BRIEF INFORMATION

Level sensors
➔ Level sensors of the fourth generation: revamped design and function
➔ Particularly high robustness against interference
➔ Continuous measurement of the engine oil level in the static and dynamic range

PRODUCT FEATURES

Application
Oil sensors in vehicles ensure that the engine does not run The sensor continuously monitors the oil level during the
with insufficient or too little oil without such a situation being entire operation of the engine. This function ensures that the
noticed. The tried-and-tested technology of ultrasonic sensors oil level does not fall below the required minimum during
works on the run-time principle and records the fill level engine operation (which would result in engine damage). It
continuously when the vehicle stands or is being driven. When also prevents overfilling of the engine in engine operation.
the engine is running (dynamic measuring range), the fill level Another advantage of the sensor is the integrated temperature
is significantly lower than the fill level when the engine is at sensor, which provides an input variable for the thermal
a standstill (static operation). An oil dipstick measures the oil management of the engine.
level in engines only in the static operation. The HELLA oil
level sensors record the oil level continuously, i.e. both in the Marginal influences such as vehicle leaning, lateral and
dynamic and static operation. Meaning information is provided longitudinal accelerations are compensated by averaging out in
about the oil level during the entire engine operation, a process the vehicle's control unit.
which can often last several hours in construction vehicles,
tractors and forklifts. The use of the oil level sensor for the measurement of special
media, e.g. transmission and hydraulic oils require prior
testing and approval by HELLA.
LEVEL SENSORS TO RECORD THE LIQUID LEVEL
(STATIC AND DYNAMIC)

Design and function

The sensor architecture of the PULS (Packed Ultrasonic Level Sensor) oil level sensor consists of one single multi-chip module that
integrates the ultrasonic sensor, the temperature sensor and also an ASIC (Application Specific Integrated Circuit). This compactness
gives the sensors a higher level of impact and vibration resistance than those sensors fitted with a large number of electronic
components. The ultrasonic sensor integrated in the multi-chip module transmits a signal that is reflected by the oil/air interface of the
engine oil. The term of the signal is measured and the liquid level is calculated using the speed of sound in the medium. The damping cup
installed above the multi-chip module is designed "to calm" the medium, (especially) in the dynamic measuring range. The damping cup
has openings at the base and at the tip, which allow the oil to flow permanently.

Flush mounting
The sensor is designed to be vertically flush-mounted from below into the bottom of the oil pan. Usually the oil level sensor is located on
a ledge in the oil pan in order to protect the sensor base. This installation position, combined with the openings which make a permanent
flow of oil possible, prevents sludge from forming within the damping cup.

Schematic diagram

Optimal sensor position in the oil pan for dynamic measurement: a central positioning in the oil pan

Left side Right side

of oil pan of oil pan Front Back
of oil pan of oil pan

Dynamic measurement of engine oil

For dynamic measurement (while the engine is running), an evaluation

Overfilled
algorithm in the control unit must be developed, which compensates for the 10 mm Sensor (Mmax)
marginal influences of the engine (oil volume, oil temperature, speed) and of
L -6 mm
end of measuring range

the vehicle (longitudinal and lateral acceleration, uphill and downhill motion).
(variant dependent)

As a result of subsequent averaging, the influences brought about by driving

conditions cancel themselves out over longer periods of time. Hence, either
static level application range (Astat)

a warning can be triggered with respect to the minimum oil volume reached
static level measurentrange (M)

FULL
or the oil volume that is actually still available can be calculated.
application range (Adyn)

measuring range (M)

M L
dynamic level

dynamic level

Adyn Astat
start of measuring range

0 (warning threshold) ADD

(variant dependent)

Levels (mm)

(Mmin)
Warning via the oil
13 mm
Mean value: 15 mm at TBE, Level ≥ 30°C
indicator lamp 17 mm at TBE, Level < 30°C
n [1/min] 3,000 values or less when
When the mean value L0
100 km is reached
falls below the warning
Temperature [°C] threshold.

