Ultrasonic level sensors are widely used in a variety of industries for non-contact level measurement in tanks, silos and open channels. These sensors use ultrasonic waves to determine the distance between the sensor and the surface of the liquid to provide accurate level readings. Like any industrial device, ultrasonic level sensors require proper maintenance to ensure reliable performance and extended service life.

Why is Ultrasonic Level Sensor Maintenance Important?

Ultrasonic level sensors typically operate in a variety of industrial environments, including harsh and corrosive environments. Regular maintenance ensures:

  • Accurate readings: Dust, dirt and environmental factors can interfere with the accuracy of the transducer.
  • Longer service life: Timely maintenance prevents wear and tear and extends the life of the sensor.
  • Cost savings: Well-maintained sensors reduce the risk of sudden failure and the cost of expensive replacements.

Main Maintenance Procedures for Ultrasonic Level Sensor

Regular Cleaning

Keeping the transducer clean is one of the most important maintenance tasks. Accumulated dust, dirt, and debris can block the ultrasonic signal and cause inaccurate readings.

  • To clean the transducer surface: Wipe the transducer with a soft cloth or sponge and a mild detergent. Avoid abrasives that may scratch the transducer surface.
  • Prevent buildup: In a heavily fouled environment (such as a wastewater treatment plant), periodically check the transducer for material buildup. If exposed to sludge or corrosive liquids, more frequent cleaning is required.

Check Installation and Alignment

  • Verify alignment: The ultrasonic transducer must be mounted properly to ensure that the signal is directed toward the liquid surface. Check alignment periodically and make adjustments as necessary.
  • Tighten loose parts: Over time, vibration or mechanical stress may loosen the transducer mounting. Ensure that the sensor is securely fastened and that no excessive vibration interferes with its performance.

Checking Electrical Connections

Faulty wiring or corroded electrical connections can cause the sensor to malfunction.

  • Check connections: Periodically inspect all wires and connectors for signs of wear or corrosion. Tighten any loose connections and replace damaged cables immediately.
  • Monitor power: Ensure that the sensor is receiving the correct voltage and is operating within its specified power range.

Perform a Functional Test

Even if cleaned and installed correctly, periodic function tests are critical to verify sensor performance.

  • Test for accuracy: Compare the sensor’s reading to a known level to ensure accuracy.
  • Check response time: Ensure that the sensor responds quickly and correctly to changes in level. If the response is delayed or erratic, further troubleshooting may be required.

Environmental Considerations

Ultrasonic level sensors are designed to withstand harsh environments, but it is important to ensure that the sensor housing provides adequate protection.

  • Temperature and humidity: Ensure that the sensor is within its operating temperature range. Excessively high or low temperatures can affect performance. Also, ensure that the sensor housing is well sealed to prevent moisture ingress.
  • Corrosive environments: If the sensor is to be used in highly corrosive environments, ensure that it has an appropriate protective coating or material that resists chemical damage.

Calibration

Over time, ultrasonic transducers may deviate from factory calibration due to environmental conditions or prolonged use.

  • Periodic calibration: Re-calibrate periodically according to the manufacturer’s guidelines, especially after a period of use or when installing the transducer in a new application.
  • Use automatic calibration: Many modern ultrasonic transducers have a self-calibration feature. Utilize this feature to ensure consistent accuracy without the need for manual calibration.

FAQs

Even with regular maintenance, there are some common problems that may occur:

Signal interference: External noise from machinery or other ultrasonic devices may cause interference. If this occurs, reposition the transducer or reduce the background noise.

Weak signal: A weak signal can be caused by buildup, incorrect alignment, or electrical problems. Often this can be resolved by cleaning, realigning, or checking the wires.

Erratic readings: Temperature changes or condensation on the sensor may cause erratic readings. In this case, make sure the sensor is suitable for the current environmental conditions.

Summary

When properly maintained, ultrasonic level sensors are highly reliable. By following these maintenance steps – cleaning regularly, checking connections, performing function tests, and scheduling calibrations – you can extend the life of your sensors and ensure continued accurate performance. Remember, maintenance is not a one-time activity, but an ongoing process. Proper maintenance of ultrasonic level sensors not only maximizes their efficiency, but also reduces downtime and unexpected costs.

Apure offers ultrasonic level sensors in addition to water quality monitoring analyzers, flow measurement instruments, temperature and pressure measurement instruments and more. Please contact us for more information.