The Ultimate Guide to

Float Level Sensors

Electrical Connection

Electrical Connection

Fitting with
threads down
A H I G H E R L E V E L O F S AT I S F A C T I O N

Threads up
L3

Float
L2

Float Stop
L1

OAL
Electrical Connection

Electrical Connection

Fitting with
threads down

Threads up

L1

OAL

Float

Float Stop
 Table of Contents

Introduction .................................................................................................................................................. 5
.
Overview of level sensors, their use and selection ............................................................................. 6

.
The float switch level sensor ................................................................................................................. 7

.
The continuous level sensor.................................................................................................................. 7

.
Magnetic float switch reliability ............................................................................................................ 7

.
Examples of level sensor use and applications ....................................................................................... 8

.
Oil/water separators ............................................................................................................................... 8
.
Food processing equipment .................................................................................................................. 8
.
Biotech..................................................................................................................................................... 8
Chemical processing and storage ......................................................................................................... 9
.
Commercial washers.............................................................................................................................. 9
.
Container level indication ...................................................................................................................... 9
.
Fuel management................................................................................................................................... 9
.
Electroplating .......................................................................................................................................... 9
.
Fluid power ............................................................................................................................................. 9
.
Food and dairy ........................................................................................................................................ 9
.
Freon recovery ...................................................................................................................................... 10
.
Humidifiers and dehumidifiers............................................................................................................ 10
.
Lubrication equipment ......................................................................................................................... 10
.
Marine applications .............................................................................................................................. 10
.
Miscellaneous ....................................................................................................................................... 10
.
Off-highway vehicles............................................................................................................................ 10
.
Industrial parts washers....................................................................................................................... 11
.
Power generation ................................................................................................................................. 11
.
Restaurant equipment.......................................................................................................................... 11
.
Semiconductor equipment .................................................................................................................. 11
.
Solvent recovery................................................................................................................................... 11
Waste oil and grease recovery ............................................................................................................ 11
.
Water treatment equipment ................................................................................................................ 11
.
Diesel fuel/oil tank and transfer systems............................................................................................ 12
.
Medical equipment............................................................................................................................... 12
.
Heating, ventilation and air conditioning ........................................................................................... 12
.
Heavy construction equipment ........................................................................................................... 12
.
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How to select custom liquid level float sensors ..................................................................................... 12

.
What is the desired operation? ........................................................................................................... 12

.
What fluid type will you be measuring? ............................................................................................. 13

.
Typical float switch materials .............................................................................................................. 13

.
What is the environment like inside and outside of the tank?.......................................................... 14

.
What is your electrical load? ............................................................................................................... 15
.
How will the sensor be mounted? ...................................................................................................... 16
.
Are there tank restrictions?.................................................................................................................. 17
.
Design details and Options.................................................................................................................. 17
.
Pipe centering disc ............................................................................................................................... 19
.
In summary… ....................................................................................................................................... 20
.
Float switch and level sensor selection checklist.................................................................................. 21
.
Liquid parameters ................................................................................................................................ 21
.
Electrical requirements ........................................................................................................................ 22
.
Mechanical component selection .................................................................................................. 22-23
.
Liquid level float switch installation guide ............................................................................................. 24
.
Basic instructions ................................................................................................................................. 24
.
Installation quick check items.............................................................................................................. 26
.
4 20 mA continuous level float sensors.............................................................................................. 26
.
0-5VDC continuous level float sensors ............................................................................................... 27
.
Maintaining a float style level switch ...................................................................................................... 28
.
Inspections ............................................................................................................................................ 28
.
Troubleshooting a float style level switch .............................................................................................. 29
.
Float is not positioned properly or moving properly ........................................................................ 29
.
Shock or damage to the floats or the sensor assembly (bent, dented, etc.) ................................... 29
.
Excessive moisture around the wires exiting the sensor or connections ....................................... 29
.
Reed switch failure ............................................................................................................................... 30
.
Float’s specific gravity does not match the liquid that is being measured ..................................... 30
.
Wire colors do not match the level switch ......................................................................................... 30
.
Troubleshooting a float style 4-20mA continuous level sensor ........................................................... 30
.
Troubleshooting a float-style 0-5VDC continuous level sensor ........................................................... 31
.
Procedure for reversing a float to change the Normal Switch State.................................................... 31
.
A brief history of float switches ............................................................................................................... 32
.
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 Table of Contents…continued

APPENDIX 1: Hazardous location considerations ................................................................................... 33

.
Condition descriptions ......................................................................................................................... 33

.
Basics of explosion risks ...................................................................................................................... 33

.
Sources of ignition ............................................................................................................................... 33
.
The difference between intrinsically safe and explosion proof........................................................ 33

.
Intrinsically safe equipment ................................................................................................................ 33
.
Explosion proof enclosures ................................................................................................................. 34
.
Intrinsically safe versus explosion proof: Advantages and disadvantages..................................... 35

.
Designing Intrinsically safe sensor circuits using simple and non-simple apparatus’................... 36

.
APPENDIX 2: Understanding electrical ratings of float switches ......................................................... 37

.
Reed switch ratings .............................................................................................................................. 37
.
Switching Resistive, inductive and capacitive loads ......................................................................... 38
.
LOAD EXAMPLES: ................................................................................................................................ 38
.
Resistive load: Resistors, dry contact input, controllers .................................................................. 38
.
Capacitive Loads: Lead wires that exceed 200 ft, electrical equipment.......................................... 38

.
Inductive Loads: Relay’s, Solenoids, Light bulb ............................................................................... 38
.
Designing for Inductive loads and Capacitive loads .................................................................... 38-39
.
APPENDIX 3: Threaded Connections ........................................................................................................ 40
.
NPT assembly instructions .................................................................................................................. 40
.
How to quickly determine the nominal size of a male NPT thread .................................................. 41
.
How to determine the nominal size of an NPT thread ................................................................. 42-43
.
4 RochesterSensors.com | 800-852-9984 | [email protected]
 Introduction

Float level sensors are both widely used About this guide
and highly useful as the first-line input The main body of this guide provides information
on float level sensor technology and its
devices for many of today’s electronic
applications. Additional detailed information
control systems for monitoring a tank’s about several important aspects of float level
liquid level. From simple on / off pump sensor selection and installation is presented in
control to highly sophisticated liquid the appendices.
level indication, float level sensors can Our knowledgeable and experienced staff is
always available to provide further information
be counted on to perform reliable and
and can be contacted through our website,
accurate liquid level measurement. www.RochesterSensors.com
Although these devices are offered in many
variations, almost all fall into two types
depending on the output they provide. Switch
type float level sensors provide an on or off signal
at a specific liquid level. Continuous level float
sensors provide analog data that is continuously
updated as the liquid level changes.
A note on terminology
Throughout this guide we will distinguish
between these two general types of float level
sensors devices by referring to them as float level
switches, liquid level switches or float switches,
and continuous level float sensors, or continuous
level sensors.
Some of the other names used to refer to float
level switches include: multi-level float switch,
ball float, magnetically activated float sensor,
liquid level sensor, and custom float sensor.
Other names that refer to continuous level float
sensors include: 4-20 mA (or 0-5 Volt) liquid level
transmitters, 4-20 mA (or 0-5 Volt) liquid level
sensors, continuous level sensor, and float type
4-20 mA liquid level sensor.

A H I G H E R L E V E L O F S AT I S F A C T I O N
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Overview of level sensors, their use and
selection
There are several different technologies and This liquid level sensor guide focuses on
categories of level sensors. In each category, float-style liquid level switches and continuous
different types of level sensing is available. The level sensors. Both types of float level sensors
main categories of level sensors are mechanical, have floats that slide on a stem for accurate
electro-mechanical and electronic. switch point measurement or continuous level
Common mechanical level sensors include: measurement and typically are used in industrial
applications. This guide also provides a step by
• Float step process to assist in selecting the best design
switches for your float
• Conductivity switch and
probes continuous
level sensor
• Dip rods
application.
• Sight glasses When selecting
• Tape levels a float switch
or continuous
level sensor
for your
application,
it can be very helpful to consider the questions
Common electro mechanical level included in the “How to select …” section that
sensors include: follows.
• Float-style continuous level sensors
• Magneto restrictive continuous level sensors
• Resistance tape

Common electronic level sensors include:

• Ultrasonic
• Guided wave
radar
• Pressure
sensors
• Laser sensors

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The float switch level sensor Freon Float Switch | LS-1198

A float switch is one of the devices most

commonly used to sense liquid level. Although
float switches are available in many styles, sizes,
materials and with many options, they typically
consist of a float with an internal magnet that
slides up and down a stem containing hermitically
sealed, magnetically calibrated switches. As the
liquid level moves up and down in the tank, the
float’s magnet activates the internal reed switch
at the designed point. The switch can be designed
to turn on or turn off when activated. The float
switch is used to close or open a circuit that is
carrying small amount of current, typically at low
voltage and amperage. This circuit generally is
used to activate an alarm or provide a signal to
turn a pump or valve on and off to fill or empty a
tank.
The continuous level sensor 0-5 VDC Continuous Level Sensor

Another model of a float-style liquid level sensor

is a continuous level sensor, which provides a
4 20mA or a 0 5VDC continuous output signal.
The signal is relative to where the float is located
on the stem. Because the float will be at the
surface of the liquid, the actual output signal is
directly relative to the level of liquid in the tank.
Continuous level sensors typically are connected
to a programmable digital display or wired to a
programmable logic controller.
Magnetic float switch reliability 3-Level Float Switch (FPO)
The sturdy construction of these float level
sensors results in a trouble free, long operating
useful life. When the effects of shock, wear and
vibration are minimized, these hermetically
sealed reed switches provide precise repeatability
and consistent actuation points over the life of the
float switch. When used properly, these magnetic
float switches typically will exceed millions of
cycles.
Engineers typically choose float style liquid level
sensors because they are economical, reliable,
simple and accurate. They are available with
a tremendous amount of mounting methods
and other options such as material selection,
temperature monitoring and adjustability. For
more information about how to select a float level
sensor for your application, visit our website,
www.RochestterSensors.com

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 Examples of level sensor use and applications
Float-style liquid level sensors are used to Biotech
perform various functions, including: Level switches are used for gene and protein
• Regulating valves research, drug discovery and development,
and biopharmaceutical manufacturing. Custom
• Turning pumps on and off
designed products used in the biotech industry
• Providing a signal to control panels including DNA and hematology analysis systems
• Sensing low level where our products are used to detect the level of
reagent.
• Providing high level alarm
• Leak detection
• Overfill shutoff
• Level and temperature control Continuous
Many different products and industries Level Sensor
with Alarm
use liquid level float sensors, performing
the tasks listed above and others as well,
in a wide variety of applications. Such
uses include, but are not limited to:
Oil/water separators
Oil/water separation equipment
benefits from using the float-style
liquid level sensors because of their
Chemical processing and storage
reliability and stable specific gravity.
Floats are designed to float in water and oil Level switches are used in cleaners, lubricants,
or float in oil only, providing accurate switch corrosion inhibitors, protective coatings,
points to turn pumps on and off and open and degreasers, greases, additives and liquid blending
close valves. Rochester supplies liquid level and packaging systems. Liquid level sensors
switches to manufacturers of oil water separators. are used in automated liquid handling systems
Applications include coalescing, emulsion to accomplish many tasks. Multi-level float
breaking, and cylindrical gravity displacement. switches control pumps, warn of dangerous level
and temperature extremes, and keep operators
Food processing equipment informed of optimal conditions during normal
Level switches are used to meet the diverse operation.
needs of converters, food service and beverage
company suppliers, food manufacturers and
packagers worldwide. Level switches and
temperature controls are typically found in
storage vessels to control pumps and valves and
for high level/low level alarm conditions. Level
indicators are also used for continuous or multi-
point monitoring.

