Installation Procedure for 5 Level Water Level Indicator:

5 Level Water Level Indicator Installation details.

Installation of our water level indicator system is a very simple task and we have made the system in such a way that it is possible to install the system yourself with minimum electrical knowledge or with the help of a simple electrician. The task of installation comprises of two parts, the Power Connection and the Sensing Connection.
The Power Connection to the Water Level Indicator is nothing but supplying single phase power (230V AC) to the Level Indicator. Sensing Connection includes the cabling of sensing wire, i.e., 4 pair CAT 5e Communication Cable from the Water Level Indicator to the Overhead Tank (OH Tank) or to the Underground Sump (UG Sump), which ever tank required to have level indication. After cabling, making the level sensing arrangement in the water tanks and Sensing connection of the sensing cable to the Water Level Indicator.

Tools required for Installation:

  1. 4 Pair CAT 5e Communication cable as per requirement. Take a rough estimate of cable length from the pump control switch location to the OH Tank and again from the pump control switch to the UG Sump (for Bore well, cable is required only for the OH tank).
  2. One length of 3/4th or 1 inch dia. PVC Electrical Pipe for sensor arrangement in the tanks.
  3. Multi strand 1.5 Copper Power cable of about 2 to 6 meters as per requirement for Power Supply.
  4. Line Tester.
  5. Insulation Tape, necessary screws and wooden gattas pieces for mounting indicator unit on the wall.
  6. Cutting Pliers or Nose Pliers.
  7. Simple Hammer-Jumper set or Drill Gun to mount the Level Indicator to wall or to wooden board.

Sensing Cable Connection to Water Level Indicator.

STEP 1. The sensing wires comprises of one bunch of six coloured wires(or Seven wires in case of Flow indication model).
STEP 2. Do complete sensing wiring from Water Level Indicator to Overhead Tank.
STEP 3. To connect the sensing wires of OH Tank, to the Water Level Indicator unit, simply twist the wires to the respective wires of Water Level Indicator unit as per the below table. Slide the PVC sleeve provided over the twisted joint completely. The advantage of having loose sensing wire over the sensing terminal block is that, loose contacts are avoided and testing of the Indicator functions can be done easily by shorting the sensing wires in the Indicator Unit itself directly.
STEP 4. OH Tank Sensing Connection with bunch of Six wires: -

Description Colour of Wire in Sensing Cable Colour of Wire in Indicator
Flow Sensing. Blue Blue.
TANK 100%. Green Green.
TANK 80%. Orange-White Yellow
TANK 60%. Brown-White Orange
TANK 40%. Green Red
TANK 20%. Green-White Brown
COMMON. Blue & Blue-White Black
Sensor Probes Connections and Sensors Level setting in Overhead Tank.

STEP 1. Do the 4 pair CAT 5e sensing wire cabling from the level indicator to overhead tank and leave 1.5 to 2 meter extra cable near overhead tank.
STEP 2. Take an electrical PVC pipe of 3/4th inch or 1 inch which is commonly available. Cut the pipe about 2 inch less than the height of the tank so that pipe can be hanged vertically inside the tank.
STEP 3. To give the Sensing connection in the Overhead Tank, initially decide the levels, where sensors have to be fixed, by deviding the tank into five parts approximately and mark the level at the PVC pipe.
STEP 4. Sleeve the outer grey sleeve of the sensing wire upto the height of the PVC pipe. Fix the grey portion of the wire to the top of the PVC pipe with insulation tape as shown in the Photo with the regular insulation tape.
STEP 5. Make the loop of the sensing wire, as shown in the Photo to hang the sensing arrangement to the top portion of the tank with the help of a hook or nail.
STEP 6. The sensing arrangement should be away from the wall of the tank and also should be away from the water falling into the tank.
STEP 7. Sleeve below mentioned wires for about 3 to 4 inch, twist the sleeved wire around the sensors provided and crimp the sensors to the end of those wires as shown in the Photo. Now fix the sensors at different levels of the pipe as per the levels decided, with insulation tape as shown in the Photo in the following order: -

  • Set the level of Common sensor (Blue & its Blue wire pair) at the bottom of the Tank.
  • Set the level of 20% sensor (Green-White wire) at the 20% level of the Tank.
  • Set the level of 40% sensor (Green wire) at the 40% level of the Tank.
  • Set the level of 60% sensor (Brown-White wire) at the 80% level of the Tank.
  • Set the level of 80% sensor (Orange-White wire) at the 80% level of the Tank.
  • Set the level of 100% sensor (Orange wire) at the Full level of the Tank.

STEP 8. Fix the Flow sensor to the mouth of the Delivery Pipe in the overhead tank as shown in the photo, with cable tie or insulation tape, in such a way that the pumped water will flow through that sensor. Connect the brown sensing wire to the flow sensor cable and insulate it. Take precautions to see that the joint will not get inside the water when tank is full. Also make sure that Flow sensor does not touch the Delivery pipe. If there is some practical problem due to which flow sensor can not be connected, then loop the brown sensing wire to the black wire in the OH Tank bunch in Level Indicator itself. This will bypass the Flow sensing function ensuring proper functionality of remaining indication features.

Important: The Sensing wire from the unit to the indicator unit should be a one-piece wire and there should be absolutely no joints in these Sensing wires and these wires should not be damaged in any way. Unit will not operate correctly in these cases. Continuity of wire should be checked before wire is laid. This sensing wire can be put inside PVC pipe throughout for extra protection.

Power Connection from the (220V AC) Water Level Indicator.

The Water Level Indicator comes with power chord and 2 pin plug. As the level indicator is independent of the pumpset, Locate the position of mounting the level indicator in such a way that it is easier to have the wiring done from the OH tank to the indicator and is close to the power point.

Testing of Complete Indication System.

STEP 1. Switch ON the Indicator and go to Overhead tank for testing.
STEP 2. It is convineant to test the indicator by having cell phone communication from the OH Tank to Indicator Unit.
STEP 3. Lift the sensing arrangement completely above the water - Indicator should not show any indication other than Power ON.
STEP 4. Now immerse common and 20% sensor probe inside water - 20% indication LED will glow.
STEP 5. Now immerse 40% sensor probe also inside water - 20% & 40% indication LED will glow.
STEP 6. Now immerse 60% sensor probe also inside water - 20%, 40% & 60% indication LED will glow.
STEP 7. Now immerse 80% sensor probe also inside water - 20%, 40%, 60% & 80% indication LED will glow.
STEP 7. Now immerse 100% sensor probe also inside water - 20%, 40%, 60%, 80% & 100% indication LED will glow.
STEP 7. If the indication system you have chosen has Flow Indication, then switch ON the pumpset.
STEP 8. Repeat the steps from STEP 4 to STEP 7 for four to five times to ensure the correct operations.
STEP 9. When water is falling into the tank, then Flow indication LED will glow.
STEP 10. When Flow indication LED is gloing and when 100% sensor is inserted, then buzzer will start sounding.
STEP 11. At this instant, if pump is switched OFF, Flow indication LED will switch OFF and Buzzers will also become silent.
STEP 12. Now the testing is complete. Repeat the procedure two more times to make sure of the functions.