1. Project Background
A European industrial park required continuous level monitoring for several wastewater and rainwater equalization tanks to support daily operation and reduce the risk of overflow. These tanks are used for temporary storage of process wastewater and stormwater, where liquid levels can fluctuate significantly depending on production activity and rainfall.
Previously, level checks were performed manually, which was time-consuming and often inconsistent, especially during periods of rapid level change. The operator was looking for a simple, non-contact, and economical level measurement solution suitable for general industrial use.
To meet these requirements, the KUM-100 ultrasonic level sensor was selected for this application.
2. Measurement Challenges
The main challenges of this application included:
● Rapid level changes during rainfall events
● Humid environments and the presence of vapors above the liquid surface
● Multiple tanks distributed across the site, making frequent manual checks inefficient
● No requirement for high-precision measurement, but reliable trend monitoring was essential
● Limited maintenance resources on site
● Sensitivity to overall project cost due to multiple measurement points
3. Solution
The KUM-100 ultrasonic level sensor provides non-contact liquid level measurement by calculating the distance between the sensor face and the liquid surface. Installed above the tank, the sensor continuously monitors level changes without coming into contact with the wastewater.
This solution offers a practical balance between performance, simplicity, and cost, making it suitable for industrial applications where stable monitoring is required without complex system integration.
3.1 Equipment Configuration
The system configuration included:
● KUM-100 integrated ultrasonic level sensor
● Simple metal mounting brackets installed above the tank opening
● 24VDC power supply
● 4–20 mA analog output connected to the local control system
● Basic outdoor protection suitable for industrial environments
3.2 Key Technical Specifications
| Parameter | Specification |
| Measuring Range | Up to 10 m |
| Measurement Accuracy | 1.0%–1.5% |
| Resolution | 0.1% of full scale |
| Blind Zone | 0.30–0.40 m |
| Ambient Temperature | -20 to +60 ℃ |
| Protection Class | IP65 / IP66 |
3.3 Implementation Process
Installation
The KUM-100 sensor was mounted above the equalization tank using a simple bracket, positioned to avoid internal structures and areas of strong surface turbulence. Installation was completed without interrupting normal plant operation.
Measurement and Monitoring
The sensor continuously measures the distance to the liquid surface and transmits level data to the local control system. Operators can easily monitor level trends and receive alerts when predefined thresholds are approached.
Data Usage
Measured level data is primarily used for real-time monitoring and basic alarm functions. Historical data supports operational analysis related to rainfall events and process discharge patterns.
Maintenance
Routine maintenance is minimal and limited to periodic visual inspection. Functional checks are performed once or twice per year, without the need for complex calibration procedures.
4. Project Results
| Performance Indicator | Result |
| Measurement Stability | Stable and repeatable |
| Data Availability | >99% |
| Maintenance Frequency | 1–2 times per year |
| Installation Time | Approx. 30 minutes per tank |
| Manual Inspection Reduction | ~70% |
| Operational Efficiency | Significantly improved |
5. Conclusion
The KUM-100 ultrasonic level sensor proved to be a reliable and economical solution for industrial equalization tank level monitoring. By replacing manual inspections with continuous non-contact measurement, the system reduced labor effort while improving responsiveness to changing liquid levels.The KUM-100 is particularly suitable for applications where high precision is not critical, but stable operation, ease of installation, and cost efficiency are key considerations, such as wastewater tanks, rainwater collection basins, and general industrial liquid storage facilities.
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