5-Level Custom Switch Sensor

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 Commercial washers Leak Detection Float Switch Fluid power
Liquid level switches are used in the commercial Rochester
dishwasher industry in applications ranging from manufactures
under the counter models in smaller applications several
to complete automated washing systems for products for
larger foodservice operations. Level switches the fluid power
are used for high level and low-level alarms, industry. Some
heater protection, and automatic fill and drain applications
applications. are assembly
robotics,
Container level indication
hydraulic
Custom designed level switches are used in systems
several products for manufacturers of drums, on heavy
liquid containers and intermediate bulk containers equipment,
(IBCs). Level indicators are used to mechanically tractors,
monitor liquid levels; level switches are typically spreaders,
used for pump/valve control and high/low level highway
alarm conditions. maintenance
Fuel management vehicles and
automated
Rochester has designed sensors for
manipulators.
manufacturers of diesel powered portable and
Level switches and temperature controls are
skid-mounted generators, large equipment and
typically found in accumulators and reservoirs
buses. Level switches and temperature controls
to protect against a high/low level or high
are typically found in diesel fuel tanks for single
temperature condition.
point, multi-point, or continuous
level monitoring. Food and dairy
Food and dairy equipment regularly use
Two Level Custom Switch Sensors custom and standard liquid level switches.
Applications include milk storage vessels, oil
extraction machines, storage silos, and other
food processing equipment. Level switches
and temperature controls are typically found in
storage vessels to control pumps and valves and
for high level/low level alarm conditions. Level
indicators are also used for continuous or multi-
point monitoring. Passivated 316L construction is
available for food safe applications.
Freon recovery
Rochester is a leader in liquid level switches
for Freon and other refrigerant recovery systems.
Freon float level sensors are commonly used
to provide a 80% full shutoff in different sizes
Electroplating of refrigerant tanks. Brass and stainless-steel
Liquid level sensors typically are used for the construction options are available. Common
electroplating and surface finishing industry designs use 3 or 4 pin receptacles for a quick and
to control a pump/valve to keep water at an easy connection.
acceptable level or to indicate an alarm situation.

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 Humidifiers and dehumidifiers Power generation
Rochester has designed level switches for Rochester is an industry leader in custom
manufacturers of humidifiers, dehumidifiers and designed sensors for manufacturers of portable
evaporative cooling systems. Level switches and skid-mounted generators. Level sensors
typically are used for high/low level conditions typically are used for indicating the level
and pump/valve control. of diesel fuel. Single point, multi-point or
continuous monitoring sensors are available in
Lubrication equipment
multiple configurations to meet any application
We supply liquid level switches to numerous requirements.
manufacturers of lubrication equipment.
Applications include filter regulator lubricators Restaurant equipment
(FRLs) and oil lube systems. Level switches and Level switches and temperature sensors are
temperature controls are typically found in lube purchased by manufacturers of restaurant
oil reservoirs. High and low-level alarms and equipment. Applications include food warmers,
pump or valve control are the two most common deep fat fryers, commercial freezers and coffee
uses for level switches. machines. Level switches are used in a wide
range of applications including condensate
Marine applications
overflow protection, and high/low level warning/
Several liquid level switch products are used in shutdown.
the marine industry. Level switches can be found
in cargo oil tanks, fuel oil service tanks, fresh
water tanks, bilges, and void areas.

Leak Detection Float Switch

Four Level Custom

Switch Sensors

Off-highway vehicles
Level switches and temperature controls can be Semiconductor equipment
found in such places as braking systems, transfer
cases, windshield washer fluid, and hydraulic Rochester supplies liquid level switches to
systems for off-highway vehicles. manufacturers in the semiconductor industry.
Applications include wet processing equipment,
Industrial parts washers from manually operated to advanced, fully
Rochester provides liquid level switches to automated stations, wafer cleaning and etching
manufacturers of precision cleaning and aqueous systems. Sensors are constructed of Teflon to
parts washing machines. Level switches and ensure accurate and reliable switching in the
temperature controls typically found in parts industry’s most aggressive chemicals.
washers control pumps, warn of high/low level
conditions, and provide heater protection. Level
indicators also are used for continuous or multi-
point monitoring.

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 Liquid
Level &
Temperature
Solvent recovery Sensor
Manufacturers of solvent recovery systems use
level switches for high-level detection and/or
pump/valve control.
Waste oil and grease recovery
Manufacturers of oil skimmers and grease
recovery/containment systems use level switches
and temperature controls in recovery tanks for
high/low level indication, pump control, and
heater protection.

Leak
Detection
Float
Water treatment equipment Switch
Custom liquid level switches are used by
manufacturers of water treatment, purification,
and reverse osmosis systems. Level switches
and temperature controls typically are found in
storage vessels to control pumps and valves and
for high level/low level alarm conditions. Level
indicators also are used for continuous or multi-
point monitoring.
Miscellaneous
When an application requires highly specialized
products, Rochester will work with you to find a s
olution. Teflon coating, high temperature cable,
and passivated wetted parts are a few examples
of specialized OEM requests. Applications include
inkjet printers, coffee makers, slush machines,
reverse osmosis systems, and water coolers.

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 How to select custom liquid level float sensors

There are many variables that go into selecting The standard overall length (OAL) is the
the best float switch or continuous level sensor measurement between the bottom of the fitting
design for a given application. When properly and the end of the sensor stem. The OAL is
designed, installed and maintained, a float switch typically automatically calculated based on the
or continuous level sensor can be expected to last Level 1 (L1) dimension. Special OAL’s can easily
millions of cycles. be accommodated. See OAL Illustration.
Float switches and continuous level sensors
OAL Illustration
come in many styles, sizes, materials and offer
many options. This guide provides a step by step
process to assist in selecting the best design
for your float switch or continuous level sensor
application.
Begin by considering the answers to the following
questions.

What is the desired operation?

Initially, it is important to consider the function
the float switch or liquid level sensor is to
perform. For example, does your system require
analog output for continuous level monitoring
or a switch output for high level alarm, low level OAL

alarm or to turn a pump on or off?

Continuous level: If you require continuous level

monitoring, check your control to see what type
of input is required. Two common analog signals
are 4-20mA and 0-5 VDC. Next, measure your tank
to determine the range of measurement required.
Continuous level sensors require a minimum
upper deadband, a measuring range and a lower
deadband. Deadband is an area where the sensor
is not abel to provide a reading. The standard
minimum deadband is typically 1” for both the Float switch output: If you require a sensor
upper and the lower deadbands. However, if less with switch outputs, determine how many
deadband is required, certain considerations individual switch points you need to accomplish
can be made to get closer to your application’s your functional requirements. Measure your
requirements. The overall length of your sensor tank to determine each switch point location.
as measured from the face of the fitting to the Take into consideration that the base of each
end of the stem must be calculated to ensure the sensor’s fitting, the inside face nearest the
sensor will fit into your tank. floats (See Figure 1), is the reference point for
all measurements. The industry standard is to

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determine the desired “Normal” switch operation Materials
for each switch when the tank is empty (aka when It is also critical to select a float switch that
the floats are away from the fitting). Single pole is constructed from the materials that are
single throw (SPST) switches should be defined compatible with the liquids and potential
as either normally open (NO), which means chemical cleaning agents of the particular
the switch is open, or off, when the float is not application. Component damage due to incorrect
floating, or normally closed (NC), which means material selection can ultimately cause failure of a
the switch is closed, or on, when the float is not float switch. This is why it’s essential you read the
floating. Alternatively, single pole double throw data sheets for each product you’re considering.
(SPDT) switches are an option for providing
both NO and NC switch operation. Note that the Typical float switch materials
complexity and sensor costs increase with SPDT Stainless steel: 316 stainless steel is a good
selection. material for high-temperature (to 300°F), high-
pressure (to 800 psig) and corrosive conditions.
It is commonly used in product cleaning and
What fluid type will you be measuring? rinsing food processing, medical equipment,
Most float switches and level sensors are hydraulic fluids, fuel oils, heating
designed to work in a variety of environments, and cooling equipment.
but some are specifically designed with only These hollow floats are
one or two applications in mind. Knowing what constructed of thin walled
you’re looking for will ensure the best selections stainless steel.
are made for your application. Keep in mind
that products can be made to meet your specific
application requirements. Buna-Nitrile: Buna-N is a good material to
consider for petroleum-based liquids, such as
lubricating oils, gasoline and diesel fuels. It is
Specific gravity widely used in fluid storage tanks for vehicles,
One of the main considerations when choosing generators, transmissions and hydraulic
a float switch is the specific gravity (sg) of your systems. Other uses are in lubrication,
liquid. To make sure the float will function recovery, refining and fuel
properly in the application – that it will actually processing equipment.
float in your liquid – the specific gravity of the These solid Buna
liquid must be greater than the float’s specific floats are very
gravity at the maximum temperature of the light and do
application. Specific gravities of floats typically not leak.
range from 0.45 to 0.93, depending on size
and the material they are made of. In some
Polypropylene (PP): Polypropylene is a good
applications, it is desirable to have a float that
material to consider for liquids containing acids
sinks in one fluid, such as oil or diesel fuel (0.7sg
and alkalis, detergents, inorganic and organic
to 0.9sg), and floats in another, such as water
chemicals, water and acidic conditions,
(1.0sg). This is occasionally referred to as an
such as found in electroplating and metal
interface float and has a specific gravity of 0.93.
cleaning. Another area of use is
Custom specific gravity values are available in
lower-temperature (to
certain float materials.
180°F) food processing
applications.

