Float Switch

Rizal Technological University
College of Engineering and Industrial Technology

Boni Ave. Mandaluyong City
Float Level Switch
Prepared by:
Custodio, Jerico Andrew G.
Partos Mhar Angelo
Enate, Leonardo C.
What is a Float Switch?
A float switch is a device used to detect the level of liquid within a tank. The
switch may be used in a pump, an indicator, an alarm, or other devices.
A float switch is used when a pump motor must be started and stopped
according to changes in the water (or other liquid) level in a tank or sump. Float
switches are designed to provide automatic control of AC and DC pump motor
magnetic starters and automatic direct control of light motor loads. Float switches
range from small to large and may be as simple as a mercury switch inside a hinged
float or as complex as a series of optical or conductance sensors producing discrete
outputs as the liquid reaches many different levels within the tank.
How does a float switch works?

There are many different types of float switches, some of which are mercury
switches that activate by allowing the liquid metal to complete the circuit. Perhaps
the most common type of float switch is simply a float raising a rod that actuates
a micro switch.
They are common in sump pumps, dishwashers and other appliances. With a
sump pump, the float switch detects flooding in the sump. It activates the switch
that starts the pump to operate. As the pump empties the sump, the float drops and
the switch stops the pump from operating.
Important Parts with Label
Float Switch Applications
Regulate single and multiple levels

Low level sensing
High level alarm
Leak Detection
Overfill shut off
Level and Temperature Control
Turbulent liquidsIndustries
Control Liquid Level (Refrigerant)
Float Switch Applications
in connection with emptying a tank
in connection with filling a tank
for alarm at high water level
for alarm at low water level
Mounting Configurations
Horizontal switch the horizontal switch is attached to a float similar to the

one seen in a toilet reservoir. As the water level rises in the sump pit, the
float pulls on a chain that engages the pump motor. These floats can get
stuck against the side of the pit, or the chain can snag on the pump
mechanism. Its important to check them regularly, especially during heavy
storm periods.
Vertical float switch a vertical float switch is connected to the pump via a
vertical rod. This eliminates the chance of snagging or catching on the side of
the sump pit. This is the most reliable of all pump switches and doesnt cost
much more than a horizontal float.
Selection/specification Requirements
Why is this important?
When one considers that float switches are usually used to protect against damage
when high or low liquid situations occur, it is important to use the right type of float
switch. The single biggest mistake that is made in float switch selection is when a
control signal needs to be provided that uses low voltage and or low currents. There
are many different types of float switches.
In general they are either:
Tethered (attached to the end of a wire or cable),
or
Non-tethered (fixed to the side, bottom or top of a tank)
These can be broken down into two other classes:

Switches used to directly switch pumps and other electrical devices.
Switches used to provide control signals to control panels, relays. PLC's
ect
Step 1 - What voltage, what current
The most important one. So take note!
Low voltage, low current (Pilot duty switches)
Contrary to popular belief, you cannot just use any type of float switch to
switch low voltages with low currents. Using the wrong type of switch here will
result in a failure at some stage. The reason is that some float switch contacts are
designed to switch arching loads.
High voltage, high current
Ensure that you have selected a float switch that is capable of handling the
current and voltage requirements. When selecting a float switch to control a pump
ensure that the float switch is capable of handling the initial startup current. For
instance, our SJE Pump Master float switches will handle a running current of
13amps, however is capable of handling a startup current of 85amps. All pumps
have a higher current when starting. This current falls back to a running current
once the motor is up to speed.
Step2 - Choose Pump Up (normally closed) or Pump Down (normally open)

