Ultrasonic Wave Oil Level Sensor

——Product specification
 Edition Record
Edition Date Content
V1.0 2015-10-29 First draft
V1.1 2017-05-20 Formal

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1. Production Overview
Ultrasonic oil level sensor is the oil quantity monitoring equipment designed for management personnel of
enterprise motorcade. It can prevent gasoline theft by drivers, optimize transportation cost, the driver’s driving
action and assist statistical decision, etc. The sensor uses ultrasonic probe to detect the oil level height and
carries out smart processing for height signal of oil quantity through built-in program of the main body. Then it
sends the oil quantity information to the system platform through GPS to generate the oil quantity report after
analysis. The sensor supports serial port and analog output and can connect with GPS of most brands/Beidou
all-in-one machine. Therefore, the sensor can be connected with the backstage monitoring system easily.
The products adopt non-contact measurement ultrasonic wave sensor technology developed independently
by our company and first created domestically and are widely used in fuel consumption monitoring projects for
vehicles and sold overseas.

2. Introduction to the product

2.1. The picture of real product is shown in the following figure.
 Main body Extension cord of the probe User interface line

2.2. Product Configuration List

Standard configuration list:

Number Name Quantity Unit Remark

1 Main body of ultrasonic 1 Set

wave oil level sensor
Ultrasonic

2 Ultrasonic probe 1 Piece The total length is 9M with extension

line

3 User interface wire 1 Piece Including power line and data

interface line
4 Auxiliary installation 1 Package Ultrasonic Complants (1 small
package box)/3.0 meter hose clamp (1
piece)/15CM ribbon (15
pieces)/sandpaper (1 piece)

Optional configuration list:

Number Name Unit Remark

1 Specific glue Bottle

 2.3. Technical parameters
Operating voltage 9~36VDC

Maximum power consumption 0.8W/12VDC

Work temperature -40℃~+85℃(Industry level)

Working humidity 5%~90%

Measurement range Determined according to materials and thickness of the

container; for steel plate of 5mm thick, the measurement scope
is 5~100cm.

Pressure bearing scope ≤0.8kg or 0.8MPa

Liquid measurement accuracy ±1%

Output signal R(10~190Ohm）、V(0-5V)、 RS232 （0.1MM）.

The default baud rate is 9600. No check bit, 8-digit data bits,
1-digit stop bit and no fluid control. The liquid level value
measured by the sensor in a real-time manner is given per 10s
Communication port parameters
after smoothing processing.
Note: The baud rate and interval of data transmission can be
customized.

2.4 Product characteristics

1. High precision: The resolution ratio of oil level height measurement of the oil level sensor is 0.2mm
and the measurement accuracy is ±0.5%. High measurement accuracy can be guaranteed at high
temperature and high cold external environment.
2. Good long-term stability: The oil level sensor adopts ultrasonic wave measurement method and
performs non contact measurement. It is different from the float-type, pressure type, magnetic sliding
system measurement methods that adopt direct contact measurement methods at present generally so as to
avoid corrosion and pollution of oil level sensor by fuel oil and maintain long-term stability.
3. Easy installation and maintenance: It only needs to install the sensor probe at the lower part of
external fuel tank. There is no need to change the existing measurement system of the fuel tank, no need to
drill hole and make change on the fuel tank. At the same time, it can guarantee normal operation of former
oil meter of vehicles.
4. Environmental sound, small energy consumption. Non contact measurement makes it unnecessary
 to bore hole on or modify the fuel tank. No dirt and pollution will be brought to the fuel oil.
5. Strong reliability: Still work normally at hostile environment; anti-damp, anti-acid, inflaming
retarding, anti-interference and Intelligent.
The product can be used independently by using the auxiliary display screen. It may also be used with GPS
equipment by transferring the data to backstage through GPS equipment for data statistics, statement
analysis and query.

2.5. Applicable scope

The ultrasonic oil level sensor is geared to all types of vehicles (such as logistics vehicles, taxi, buses
and passenger cars, etc) to record the refueling, oil consumption of vehicles with digitalization to prevent
occurrence of fuel theft, avoid resources waste, improve management efficiency and traffic safety and
enhance operation management level.

3. Product package
3.1 Description of main equipment
Digital display screen

LED indicator light

Display key

Connector of probe
User interface
extension line

1) Port definition of user interface line

Pin position Function Description

Positive pole of 9~36VDC
1
power supply
2 Negative pole of
 power supply
3 TX RS232 transmitting terminal
4 RX RS232 receiving terminal
5 B RS485 B
6 A RS485 A
7 NC Reserved
8 NC Reserved
9 AOUT Analog voltage output
10 GND Reference ground
11 NC Reserved
12 NC Reserved

2) Definition of LED light

Green light on: the probe works normally

Red light on: the probe is abnormal (the probe line is not inserted or probe drops off).

3.2. Description of user interface

Wire color Function Description
Red Positive pole of 9~36VDC
power supply
Black Negative pole of
power supply
RS232: transmitting terminal
Yellow TXD
of the device
RS232 receiving terminal of
Blue RXD
the device
Brown B Port B of RS485 interface
Purple A Port A of RS485 interface
Green AOUT Analog voltage output
Black GND

4. Guide for installation steps

4.1. Installation preparation
1. Standard configuration: main body of the sensor (one piece), probe (one piece), extension line (one piece),
user interface line (one piece), coupling agent (one box), 2.8-meter long hose clamp (one piece) and sand paper
(one piece).
2. Glue
3. The customers need to prepare: 12V mobile power supply, isolating tape, and duster cloth and paper tissue
(used to wipe off grease dirt).
Note: Before installing the sensor on the vehicle, please fill oil to the vehicle fully or at least higher than half of
the oil tank. (Installation is the optimal at such state).