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Polypropylene floats also are a good choice for Viscous fluids
general-purpose applications in commercial or Liquids with high viscosity do not flow readily,
consumer appliances and equipment. The are so floats used in viscous liquids should have a
available both as solid floats (made of foamed rounded shape to eliminate places fluid could
polypropylene) as well as hollow floats molded accumulate or pool. It is important to ensure that
with thin wall polypropylene. the liquid’s changing viscosity (with temperature
Kynar: This is a good material to consider if or drying out or separating) does not interfere
harsh chemicals are used in your process. Kynar’s with the ability of the float to slide up and down
solvent-resistant properties make this material the stem of the sensor.
a real problem solver for many applications.
Its high-purity nature is ideal for food handling
and sensitive laboratory or test equipment. The Fluids with solids or magnetic particles
hollow floats are typically molded in 2 pieces and It is important to determine whether solids,
sonically welded together. semi-solids or magnetic particles are present in
your liquid. If they are, special considerations
must be made to prevent these materials from
Chemical compatibility causing problems with the float’s movement
Selection of the most suitable materials for a float and/or operation. An alternative design can be
switch can be made by referring to a Chemical engineered so these materials have little to no
Compatibility table. There are several good effect on the float’s operation. The trombone
chemical compatibility charts available on the float style, for example, has a float attached to
internet, for example the Cole-Parmer chemical an extended arm that, when moved, triggers the
compatibility database. Simply do a search for switch function. This type of switch is ideal for
“chemical compatibility of 316SS and sulfuric use in heavy-bodied liquids or in fluids containing
acid,” for example. These tables provide a good metal particles that would otherwise be attracted
indication of the suitability of the various float to a conventional style float.
switch materials in a wide range of liquids.
For some process liquids, it may be necessary
to obtain a sample float switch to test the What is the environment like inside and
compatibility. Keep in mind that products can be outside of the tank?
manufactured to be compatible with nearly every Temperature
liquid possible.
Your application’s maximum and minimum
temperatures must be determined to guide
the sensor design selections. For example,
316 stainless steel is ideal for applications
with temperatures to 300° F (and greater with
special design considerations). On the other
hand, polypropylene should only be used when
temperatures will be 180°F or lower. Buna-N and
nitrile, as well as other common materials, are
rated to 180 F° maximum. Temperature extremes
can affect the internal switches as well as the
epoxy used to seal the end of the sensor.

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Pressure Hazardous locations
Is your tank under pressure or vacuum? If so, If your area is classified as a hazardous location,
what is the maximum pressure or vacuum? the correct device must be selected to ensure
Different styles of floats and mounting fittings proper safety and meet your hazardous location
have different pressure ratings. Polypropylene requirements.
and Buna floats, for example, typically have a For more details regarding sensor selection for hazardous
pressure rating of about 150 psi. Stainless steel locations, refer to the appendix, “Hazardous location
floats, on the other hand, can have pressure considerations.”
ratings of up to 800 psi.

Vibration What is your electrical load?

Small vibrations typically have no impact on the Resistive vs. inductive loads
float sensor’s operation. Significant vibration has
the potential to interfere with proper float switch It is important to fully understand the nature of
operation and may result in erroneous signals. the load that needs to be switched and to ensure
Turbulence can be caused by a vibrating tank, that the float switch is capable of handling this
mixer agitation, or liquid swirling around as the load. The electrical ratings most manufacturers
tank is filled. Vibration and turbulence can cause provide in their float switch specifications
erratic sensor operation. There are many design typically are listed for resistive loads. Any loads
options available to protect sensor operation and that are inductive, such as a relay coil or light
reliability in an environment where significant bulb, will potentially have inrush current and/
vibration and or liquid turbulence is present. or flyback power spikes. For these applications,
determine the peak inrush current and voltage
ratings to decide on the proper float switch rating.
Sanitary applications or cleaning maintenance Inrush and flyback current often can be 10-50
times or more of the rated operating current. To
Is your application a sanitary environment
switch a circuit where the electrical load exceeds
and or an application that requires occasional
the float switches
washdown? If so, the sensor should be designed
rating, connect the
to withstand the rigors of high-temperature,
load to an appropriate
high-pressure caustic washdowns. It is important
relay and wire the
to identify the cleaning solution used as well as
level sensor to control
the washdown process. If the end of the sensor
the relay operation.
where the lead wires exit will be exposed to
washdown, then waterproof NEMA 4X housings
are a good option to consider. Electrical ratings
After the maximum
Outdoor locations load parameters are determined, the next step is
to select a float switch with ratings that will meet
For outdoor applications, special attention must
your load requirements. Care must be taken
be given to the area where the lead wires exit the
so that your load does not exceed any of the
sensor and the conduit. An integrated outdoor
maximum parameters of the float switch selected,
rated NEMA 4X housing is a good option to
including maximum wattage, maximum current
consider. This option provides space to terminate
(amps) and maximum voltage ratings. The most
your wires and protects the inside of the housing
common float switch rating is a 50-watt switch
from the elements commonly found in outdoor
with maximum “do not exceed” parameters of 1
applications.
amp, 265 volts and 50 watts. You must know two
of these three values to determine if any of the
values will be exceeded in your application using
the formula Watts=Volts x Amps.

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For example, if your process runs on 120 volts Vertical vs. horizontal mounting
and a 50 watt switch is used, it is important to The main sensor mounting orientations are
determine the maximum allowable current for horizontal/side mount and vertical mount.
this switch. The horizontal/side mount type normally has
To calculate this, simply divide the switch’s a threaded fitting, which passes through the
wattage rating by the voltage of your process sidewall of a tank with a hinged float attached to
using the formula Watts/Volts = Current (in the stem. Vertical mount types normally have a
amps). The maximum allowable current for vertical stem, which is installed through the top or
this application would be 50/120 = 0.4 amps. In bottom of a tank.
this case, if 120V is used, your load is limited to
0.4 amps (400mA) maximum. If switching an
inductive load, the maximum parameters must be Threads-up versus threads-down
based on the inrush current. If the sensor is to be mounted from inside the
Refer to the appendix “Understanding electrical ratings of tank and you require a threaded fitting, a threads-
float switches” for more detail regarding surge protection up style fitting must be selected and you must
devices. make sure you have access to the inside of the
tank. If the sensor is to be mounted from outside
the tank and you require a threaded fitting, then
Wire a threads-down style fitting must be selected and
Another step is to consider the type of wire or proper size floats must be selected. Be sure that
cable required for your application and the length the floats will physically fit through the opening in
needed. Common wire sizes for most float switch your tank.
applications are 18 and 22 gauge. Teflon coated
leads are typically standard and are suitable for
most applications, however nearly any type of Fittings
cable can be provided. Common sensor mounting fitting types are NPT
(tapered thread), BSPP (straight thread), SAE
threads (straight) and flanges. Quick-connect
How will the sensor be mounted? fittings such as sanitary tri-clamp or camlock
The choice of mounting styles that may be fittings are also common for applications where
suitable for an application will depend on the easy access is required for cleaning or testing
physical arrangement of the tank, the available of the float. Virtually any type of custom fitting
mounting positions and whether access is can be supplied to meet
available to the outside or inside of the tank. your specific application
Make sure the fitting is large enough for the float requirements.
to fit through the opening if the sensor is to be For more information
mounted from the outside top of the tank. regarding NPT
threading
considerations,
refer to the
appendix, “NPT
Connections.”

16 RochesterSensors.com | 800-852-9984 | [email protected]

 Are there tank restrictions? Short tank height
Obstructions If you have a very short tank with very tight
switch points, you may want to consider what is
It is important that nothing inhibits the movement
commonly called a shared float switch assembly.
of the float. Make sure the float sensor has
Using a shared float, near-zero separation switch
adequate clearance of the tank walls as well as
points can be achieved. This feature often is
internal tank objects such as baffles, agitators,
used on diesel fuel belly tanks, located on power
mixers etc.
generators where space often is limited and
switch points must be very close to each other.
Magnetic Field Interference
Ferrous material mounted near the sensor can Design details and options
affect the magnetic field of the senor and interfere Just about any option you require can be
with the sensor’s operation. Be sure to design engineered into your float switch. Here are a few
the tank fittings for sensor mounting to insure of the more common options available along with
sensor’s switch points or measuring ranges are where and why they are used.
not near ferrous materials or electromagnetic
fields.
Housings
Virtually any housing or enclosure can be
Tank wall provided to meet your application requirements.
For thick-walled tanks, or tanks with insulation, For wet or outdoor applications, integrally
make sure the length of the float stem is long mounted NEMA 4X waterproof housings are
enough to reach into the tank so that desired level recommended to protect the potted lead wires.
points are accurately achieved. For thin-walled For less demanding applications, watertight
tanks, make sure that the tank wall is strong enclosures such as 3-hole outlet boxes, LB and
enough to support the sensor assembly selected. SLB conduit boxes can be integrally mounted
to your float switch for ease of wiring to your
system.
Standoff
If the sensor is mounted on a standoff fitting, it is Displays
essential to adjust your level points or measuring
range to offset the standoff mounting height. Various digital displays are available to meet both
The sensor’s overall length and the switch point your digital and analog process requirements.
dimensions are relative to the face of the sensors These can be mounted either directly to a level
fittings, therefor the difference between the sensor or mounted remotely.
standoff fitting and the inside top of your tank will
need to be taken into consideration for accurate Wire, cable, seals
sensor readings. Teflon coated lead wire (24” long) are standard
and suitable for most applications. If you need to
Tall tank height customize the lead wire on a standard switch, a
full range of value-added options are available.
Tank height must be considered when selecting a Common options are extra-long or short lead
float sensor. Custom suspended cable assemblies lengths; special wire or multi-conductor cable;
can be configured to operate on even the tallest ungrounded, grounded or shielded cable to
tanks and silos. Compression unions can also be eliminate electrical noise; shrink tubing for wire
utilized for ease of installation and to minimize protection, terminations and connectors; cord
shipping costs on long length rigid stem float grips and special sealing materials, such as Viton
switch assemblies. or Buna-N gaskets and O-rings, for applications
where corrosive or caustic chemicals are present.

