5 Things to Know Before Buying Ultrasonic Level Transmitter

Which Liquid Level Sensor Should You Choose?

Choosing the right level sensor for your application can significantly impact operational efficiency, accuracy, and cost. For years, ultrasonic level sensors were the industry standard due to their affordability and simplicity. However, as technology has advanced, submersible level sensors and radar level sensors have proven to be more reliable and accurate, especially in harsh environments.

For more information, please visit our website.

Ultrasonic sensors struggle in the presence of foam, vapor, turbulence, and condensation, while Icon Process Controls’ 100 Series Submersible Level Sensor and ProScan 3 80G Radar Sensor offer precise, consistent readings under these conditions. This blog will outline the 5 key differences between these sensors, highlighting why submersible and radar sensors are the superior choice. We’ll also explore how each technology works, the pros and cons, and why industries are phasing out ultrasonic sensors in favor of more advanced solutions from Icon Process Controls.

1. Accuracy and Performance in Harsh Conditions

Submersible and Radar Level Sensors Are Unaffected by Foam, Vapor, and Condensation

Ultrasonic sensors rely on sound waves to measure liquid levels, but foam, vapor, and condensation interfere with these waves, causing distorted or erratic readings. On the other hand, the 100 Series Submersible Level Sensor and ProScan3 80G Radar Sensor are built to provide consistent accuracy, even in the presence of foam or vapor.

How They Compare:

• Ultrasonic Sensors: Unreliable in foam, vapor, and turbulent conditions.
• 100 Series Submersible LevelSensor: Fully submerged, unaffected by surface conditions, and offers precise readings.
• ProScan 3 80G Radar Level Sensor: High-frequency radar waves (80GHz) cut through foam, vapor, and condensation with pinpoint accuracy.

Testimonial:
Sarah L., a chemical processing facility manager, shared, “We constantly battled erratic readings from our ultrasonic sensors due to foam and vapor. Since switching to the LevelPro submersible sensor, we’ve had consistent, reliable measurements.”

Key Takeaway: If your tanks contain foam, vapor, or turbulent liquid, you’ll get better results with submersible or radar sensors compared to ultrasonic sensors.

2. Installation, Setup, and Programming

Submersible Sensors Are Plug-and-Play, While Ultrasonic and Radar Require Calibration

Installing and setting up a level sensor can be time-consuming, especially if you have to program “empty” and “full” points for accurate readings. Ultrasonic and radar sensors require manual calibration, while submersible sensors are plug-and-play. The 100 Series from Icon Process Controls can be installed in minutes.

How They Compare:

• Ultrasonic Sensors: Require precise alignment, clear paths, and initial calibration.
• 100 Series Submersible Sensor: Plug-and-play; drop it into the tank, and it works instantly.
• ProScan 3 80G Radar Sensor: Requires calibration but offers automatic signal processing.

What Makes the 100 Series Stand Out?

• No calibration required.
• No complicated software configurations.
• No risk of signal interference from internal tank components like ladders or mixers.

Testimonial:
John M., a wastewater treatment facility supervisor, said, “We saved hours on setup time with the 100 Series. No calibration, no issues, just plug it in and it works.”

Key Takeaway: For fast, hassle-free installation, submersible sensors are the easiest to deploy. They eliminate the need for reprogramming or recalibration, unlike ultrasonic and radar sensors.

3. Cost, Maintenance, and Long-Term Affordability

Submersible Level Sensors Are a Cost-Effective Long-Term Solution

Many companies choose ultrasonic sensors initially due to their low purchase price, but they often overlook the ongoing costs of maintenance and calibration. Ultrasonic sensors need constant recalibration, and they are prone to failure due to vapor, foam, or turbulence.

Cost Breakdown:

Sensor Type Initial Cost Maintenance Cost Calibration Required Long-Term Cost Ultrasonic Sensor Low High Frequent Recalibration High (False Alarms) 100 Series Submersible Medium Low None Low ProScan3 80G Radar Higher Low Occasional Calibration Low

Key Takeaway: While submersible and radar sensors have higher initial costs, they save money in the long run by eliminating false readings, reducing maintenance, and avoiding downtime.

