In this exercise, you will study the construction and operation of a magnetic reed

float switch. You will use a float switch to limit the amount of liquid pumped into a
column.

The Discussion of this exercise covers the following points:

Introduction

Reed switch float switches

Industrial applications

Advantages and limitations

A float switch is a point-level detection device used to actuate another device

when the level in a vessel rises above, or drops below, a set point. Like all point-

level sensors, float switches allow level detection of a single discrete level.

A float switch that stops a pump when a tank is full is an example of a typical

float switch application. Figure 4-3 shows a point-level detection mechanism that

uses a simple float switch.

Figure 4-3. Float switch application.

In this example, the float of a float switch is displaced when its buoyancy makes

it move upward when it comes in contact with the liquid. The float can be linked
mechanically to an actuator, such as in the example of Figure 4-3, or via another

mechanism, such as a reed switch and magnet mechanism. The working

principle of float switches using this type of mechanism is described in the

section below.

Reed switch float switches have two main components: a reed switch and a float

with an encased magnet. Depending on its position along a stem, the float
actuates (or does not actuate) the reed switch.

The reed switches used in float switches usually have a single-pole, single-throw

(SPST) or a single-pole, double-throw (SPDT) contact configuration. The reed

switch in the float switch of the training system is of the SPST type.

The reed switch was invented in 1936 by Walter B. Ellwood from the Bell

Telephone Laboratories. As stated in the original patent application, this device

eliminates the complicated mechanical and magnetic structures of the usual

Figure 4-4 shows a typical reed switch diagram. This type of switch is named

after the thin metal reeds enclosed in its glass capsule. The capsule is filled with
an inert gas to prevent the reeds from rusting. The portions of the reeds that

come in contact when the switch closes are plated with precious metal to ensure

good conductivity.

Glass capsule
Reed

Inert gas

Terminal Gap Contact plating

Figure 4-4. Reed switch.

The working principle of a reed switch is simple. In the absence of an outside

force, the reed switch is open. The gap between the two reeds isolates them and

no current can flow through the switch. However, if a permanent magnet is

two reeds together. As shown in Figure 4-5, the plated tip of one of the reeds

becomes a magnetic north pole, while the tip of the other reed becomes a

magnetic south pole1. Since the tips of the reeds have opposite magnetic poles,
they attract each other and the two reeds snap together to close the electric

circuit. When the magnet is removed from the proximity of the switch, the

stiffness of the reeds brings them apart and the electrical circuit is open again.

1Note that each reed also has an opposite pole at its other extremity. Magnetic poles

always come in pairs; a magnetic monopole has never been observed.

Permanent magnet

Magnetic flux
S N

N
N S

Contact closed

Figure 4-5. Actuated reed switch.

In a float switch, the reed switch described above is located in the stem, a non-

magnetic tube. The stem is waterproof and protects the reed switch from water.

The float has a cylindrical shape and the stem passes through a hole along its

axis. The float is made of a material of a lesser density than water so that it

floats. A permanent magnet is embedded in the float and, when the float moves

along the stem, the magnet changes the state of the reed contact.

The working principle of the float switch can be summarized as follows. The float

is made of a material that is lighter than water and incorporates a permanent

magnet. As the float rises and falls with the changes in the water level, it moves
the magnet along the stem, thereby opening and closing the reed switch contact,

which consists of two thin moveable blades of ferromagnetic metal. The free

ends of the reeds are the contact points and form the actual reed contact.

Float switches can be normally open or normally closed switches. For example,

the factory default configuration for the float switch, Model 6570, is with the reed

contact acting as a normally closed contact. With this configuration, the magnet

in the float closes the reed contact when the level is below the float. When the
level rises above the float, the magnet rises with the float and, because it is too

far from the reed switch, its magnetic field is too weak to keep the reed switch

contact closed. Thus, the two reeds separate from each other and the circuit

opens. Figure 4-6 shows how a float switch operates in NC configuration.

Stem

Contact open

Contact closed

Float

Lower stop

Figure 4-6. Float switch (NC configuration).

Float switches are mainly used to perform on/off control and to start sequential
operations in batch processes. They are also used to trigger alarms when high or

low liquid levels are detected in vessels. High levels can indicate unusual change

in normal load demand due to clogged pipes or valves accidentally closing, while

low levels can indicate pump or liquid supply failure.

Float switches are relatively inexpensive, reliable, and require minimum

maintenance. However, they are limited in their use as on/off control devices or

alarm switches. They do not provide continuous measurement of the liquid level.

Moreover, some types of float switches are not recommended for processes
where dirty liquids are handled. For example, liquids that contain particles of

ferrous metal can cause malfunction of magnetically operated float switches.