RochesterSensors.com | 800-852-9984 | [email protected] 17

Fitting and stem material Switch output types and ratings
A variety of fitting and stem materials are Switch outputs are available as either single
available, including stainless steel, brass, PVC, pole single throw (SPST) or single pole double
polypropylene, Teflon and others. Custom throw (SPDT). SPST output types are the most
materials can be provided to ensure chemical common and are available with either normally
compatibility with your process. open (NO) or normally closed (NC) contacts.
Common switch ratings are 10 watts (500mA,
175 V), 50 watts (1 amp, 265 V) and 100 watts (3
Fitting types and sizes
amp, 265 V), with the 50-watt switch being the
Nearly any fitting type and size can be provided. most commonly used switch. For applications
Some of the most common threaded fittings are where redundancy is desired, it is possible to
NPT (tapered thread) in ¼”, ½”, ¾”, 1”, 1¼”, 1½”, build a liquid level float switch with side by side,
2”, 3” and 4” sizes. Metric British Straight Thread redundant switches.
(BST) and threaded bulkhead fittings are also
common fittings. Common non-threaded fittings
are 150 lb. flanges and fittings for quick-access, Continuous level alarm output
such as camlock fittings or 316 stainless steel Tri- High and low alarm switch output options are
Clamp sanitary fittings. available on continuous level sensors. These
alarms can be located above, below or within the
measurement range.
Thread orientation
Threaded fittings are available as threads
up or threads down. Threads
up is used when installing a
sensor from the inside of a
tank. Threads down is used However,
when installing if the alarm is
a sensor from located in the middle of
outside the tank. the measurement range, the
switch contact may be momentary.
Float stops
Float stops are used to keep the float in the Field adjustable stem length
proper area to insure reliable sensor operation. When accurate positioning of the switch points
Retaining rings are standard and suitable for is critical, a field adjustable stem option may be
most applications. For applications exposed to a good solution. These field adjustable stem
high vibration, caustic, corrosive liquids or where lengths can help compensate for the variations
adjustability is required, stainless steel set collars in how far the NPT fitting’s threads into the
may be a better option. tank coupling. It also assists to accommodate
variables in the overall tank depth. To obtain
Float materials and specific gravities precise level measurement a field adjustable
stem length option allows the stem length to be
Floats can be provided in nearly any material you adjusted, in the field, to fine tune the exact switch
require. Some of the most common materials actuation points. This feature is available as fully
of construction are stainless steel, Buna, adjustable, which allows for repeat adjustments
Polypropylene, Teflon and PVC. The specific (Delrin ferrule), or as fixed adjustability (metal
gravity of the float determines how it floats in ferrule) which allows for a one-time adjustment.
your liquid. The most common float specific See adjustable illustration.
gravities (SG) are 0.6 SG and 0.93 SG.

18 RochesterSensors.com | 800-852-9984 | [email protected]

Adjustable illustration Pipe centering disc
For special applications where the sensor will
be mounted in a stand-off pipe or stilling well, a
ADJUSTABLE
centering disc would be a good option to consider
keeping the floats centered in the pipe and ensure
proper unrestricted operation.

Suspended cable
For tall tanks and silos, a suspended cable option
can be used to cover a large span providing ease
of installation.

Compression unions
Compression unions on stems are available on
long length assemblies for ease of installation
and to minimize shipping costs.
L1
Float test rod
This option allows for testing of the floats without
having to remove the assembly from the tank.
As shown on Figure 3, the push/pull test rod is
Combined level and temperature sensing accessible on the top of the sensor’s mounting
Thermocouples, thermistors, resistance fitting. The remote push/pull rod feature saves
temperature detectors (RTDs), temperature time and money wherever scheduled testing of
switches and other sensing devices can be added floats is required. See Test rod illustration.
and as built-in features of the level sensor. Such
a combined sensor can reduce costs, minimize
SKUs, reduce labor, improve reliability and can
eliminate an entry point or use of another fitting
on your tank.
For temperature switches, be sure to specify
normally open (NO) or normally closed (NC) and
the set point in degrees Fahrenheit.

Slosh shields
A slosh shield is a low-cost solution that will
protect a float switch from premature failure due
to chattering and allow it to perform accurately
in environments where intensive agitation or
turbulence occurs.

L1
NC or NO
.5 sq

Test rod illustration

RochesterSensors.com | 800-852-9984 | [email protected] 19

Dual stem Shared float
Dual stem assemblies are basically two-float stem This option provides two switch outputs using
assemblies incorporated into one fitting. This one shared float. The result is a near-zero
option is a real problem-solver where limited float spacing, which is a real problem-solver
mounting space exists, or where only one tank for applications where tight switch points are
fitting is available and multiple or redundant required. A shared float can also be used where
switch points are required. It is most common redundant switch points are required.
to build each stem adjustable to fine tune each
stems level setting. See Dual Stem illustration.
Hazardous locations
Dual Stem illustration Intrinsically safe sensors and safety barriers are
available for use in areas classified as hazardous
locations.
For more details regarding sensor selection for hazardous
locations, refer to the appendix, “Hazardous location
considerations.”

In summary…
There are many choices for monitoring
liquid level. Selecting the ideal sensor for an
application can be difficult simply due to the
number of options available. The challenge is
L3 determining the “best” option based on the
NC
.5 sq
L2
NO
application and design goals. One shortcut to
.5 sq
finding a quick and successful solution is to work
with a knowledgeable partner with broad product
expertise and good application experience. By
L1
NC choosing to work with a leading sensor company,
.5 sq
your design group can reduce risk, optimize

resources, and speed development.

Remote float
This design has a remote float attached to an
extended arm that, when moved, triggers the
switch function. This design is ideal for use in
heavy-bodied liquids, liquids containing solids or
in liquids containing metal particles that would
otherwise be attracted to a conventional style
float and cause fouling.

20 RochesterSensors.com | 800-852-9984 | [email protected]

 Float switch and level sensor selection checklist

Here are the main questions that need to be considered when selecting a float level switch or
continuous level float sensor for a particular application.

Liquid parameters

What is the type and concentration of the liquid involved? ___________________________________________

What is the specific gravity of the liquid? ____________ sg

Are solids present in the liquid? o Yes o No

Will the liquid coat and build up on the float switch? o Yes o No
Are caustic or corrosive chemicals present? o Yes o No
If so, what is the concentration? _______________%

Is the liquid surface turbulent or is tank vibration present? o Yes o No

What temperature range will the float switch be exposed to? ________ ° F Max. ________ ° F Min.

What is the maximum tank pressure/vacuum the float switch will be exposed to? ______________ psi/vac

What function is the control to perform (example: keep tank full)? ___________________________________

Are switch output, continuous level output, or both required? _______________________________________

For switch output applications: What are the switch point locations on the tank (use the base of the

sensors fitting as a reference) L1: _____", L2: _____", L3: _____", L4: _____", L5: _____", L6 _____", L7 _____"

SHOULD WE REFERENCE A DIAGRAM? o Yes o No

If a switch output is required, do you need SPST or SPDT? ________________

If a SPST, do you need normally open (NO) or normally closed (NC) contacts? __________

For continuous level output applications: What is the measurement range required on the tank?

(use the base of the sensor fitting as a reference) __________________________"

Do you need 4-20mA or 0-5VDC analog output? ___________________________

RochesterSensors.com | 800-852-9984 | [email protected] 21

 Electrical requirements

What will the device be wired to? (example: PLC, relay) _____________________________________________

What is the maximum voltage of the load? _____________ VAC (or) ____________ VDC

What is the maximum current draw of the load? _________________ amps

Is the load resistive or inductive? _____________________________________

If an inductive load, what is the maximum inrush current? ______________ amps

Is the location classified as a Hazardous location? o Y o N (see also appendix)

Will the float switch be located indoors or outdoors? ___________________________

Are there any approvals required (i.e., UL, CSA)? o Yes o No

For more details regarding electrical loads versus ratings regarding sensor selection, refer to the
appendix, “Understanding electrical ratings of float switches.”

Mechanical component selection

What is the maximum overall length (OAL) allowed to fit into your tank? _____________________" max.

Specify an option from each category.

1. The float level sensor will be mounted from the: o side, o top, o bottom of the tank.

2. The sensor will be installed from the o inside, o outside of the tank.

3. Select mount fitting and size: o _______" Male NPT, o ________" Straight thread, o 150lb Flange,

o _______Sanitary Flange, o Tube, o Quick Connect Cam Lock Fitting, o Other _________________
______________________________________________________________________________________________

4. Include a ½" conduit connection? o No o Yes

If yes, select: o Male or o Female.

Check desired construction materials: (other materials available)

o Brass, o Buna-N, o 304 Stainless, o 316 Stainless, o Polypropylene, o Polyethylene,

o CPVC, o PVC, o PVDF, o Kynar, o Teflon

22 RochesterSensors.com | 800-852-9984 | [email protected]

5. What is the desired float material? _____________________________________________________________

6. What is the acceptable maximum size of the float (example: need to fit through mounting hole of

.75") ________________".

