Float switch

A float switch is a type of level sensor, a device used to detect the level of liquid within a
tank. The switch may be used to control a pump, as an indicator, an alarm, or to control other
devices.
One type of float switch uses a mercury switch inside a hinged float. Another common type
is a float that raises a rod to actuates a microswitch. One pattern uses a reed switch mounted in a
tube; a float, containing a magnet, surrounds the tube and is guided by it. When the float raises the
magnet to the reed switch, it closes. Several reeds can be mounted in the tube for different level
indications by one assembly.

Switch on Switch off

A very common application is in sump pumps and condensate pumps where the switch
detects the rising level of liquid in the sump or tank and energizes an electrical pump which then
pumps liquid out until the level of the liquid has been substantially reduced, at which point the
pump is switched off again. Float switches are often adjustable and can include substantial
hysteresis. That is, the switch's "turn on" point may be much higher than the "shut off" point. This
minimizes the on-off cycling of the associated pump.
Some float switches contain a two-stage switch. As liquid rises to the trigger point of the
first stage, the associated pump is activated. If the liquid continues to rise (perhaps because the
pump has failed or its discharge is blocked), the second stage will be triggered. This stage may
switch off the source of the liquid being pumped, trigger an alarm, or both.
Where level must be sensed inside a pressurized vessel, often a magnet is used to couple the
motion of the float to a switch located outside the pressurized volume. In some cases, a rod through
a stuffing box can be used to operate a switch, but this creates high drag and has a potential for
leakage. Successful float switch installations minimize the opportunity for accumulation of dirt on
the float that would impede its motion. Float switch materials are selected to resists the deleterious
effects of corrosive process liquids. In some systems, a properly selected and sized float can be used
to sense the interface level between two liquids of different density.

Level sensors detect the level of liquids and other fluids and fluidized solids, including
slurries, granular materials, and powders that exhibit an upper free surface. Substances that flow
become essentially horizontal in their containers (or other physical boundaries) because of gravity
whereas most bulk solids pile at an angle of repose to a peak. The substance to be measured can be
inside a container or can be in its natural form (e.g., a river or a lake). The level measurement can
be either continuous or point values. Continuous level sensors measure level within a specified
range and determine the exact amount of substance in a certain place, while point-level sensors only
indicate whether the substance is above or below the sensing point. Generally the latter detect levels
that are excessively high or low.
There are many physical and application variables that affect the selection of the optimal
level monitoring method for industrial and commercial processes. The selection criteria include the
physical: phase (liquid, solid or slurry), temperature, pressure or vacuum, chemistry, dielectric
constant of medium, density (specific gravity) of medium, agitation (action), acoustical or electrical
noise, vibration, mechanical shock, tank or bin size and shape. Also important are the application
constraints: price, accuracy, appearance, response rate, ease of calibration or programming, physical
size and mounting of the instrument, monitoring or control of continuous or discrete (point) levels.
In short, level sensors are one of the very important sensors and play very important role in a
variety of consumer/ industrial applications. As with other types of sensors, level sensors are
available or can be designed using a variety of sensing principles. Selection of an appropriate type
of sensor suiting to the application requirement is very important.