You will now need to decide how your float switch is going to be used. To
explain the Pump Up and Pump Down concept we are going to use the situation
where there is a tank with a pump connected to it.
If you want the pump to start when that tank is full and to stop when the tank
is empty, then you will require a float switch that is Pump Down (you want to
stop the pump at some stage when the level is going down).
If the tank is low and you want the pump to start and then to stop when the
tank is full, you will require a Pump Up switch (stop the pump at some stage
as the level goes up).
Float switches that are pump up or pump down have 2 wires attached to
them. There is another type of float switch that is called a SPDT float switch. This
float switch uses 3 wires and can be used to pump up or down depending on which
2 wires are used. One wire is common to both contacts. SPDT stands for Single Pole,
Double Throw.
Step 3 - Select the pumping range or switching range.
Float switches are designed to work over a range. For tethered float switches,
the length of the tether dictates the level range. A longer tether results in a larger
range between the float switch switching on or off. There is always a minimum and
a maximum range that a float switch can handle.
The minimum is range is limited by the stiffness of the float switch cable. If
the tether is too short, the float switch cannot bend up or down.
The maximum range is generally dictated by the weight of the cable. If the
tether length is too long, the float cannot support the weight of the cable.
All good makes of float switches will have an installation document that will
show the pumping range for different tether lengths.
Step 4 - Narrow angle or wide angle switch
Tethered switches can be either narrow angle of wide angle. Narrow angle
means that the switch will switch over a very short range. These switches are
usually used to maintain an accurate level in a tank.
Never use a narrow angle switch to control a pump. The pump will turn on
and off with the slightest wave action (called short cycling) resulting in pumps
and/or switch damage. Use a wide-angle float switch for pump control.
Step 5 - Turbulent or calm conditions
Some float switches are only suitable for use in calm conditions. Using float
switches that are not designed for use in turbulent conditions, can result in damage
to the equipment attached. The reason for this is that the contacts in the float
switch will toggle on and off as the float switch approaches the level at which it will
switch.
Float switches suitable for turbulent conditions are usually mechanical
switches and the manufacturers specification will state that the switch is suitable
for turbulent conditions.
Step 6 - Mercury or mechanical switches
The internal switching mechanism in float switches is usually mercury or
some form of mechanical activation using a ball. Mercury switches are falling out of
favor due to potential toxicity concerns and ROHS compliance issues in Europe.
Mercury switches are usually cheaper than mechanically activated float switches.
Mercury switches are generally not suitable for turbulent environments and high
current applications.
Step 7 - Pole mounted or weighted
Tethered float switches can be mounted in one of two ways
Pole mounted: here the floats switch cable is attached to an inlet/outlet pipe
located inside the tank. The cable is usually attached to the pipe by using a
specially designed stainless steel clamp
Weighted: if the tethered float switch can be suspended from the top of the
tank, then you can use a cable weight to hold the float switch at the correct
level. Cable weight is usually available as an optional extra when ordering
float switches. These weights are clipped onto the cable and are easy to
adjust. You need to apply some caution in using suspended floats switches in
tanks where there is a strong swirling action.
Standard requirements
Rated Voltage
Rated Current
Power Rating
Cable Lenght
Pressure Limits
Temperature Limits
Mounting Orientation
Preventive Maintenance
Periodic inspections are a necessary means to keep your level control in good
working order. This control is, in reality, a safety device to protect the valuable
equipment it serves. Therefore, a systematic program of "preventive maintenance"
should be implemented when control is placed into service. If the following sections
on "what to do" and "what to avoid" are observed, your control will provide reliable
protection of your capital equipment for many years.
WHAT TO DO
Keep control clean
NEVER leave switch housing cover off the control. This cover is
designed to keep dust and dirt from interfering with switch mechanism
operation. In addition, it protects against damaging moisture and acts
as a safety feature by keeping bare wires and terminals from being
exposed. Should the housing cover become damaged or misplaced,
order a replacement immediately.
Inspect switch mechanisms, terminals and connections monthly.
Mercury switches may be visually inspected for short circuit damage.
Check for small cracks in the glass tube containing the mercury. Such
cracks can allow entrance of air into the tube causing the mercury to
"oxidize". This is noticeable as the mercury will appear dirty and have a
tendency to "string out" like water, instead of breaking into round
pools. If these conditions exist, replace the mercury switch
immediately.
Dry contact switches should be inspected for excessive wear on

actuating lever or misalignment of adjusting screw at point of contact
between screw and lever. Such wear can cause false switch actuating
levels. Adjust switch mechanism to compensate (if possible) or replace
switch.
Do NOT operate your control with defective or maladjusted switch
mechanisms (refer to bulletin on switch mechanism furnished for
service instructions).
Controls may sometimes be exposed to excessive heat or moisture.
Under such conditions, insulation on electrical wires may become
brittle, eventually breaking or peeling away. The resulting "bare" wires
can cause short circuits.
Check wiring carefully and replace at first sign of brittle insulation.
Vibration may sometimes cause terminal screws to work loose. Check
all terminal connections to be certain that screws are tight. Air (or gas)
operating medium lines subjected to vibration may eventually crack or
become loose at connections causing leakage. Check lines and
connections carefully and repair or replace, if necessary.
On units with pneumatic switches, air (or gas) operating medium lines
subjected to vibration, may eventually crack or become loose at
connections carefully and repair or replace, if necessary.
Inspect entire unit periodically
Isolate control from vessel. Raise and lower liquid level to check for
switch contact and reset.
WHAT TO AVOID
NEVER leave switch housing cover off the control longer than
necessary to make routine inspections.
NEVER use lubricants on pivots of switch mechanisms. A sufficient
amount of lubricant has been applied at the factory to insure a lifetime of
service. Further oiling is unnecessary and will only tend to attract dust and
dirt which can interfere with mechanism operation.
NEVER place a jumper wire across terminals to "cutout the control. If
a "jumper" is necessary for test purposes, be certain it is removed before
placing control into service.
NEVER attempt to make adjustments or replace switches without
reading instructions carefully. Certain adjustments provided for in controls
should not be attempted in the field.

Float Switch

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Rizal Technological University

College of Engineering and Industrial Technology

Float Level Switch

What is a Float Switch?

How does a float switch works?

Important Parts with Label

Float Switch Applications

Regulate single and multiple levels

Horizontal switch the horizontal switch is attached to a float similar to the

These can be broken down into two other classes:

Step2 - Choose Pump Up (normally closed) or Pump Down (normally open)

Dry contact switches should be inspected for excessive wear on

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