7. Electrical wiring to each switch will have: o individual wires o a shared common wire

8. Add an electrical junction box? o Yes o No

If yes, box desired:

o NEMA 4X waterproof, o LB, o SLB, o 3-hole outlet box, o other

9. Wire leads: o 24" long (std.) o optional length _______________"

10. Select desired type of Lead Wire: o PTFE insulated wire o Jacketed cable, o Shielded cable,

o Other __________________________ o Connector: type desired _________________________________

11. Is a display needed? o Yes o No

12. Do you require field-adjustable positioning of the float stem? o Yes o No

13. If so, do you prefer fully adjustable (plastic ferrule) or one-time adjustability? ______________________

14. Is a built in temperature sensor desired? o Yes o No

15. Is remote testing of the float switch required? o Yes o No

RochesterSensors.com | 800-852-9984 | [email protected] 23

 Liquid level float sensor installation guide

Basic instructions Mounting

Sensors typically are mounted with a female
Pre-Installation coupler at the top, bottom or side of the tank
that has threads matching the sensor. Sensors
1. Make sure the area of installation is free from can be mounted up to 30° off the straight-line
hazardous or flammable materials. If not,
orientation.
then be sure to use appropriate enclosure and
protection. When threading metal threads into a metal
coupling, pipe sealant or Teflon tape is
2. Confirm the pressure and temperature recommended. To avoid potential compatibility
limitations of the sensor will not be exceeded. problems, a compatible pipe sealant is
3. Confirm that the sensors’ materials are recommended when sealing plastic threaded
compatible with the liquid and environment in units. Engage the thread by hand, then use a
which the sensor will be operating. wrench to rotate the sensor clockwise until it
is tight within the mounting. When threading
4. Ensure that the electrical load placed on the
the sensor into the coupling, be sure to avoid
sensor switches does not exceed its maximum
overtightening, which can strip or damage
ratings.
the thread. The actuation points are typically
5. Minimize both shock and vibration to provide measured from the face of the fitting, so the
maximum sensor switch life. distance that the fitting is threaded into the
6. Make sure the sensor is mounted in a tank area coupling at installation will affect the exact
that is free of severe turbulence or is protected actuation point(s).
from such turbulence by appropriate slosh
shields. Wiring:
7. Inspect the sensor housing and electrical When connecting the wires to the sensor, be
terminations to ensure they are clean and dry. sure to confirm the proper wire color. Take care
8. Inspect all components for damage and report when handling the wires and feeding the wires
any damage to the carrier within 24 hours of through conduit or tight spaces to insure lead
receipt. wire insulation is not compromised or damaged.
Do not allow lead wires to be contacting sharp
9. Ensure that the length and the inside diameter metal surfaces. It is important that lead wires are
of the mounting are sized correctly to
terminated in a controlled environment (inside
accommodate the application.
a housing or enclosure) or terminated with a
weather proof termination. Make sure the point
Handling where the insulation is removed from the wire
is not exposed to high moisture content as the
Be careful to not bend the sensor stem during space between the wire and the insulation can
installation. Most float style liquid level sensors leach moisture into the sensor. It is best practice
have an internal, hermetically sealed glass to route the sensor wires in their own conduit
switch(s) that can be damaged by bending. with a reasonable separation from high power
Also, be careful not to apply excessive shock or wires to minimize electrical noise problems.
vibration to the sensor during installation.

24 RochesterSensors.com | 800-852-9984 | [email protected]

Contact protection Conduit illustration

To maintain the life and reliability of the internal

reed switch, it is essential to provide protection
when switching inductive loads. In an inductive
load, when the switch opens the energy stored
in the load can generate high frequency voltage
spikes across the switch contacts. (known as “Fly
Back” power) If the power is large enough, it can
initiate arcing and weld the contacts together.
Damage can be minimized by suppressing the
voltage and current spikes. In some applications,
a relay is required to isolate the float switch from
a large load. In this scenario, the float switch will
be connected in series with a relay input coil that
will activate the main relay contacts typically
draws less than 500 mA. When the float switch is
closed, the relay coil is activated and closes the
relay output contacts. These contacts turn on or
off the high current required by the large load, L1

such as a pump. .5 SG

Moisture protection
The lead wires exiting the sensor are typically There are design options that can be
potted with epoxy. Although this potting provides considered to protect the sensor from moisture
some protection to the interior of the sensor, contaminating the internals of the sensor. One
if moisture is present in the conduit, there is a popular option is to select a cable for lead wires
potential for this moisture to wick down the wire and a sealed “cord grip” to create a water tight
leads into the sensor’s internal assembly where seal at the end of the sensor. There are other
the moisture can contaminate the internal wire options create a water tight sensor. Contact
harness and switches resulting in the failure of Rochester to discuss your specific application re
the sensor. Keeping the moisture away from the quirements.
area where the leads exit the sensor and away
from the area where the insulation is stripped
from the lead wire will help minimize this Compression tube fittings installation procedure
potential problem. See Conduit illustration. Compression fittings are typically found on units
When running conduit to the sensor, be sure to with the field adjustable stem length option and
run the conduit below the connection point to long sensors that exceed 100" or sensors where
the sensor to create a water trap (like a sink drain installation clearance above the tank is limited.
trap) This trap will collect the condensation build For an adjustable sensor, loosen the compression
up, preventing the moisture from accumulating fitting and slide the stem so the floats are at
on the end of the sensor where the leads exit. the desired depth in the tank and then tighten
compression fitting. For tube connections, loosen
the nut on the fitting and insert tubing until the
tube bottoms in the fitting body. Tube alignment
with fitting is very important. Tighten nut finger
tight, then wrench tighten 1¼ more turns).

RochesterSensors.com | 800-852-9984 | [email protected] 25

 Installation quick check items the “Liquid Level Float Sensor Installation Guide”
section.
1. Confirm the peak electrical load across the This sensor should be wired by qualified, licensed
sensors switches do not exceed the switch’s technicians (CL wiring diagram). The 4-20mA
maximum rating loop powered sensor has two wires exiting the
2. Confirm the maximum temperature of the housing of the sensor. The red wire connects
system does not exceed the maximum to signal (or + VDC), the black wire connects
temperature rating of the sensor to - VDC. To protect the sensor, we suggest the
power supply be wired with a fast blow fuse rated
3. Confirm the pressure in the tank does not between 30mA and 100mA.
exceed the maximum pressure rating of the
sensor
Operation
4. Be sure there is not ferrous material near The 4-20mA sensor operates on a loop power or a
the sensor. Nearby (as a guideline, within 6 separate power supply of 10-30 VDC. The sensor
inches, however further separation may be will provide a linear output between 4-20mA
required for certain sensors) ferrous material across the measuring range. When the float is
can disrupt the sensors magnetic field and at the bottom of the measuring range (furthest
interfere with the sensors operation. away from the fitting) the signal output will be
5. Confirm the wiring and conduit are properly 4mA. As the float moves closer to the fitting, the
installed to insure moisture does not mA output will increase until it reaches the top of
accumulate in the area the leads exit the the measuring range, providing a 20mA signal.
sensor and the lead wire connections are The mA signal will change every 1/4" of float
protected against moisture contamination. movement. The mA value will change with every
1/4" of float movement. The value of mA change
per 1/4" of float movement equals 4 divided by
4 20 mA continuous level float sensors total measuring range in inches.
Our loop powered 4-20mA sensors are reliable
Installation and easy to install. These sensors will arrive at
When initially installing the continuous level your plant, ready to install into your equipment.
sensor, mount the sensor into the tank with the No calibration is needed. Simply install into your
matching fitting. When threading metal threads tank and connect the two wires — that’s it. These
into a metal coupling, pipe sealant or Teflon tape sensors are tough. They are used in demanding
is recommended. After the sensor is mounted in applications with years of reliable, accurate
the tank, add the conduit. Use only appropriate performance. There is no drift and they never
conduit hubs that are specified to maintain the need calibration.
desired UL/CSA rating. For more information see

LCD Display
CL Wiring Diagram

100.0

+ –

Sensor
+
Red Wire
10–30 VDC
–
Sensor
Black Wire

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 0-5VDC continuous level float sensors Operation
The 0-5 VDC sensor operates on a power
Installation supply of 10-30 VDC. The sensor will provide
When initially installing, mount the sensor a linear output between 0 and 5 VDC across
into the tank with the matching fitting. When the measuring range. When the float is at the
threading metal threads into a metal coupling, bottom of the measuring range (furthest away
pipe sealant or Teflon tape is recommended. from the fitting) the signal output will be 0 VDC.
After the sensor is mounted in the tank, add the As the float moves closer to the fitting, the VDC
conduit. Use only appropriate conduit hubs that output will increase until it reaches the top of
are specified to maintain the desired UL/CSA the measuring range, providing a 5 VDC output.
rating. For more information see the “Liquid The VDC signal will change every 1/4" of float
Level Float Sensor Installation Guide” section. movement. The VDC value will change with every
1/4" of float movement. The value of VDC change
per 1/4" of float movement equals 1.25 divided by
This sensor should be wired by qualified, licensed total measuring range in inches.
technicians (0-5 VDC CL sensor wiring diagram).
Our 0-5 VDC sensors are reliable and easy to
The 0-5vdc continuous level sensor has three
install. These sensors arrive at your plant, ready
wires exiting the sensor. The red wire connects
to install into your equipment. No calibration is
to the + of your meter or controller, the white
needed. Simply install into your tank and connect
wire connects to + VDC, the black wire connects
the two wires — that’s it. These sensors are
to - VDC and the - of your meter or controller. To
tough. They are used in demanding applications
protect the sensor, we suggest the power supply
with years of reliable, accurate performance.
be wired with a fast blow fuse rated between
There is no drift and they never need calibration.
30mA and 100mA.

0-5 VDC CL sensor wiring diagram

LCD Display

100.0

+ –

Sensor
+
Red Wire
10–30 VDC
–
Sensor
Black Wire

RochesterSensors.com | 800-852-9984 | [email protected] 27

 Maintaining a float style level sensor

Inspections

Scheduled maintenance of your liquid level

sensor is suggested for applications where there
is a potential for material buildup that would
prevent the float from operating.
For cleaning, remove the sensor assembly from
the tank and inspect for any material build up. If
build up is present, select a cleaning solution that
is compatible with the sensor’s float and stem
material and clean appropriately. If the float needs
to be removed, make sure the top of the float
and the float stop locations are identified (with a
magic marker) to ensure the float goes back onto
the stem with the proper orientation and the float
stops are returned to their original locations. To
confirm the float sensors operation, disconnect
the wires from your control system.
For a float switch, connect an ohm meter or
continuity meter to the sensor wires. Move the
float up and down to verify the switch opens and
closes in the designed float location. The design
dimensions of the sensor are typically measured
from the face of the mounting fitting. See the
specific float switch drawing for more detailed
information.
For a continuous level sensor, connect an
independent power supply (12 or 24 VDC is most
common) and appropriate meter wired as shown
on the installation guide wire diagrams.

