bulletDiscrete - Float-type switches signal the controller when a level is reached.  Applies to both package and piece type dyeing machines.  Typically there will be a switch for drain level, fill level 1 and fill level 2.
bulletAnalog - Analog level indication devices put out a proportional signal that varies with the water level in the machine.  Some machines may use a device external to the machine (Gems Sure-Site) that provides a visual indication by means of colored flags on a vertical pipe.  Other types include pressure transmitters which measure the level in inches of water pressure.
bulletFlowmeter - Most machines are equipped with fill flowmeters that measure the gallons or liters.  Typically this is a turbine or paddlewheel type meter installed in the fill water line.


1.  Discrete level controls

1.1.  Jet Dyeing Machines

There are two common types of level switches on jet dyeing machines - rod-mounted float switches (commonly found on machines manufactured prior to 1990), and switches mounted on an external pipe.  Drain sensors may be mounted in a separate chamber mounted near the lowest point in the system piping.  Please refer to your machine schematics for the location of these devices.

Level settings for discrete-type control should be determined by the requirements of the dyer and these settings are typically set for the load size and liquor ratio requirements of the machine.  To adjust the running levels the switches can be moved up or down until the desired level is set.

With rod mounted level switches, the float switch is screwed onto the end of a hollow pipe that is threaded at the bottom to accept the switch.  Wires from the switch are run upward through the pipe and terminated in a junction box attached to the top of the pipe.  The pipe is inserted through a compression fitting on the top of the kier and is secured near the bottom with a U-clamp.  To adjust the level, the compression fitting and the clamp are loosened and the rod may be slid up or down as necessary.  Once the level is set, retighten the compression fitting and clamp.

On external switches, reed-type switches are clamped to the outside of a pipe.  A floating ball with magnets travels inside the pipe activating the switches as it passes by them.  These level switches may be adjusted by loosening the clamp holding them to the pipe and sliding them up or down as necessary.

1.2.  Package dyeing machines

1.2.1.  Machines with expansion tanks

On package machines with expansion tanks, the level switches are attached to pipes mounted in the bottom of the expansion tanks, and are normally adjustable only by changing the pipe to a different length.  The float switch is typically installed in a chamber to prevent turbulence in the tank from affecting the float.  All machines require a level 1 switch, but some may include a level 2 switch or also a tandem level switch if the machine is part of a tandem machine configuration.

1.2.2.  Air pad package machines

Air pad machines do not have expansion tanks, and normally do not use discrete-type level switches.  (See analog level controls)

2.  Analog level controls

Analog level transmitters may be either a Gem's Sure Site transmitter or a differential pressure transmitter attached to the kier.  The output of these devices is 4-20 milliamps and the output varies with the level of water inside the vessel.


Most machines are equipped with fill flowmeters.  This allows the operator to program a specific fill quantity using the codes FILQ (fill by quantity), or FILR (fill by ratio), and also to wash with a specific quantity using WASQ (wash by quantity) or WASR (wash by ratio).





Copyright 2003 by Gaston County Dyeing Machine Company.  All rights reserved. 

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