3D characteristic diagram: compensation of engine speed and oil temperature

 T1: Temperature evaluation (T1 Temp) T2: Temperature evaluation (T2 Level)

T1[ms] T2[ms]

163.125°C:
RTD broken
88 ms or DC = 0.8 Default-Value 88 ms or DC = 0.8
87 ms or DC = 0.789 RTD broken 87.86 ms or DC = 0.798

S = 3.125 K/ms S = 2.3125 mm/ms

or or
100/32 K/ms 74/32 mm/ms

-43.125°C: 28.622 ms or DC = 0.260 -2.3125 mm

23 ms or DC = 0.209 RTD short Default-Value 23 ms or DC = 0.209 low maturity Default-Value fo
22 ms or DC = 0.2 RTD short 22 ms or DC = 0.2 „low maturity“

-40°C +160°C T[°C] 0 mm 13 mm 150 mm T[mm]

T1/T = DC = 0.2 : T1 = 22 ms => S

 hort circuit temperature sensor (-43 to125°C) T2/T = DC = 0.2 : T2 = 22 ms => U
 nreliable signal
T1/T = DC = 0.209 : T1 = 23 ms => -40°C (Level output -2.3125 mm)
T1/T = DC = 0.789 : T1 = 87 ms => 160°C T2/T = DC = 0.209 : T2 = 23 ms => Level = 0 mm
T1/T = DC = 0.8 : T1 = 88 ms => Temperature sensor defective (163 to125°C) T2/T = DC = 0.260 : T2 = 28.622 ms => Level = 13 mm
T2/T = DC = 0.798 : T2 = 87.86 ms => Level = 150 mm
For levels below 13 mm or above 150 mm, T2 is fixed at 28.622 ms or
alternatively at 87.86 ms.

T3: Diagnostic evaluation

PWM Pulse Transmission priority

Diagnostics of
(Diagnostic values marked in bold print) Diagnostics diagnostics
Diagnostic Information environmental
of sensor failure (Signal with the highest
Temp. T1 Level T2 Diagnostics T3 conditions
priority is transmitted)
23…87 ms 23…87.86 ms 22 ms Status OK 5
28,62 ms Level outside the range
23…87 ms 66 ms X 4
(13 mm) (<13 mm)
87,86 ms Level outside the range
23…87 ms 66 ms X 4
(150 mm) (>150 mm)
≤ 10°C 22 ms Temperature outside the
66 ms X 4
23…32.6 ms (-2.3125 mm) range for level measurement
≤ 10°C 22 ms
66 ms Level out of range (noise) X 4
23…32.6 ms (-2.3125 mm)
22 ms 22 ms Temperature element
55 ms X 1
(-43 to 125°C) (-2.3125 mm) short-circuited
22 ms Temperature out of
23 ms (-40°C) 55 ms X 1
(-2.3125 mm) range (low)
87 ms 22 ms Temperature out of
55 ms X 1
(-160°C) (-2.3125 mm) range (high)
88 ms
22 ms Temperature element
(-163 55 ms X 1
(-2.3125 mm) broken
to125°C)
22 ms Piezoceramics
32.6…87 ms 44 ms X 3
(-2.3125 mm) open/short-circuited
22 ms Voltage out
32.6…87 ms 33 ms X 2
(-2.3125 mm) of range
T3/T = DC
DC = 0.2, 0.3, 0.4, 0.5 or 0.6

T2: Temperature evaluation (T2 Level)

Tempcomp [°C] = 3.125 K • T1 • 110 ms - 23 ms - 40 K Levelcomp [mm] = 2.3125

mm
•
T[ms]
• T2[ms] •
110 ms
- 23 ms
ms T[ms] ms 110 ms T[ms]
or or
Tempcomp [°C] = 100 K • T1 • 110 ms - 23 ms - 40 K Levelcomp [mm] = 2.3125
mm
• T2[ms] - 23 ms •
T[ms]
32 ms T[ms] ms 110 ms
or
74 mm T[ms]
diagnostic[ms] = T3[ms] Levelcomp [mm] = • T2[ms] - 23 ms •
32 ms 110 ms
 PWM (open collector) signal evaluation

The PWM output signal consists of three pulses that are repeated cyclically every 1,000 ms ± 10%. The pulses contain encoded information on oil temperature,
the oil level and on diagnostics.

