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 Float Stop

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 able 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.

The Ultimate Guide to Float Level Sensors

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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.”

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 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.

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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.

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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

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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.

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 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?

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 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

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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

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