Ultrasonic level sensors are widely used across industries for measuring liquid levels in tanks, reservoirs, and other storage containers. These sensors work by emitting ultrasonic sound waves and measuring the time it takes for the sound to bounce back after hitting the liquid surface. Despite their effectiveness, many users encounter problems during installation or operation due to common mistakes. In this article, we will explore the top 10 mistakes made when applying ultrasonic level sensors and how to avoid them.

#1. Improper Ultrasonic Level Sensor Adjustments

One of the most common mistakes when using ultrasonic level sensors is failing to properly adjust the sensor settings. Many users assume that the sensor will work optimally with its default settings, but this is rarely the case. Proper calibration and adjustments are critical for ensuring accurate readings. This involves setting parameters such as the range, sensitivity, and output based on the specific application.

Failing to adjust these settings can result in inaccurate level measurements, leading to operational inefficiencies or even equipment damage. For instance, if the sensor is not adjusted to the correct range, it might not detect the liquid level accurately, causing overfilling or underfilling issues.

#2. Ignoring the Ultrasonic Level Sensor’s Blanking Distance

The blanking distance is the minimum distance from the sensor’s face where it cannot detect objects. This area is also known as the dead zone. Ignoring this blanking distance can result in measurement errors, especially if the liquid level falls within this zone.

For example, if the tank’s level is too close to the sensor, the ultrasonic waves may not be able to return to the sensor properly, leading to false readings. To avoid this, always ensure that the sensor is installed at a height where the liquid level will not enter the blanking distance.

#3. Poor Ultrasonic Level Sensor Mounting Location

Where you mount your ultrasonic level sensor can greatly impact its performance. If the sensor is placed too close to tank walls, pipes, or other obstructions, the ultrasonic waves can bounce off these surfaces and create false echoes, leading to inaccurate level readings. Similarly, if the sensor is mounted in a location with excessive vibration or turbulence, it can affect the stability of the readings.

To avoid these issues, it is essential to choose a mounting location that is free from obstructions and vibration. The sensor should be installed in a position where it has a clear, unobstructed view of the liquid surface.

#4. Inappropriate Application

Not every ultrasonic level sensor is suitable for all applications. Using the wrong sensor for a specific application can lead to poor performance and unreliable measurements. For example, some ultrasonic sensors are designed for clean liquids, while others can handle more challenging environments like viscous fluids, slurries, or foaming liquids.

It is important to consider the specific conditions of your application when selecting an ultrasonic level sensor. This includes factors such as the type of liquid, the presence of foam or bubbles, and the temperature and pressure of the environment. Choosing the right sensor for your application will ensure reliable and accurate measurements.

#5. Poor Mounting Angle

The angle at which the ultrasonic level sensor is mounted can significantly impact its performance. If the sensor is mounted at an incorrect angle, the ultrasonic waves may not be directed properly at the liquid surface, resulting in inaccurate readings. Ideally, the sensor should be mounted perpendicular to the liquid surface to ensure that the sound waves travel directly to and from the surface.

Mounting the sensor at an angle can cause the sound waves to reflect away from the sensor, leading to measurement errors. To avoid this, make sure that the sensor is mounted at the correct angle and is aligned properly with the liquid surface.

#6. Chemical Incompatibility

Chemical compatibility is a critical consideration when using ultrasonic level sensors, especially in industrial applications where the sensor may come into contact with aggressive chemicals. Using a sensor that is not compatible with the chemicals in your application can lead to sensor damage, degraded performance, and even sensor failure.

For example, certain chemicals can corrode or degrade the materials used in the sensor housing, leading to leaks or malfunction. To avoid this, always check the chemical compatibility of the sensor with the liquids in your application and choose a sensor with appropriate materials that can withstand the chemical environment.

#7. Choosing an Ultrasonic Level Sensor with Inadequate Sensing Range

Each ultrasonic level sensor has a specific sensing range, which is the maximum distance the sensor can accurately measure. Choosing a sensor with an inadequate sensing range for your application can result in measurement errors or even failure to detect the liquid level at all.

For example, if your tank is too tall for the sensor’s range, the sensor may not be able to measure the full liquid level, leading to inaccurate readings. To avoid this, ensure that you select a sensor with a sensing range that is appropriate for the size of your tank or container.

#8. Not Using Shielded Cable

Electrical noise and interference can significantly impact the performance of ultrasonic level sensors, especially in industrial environments with a lot of electrical equipment. One common mistake is not using shielded cables when wiring the sensor. Shielded cables help to reduce electrical noise and prevent interference that can lead to unstable or inaccurate readings.

If the sensor wiring is exposed to electrical noise without proper shielding, the sensor’s performance may be compromised, resulting in fluctuating or incorrect level readings. To ensure reliable performance, always use shielded cables when wiring your ultrasonic level sensor, especially in electrically noisy environments.

#9. Improper Cable Routing

Improper cable routing is another common mistake that can affect the performance of ultrasonic level sensors. If the sensor cables are routed near high-power electrical equipment, motors, or other sources of electrical interference, it can introduce noise into the sensor’s signal, leading to inaccurate readings.

To avoid this, always route the sensor cables away from sources of electrical noise and interference. Use separate conduits for the sensor cables if possible, and avoid running them parallel to high-voltage cables or other equipment that can generate electrical noise.

#10. Poor Quality Power Source

The quality of the power source used to operate the ultrasonic level sensor is often overlooked but can have a significant impact on the sensor’s performance. A poor-quality power source can introduce noise and fluctuations in the sensor’s signal, leading to unstable or inaccurate level measurements.

For instance, using a power supply with unstable voltage or excessive ripple can cause the sensor to produce erratic readings. To avoid this, ensure that the sensor is powered by a stable and reliable power source with minimal noise and fluctuations.

Summary

Ultrasonic level sensors are highly effective tools for measuring liquid levels, but their performance can be compromised by a variety of factors if not applied correctly. By avoiding these top 10 mistakes—such as improper sensor adjustments, poor mounting locations, and choosing the wrong sensor for your application—you can ensure reliable and accurate measurements in your liquid level monitoring systems.

For more information on level measuring instruments, please visit our website or contact our team of experts. We are here to help you find the perfect solution for your level measurement needs.

“Feel free to share this blog with your colleagues and friends who might find it useful.”