T1 Temperature T2 Level T3 Diagnostic Temp.

TTemp. TLevel TDiag. Break

22ms 22ms 22ms 22ms

10ms DC=0,2 80%
920ms
(20%) T=110ms±10ms T=110ms±10ms T=110ms+10ms 670ms±67ms
Startup/
Checksum
TSignal =1000ms±100ms

TECHNICAL DETAILS

Technical data Dimensional sketch

Operating voltage
9 – 16 V
(for oil level measurement)
Ø 39.11 ± 0.3
Operating voltage
(for temperature 9 – 16 V Ø 20 ± 0.25 39.77 ± 0.3
measurement)
Polarity reversal voltage - 14 V / 60 s min. Ø 71 = K

12.4 ± 0.5
9.25 ± 0.2
Ø 39.11 ± 0.3
L

15 s at 28 V Ø 40.5 -0.3

Overvoltage
Ø 20 ± 0.25 250 ms at 32 V 39.77 ± 0.3
Measuring range (static and
13 mm to L -6 mm1)
dynamic)
Operating temperature -40°C to +160°C min. Ø 37
71± =1 47
K± 1 110
°
12.4 ± 0.5
9.25 ± 0.2

Operating temperature
L

(for oil level measurement)1)

-10°C to +150°C Ø 40.5 -0.3

120°
3 2 1
max. 5,700 h at 125°C
Reheating temperature max. 240 h at 145°C
max. 60 h at 160°C (3x) Ø 6.6 ± 0.2
Ø 60
Storage temperature -40°C to +150°C

Current consumption 8 mA

37 ± 1 47 ± 1 °
Max. Current consumption 110 Pin assignment
50 mA
during measurement
Protocol2) PWM
Pin 1: O
 UTPUT
120°

3 2 1 Pin 2: K
 L 31 GND
Mating connector3) MLK 872-858-541 (3way 1.2 SealStar) Pin 3: K
 L 15 VBAT
Protection class IP 6K9K
(3x) Ø 6.6 ± 0.2
Weight depending Ø
on60
variant
Tolerance of level measurement
Viscosities 1 mm2/s to 1,300 mm2/s Temperature Operating
Oil level Tolerance
range voltage
1)
 ependent on damping cup length (see variant overview).
D
2)
Level output above -10°C. At temperatures below -10°C, an "empty" 13 mm to L -6 mm -10°C ≤ T < 30°C 9 to 16 V ± 4 mm
signal is sent (18 mm) together with the diagnostic signal "out of 13 mm to L -6 mm 30°C ≤ T < 150°C 9 to 16 V + 2 mm
tolerance".
3)
This accessory is not included in the scope of delivery.
Available from Hirschmann. Temperature measurement tolerance
Temperature Operating
Oil level Tolerance
range voltage
All 60°C ≤ T < 120°C 6 to 16 V ± 2 K
 HELLA GmbH & Co. KGaA
Rixbecker Straße 75
59552 Lippstadt, Germany
Tel.: +49 2941 38-0
Fax: +49 2941 38-7133
Internet: www.hella.com

© HELLA GmbH & Co. KGaA, Lippstadt

J01695/09.20
Subject to technical and price modifications.

PROGRAMME OVERVIEW

Length of damping cup Supply voltage Measuring range Part number

85 mm 12 V Static and dynamic 13 – 79 mm On request

95 mm 12 V Static and dynamic 13 – 89 mm On request

109,8 mm 12 V Static and dynamic 13 – 103.8 mm On request

135 mm 12 V Static and dynamic 13 – 129 mm On request

150 mm 12 V Static and dynamic 13 – 144 mm On request

Accessories

Sealing ring* On request

* Whenever the sensor is remounted, a new sealing ring must be used. This can be obtained from HELLA.