Wired & Wireless Sensors

What types of tank level sensors are there?

There are four common types of tank level sensor: submersible pressure sensors, magnetostrictive floats, non-contact radar, and non-contact ultrasonic. LevelCon offers all four, plus wireless sensor nodes for sites where running wire to the tank isn't practical.

• Submersible (hydrostatic pressure) sensors sit at the bottom of the tank and calculate level from the pressure of the liquid column above them. They are accurate and cost-effective, but must be rated for the specific liquid, such as corrosive fuels, chemicals, or water.
• Magnetostrictive float sensors track a float on the liquid surface for high-accuracy level readings in fuel and chemical storage tanks, where inventory reconciliation matters.
• Radar sensors (LevelCon uses Vega radar) send a microwave signal from the top of the tank and time the echo off the surface, without touching the product.
• Ultrasonic sensors (LevelCon uses Senix ultrasonic) work the same way with a sound pulse. They are the lower-cost non-contact option for clean liquids in open, stable tanks.
• Wireless sensor nodes (radar, differential pressure, laser, and flow) are battery-powered and report to a LevelCon gateway with no conduit or field wiring.

How do you choose a level sensor for a tank?

Choose a level sensor for a tank by matching it to four things: the liquid, the tank's construction and conditions, the accuracy you need, and the power available at the site.

For a side-by-side breakdown of the two non-contact options, see ultrasonic vs radar level sensors by application.

• The liquid. Corrosive fuels and chemicals need compatible wetted materials, or a non-contact sensor that never touches the product. Viscous liquids are also better suited to non-contact measurement.
• The tank. Pressurized or sealed tanks should use radar, since pressure changes affect how sound travels and throw off ultrasonic readings. Vapor, foam, large temperature swings, and tall tanks also point toward radar. Vertical and underground tanks are often a good fit for submersible sensors.
• Accuracy. For inventory reconciliation and regulatory reporting, magnetostrictive floats and radar offer millimeter-level accuracy.
• Power. Ultrasonic sensors generally draw less power than radar, which matters on battery-powered remote tanks. Solar-powered radar units such as the XSync R close that gap for off-grid sites.

Contact vs non-contact level sensors: which is better?

Neither is better for every tank. Contact sensors measure level directly from inside the liquid, while non-contact sensors measure from above the tank without touching the product, which is useful for corrosive, viscous, or hazardous liquids.

Contact sensors (submersible and magnetostrictive float) are a strong choice when the liquid is compatible with the sensor materials and you want an accurate, cost-effective reading. Because they sit in the product, they must be rated for that specific liquid. A submersible sensor built for water is not automatically safe for fuel or chemicals.

Non-contact sensors (radar and ultrasonic) mount at the top of the tank, so nothing is wetted and there is less to foul or corrode. The tradeoff is that the sensor must be mounted with enough clearance above the maximum fill level to stay out of its dead zone, and ultrasonic readings degrade with vapor, foam, temperature swings, and pressure. Radar handles those conditions much better. Our guide to radar vs ultrasonic tank level sensors covers the details.

Can a level sensor work with a remote monitoring gateway?

Yes. A level sensor becomes a remote level sensor when it is wired or wirelessly linked to a gateway, which sends its readings on a schedule over cellular or satellite to the LevelCon platform.

The F200 gateway accepts the common industrial sensor outputs through a single watertight connector: 4-20 mA and 0-5 V analog inputs, RS-485 and RS-232 digital inputs (including Modbus devices), and pulse counting up to 16 MHz for flow and gas meters. That lets it work with submersible pressure sensors, radar and ultrasonic level sensors, and many sensors already installed on a tank.

If you'd rather not assemble separate parts, stationary tank monitors combine a level sensor and gateway in one enclosure, and the XSync family builds the sensor into the telemetry unit itself. Browse all gateways to compare connectivity options, including satellite fallback for sites without reliable cellular coverage.

What is the best pressure sensor for tanks?

For tank level, the most common pressure sensor is a submersible hydrostatic sensor, which converts the pressure of the liquid column into a level reading. For pressurized vessels and process lines, a direct-mount pressure sensor measures the pressure itself.

LevelCon covers both cases. Submersible sensors connect to the F200 for level in vertical and underground tanks. Wireless differential pressure nodes support level-by-pressure applications without new wiring. The XSync P mounts directly to a pipe or vessel through a threaded process connection and sends near-live pressure readings with no separate transmitter to wire in.

Which sensors fit hazardous or corrosive tanks?

For corrosive tanks, use a non-contact radar sensor or a contact sensor with wetted materials selected for that chemical. For hazardous locations, pair the sensor with hazardous-location rated hardware.

Not sure which sensor fits your tank? Contact a LevelCon engineer with the liquid, tank size, and site conditions for a recommendation.

• Corrosive liquids: LevelCon selects sensor housings and wetted materials per application to withstand corrosive fuels and industrial chemicals, and radar avoids contact with the product entirely. See chemical applications.
• Hazardous locations: The F200 is certified for Class I, Division 1, Group D hazardous locations with a T4 rating. XSync R and XSync P carry a CID1 rating (certification applied for). Both suit wellheads, tank batteries, and chemical storage in oil & gas.
• Water and agriculture: Submersible and ultrasonic sensors are common, cost-effective choices for water and wastewater and agriculture tanks.