Magnetic and mechanical float

The principle behind magnetic, mechanical, cable, and other float level sensors often
involves the opening or closing of a mechanical switch, either through direct contact with the
switch, or magnetic operation of a reed. In other instances, such as magnetostrictive sensors,
continuous monitoring is possible using a float principle.
With magnetically actuated float sensors, switching occurs when a permanent magnet sealed
inside a float rises or falls to the actuation level. With a mechanically actuated float, switching
occurs as a result of the movement of a float against a miniature (micro) switch. For both magnetic
and mechanical float level sensors, chemical compatibility, temperature, specific gravity (density),
buoyancy, and viscosity affect the selection of the stem and the float. For example, larger floats may
be used with liquids with specific gravities as low as 0.5 while still maintaining buoyancy. The
choice of float material is also influenced by temperature-induced changes in specific gravity and
viscosity – changes that directly affect buoyancy.[2]
Float-type sensors can be designed so that a shield protects the float itself from turbulence
and wave motion. Float sensors operate well in a wide variety of liquids, including corrosives.
When used for organic solvents, however, one will need to verify that these liquids are chemically
compatible with the materials used to construct the sensor. Float-style sensors should not be used
with high viscosity (thick) liquids, sludge or liquids that adhere to the stem or floats, or materials
that contain contaminants such as metal chips; other sensing technologies are better suited for these
applications.
A special application of float-type sensors is the determination of interface level in oil-water
separation systems. Two floats can be used with each float sized to match the specific gravity of the
oil on one hand, and the water on the other. Another special application of a stem type float switch
is the installation of temperature or pressure sensors to create a multi-parameter sensor. Magnetic
float switches are popular for simplicity, dependability and low cost.
Conductive
Conductive level sensors are ideal for the point level detection of a wide range of conductive
liquids such as water, and is especially well suited for highly corrosive liquids such as caustic soda,
hydrochloric acid, nitric acid, ferric chloride, and similar liquids. For those conductive liquids that
are corrosive, the sensor’s electrodes need to be constructed from titanium, Hastelloy B or C, or 316
stainless steel and insulated with spacers, separators or holders of ceramic, polyethylene and Teflon-
based materials. Depending on their design, multiple electrodes of differing lengths can be used
with one holder. Since corrosive liquids become more aggressive as temperature and pressure
increase, these extreme conditions need to be considered when specifying these sensors.
Conductive level sensors use a low-voltage, current-limited power source applied across
separate electrodes. The power supply is matched to the conductivity of the liquid, with higher
voltage versions designed to operate in less conductive (higher resistance) mediums. The power
source frequently incorporates some aspect of control, such as high-low or alternating pump
control. A conductive liquid contacting both the longest probe (common) and a shorter probe
(return) completes a conductive circuit. Conductive sensors are extremely safe because they use low
voltages and currents. Since the current and voltage used is inherently small, for personal safety
reasons, the technique is also capable of being made “Intrinsically Safe” to meet international
standards for hazardous locations. Conductive probes have the additional benefit of being solid-
state devices and are very simple to install and use. In some liquids and applications, maintenance
can be an issue. The probe must continue to be conductive. If buildup insulates the probe from the
medium, it will stop working properly. A simple inspection of the probe will require an ohmmeter
connected across the suspect probe and the ground reference.
Typically, in most water and wastewater wells, the well itself with its ladders, pumps and
other metal installations, provides a ground return. However, in chemical tanks, and other non-
grounded wells, the installer must supply a ground return, typically an earth rod.

Ultrasonic
Ultrasonic level sensors are used for non-contact level sensing of highly viscous liquids, as
well as bulk solids. They are also widely used in water treatment applications for pump control and
open channel flow measurement. The sensors emit high frequency (20 kHz to 200 kHz) acoustic
waves that are reflected back to and detected by the emitting transducer.
Ultrasonic level sensors are also affected by the changing speed of sound due to moisture,
temperature, and pressures. Correction factors can be applied to the level measurement to improve
the accuracy of measurement.
Turbulence, foam, steam, chemical mists (vapors), and changes in the concentration of the
process material also affect the ultrasonic sensor’s response. Turbulence and foam prevent the
sound wave from being properly reflected to the sensor; steam and chemical mists and vapors
distort or absorb the sound wave; and variations in concentration cause changes in the amount of
energy in the sound wave that is reflected back to the sensor. Stilling wells and waveguides are used
to prevent errors caused by these factors.
Proper mounting of the transducer is required to ensure the best response to reflected sound.
In addition, the hopper, bin, or tank should be relatively free of obstacles such as weldments,
brackets, or ladders to minimise false returns and the resulting erroneous response, although most
modern systems have sufficiently "intelligent" echo processing to make engineering changes largely
unnecessary except where an intrusion blocks the "line of sight" of the transducer to the target.
Since the ultrasonic transducer is used both for transmitting and receiving the acoustic energy, it is
subject to a period of mechanical vibration known as “ringing”. This vibration must attenuate (stop)
before the echoed signal can be processed. The net result is a distance from the face of the
transducer that is blind and cannot detect an object. It is known as the “blanking zone”, typically
150mm – 1m, depending on the range of the transducer.
The requirement for electronic signal processing circuitry can be used to make the ultrasonic
sensor an intelligent device. Ultrasonic sensors can be designed to provide point level control,
continuous monitoring or both. Due to the presence of a microprocessor and relatively low power
consumption, there is also the capability for serial communication from to other computing devices
making this a good technique for adjusting calibration and filtering of the sensor signal, remote
wireless monitoring or plant network communications. The ultrasonic sensor enjoys wide popularity
due to the powerful mix of low price and high functionality.