28 RochesterSensors.com | 800-852-9984 | [email protected]

 Troubleshooting a float style level switch

If your float level switch sensor is not operating of the center line of the float when the float is
correctly, follow these steps: positioned in the center of the float stops. This
measurement should be equal to (+/- 1/8”) the
1. Remove the sensor from your tank and designed level dimension. When the centerline
disconnect the lead wires from your system of the float is at the designed dimension, the top
2. Verify the lead wire colors for the float switch and bottom float stops should be 3/16” away
that will be tested and connect an ohm meter from the top and bottom end of the float. Inspect
to the lead wires. Verify the testing meter is set for debris or build up on the floats that would
to measure ohms. prevent the float from moving properly. Move
each float fully up and down to make sure you get
3. Move the float so it is positioned away from a single on and off switch point and not a “double
the sensor’s fitting (if there is no fitting, then read.”
away for the end of the sensor where the lead
wires exit) and observe the ohm meter reading.
When the specific float switch is in the closed Shock or damage to the floats or the sensor
state, the meter should read 5 ohms or less, assembly (bent, dented, etc.)
when the specific float switch is in the open
state, the meter should read above 2 Meg Sensors need to be handled and installed with
ohms or infinite (Note, be sure the exposed care. Check to make sure the shipping container
test lead wires are not touching a conductive was not damaged. An internal reed switch has a
surface and are not touching a person’s hands.) hermitically sealed glass housing that can break
or can be “magnetically reset” so that it no longer
4. Next move the float so that it is nearest the
is activated by the float. Floats have magnets
fitting (or where the lead wires exit the sensor)
inside that can break or become dislodged from
and observe the ohm meter. The meter should
rough handling or significant shock or vibration.
now read opposite of what it read prior to
If the float sinks, inspect the float for ruptures and
moving the float towards the fitting.
check to see if the float is filled with liquid.
5. Move the float slowly to accurately observe
when the meter is changing. Be sure to move
the float all the way to the float stop and even Excessive moisture around the wires exiting
rotate the float when it is against the float the sensor or connections
stop to insure there is not a change (multiple
changes between the float stops) in your meter Internal moisture typically results in a switch not
other than the designed float switch point. fully turning off and possibly an internal short to
ground. Inspect the wires exiting the sensor for
If the ohm reading is not correct and/or the sensor signs of moisture. Although the lead wires are
is not operating properly, there are numerous fully potted where they exit the sensors stem, it
potential reasons: is possible for moisture to wick into the sensor
between the edge of the lead wire and the epoxy.
Note that wire and cable can wick moisture inside
Float is not positioned properly or moving the wire insulation into the sensor. The source
properly of liquid usually comes from the area where
the insulation is stripped from the wires for
The float stops (clips or collars) may have come connection.
loose, may have been moved or may not be in the
proper place. To confirm the float and float stops
are in the proper position, measure the distance

RochesterSensors.com | 800-852-9984 | [email protected] 29

 Reed switch failure Float’s specific gravity does not match the
liquid that is being measured
Reed switch failure can be a result of high voltage
or current (or a short) exceeding the switch’s The floats specific gravity must be less than the
switching capacity. Overpowered reed switches applications liquid specific gravity. If the floats
can fail either in the open or closed position. specific gravity is greater than the liquids specific
Typically, you will read resistance between 50 gravity, then the float will not float in the liquid
ohms to 10K ohms if the reed switch is stuck and the switch will not change state. To estimate
closed due to being overpowered. Sometimes the specific gravity of the float, submerse the float
a slight tap on the stem will cause the reed in room temperature water (while the float is on
switch to become unstuck. If this happens, it a stem to keep the float upright) and estimate the
is an indication that too much power is being percentage of the float that is submersed. The
applied to the reed switch. Though it may percentage is an estimate of the floats specific
appear the reed switch is now working normally, gravity.
it is recommended that the sensor is repaired,
and new switches are installed as the original
switch is damaged and potentially will cause Wire colors do not match the level switch
a premature failure. In addition, the circuit
When connected to one switch, attempt to
must be examined to determine the reason for
activate/deactivate all switches to determine
over powering the switch. If the switch was
which switch is connected to what wire color.
significantly over powered, it can be destroyed
and it remains open.

Troubleshooting a float style 4-20mA continuous level sensor

Verify that the wiring is correct and proper power If the signal is not correct, double check that you
is being applied to the sensor. If the system is still have wired the meter according to the wiring
not working, completely disconnect the sensor diagram and the separate power supply is
from the system, apply 24VDC and monitor the supplying 10-30VDC. Confirm that the wires are
sensor output with an independent mA meter. isolated from each other and not contacting any
Wire the independent meter and power supply metal or conductive material.
as shown in CL wiring diagram above. Move the
This sensor should be wired by qualified, licensed
float up to the ½ way point and confirm that the
technicians (CL wiring diagram). The 4-20mA
meter is reading approximately 12mA. Move the
loop powered sensor has two wires exiting the
float to the ¼ of the measuring range and the
housing of the sensor. The red wire connects
meter should read approximately 8mA. Move
to signal (or + VDC), the black wire connects
the float to the ¾ of the measuring range and the
to - VDC. To protect the sensor, we suggest the
meter should read approximately 16mA.
power supply be wired with a fast blow fuse rated
CL Wiring Diagram LCD Display between 30mA and 100mA.

100.0
If the sensor is not operating correctly, contact
Rochester for assistance.
+ –

Sensor
+
Red Wire
10–30 VDC
–
Sensor
Black Wire

30 RochesterSensors.com | 800-852-9984 | [email protected]

 Troubleshooting a float-style 0-5VDC continuous level sensor

This sensor should be wired by qualified, licensed approximately 1.25VDC. Move the float to the ¾
technicians (0-5 VDC CL sensor wiring diagram). of the measuring range and the meter should read
The 0-5vdc continuous level sensor has three wires approximately 13.75 VDC.
exiting the sensor. The red wire connects to the + of If the signal is not correct, double check that you have
your meter or controller, the white wire connects to wired the meter according to the wiring diagram and
+ VDC, the black wire connects to - VDC and the - of the separate power supply is supplying 10-30VDC.
your meter or controller. To protect the sensor, we Confirm that the wires are isolated from each other
suggest the power supply be wired with a fast blow and not contacting any metal or conductive material.
fuse rated between 30mA and 100mA.
If the sensor is still not operating, contact Rochester
Verify that the wiring is correct and proper power for assistance.
is being applied to the sensor. If the system is still LCD Display

not working, completely disconnect the sensor from 0-5 VDC CL sensor
100.0
the system, apply 24VDC and monitor the sensor wiring diagram
output with an independent DC volt meter. Wire the + –

independent meter and power supply as shown in

0-5VDC CL wiring diagram. Move the float up to the +
Sensor
Red Wire
10–30 VDC
1/2 way point and confirm that the meter is reading –
Sensor
approximately 2.5 VDCs. Move the float to the 1/4 Black Wire
of the measuring range and the meter should read

Procedure for reversing a float to change the Normal Switch State

The operation of a Rochester float level sensor might 5. Flip the float over so the mark you made is now
be reversed from normally open to normally closed, on the bottom and slide the float onto the stem.
or from normally closed to normally open by Replace the float stops back to the marked points.
reversing the float orientation. The float should now be able to freely move up
Note that “normal” position is referenced when the and down about 3/8” between the top float stop
float is not floating and the threads are mounted on and the bottom float stop. Due to tolerances in
the top side of the tank. the switch and float, it may be necessary to adjust
the placement of the float stops so that the float
To reverse the float orientation: operates with proper travel between the float
1. Mark on the stem the current location of the stops.
retaining rings or set collars float stops with a 6. To test, connect a continuity meter or ohm meter
black marker. to the float switch. Slowly move the float up and
2. Mark the top side of the float so it is clear how it down between the clips and note where the float
should be repositioned. is positioned when the switch changes state.
Ideally the float should move a minimum of 1/8"
3. We suggest taking a picture of the float and
and a maximum of 1/4" from the float stop prior
float stops for reference before moving any
to changing conditions. Adjust the float stop as
components. Slide the bottom clip off the stem
needed to achieve this switch operation and float
(Note: Do not over expand the clip as over
travel guidelines. Be sure to check that the switch
expanding will destroy it).
only changes state once as the float travels from
4. Slide the float off the stem. Note that if multiple the bottom float stop to the top float stop.
floats need to be reversed, it is necessary to repeat
this process for each of the floats and float stops
that need to be removed.

RochesterSensors.com | 800-852-9984 | [email protected] 31

 A brief history of float switches

A float switch is a device used to detect the level Figure 8. U.S. Patent Office, filing No. 530,592
of liquid within a tank. The switch may be used to MAGNETIC WATER GAGE, Patented December 11, 1894
control a pump or send a signal to an indicator,
alarm, controller or other devices.
A search of the patents for float level sensors
and float switches will uncover several patents
dated back to the late 1800s. One invention
(Figure 8) references a magnetic float used to
induce movement of needles that will give an
indication of the liquid level. Like everything else,
float switches have progressed much through the
years.
Current float level sensors are certainly more
sophisticated, reliable and versatile than previous
devices. Today’s liquid level float sensors, also
known as float switches, float level switches
and float level sensors, use permanent magnets
mounted in a float that slides up and down a
stem. The float sensor stem contains magnetically
activated reed switches that typically are
calibrated to the float’s magnetic field. The reed
switch is activated as the float’s magnetic field
surrounds it. This results in switch activation
as the float rises and falls with the liquid level.
The activating magnet is sealed in the float and
the stem’s internal reed switch is hermetically
sealed and electrically isolated from the stem. The
stem is made of nonmagnetic metals or rugged,
engineered plastics (so to not interfere with the
magnetic field). This vertical float level sensor
design results in a switch point accuracy of ±1/8
inch. Multi-point float switches use a separate
reed switch for each level point being monitored.
Side-mounted float switches, also known as
horizontally mounted magnetic float switches,
use different actuation methods to accommodate
their horizontal mounting position. The basic
principle, however, is the same: As a direct result
of rising or falling liquid level, a magnetic field
is moved into the proximity of a reed switch,
causing its actuation.

32 RochesterSensors.com | 800-852-9984 | [email protected]

 APPENDIX 1: Hazardous location considerations

Note: This document is for informational purposes (NEC) in the US, or the Canadian Electrical Code
only. Associated apparatus must be installed in
(CEC) in Canada. When equipment must be
accordance with its manufacturers control drawing
and Article 504 of the National Electrical Code installed in hazardous locations, there are strict
(ANSI/NFPA 70) for installation in the United States, requirements to prevent inadvertent ignition of
or Section 18 of the Canadian Electrical code for combustible dust, gases and vapors.
installations in Canada. Suitability for installation In North America, the categorization of hazardous
applications is at the discretion of the authority having areas is done in accordance with NEC article 500
jurisdiction (AHJ). and other associated articles. The class rating will
At times, sensors must be installed in areas tell you if the hazardous material is a gas or is
where combustible dust, vapors and gases dust. The division rating indicates the probability
are used or may be present. These areas are of the hazard being present; and the group
commonly referred to as “hazardous locations,” reveals the type of the hazardous substance and
and are defined by the National Electrical Code its volatility.

