FAQs
Shipping & Purchasing
Some of our products can be added to the cart and purchased via our e-commerce website.
For all other products please submit your information on the Get A Quote tab under the Products or Shop pages. Migatron will then contact you to assist and place the order. You can also call 815-338-5800 or email sales@migatron.com.
Migatron accepts approved company purchase orders, American Express, Visa, and MasterCard.
Yes. Migatron provides direct access to our engineers for troubleshooting and technical questions. We can schedule phone calls or video conferences with your team for in-depth discussions, and we also offer customization and design services to support your project from concept to completion.
Yes, standard orders can be canceled before they are shipped. Custom orders may accrue a fee for cancellation.
Please view our terms of service for specifics on our return policy.
Migatron ships orders daily to both domestic and international customers. Many of our sensors are kept in stock and typically ship within 1 business day. Expedited shipping options are available upon request to meet urgent project needs.
Migatron products are warranted against defects in material and workmanship for one year from the date of shipment. This warranty does not cover failures due to improper installation, misuse, or abnormal operating conditions. Products not manufactured by Migatron carry the original manufacturer’s warranty.
General Ultrasonic Sensor Knowledge
Analog ultrasonic sensors function by reflecting ultrasonic sound off a target. The time it takes for the ultrasonic sound to reach the target and return to the sensor is called Time-of-Flight (TOF). TOF equates to the distance from the sensor. As the TOF varies, the output voltage changes accordingly. As the target moves further from the sensor the TOF and output voltage will increase. Likewise as the target moves closer to the sensor the TOF and output voltage will decrease.
An ultrasonic sensor uses high frequency sound waves to measure distance without physical contact. The sensor sends out a burst of sound and measures the time it takes for the echo to return. This principle allows ultrasonic sensors to function as reliable distance measurement sensors for tank level monitoring, object detection, material handling, and automation systems.
Ultrasonic sensors can perform two main functions: object detection and distance measurement. While both rely on the same principle—sending sound waves and timing their return—the way each function is used and configured differs significantly.
Proximity Sensors (object detection sensors) act like a switch. They are designed to sense the presence or absence of a target within a defined range. Once an object enters the detection zone, the sensor provides a discrete output signal (such as PNP, NPN, or relay). These sensors are ideal for applications like part counting, conveyor control, and verifying object presence. They offer fast response and high reliability regardless of color, reflectivity, or surface texture.
Analog Proximity Sensors
(distance measurement sensors) provide a continuous output—either analog (4–20 mA or 0–10 V)—that represents the exact distance to the target. Instead of simply detecting that an object is present, these sensors measure how far away it is. This makes them suitable for precise control applications such as level measurement in tanks, roll diameter monitoring, or position feedback in automated systems.
Why It Matters
Choosing between detection and measurement comes down to the control objective:
- If you need a go/no-go signal, use an object detection sensor.
- If you need real-time distance or level data, select a distance measurement model.
Selecting the right type ensures optimal performance, signal compatibility with your control system, and cost efficiency. Migatron offers both styles—discrete and analog output ultrasonic sensors—engineered for reliable performance in demanding industrial environments. For more detailed information view our Sensor Comparison Chart.
Ultrasonic sensors operate reliably in conditions where optical or mechanical sensors may fail. They are unaffected by color or transparency and can work in dusty, humid, or dirty environments. This makes them highly versatile as automation sensors for OEM machinery and industrial equipment.
Ultrasonic sensors are used across many industries, including oil & gas, mining, agriculture, manufacturing, water and wastewater. Applications range from tank level monitoring, object detection, distance ranging, inventory systems, conveyor alignment and material handling.
Ultrasonic sensors measure distance by timing how sound travels through air, and the speed of sound changes with temperature. To maintain accuracy, Migatron sensors such as the RPS-409A include automatic temperature compensation, adjusting readings in real time to offset environmental fluctuations.
The blind zone is the minimum distance from the sensor face where accurate measurement cannot occur, due to the time it takes for the transducer to switch from transmitting to receiving. For example, a sensor with a 4-inch minimum range cannot detect objects closer than 4 inches. Always position sensors so the target falls outside of this blind zone. For tank applications, see our Tank Level Ultrasonic Sensors.
Analog ultrasonic sensors function by reflecting ultrasonic sound off a target. The time it takes for the ultrasonic sound to reach the target and return to the sensor is called Time-of-Flight (TOF). TOF equates to the distance from the sensor. As the TOF varies, the output voltage changes accordingly. As the target moves further from the sensor the TOF and output voltage will increase. Likewise as the target moves closer to the sensor the TOF and output voltage will decrease.