The float switch is not designed to operate in a pressurized column. To avoid damage to

the equipment, be sure the column is open to atmosphere when using the float switch.

The float switch is designed to be installed in the column, through the opening at

the top of the column. Use Figure 4-7 and the instructions below to install the

float switch on your system.

a. Loosen the positioning lock of the mounting screw on the float switch.

b. Insert the float switch all the way into the column. Secure the float switch

to the column by tightening its mounting screw fully.

c. By making the float switch slide within the column, adjust its position so

that the bottom of its float is aligned with the desired mark on the

graduated ruler of the column. Lock the float switch into position by

tightening its positioning lock fully.

Positioning
lock

Mounting

screw

(a) (b) (c)

Figure 4-7. Installing the float switch.

The Procedure is divided into the following sections:

Set up and connections

Level regulation

End of the exercise

1. Set up the system shown in Figure 4-8. In this circuit, the float switch is used

to limit the amount of water that can be pumped into the column. Adjust the

position of the float switch so that the bottom of the float is aligned with

the 52 cm (20.5 in) mark on the graduated ruler of the column.

Overflow hose

Plug

Figure 4-8. Using a float switch to limit the amount of water pumped into a column.

a The overflow hose causes the column to be open to atmosphere through the
reservoir of the pumping unit.

2. Make sure the reservoir of the pumping unit is filled with about 12 liters
(3.2 gallons) of water. Make sure the baffle plate is properly installed at the

bottom of the reservoir.

3. On the pumping unit, adjust pump valves HV1 to HV3 as follows:

Open HV1 completely.

Close HV2 completely.

Set HV3 for directing the full reservoir flow to the pump inlet.

4. Turn on the pumping unit.

5. Make the pump rotate at maximum speed.

6. Observe the water level as it rises within the column. What happens when

the level reaches the activation level of the float switch? Explain.

The contacts of the oat switch were closed while the column was
being lled but when the water level reached the activation level of

the oat switch the pump turned o , causing the water in the column

to ow back to the reservoir.

7. What causes the pump to alternately start and stop? Explain.

When the oat inside the oat switch reaches the lower stop due to

low water level, the reed switch inside the oat switch will close its
contacts causing the pump to start. When the oat reaches the upper

stop, the reed switch will open its contacts causing the pump to stop.

8. Note and record the level of the water in the column when the float switch

activates and when it deactivates.

The oat switch activates the pump at a water level of 16.75”, and

deactivates the pump at a water level of 17.5”. Therefore, there was

0.75” between start and stop.

9. Stop the pump.

10. Reposition the float switch tube so that the bottom of the float is aligned with

the 47 cm (18.5 in) mark on the graduated ruler of the column.

11. Restart the pump at maximum speed. Does the float switch activate and

deactivate at the levels recorded in step 8? Explain.

After the oat switch was repositioned higher in the column, there

was still 0.75” between the starting and stopping of the pump. The

only di erence was that the pump would start at 18.5” and stop at

19.25”.

12. Set pump speed to 50%. Do you observe a difference in the levels at which

the float switch activates and deactivates? Explain.

After setting the pump speed to 50%, the pump would start at 18.5”

and stop at 19”. Therefore there was only 0.5” between start and

stop. With the pump at a slower speed, there will be less water

pumped into the column after the oat has reached the upper limit.
This shows that the oat switch is less precise when the pump is

operating at max speed.

13. Stop the pump and turn off the pumping unit.

14. Disconnect the circuit. Return the components and hoses to their storage

location.

15. Wipe off any water from the floor and the training system.

In this exercise, you used a float switch to limit the amount of water pumped into
a column. You saw that the float switch automatically turned off the pump when

the water level approached the top of the column. It automatically restarted the

pump after the water level had returned below the activation point of the switch.

1. What are the most common functions for the float switches?

The most common function of a oat switch is a level detecting

device. For example, stopping a pump when a tank/reservoir is full

of uid or starting a pump when the uid drops below a set level.

2. Name one advantage of using a reed switch.

An advantage of using a reed switch is that it is simple to use and

very reliable.

3. Explain how a reed switch works.

A reed switch is a glass capsule lled with inert gas. The capsule contains two

metal reeds which are separated by a small air gap when the switch is open. When

a magnetic force is brought close enough to the capsule, the two reeds will

become opposite magnetic poles and will attract each other and connect. When

the two reeds are connected due to magnetism, the reed switch will be closed.

4. Why is the reed switch glass capsule filled with an inert gas?

The inert gas inside the capsule is to prevent the metal reeds from

rusting, because rust would a ect the conductivity between the

reeds.

5. Name one advantage and one limitation of float switches.

An advantage of oat switches is that they are reliable and therefore

require minimum maintenance. A disadvantage is that they are limited to

on/o control and cannot provide measurements.