4.2. Actual oil quantity and installation environment

confirmation
1. Oil level prediction: Judge the approximate oil level height of the fuel tank by checking oil meter of the
vehicle, knocking the oil tank or opening the tank cover with the help of long and thin wire and make record
(for example, the prediction is about 300mm).
2. Before installing on the vehicle, ensure that the vehicle stops at horizontal ground and the oil tank is placed
on frame horizontally (with the help of gradienter).

4.3. Seek installation area

1. The installation area of probe should avoid the oil filler, oil outlet, oil return pipe, oil float and baffle, etc.
Select the flat part at oil tank bottom or close to the central area as possible (see the following figure for the
internal structure of the oil tank).
2. For circular oil tank, in addition to avoiding the barrier, the tangent plane closest to the ground should be
selected.

4.4. Confirm installation location of coupling agent

1. Connect the main body of the sensor with user interface line, extension line, probe connection line properly
and power on. The liquid level is displayed 000.0 at the moment.
2. Clean the area where the oil tank is installed.
3. Apply coupling agent on probe surface. Press the probe at the selected installation position. The display of
 the main body displays the currently measured liquid level (shown in the figure below).

4. Hold down “key 1” in the figure below for more than 8 seconds and release it to enter input state of total oil
tank height. F060 in the figure below means that total height of the oil tank is 60cm. Press “key 2” to increase
and press “key 3” to decrease. Hold down “key 1” for 8 second to confirm the parameters.

5. After total height of the oil tank is put properly, it enters the input state for current liquid level of the oil tank.
E030 in the figure below means that current liquid level height is 30cm. Press “key 2” to increase and press
“key 3” to decrease. (When it is difficult to determine the current liquid level in the oil tank, it may not input.
Hold down “key 1” more than 8 seconds to skip).

6. After the current liquid level of the oil tank is put properly, press “key 1” more than 8 seconds to enter the
automatic adjustment state of oil tank signal strength. At the moment, you may observe whether the displayed
height on the display screen is consistent with actual oil level (for example, the predicted level is about 300mm
and displayed 285.2mm). If the display screen displays 000.0 or the displayed height is quite different from the
actual condition, the probe may be moved slightly or grind the oil tank wall more. In addition, the buzzer in the
equipment sounds continuously (if the buzzer sounds on and off or does not sound, it needs to seek the
installation point or grind the oil tank wall more until the buzzer does not sound). At the moment, hold down
“key 1" in the right figure more than 8 seconds to complete search and test of installation point.

4.5. Fix the probe

1. If the location where the probe is pasted at the oil tank bottom still has paint, it is necessary to grind the paint
away with sandpaper at the pasting position. Wipe away the oil stain and water to keep the surface dry and
clean.
2. Use glue to paste: Use a screwdriver to squeeze component A and component B glue of a graduation and
drop them on the probe center. Stir even quickly. The higher the temperature is, the faster the curing speed is. If
the temperature is lower than 8℃, it is necessary to preheat the probe surface before glue is dropped. Paste the
probe at the installation location along the direction of vehicle frame. After confirming that the displayed height
is correct compared with the actual liquid level and stable (if it is not correct, take off the probe immediately.
Wipe dry the glue on oil tank bottom and probe. Select another position beside to paste until the stable pasting
position with correct height is found). Press the probe continuously for more than 5 minutes to make the glue
cure initially. Use long ribbon to bind the probe and fix it well with proper tightness.
After the probe is fixed, please make confirmation again whether height of the display screen is consistent with
the oil level of the residual oil.
Above belongs to standard mode and the mode suggest to be adopted. If the installation personnel think
it is troublesome, they can check the indicator light on the display screen directly to confirm the
installation position. If the displayed liquid level on the display screen is consistent with actual liquid
level, the indicator light on the display screen is on with green (see the figure below). This indicates that
the installation position is suitable for installation basically. The probe may be fixed basically. This
method is simple. But the data stability may be influenced if the environment is poor. It is not suggested
to use generally.
 4.6.Wiring
1. Arrange the extension line into the cab. Wiring should follow the crossbeam of the vehicle at the time of
wiring. It should not affect the original self unloading hopper, head repair, etc and other original functions.
2. The extension line should be away from the vehicle’s motor to avoid producing electromagnetic interference
produced by the motor.
3. The terminal of the probe line and extension line should be convolved properly to prevent falling off.
4. The extension line should be at least 20cm distance to the heating parts of the vehicle. Fixing ribbon is used
to fix the extension line every 50cm. Arrange the wire at the installation position of the vehicle reasonably.

4.7. Connect the vehicles and confirm platform data

1. Disconnect with the power supply and fix the main body at the position close to GPS (where water leakage
will not occur) and fix it properly;
2. The red and black wire of user interface line is connected to the public power supply of the vehicle with red
wire connecting the positive role and black wire connecting the negative pole. Connect it in this
way
Select the interface mode according to collection oil consumption interface of GPS.
A. analog quantity: The green line is connected with GPS collection analog port. The black wire is
connected with GPS collection analog ground;
B. RS232 Communication: The yellow wire (TX) is connected with GPS RX and the blue wire (RX) is
connected with GPS TX. The black wire (GND) is connected with GPS ground.
C. RS485 Communication: The brown wire (B) is connected with B of GPS; the purple wire (A) is connected
with A of GPS and the white wire is connected with GPS ground.
3. Power on and check whether the platform provides oil consumption data.