Condition descriptions
There are three classes of hazardous conditions:

Class I Locations: Class II Locations Class III Locations

Gases and Vapor Combustible Dust Fibers and Filings

• Petroleum refineries, • Grain elevators • Textile mills, cotton

and gasoline storage gins
• Flour and feed mills
and dispensing areas • Cotton seed mills, flax
• Plants that manufacture, processing plants
• Dry cleaning facilities
use or store magnesium
where vapors from • Plants that shape,
or aluminum powders
cleaning fluids are pulverize or cut wood
present • Plastic, medicine and and create sawdust or
firework manufacturers filings
• Spray finishing areas
• Starch or candy
• Aircraft hangars and
producers
fuel servicing areas
• Spice-grinding plants,
• Utility gas plants and
sugar plants and cocoa
operations involving the
plants
storage and handling of
liquefied petroleum gas • Coal preparation plants
or natural gas and other carbon
handling or processing
areas

RochesterSensors.com | 800-852-9984 | [email protected] 33

Most hazardous locations for liquid level sensors In applying these principles, the quantity of the
are Class I locations. This guide will focus on flammable liquid or vapor that may be present
Class I locations because the level sensors are and its flammable characteristics must be
mostly used in liquids that are typically hazardous recognized.
when in a gas or vapor form.

Class I locations have two divisions of hazardous Sources of ignition

conditions:
A source of energy is needed to create an
Division 1: The gases or vapors are always explosion when flammable gases or combustible
present at sufficient concentrations to be an dusts are mixed in the proper proportion with
explosion hazard. air. Equipment such as switches, pushbutton
stations, plugs and receptacles, can produce arcs
Division 2: The gases or vapors may be
or sparks in normal operation when contacts
present, and if they are, they are likely to be
are opened and closed. This could easily cause
in sufficient concentrations to be an explosion
ignition. Electrical safety, therefore, is of crucial
hazard.
importance. The electrical installation must
In Class I locations there are four Groups (A, B, prevent accidental ignition of flammable liquids,
C, D) that are classifications of substances and vapors and dusts released to the atmosphere.
their degree of volatility, with A being the most
hazardous and D being the least volatile group for
gases and vapors. The difference between intrinsically safe and
explosion proof
Group A: Acetylene
The two most common methods of protecting
Group B: Hydrogen and manufactured gases a sensor circuit in a hazardous location are
containing hydrogen Intrinsically Safe and Explosion Proof.
When using “explosion-proof rating” to address
Group C: Ethyl-ether vapors, ethylene, or the hazardous rating protection, the internals
cyclo-propane
of the sensor and affiliated equipment must be
Group D: Gasoline, hexane, naphtha, benzene, engineered to contain an internal explosion and
butane, propane, alcohol, acetone, benzol, avert a much larger detonation.
lacquer An “intrinsically safe rating” means the
electronics are designed and or controlled so that
a spark does not create enough energy to ignite
Basics of explosion risks
the substances in the hazardous location.
For an explosion to occur, there must be three
basic conditions present:
Intrinsically safe equipment
1. A flammable liquid, vapor or combustible dust
must be present in sufficient quantity Intrinsic safety (I.S.) is a protection method for
electrical equipment used in hazardous locations
2. The flammable liquid, vapor or combustible where the energy allowed into and stored within
dust must be mixed with air or oxygen in the an area is limited to a level that is incapable of
proportions required to produce an explosive causing ignition. I.S. equipment is designed and
mixture evaluated to ensure that the amount of electrical
energy stored within the device is reliably limited
3. A source of energy must be applied to the to predetermined safe levels.
explosive mixture.

34 RochesterSensors.com | 800-852-9984 | [email protected]

The use of intrinsically safe equipment is suitable Intrinsically safe versus explosion proof:
to process control instrumentation such as float Advantages and disadvantages
switches and level transmitters because these
electrical systems lend themselves to low energy Explosion proof
requirements. An I.S. barrier must be used to limit Although an explosion proof system for liquid
the amount of energy entering the hazardous level sensor applications is generally considered
area and the I.S. barrier must be selected to be somewhat simpler to design, it is generally more
compatible with the connected IS equipment both expensive to install because of the high cost of
from a safety and functional perspective. running field wiring inside a conduit, which must
be sealed between the safe and hazardous areas.
Explosion-proof equipment can also be more
Explosion proof enclosures difficult to maintain since either the area must
The explosion-proof protection method relies on be known to be non-hazardous or the equipment
equipment and wiring enclosures to prevent an must have the energy drained before covers can
internal ignition from escaping to the surrounding be removed.
atmosphere. Such housings usually are made Liquid level sensor explosion proof systems have
of cast aluminum or stainless steel and are of their own hazards, particularly because they do
enough mass and strength to safely contain an not actually avoid creating an explosion. The
explosion should flammable gases or vapors housing is designed to contain the explosion.
penetrate the housing and the internal electronics The risk is that with corrosion, nicks or cuts to the
or wiring cause an ignition. housing, or if screws are not screwed in all the
In Class I, Division 1 and 2 locations, conventional way, a much larger explosion could occur outside
relays, contactors and switches that have arcing the housing.
contacts should be enclosed in explosion proof
Intrinsically safe
housings.
Liquid level sensor intrinsically safe systems are
The NEC defines explosion proof apparatus as
commonly considered safer, less expensive, and
“apparatus enclosed in a case that is capable
easier to install and maintain. With intrinsically
of withstanding an explosion of a specified
safe designs, system integrity is less of a concern
gas or vapor that may occur within it and of
because explosions cannot occur. Intrinsically
preventing the ignition of a specified gas or vapor
safe liquid level sensor systems offer significant
surrounding the enclosure by sparks, flashes, or
labor savings over traditional explosion proof
explosion of the gas or vapor within, and that
protection methods because there are no heavy
operates at such an external temperature that a
conduits or bolted enclosures. Material costs are
surrounding flammable atmosphere will not be
typically less because a standard enclosure is the
ignited thereby.” These enclosures must prevent
only major expense for mounting the barriers.
the ignition of an explosive gas or vapor that may
And unlike most explosion protection methods,
surround it. In other words, an explosion inside
intrinsically safe systems operate seamlessly
the enclosure must be prevented from starting a
with retrofit applications and with modern
larger explosion on the outside.
technologies such as fieldbus. The affinity to
newer technology is one reason intrinsically safe
designs are becoming a preferred hazardous
location protection method.
The main disadvantage of intrinsically safe
systems is that it can be used for low power
circuits. Typically, measuring and control
instruments (like level sensors, level transmitters
etc.) are low power circuits which makes them a
good candidate for Intrinsically Safe designs.

RochesterSensors.com | 800-852-9984 | [email protected] 35

Selecting the best choice Float Switches
Intrinsically safe systems seem to be considered A float switch is considered a simple apparatus
the preferred solution for low power sensor by UL’s Hazardous Location approving agency.
circuits including level switches, level A simple apparatus does not require a special
transmitters, RTDs, pushbuttons, and low-power hazardous location rating (Class I, II or III);
solenoids. however, it does require connection to an
This approach is embodied in the principle of appropriate intrinsically safe barrier. The
intrinsically safe systems where the sparks are intrinsically safe barriers have certifications that
prevented from ever causing an explosion. are extended to the attached simple apparatus
In contrast, the explosion proof method of when installed properly.
protection is mitigative: when sparking happens
Transmitters
in a hazardous area, the explosion does occur, but
the effects are mitigated to some extent. A continuous output transmitter is considered a
non-simple apparatus by UL’s Hazardous Location
approving agency. A non-simple apparatus
Designing Intrinsically safe sensor circuits requires a hazardous location rating and needs to
using simple and non-simple apparatus’ be connected to an appropriate intrinsically safe
barrier. Refer to the control drawing below for
Simple apparatus (switches) vs non-simple an example of our continuous level sensor with
apparatus (transmitters) intrinsically safe barrier.
An intrinsically safe apparatus is classified either Note: this document is for informational purposes
as a simple apparatus or non-simple apparatus. only. Associated apparatus must be installed in
accordance with its manufacturers control drawing
Simple apparatus is defined in paragraph 3.12 and Article 504 of the National Electrical Code
of ANSI/ISA-RP 12.6-1987 as any device which (ANSI/NFPA 70) for installation in the United States,
will neither generate nor store more than 1.2 or Section 18 of the Canadian Electrical code for
volts, 0.1 amps, 25 mow or 20 μJ. Float switches, installations in Canada. Suitability for installation
simple switches, contacts, thermocouples, and applications is at the discretion of the authority having
resistors are examples of a simple apparatus. jurisdiction (AHJ).
These devices themselves do not need to be
approved as intrinsically safe when connected to
an approved intrinsically safe barrier.
A non-simple apparatus, on the other hand,
can create or store levels of energy beyond
what is listed above as safe and thus the device
itself needs to carry an intrinsically safe rating
and be connected to an approved intrinsically
safe barrier. Typical examples are transmitters,
transducers, and relays. These approved
intrinsically safe devices will have a required
control drawing that indicates the intrinsically
safe barrier parameters and wiring requirements.

36 RochesterSensors.com | 800-852-9984 | [email protected]

 APPENDIX 2: Understanding electrical ratings of float switches

A common inquiry about float switches is if the of your load parameters exceeds the switches
switch can properly handle the applications parameters, a different switch or different circuit
electrical load. It is easier to determine electrical design must be used.
load capabilities if you understand how the liquid Assuming some common load voltages, the
level sensors internal components work. Float following table shows the maximum amperage
level switches utilize reed switch technology. that can be drawn through the system.
Specifically, they are glass encapsulated,
hermetically sealed, magnetically actuated reed Maximum current allowed based on voltage used
switches. When a magnetic field (contained in the and wattage of reed switch selected
float) surrounds or comes in close proximity to
the reed switch, the contact changes state. The Wattage of selected Voltage used Maximum current
size of the reed switch limits its electrical load reed switch (amps)

handling capability. The internal reed switches 240 AC 0.04
can only handle a relatively small load. See reed
10W 120 AC 0.08
switch ratings below for more detail.
24 DC 0.4

240 AC 0.2
Reed switch ratings
50W 120 AC 0.4
When selecting your float level sensor, it is
24 DC 1.0
important that your electrical load requirements

do not exceed the switch’s rating. Care must be 240 AC 0.4

taken so that your load does not exceed ANY 100 W 120 AC 0.8
of the maximum ratings for wattage, current, 24 DC 3
and voltage of the reed switch selected. See the

following table for an example of maximum reed — Formula used: Imax (current)= Watts/Voltage
switch electrical parameters. — These ratings are for resistive loads only. For inductive
loads, it is important to determine your load’s peak in rush
Maximum wattage, voltage and current ratings of current and voltage
reed switches
Note: The power drawn by loads can be expressed in
Switch Max. wattage Max. voltage Max. current either Watts (W) or Volt-Amps (VA). The power in Watts is
the actual power drawn by the equipment and Volt-amps
10W switch 10 watts 175 VAC/VDC 500 mA is used for apparent power in AC circuits and equals
50W switch 50 watts 265 VAC/VDC 1 amp Volts x Amps. Volt-Amps is the product of voltage and
current, without considering the type of load (resistive or
100W switch 100 watts 265 VAC/VDC 3 amp inductive). When talking about resistive loads, Watts and
VA can be used interchangeably in the chart above.

