Which fuel level sensor would afford more SAVINGS? 

Choosing the right fuel level sensor(s) for your needs will allow you huge savings. To avoid wasting time, follow the  7 key features below to compare Resistive fuel Sensors, Ultrasonic fuel Sensors,  CAN Bus Fuel Sensors and High Precision Fuel Level Sensors.

Let’s begin!

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. 

Important to realize is 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 do not require any additional calibrations in its life spam.

Ex proof Fuel Level Sensors

In fact, all those companies operating in areas subject to EXPLOSION will require CERTIFIED EXPROOF Fuel level sensors.  if this is your case of course you must  include this in your buying criteria.  Also some companies with high volume tanks will require CERTIFIED EXPROOF Fuel Level Sensors.

This could mean two things:

(1) Electrical and electronic components work in such low voltage and current that an spark won’t be generated.

(2) Electrical and electronic components work in 12V or 24V so will be able to produce sparks but those electronics are fully isolated from environment.


EXPROOF Fuel Level Sensors
Additionally, if you have large tanks you need a software capable of reporting fuel in large tanks and also fuel in vehicles. Also you will need sensors capable of reaching 2 or 3 meters.

Specifically if you purchase 10.000 Gallons you could be sure that those get delivered in your tank.  Also you will be able to track how much fuel was transferred from that tank identify to which particular vehicle.

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

For certain it would be important for you to do business with a provider with this capability.

In summary using one software to track fuel in vehicles and other software to track your large tanks will negatively impact traceability.


Turn key solution

Once the system is installed, having a software that integrates in one screen all information needed is a must. In fact your team will value seeing in one screen:

  • Route,
  • Voltage,
  • Fuel Volume
  • and Speed.

With these 4 variables it will be possible in a second to identify: draining, refueling, accumulator stolen, overconsumption and so on.


At last, installing a fuel level sensors takes some hours. After that production begins, it could last 5, 10  or 15 years. if you have chosen fuel sensors which do not require periodic calibrations on vehicle maintenance won’t be needed. Anyway, other important aspects will take relevance:


  • Training,
  • Support,
  • Acompaniment to identify unauthorized behaviors.
  • and 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 identifies:
Low filling detected by High Precision Fuel Level Sensor

Fillings lower than expected

Gas Station meters not calibrated

Gas stations with meters not calibrated

Fuel Draining prevention


Fuel Sensor draining drop by drop

Drop by Drop Draining

Finally, we invite you to evaluate by these 7 criteria Resistive Fuel Level Sensors, Ultrasonic Fuel Level Sensors,  CANBUS Fuel Sensors and High Precision Fuel Level Sensors and find best technology for your need. Also you can fill the registration form above and start evaluating the cheapest fuel level sensor.

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