Intrinsically Safe Ultrasonic Sensors for use in Hazardous Areas
An intrinsically safe ultrasonic sensor is designed for hazardous areas where explosive gases or dust may be present. By limiting the energy in the circuit, the sensor ensures sparks or heat cannot cause ignition, making it compliant with Class I, Division 1 and Zone 0 requirements.
If your process involves flammable gases, dust, or fibers, such as in grain silos, oil & gas or mining — an intrinsically safe sensor is required for compliance and worker safety. These sensors are designed to meet strict international safety standards.
Migatron’s intrinsically safe sensors carry ANZEx, ATEX, IECEx, and UL/cUL certifications. To download full approval documentation, visit the downloads tab on the IS sensor product page.
In some cases Intrinsically safe ultrasonic sensors need to be paired with an approved safety barrier to ensure compliance with hazardous location standards. For example, Migatron’s ZSB-409A Safety Barrier provides a space saving, three-channel design compatible with our RPS-409A-IS family of sensors. It ensures safe operation while maintaining system approvals.
Tank Level & Liquid Monitoring
Mounted above the liquid surface, a tank level sensor emits ultrasonic pulses that reflect off the liquid. By measuring the time of flight, the sensor calculates the distance to the liquid surface, enabling accurate non-contact level monitoring.
With proper placement, ultrasonic sensors like the RPS-409A can provide reliable level measurement even in challenging tank environments that include foam, vapor, or agitation.
Non-contact measurement eliminates the risk of corrosion, contamination, or mechanical wear. This makes ultrasonic sensors an ideal choice for industries such as water and wastewater, chemicals, and food processing where accuracy and hygiene are critical.
Automation & Material Handling
Ultrasonic sensors are precise automation sensors used in production lines, detecting objects, monitor process levels, verifying part spacing, and feeding real time data to PLCs. They are widely used in OEM machinery for distance measurement and automation.
Yes. Ultrasonic sensors can be mounted to monitor belt edges and ensure proper tracking. By detecting lateral movement, they help keep the conveyor centered and reduce downtime from misalignment. The RPS-429-IS intrinsically safe ultrasonic sensor is a proven choice for conveyor alignment and monitoring.
Applications include detecting packages on conveyors, bulk material levels on conveyors, monitoring bin or hopper levels, and verifying stack heights. For more details, see our material handling applications.
The RPS-150A ultrasonic sensor uses a wide beam angle to reliably detect material on conveyor belts, even when products vary in size, shape, or position. This makes it ideal for ensuring consistent flow in automated material handling.
Yes. Ultrasonic sensors are well suited for roll diameter measurement because they track the changing distance to the outer surface of a wound roll without making contact. As the roll increases or decreases in size, the sensor’s analog output provides a continuous distance signal that a PLC can convert to diameter. Migatron’s RPS-409A-IS3 is a strong fit for this application. It provides non-contact analog distance measurement with intrinsic safety approvals and stable performance in dusty or solvent-heavy environments often found in converting operations. Since ultrasonic measurement depends on receiving a clean echo, proper sensor alignment is essential. The sensor must be aimed squarely at the roll surface to maintain a strong return signal throughout the roll’s full diameter range. This method works across a wide variety of materials—paper, film, foil, rubber, textiles, plastics—any product wound on a core. Contact us if you’d like help confirming range, alignment, or mounting for your roll diameter setup.
Sensor Selection, Outputs & Maintenance
Selecting the right sensor depends on sensing range, output type, housing material, and whether intrinsic safety approvals are required. For a full overview of available models, visit our product page and contact us to assist in your selection process.
Ultrasonic sensors offer either switch type outputs (PNP, NPN or relays) for simple detection or analog outputs (4–20 mA, 0–10 V) for continuous measurement. For example, the RPS-412A provides a high-accuracy 4–20 mA output for precise distance monitoring.
Both are analog output options for ultrasonic sensors. A 4–20 mA analog current output is less susceptible to electrical noise and allows longer cable runs, making it the preferred choice in most industrial environments. A 0–10 V analog voltage output is more sensitive to cable length and electrical noise. The choice depends on your sensor installation/application, and control system’s input requirements.
Migatron ultrasonic sensors can be directly wired into standard PLC analog input cards. For switching applications, sensors can also be paired with a set point controller such as the SPC-701 or SPC-704 which provide relay outputs and additional flexibility. Always consult the wiring diagrams in the datasheet to ensure proper grounding and signal integrity.
Maintenance is minimal. Keep the transducer surface clean, check alignment periodically, and verify wiring connections. If you need assistance, our team can assist you — contact us directly and we’ll be happy to help!