To determine if your electrical load will not

exceed the float switches capability, determine
the operating voltage and multiple that by the
current draw of your load. This will give you the
Wattage of your electrical load. (Watts=Volts x
Amps) Now compare your wattage, voltage and
current values of your electrical load to insure
all 3 of these values are less than the maximum
ratings of the switch. Remember if any one

RochesterSensors.com | 800-852-9984 | [email protected] 37

 Switching Resistive, inductive and capacitive contacts carry the high in-rush current created by
loads the applications inductive load.

It is important to understand the characteristics Design suggestions for both DC INDUCTIVE and
of your load that you are switching to ensure that CAPACITIVE LOADS
the float switch can handle the electrical load. The
DC voltage lamps, DC Inductive or DC Capacitive
electrical ratings of the float switch are commonly
defined as peak load ratings. Resistive loads or Loads:
“dry contact” loads (Common for PLC’s or custom When switching DC voltage inductive or
controllers) are typically stable because the capacitive loads, a high peak power spike can be
switching load is similar to the ongoing carrying experienced when the switch opens. These “fly
load. Inductive loads, such as a solenoid, small back” spikes can be 10 times or more the normal
motor, or light bulbs can have “flyback power” voltage and/or current state. One solution to
where the peak voltage or current and peak protect the switch in these situations is to install
wattage can be 10 times – 20 times (or more) than a diode in parallel with the DC load. This diode
the rated steady state electrical load when the provides a path for the fly back current that is
circuit opens. Capacitive loads “store” energy generated from the inductive field, protecting
and when the switch is opened up, a large power the reed switch from being exposed to this
spike can result as the stored energy is drained power spike. A
from the load. An example of this would be “1N4004” diode is
long lead wire or electrical circuitry with a large a common choice.
current load. If these load characteristics are not Install the diode
Load
taken into consideration, these peak currents and so the cathode +
voltage spikes can easily damage your float level side (white ring) Sensor Switch –
DC Power

sensor switch. is connected to

the positive power
Diode circuit diagram
LOAD EXAMPLES: side of the load.
Resistive load: Resistors, dry contact (Diode circuit diagram)
input, controllers Alternatively, another option is to install a resistor
in series with the reed switch. It is important
Capacitive Loads: Lead wires that exceed
to understand the resistor could affect your
200 ft, electrical equipment
applications performance. We suggest you test
Inductive Loads: Relay’s, Solenoids, Light to insure the additional resistance added to your
bulb electrical load does not cause any performance
problems. For best protection, the larger the
resistor value, the more protected your switch will
Designing for Inductive loads and Capacitive be. If your circuitry
loads allows for it, a 470- Load & Power
ohm resistor is a
If your load’s capacitive or inductive peaks are not common choice.
managed correctly, the internal reed switch can (Resistor circuit
Sensor Switch
be damaged and can result in pre-mature sensor diagram)
failure. One option to protect the sensors’ reed Resistor
switch is to design a general-purpose isolation
Resistor circuit diagram
relay in the application. In this scenario, the
float switch will be connected to the relay coil,
although this is an inductive load, typically will
have a peak current less than 500 mA. The
float switch will control the relay coil and open
and close the relay’s output contacts. The relay

38 RochesterSensors.com | 800-852-9984 | [email protected]

Design suggestions for both AC INDUCTIVE and In summary
CAPACITIVE LOADS Electrical current overload is a common cause
of failure for reed switch-based liquid level
AC Relay Coil, AC Solenoid, AC Motors and other
switches. If proper measures are not taken with
AC inductive loads: your sensor design, switch failure will likely occur
AC inductive loads can have peak power spikes when switching inductive and capacitive loads.
10-20 times greater than the rated full load power. When you take the proper protective measures to
This peak power spike exists both when the ensure that your liquid level switch is operated at
switch closes and when the switch opens (Lasting its rated electrical load, you can expect this highly
a fraction of a second or longer). Although this reliable reed to deliver millions of switching
power pike only lasts a very short time, it will still cycles over the course of its lifetime.
damage and/or destroy the switch. There are
several solutions to help reduce the impact of the
AC power spikes to the sensor’s switch.
Across the sensor’s switch (parallel wiring), wire
a resistor and capacitor in series. Calculate the
approximate resistor value by multiplying 2
times the peak
voltage value Load & Power
divided by the
current across
the switch. A
Sensor Switch
resistor within
20% of this
value is a good
starting point.
Commonly a .1uF
RC network
capacitor is used.
RC network diagram
See (RC network
diagram).
Another option is to wire a varistor in parallel
with the sensor’s switch. Consult with the varistor
manufacturer to determine the correct model
and rating of the
varistor for your Load & Power
application.
(Varistor
Sensor Switch
diagram)

Varistor
Varistor diagram

RochesterSensors.com | 800-852-9984 | [email protected] 39

 APPENDIX 3: Threaded Connections

Threaded Fittings are some of the most common Torque installation of pipe fittings is not
way of mounting float style liquid level sensors: recommended. Thread taper, quality, port and
The most common types of threaded fittings are fitting materials, plating thickness and types,
NPT (national pipe thread) and straight threads thread sealants, and orientation reduce the
(SAE or BSP). reliability of a torqued connection.

NPT threads create a seal because the threads One of the challenges with stainless steel NPT
are tapered. The tapered fitting threads and threads is that tightening the fittings without
the adapter seal together due to the friction lubrication can cause galling, making it very
created in the friction of tightening two tapered difficult to remove the sensor in the future.
threads. For pressure seal using NPT fittings, it Thread sealant or Teflon tape is needed to prevent
is recommended to use a pipe sealant. The pipe galling. If using Teflon tape, be careful to apply
sealant helps create a seal as well as prevents it sparingly as the extra material can prevent the
galling of stainless steel fittings. Straight threads threads from sealing properly.
do not seal by tightening them together. To seal
straight threads an external seal, such as gaskets
or O-rings are required.

NPT assembly instructions

1. Inspect the tank fitting port and sensor fitting
to ensure that both are free of contaminants
and burrs.
2. Apply a stripe of an anaerobic liquid pipe
sealant around the male threads leaving
the first two threads uncovered. If no liquid
sealant is available, wrap Teflon tape 1-1/2
turns in a clockwise direction, viewed from
the pipe end, leaving the first two threads
uncovered.
3. Screw the fitting finger tight into the port.
4. Wrench tighten the fitting 2-4 turns past finger
tight position (based on fitting size) so that
total thread engagement is achieved as shown
in the table 1 below.
5. An NPT fitting’s engagement length – the
amount of overlap between the male and the
female fittings – depends on pipe size and
the applied torque. In the figure below, the
dimension below each fitting is the hand tight
engagement length.
CAUTION: Never back off an installed pipe fitting to
achieve proper alignment. Loosening installed pipe
fittings will corrupt the seal and contribute to leakage
and failure.

40 RochesterSensors.com | 800-852-9984 | [email protected]

 How to quickly determine the nominal size
of a male NPT thread
NPT fitting sizes do not match the outside Fitting sizes may also be referred to using a
or inside thread diameter. An NPT fitting’s dash number. Dash numbers refer to the size in
engagement length, the amount of overlap sixteenths of an inch using the numerator over a
between the male and the female fittings, denominator of 16. In the example above, ½" pipe
depends on pipe size and the applied torque. In thread is converted to 8/16" and written as -08.
the figure 13 following, the dimension below each O-ring fittings used with hydraulic straight thread
fitting is the estimated hand tight engagement fittings are referred to in this way.
length.

NPT dimensions

1/2" NPT 3/8" NPT 1/4" NPT 1/4" NPT

.840" O.D. .680" O.D. .540" O.D. .540" O.D.
.78" .59" .53" .53"

2" NPT
2.375" O.D.
.16"
.23"
1.00"
.24"
.32"
1-1/4" NPT
1" NPT 1.687" O.D.
3/4" NPT
1.05" O.D. 1.312" O.D.
.90"
.80"
.79"

.34"
.40"
.44"
.42"

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 How to determine the nominal size of an NPT Pipe thread
thread dimensions

NPT fitting sizes do not match the pipe’s actual

physical dimensions. The outside diameter
(OD) of the pipe fitting should be measured and
compared to the reference table 1 following for
identification. A

Male threads
Referencing NPT Dimensions, measure the B
outside diameter of the large portion of the
thread, shown as A. Find the figure nearest this
dimension in column 1 or 2 of the table 1. The
number in column 3 is then the nominal pipe
thread size. For example, a male thread with an
A dimension of 2 3/8" will have a nominal pipe
fitting size of 2" as shown in table 1.

Female threads
Referencing Pipe Thread Dimensions, measure the
top diameter of the thread, shown as B. Find the C
figure nearest this dimension in column 1 or 2 of
the table 1. The dimension in column 3 is then the
nominal pipe thread size. For example, a female
thread with a B dimension of 2 3/8" will have a
nominal pipe fitting size of 2" as shown in 1.

42 RochesterSensors.com | 800-852-9984 | [email protected]

 Table 1

Nominal Dash Size OD/ID TPI Normal engagement

Pipe Size in decimal threads per for a tight joint

inches inch (dimension "C")

1/4" -04 0.540" 18 0.4018"

3/8" -06 0.675" 18 0.4078"

1/2" -08 0.840" 14 0.5337"

3/4" -12 1.050" 14 0.5457"

1" -16 1.315" 11-1/2 0.6828"

1-1/4" -20 1.660" 11-1/2 0.7068"

1-1/2" -28 1.900" 11-1/2 0.7235"

2" -32 2.375" 11-1/2 0.7565"

2-1/2" -40 2.875" 8 1.1375"

3" -48 3.500" 8 1.2000"

3-1/2" -56 4.000" 8 1.2500"

4" -64 4.500" 8 1.300"

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