1. Project Background
An industrial facility in Munich, Germany required continuous level monitoring for an outdoor industrial storage basin, used for process water storage and rainwater collection. Operators needed real-time visibility of liquid levels to prevent overflow and ensure proper water management.
Previously, liquid levels were checked manually, which was time-consuming and did not provide timely information during sudden inflow events. To address this, the KUS-M56 ultrasonic level sensor was installed on a support bracket, suspended above the basin, providing continuous, non-contact level monitoring.
2. Measurement Challenges
The main challenges of this application included:
● Outdoor environment, requiring reliable long-term operation
● Open-top industrial basin, with liquid levels changing during rainfall and operations
● Limited installation space, necessitating a compact sensor design
● Direct integration with the facility PLC using 4–20 mA analog output
● Simple installation and low maintenance for on-site staff
3. Solution
The KUS-M56 sensor measures the distance from the sensor face to the liquid surface, providing continuous level data. In this project, the 4–20 mA analog output was connected directly to the PLC for real-time monitoring and high/low level alarms.
3.1 Equipment Configuration
- KUS-M56 ultrasonic sensor
- Support bracket, clamped above the industrial storage basin
- 24VDC power supply
- 4–20 mA analog output connected to PLC
- LED display used for local verification
3.2 Key Technical Specifications
| Parameter | Specification |
| Measuring Range | Up to 6 m |
| Measurement Accuracy | 0.5% – 1.0% |
| Emission Angle | 20° |
| Output Used | 4–20 mA |
| Display | Integrated LED |
| Ambient Temperature | -20 to +60 ℃ |
| Protection Class | IP66 |
3.3 Implementation Process
Installation
The KUS-M56 ultrasonic level sensor was mounted above the industrial storage basin using a support bracket, ensuring a clear path to the liquid surface. Installation was completed without disrupting facility operations.
Operation
The sensor continuously monitors the basin level and sends the 4–20 mA signal to the PLC. The PLC converts the signal into level percentage and triggers high/low alarms when thresholds are reached.
Maintenance
Non-contact operation eliminates mechanical wear. Routine maintenance is limited to visual inspections and basic functional checks.
4. Project Results & Performance
| Performance Indicator | Result |
| Measurement Stability | Stable and repeatable |
| System Availability | >99% |
| Maintenance Frequency | Visual check only |
| Installation Time | ~20–30 minutes per basin |
| Manual Inspection Reduction | Significant |
| Operator Feedback | Positive; LED display clear, PLC signal reliable |
5. Conclusion
The KUS-M56 ultrasonic sensor provides a compact, reliable, and easy-to-install solution for outdoor industrial storage basin level monitoring. Continuous non-contact measurement and PLC integration allow operators to monitor liquid levels in real time, reduce manual inspections, and improve operational management.This solution is suitable for industrial storage basins, process water basins, rainwater collection basins, and general liquid storage applications, where stable level monitoring and simple integration are key requirements.
For more technical details, wiring diagrams, or model selection guidance, please click here to learn more or contact our technical team.