4. Performance in Tanks with Obstructions (Mixers, Ladders, and Baffles)

Submersible Level Sensors Are Immune to Internal Tank Obstructions

Ultrasonic and radar sensors rely on unobstructed signal paths. Internal tank structures like ladders, mixers, and pipes can block sound and radar waves, leading to false readings. Submersible sensors have no such issues.

How They Compare:

• Ultrasonic Sensors: False readings when ladders, pipes, or mixers block sound waves.
• 100 Series Submersible Sensor: Immune to obstructions; directly measures the liquid regardless of tank design.
• ProScan 3 80G Radar Sensor: Narrow beam angle avoids most obstructions, but ladders or pipes may still interfere.

Testimonial:
Mark L., an engineer at a beverage processing plant, shared, “Our ultrasonic sensor kept misfiring due to the tank’s internal structures. Switching to the 100 Series solved it immediately.”

Key Takeaway: Submersible sensors work in any tank, no matter how complex its geometry. Radar sensors perform well too, but obstructions may still affect signal paths.

5. Accuracy, Reliability, and Consistency

Submersible and Radar Sensors Provide Consistent Results 24/7

Ultrasonic sensors often provide erratic readings due to interference from foam, vapor, and turbulence. This inconsistency can result in false alarms, shutdowns, or tank overflows. Submersible and radar sensors offer consistent, reliable performance.

How They Compare:

• Ultrasonic Sensors: Erratic readings due to vapor, foam, and turbulent surfaces.
• 100 Series Submersible Sensor: Consistent readings since it directly measures liquid from within.
• ProScan 3 80G Radar Sensor: Consistent readings in the harshest environments.

Key Takeaway: For consistent, reliable readings, submersible and radar sensors outperform ultrasonic sensors in every scenario.

100 Series Submersible Sensor and ProScan3 80G Radar Sensor — How They Work

How the 100 Series Submersible level Sensor Works:

• Submersed in the liquid.
• Measures hydrostatic pressure.
• Converts pressure to an electrical signal.
• Provides real-time data to control systems.

How the ProScan3 80G Radar Sensor Works:

• Emits 80GHz radar waves toward the liquid surface.
• Waves reflect back to the sensor.
• Measures the time delay to calculate distance.

Which Should You Choose?

• Use Submersible Sensors when internal obstructions are present, like ladders, mixers, or pipes.
• Use Radar Sensors when you need non-contact measurement or have chemicals that shouldn’t touch sensors.

Choose Icon Process Controls for Superior Level Sensors

If you’re looking for reliable level measurement, avoid the pitfalls of ultrasonic sensors. Choose a more dependable option with the 100 Series Submersible Sensor or ProScan3 80G Radar Sensor from Icon Process Controls. These sensors offer better accuracy, lower maintenance, and long-term savings.

In order to choose the technology that will best suit your process, it is important to know the nature of the product that will be measured. Is it a liquid, paste or loose solids? If it is a liquid, is there foam on the surface of the liquid?

Level measurement technologies can be divided into two groups: contact and non-contact. Non-contact technologies are more appropriate for use in extreme environments or with aggressive products. Non-contact level measurement also has the advantage that there is no risk of contaminating the product.

As with any sensor, the measuring range is very import and care must be taken to consider the position of the sensor in relation to the product. For example, if you install a sensor at the top of a silo and there is 1 meter in height between the sensor and the maximum height of the product in the silo, you must take this meter into account when evaluating the level range to be measured.

It is important to choose a level sensor that is resistant to the  pressure and temperature of the process conditions and has an output signal that is compatible with the measuring system: analog or digital output; with or without display; relay output; etc.

The principle of a float level sensor is relatively simple: a float slides on a vertical axis as the level of a liquid changes. To measure the liquid level, simply measure the position of the float on the vertical axis.

Explore more:
5 Must-Have Features in a Welding Fire Blanket
NPK 12 12 17 vs. Other Fertilizers: Which One Wins?
Fiberglass Chopped Strands: The Ultimate Guide to Using Them

With competitive price and timely delivery, gallopsensor sincerely hope to be your supplier and partner.

It is a precise type of sensor, using a simple and proven process, and the measurement is unaffected by the viscosity of the liquid or the presence of foam on its surface. Nevertheless, the measurement is sensitive to disturbances on the liquid’s surface, such as waves. These sensors are inexpensive and do not require regular maintenance, but are not suitable for corrosive products.

