no compensantion for physiological leaks

  When there are not accumulated leaks, no compensation is applied. 

So, an over compensation is not applicable.


Compensation rapid leaks

  • The leak rate of a tank cannot exceed maximum weighing capacity of the pump to which it is connected.
  • The capacity of the pump, generally, decreases when the system pressure increases
  • The capacity of the tank and of the pump are strictly connected.

Some leaks of oil are due to the system’s own nature, and are required and controlled by the system in well-recognised specific moments.

The INTEGRAL LEVEL compensates with the highest precision these events through:

  • Initial stand-by time when the pump starts (time of charge of accumulators)
  • Time of compensation of leaks on each event, with its related start input.
  • Rated speed of tank draining (maximum pump capacity).
  • A factor which reduces the leak speed (varies 1 to 16)

Performance of the pan level, in case of:

  • Initial leak rate of tank for accumulators charge
  • Fall of the main cylinder of a probe

Red lines in the above figure indicate a due speed compensation used for an initial charge of systems with high capacity accumulators.