Accuracy & Precision

“Success relies on fuel level sensor precision”

Foremost, there are diesel fuel level sensors that are installed in 120G  tanks that could reach a 20G  margin of error.  This happens because vehicle manufacturers put these devices in place to alert the driver when to refuel.  At the same time, there are fuel sensors available that could reach 1G  margin of error  for the same tank.  Usually the most advanced fuel level sensors provide ±1% margin of error.  

Fuel Level Sensor Precision and Accuracy

Fuel Level Sensor Filtering

Due to:

  • Level inclination
  • Hard turning
  • Breaking
  • Revving (Accelerating) 

Fuel experiences high G forces. Consequently, those G forces generate fuel waves inside the tank. In order to avoid false draining alarms, fuel sensors that are chosen must provide advance electronics to leveled fuel volume.   For instance, resistive fuel level sensors waving in a 120G tank would be around 20G.

To sum up, it is incorrect to use resistive fuel sensors to read fuel volume.  if someone challenges this would have to use long averaging at software level.  Indeed when this path is taken 10 to 15 minutes averaging have to be activated at software level, which will decrease the possibility to detect draining.  A High precision fuel control system usually provide fuel volume every 20 seconds in software without any averaging.

Dead Zones

Furthermore you need to asure that the sensor chosen measures the whole tank. In fact there are many fuel level sensors in the market that do not measure 10G at the bottom and or 15G at the top of the tank.  This issue is normally found in all fuel level sensors provided by vehicle manufacturers.  To test it out refill the vehicle, drive 10 miles and observe that the gauge has not changed

This issue is well known as “top dead zone” and  or  “bottom dead zone”.  This behavior is usually derived from a type of buoy.

Consequently fuel level sensors with dead zones  will not afford any savings, as a result of 12G draining  being undetected while tank is full.

Unfortunately many providers try resolving this by using extenders, however extenders  will cause more waiving and additional maintenance costs.


Fuel Level Sensor Mean Time Between Failures

Moreover, it is important to consider the longevity of the fuel level sensor operating under normal conditions.

Take into consideration the warranty period and remember that cheap fuel level sensors tend to fail quickly.  Subsequently replacing costs will impact your budget specifically for a fleet that is geographically disperse. 

It Is important to acknowledge how often fuel sensor needs calibration because they involve cost of having the vehicle not operating.  

We strongly suggest to assure a fuel level sensor with a principle of operation that does not require any additional calibrations in its life spam.

Ex Proof Fuel Level Sensors

All companies operating in areas subject to EXPLOSION will require CERTIFIED EX PROOF fuel level sensors.  if this is the case of course you must  include this in the buying criteria.  Also some companies with high volume tanks will require CERTIFIED EX PROOF fuel level sensors.

Manufacturers achieve the certification in two ways:

(1) Using electronic components working in such low voltages to assure sparks won’t be generated.

(2) Electrical and electronic components working at 12V/24V will be able to produce sparks, but those components are fully isolated from the environment. 


EXPROOF Fuel Level Sensors

Additionally, if you have large tanks you need a software capable of reporting fuel in them and simultaneously in the vehicles.

Furthermore, you will need sensors capable of reaching 2 to 3 meters.

Therefore, if you purchase 10,000G you could be certain that those will be dispatched to your tank.  will On top of that you will be able to track how much fuel was transferred from the tank pinpointing the vehicle, machine and or ship.

When fuel is not transferred to unauthorized recipients profit will be positively impacted.

Indubitably  it is critical for you to conduct business with a provider with this capability.

To sum up, using two different softwares will have a negative impact in tracking fuel in vehicles as well as large tanks.


Turn Key Solution

Once the system is installed, having a software that integrates into one screen all relevant information would make it much more practical.

In fact your team will value seeing  the following variables one screen:

  • Route
  • Voltage
  • Fuel Volume
  • Speed

With these 4 variables it will be possible to quickly identify: draining, refueling, stolen accumulators, and overconsumption.


Lastly, installing a fuel level sensors can be time consuming. After that output begins it can last anywhere from 5 to 15 years. If you have chosen fuel sensors that do not require periodic calibrations, then maintenance will not be needed.

Relevant aspects:


  • Training
  • Support to identify unauthorized behaviors
  • Time response

Conclusions on How to Select a Fuel Level Sensor

In essence if you follow these 7 criteria  you will end up using Fuel Level Sensors that identify:

Low filling detected by High Precision Fuel Level Sensor

Fillings lower than expected

Gas Station meters not calibrated

Gas stations with tampered meters

Fuel Draining prevention


Fuel Sensor draining drop by drop

Drop by Drop Draining


Finally, we invite you to evaluate these 7 criteria on  Resistive Fuel Level Sensors, Ultrasonic Fuel Level Sensors,  CAN bus Fuel Sensors and High Precision Fuel Level Sensors so you can find the best technology for your needs.

Go ahead and fill the registration form below and start evaluating the cheapest fuel level sensor.



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