Hi guys, sorry, been neglecting this post to work on pump controls, but actually I have some updates for this. But first, the questions.
Indeed, I am using an ultrasonic. Flowline dt-34. Is it considered good quality? Seems well made. It has some programmable relays which I utilize for low and high switches. (It also outputs 4..20mA on its power supply line, which is useful for debugging). But I do need the relays, as I am going PLC-free, heh.
Update. It now seems that the problem is electrical in nature. When drawing down the tanks with a pump (surface level completely calm, no falling water), the phantom relay activation/sticking still occurs. Sometimes the all relays of the sensor will suddely activate and then go off soon after. This is more rare, usually the relays just keep their state even if the switch condition has changed. The correct state is assumed immediately after all the pumps are stopped. This does not happen if draining the tank by gravity. Switching occurs at prescribed levels as would be expected. The 4..20 mA output does not die (eg go to some default value) during these phoenomena, instead it still shows a "reasonable" value and keeps changing. Seems like the problem is caused by having the signal cables near the power cables, yes? However, I am using shielded cable, 220 VAC signal level and have grounded the cable only on one end. The instrument ground and motor ground are tied together at the panel unfortunately.
Any ideas?
PS. About to test with the signal cable running through the air away from the motor cables.