The measuring range is limited by the length of the indicator tube and is usually less than one meter.

Hydrostatic level sensors are submersible pressure sensors. They measure the hydrostatic pressure which is proportional to the height of the liquid above the sensor. This technology is only suitable for liquids.

Hydrostatic level sensors offer a wide measuring range and are unaffected by foam formation. However, the measurement depends on the density of the liquid and the pressure in the tank. Both accurate and simple to install (the sensor is often mounted at the bottom of the tank), this technology is widely used in the food industry and in water treatment plants. This kind of sensor must be maintained, however, as deposits can form on the diaphragm and falsify the measurement. It is also necessary to empty the tank beforehand for any intervention on a sensor installed on the tank bottom (installation, removal, etc.).

The radar level sensor is installed on top of the tank, above the product. It sends microwaves to the product surface, which in turn reflects them back to the sensor. By measuring the travel time between the emitted and reflected wave, the distance between the sensor and the product surface can be deduced. This makes it possible to calculate the level of the product.

The main advantage of this type of sensor is that it can measure the level of any type of product (liquids, pastes, solids, etc.) as long as it is not electrically conductive. Radar sensors are extremely accurate and insensitive to product properties (temperature, pressure, density, conductivity, etc.).

As this is a completely contactless technology, these sensors can be used in harsh environments or with products that are abrasive, corrosive, etc.

Another advantage is that these sensors are installed above the product level, usually at the top of the tank, so they can easily be removed without needing to empty the tank.

There is an interesting alternative to radar technology: the guided radar sensor or guided wave sensor. This type of sensor works on the same principle, but the microwaves are guided along a rod or a cable which is immersed in the product. By guiding the wave in both directions, the sensor is less sensitive to disturbances, in particular to disturbances on the product surface (i.e. an agitated surface, foam generation, drain cones for loose solids, etc.) and by elements in the tank (internal structural elements or equipment with wave-reflecting surfaces).

Like radar level sensors, ultrasonic level sensors are installed above the product. The principle is similar, they emit ultrasonic pulses that are reflected by the product surface. By measuring the wave travel time between emission and reception of the reflected wave, the distance between the sensor and the product surface can be calculated.

This technology allows for non-contact measurement and has the same advantages as radar sensors: this type of sensor is easy to install and uninstall, it does not require the tank or vessel to be emptied.

An additional advantage is that the ultrasonic vibration of the sensor ensures permanent self-cleaning, which prevents the sensor from clogging due to dust deposits, for example.

These sensors also offer a wide measuring range, making them suitable for use in many applications.

Ultrasonic sensors are used to measure the level of liquids and solids, but are not suitable for foamy or dusty products, which dampen the waves. These sensors are also sensitive to temperature variations and are unsuitable for high temperatures and high pressures.

The principle of the capacitive level sensor is that a sensor and vessel form an electrical capacitor whose electrical capacitance value depends directly on the height of the product in the tank.

Capacitive sensors are particularly heavy duty and can withstand very high temperatures and pressures. They are easy to install and remain reliable, even with viscous or highly adhesive products. They can be used with liquids, granular products or powders. Unlike ultrasonic and radar sensors, capacitive sensors are not sensitive to electrically conductive products.

These sensors are generally used in the chemical, food and plastics industries.

Radiometric level sensors use a radioactive source that emits gamma rays that are attenuated as they pass through matter. This technology requires a source and a sensor set up so that the gamma rays pass through the tank. The gamma rays will be more or less attenuated depending on the height of the product in the tank.

The main advantage of this type of sensor is that it can be used for all applications. It allows for non-contact and non-intrusive measurement as it is installed outside the tank (gamma rays pass through the walls), which means you don’t have to stop production. This type of sensor is unaffected by product characteristics and can therefore be used with aggressive media and under extreme conditions (temperature and pressure).

This technique is reliable and despite the use of gamma rays, it is very safe for the user.

While it could be used everywhere, this technology is very expensive and is only deployed in cases when no other type of level sensor can be used.

If you are looking for more details, kindly visit Ultrasonic Level Transmitter.