APPLICATION NOTE

AN1602-1

LIQUID LEVEL SENSING USING

REED SWITCH TECHNOLOGY
When measuring discrete levels of liquids such as automobile The system shown in Figure 1 is typical configuration used for
brake fluid, reed switch technology is simple, inexpensive and brake fluid level monitoring in automobiles, to test that the res-
reliable. The principle involves a magnet mounted on a float ervoir is FULL. Note that if the wires to the sensor are severed,
that closes an adjacent magnetic reed switch as the magnet ap- the reed switch appears to be open and the sensor registers
proaches the switch. Typically, the reed switch is mounted and low. It is therefore fail-safe in this application. Other applica-
sealed in a plastic or non-magnetic metal tube, and a ring mag- tions such as monitoring that a tank, sump or overflow vessel
net mounted on a float rides up and down the tube depending is EMPTY require that the reed switch is mounted lower, so it is
on the liquid level. Since the tube is non-ferrous, it does not closed when the magnet is low. If the vessel fills, the float mag-
impede the magnetic field, so the switch operates when the net rises and the reed switch opens. Severed sensor wires then
field intensity reaches a threshold level. Thus the reed switch is register as a vessel overflow condition – a false positive signal,
protected from the fluid being monitored. The tube should be but one which ensures that vessel overflow cannot be missed.
designed so that the point of entry of the sensor leads is above
the highest liquid level. Typically, a magnet made with inex-
pensive plastic bonded ferrite with an energy product of about Simulation tools developed by Coto and used for
16 KJ/m3 can be used. Such magnets only cost a few cents. The customer support allow magnet-switch system
principle is shown here. designs to be rapidly prototyped.

Using a ring magnet is a good solution since as the magnet

sweeps by the reed switch, only one closure occurs as the plane The method described so far frequently implemented in auto-
of the magnet lines up with the contact gap of the switch. mobiles for monitoring brake fluid levels. It can be modified
Other types of magnets and polar angles can cause two or even to register multiple levels by incorporating a chain of reed
three closures, causing potential problems in the software used switches and a resistor ladder that provides a varying resistance
to monitor the level sensor. or voltage depending on the liquid level. For example, using
three reed switches instead of one, the reed switch level sensor
can register a RED alert - “stop and check brake fluid immedi-
OFF ON ately,” ORANGE – “check brake fluid level soon,” and GREEN –
“brake fluid level OK.”

Discrete voltage levels corresponding to each switch closure

can be developed using a resistor ladder. A typical configu-
ration for a 4-switch system is shown in Figure 2. The resistor
network can be extended to any number of levels within the
resolution range of the A/D converter that is being used. Thus
deep tanks can be monitored with many discrete levels. Vari-
able switch spacing schemes can also be devised to suit tanks
with spherical or other varying cross sections.

In the case of a three-level sensor, the vehicle’s computer can

Fig. 1 LEFT – liquid level low, reed switch open. RIGHT – liquid
monitor VOUT and unambiguously determine the three differ-
level high, switch closed. ent liquid alert levels. With this scheme, the sensor designer
should space the reed switches so that only one is closed at

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 APPLICATION NOTE
AN1602-1

any given time. The required spacing can be determined by such as Coto Technology’s CT05 or CT10 series. They consist of
experimentation, or by magnetic field simulation. Simulation a high-quality reed switch encapsulated in a hard epoxy resin,
tools developed by Coto and used for customer support allow which effectively “splints” the reed switch, protecting it from
magnet-switch system designs to be rapidly prototyped. For shock, vibration and environmental damage. As such, they are
example, Figure 3 shows a simulation of a three switch level ideal for under-hood automobile operation.
sensor using a 6 mm internal diameter ring magnet. The sim-
ulation calculates the expected magnetic flux density in each
switch and the forces in the contact gap as the magnet travers-
es up and down the switch array. Animations of the changing
1.758e+000 : > 1.851e+000

field are developed; 1.666e+000 : 1.758e+000

1.574e+000 : 1.666e+000
1.481e+000 : 1.574e+000
1.389e+000 : 1.481e+000
1.296e+000 : 1.389e+000
1.204e+000 : 1.296e+000
1.112e+000 : 1.204e+000
1.019e+000 : 1.112e+000
9.268e-001 : 1.019e+000

+12V VOUT
8.344e-001 : 9.268e-001
7.419e-001 : 8.344e-001

MORE
6.495e-001 : 7.419e-001
5.571e-001 : 6.495e-001

SW1 2R
4.647e-001 : 5.571e-001

STEPS 3.723e-001 : 4.647e-001

2.799e-001 : 3.723e-001

IF NEEDED
1.875e-001: 2.799e-001
9.504e-002 : 1.875e-001
<2.623e-003 : 9.504e-002
Density Plot: |B|, Tesla

R Flux density
in switch (T)
SW2 2R

SW3 2R R
Fig. 3 Magnetic field simulation of three reed switch level sensor.
Plastic foam float supporting the magnet is non-magnetic, and is
omitted for clarity.
SW4 2R R
The CT05 series switches are surface mount devices 6.4 mm
long (9.55 mm including leads), and are also available in a
R=10KW 2R slightly short J-bend format. The CT10 series is 12.8 mm long
2R=20KW
(16.4 mm with leads). Apart from the advantages of increased
ruggedness, the surface mount format makes it simple to at-
tach the switches to printed circuit boards or flex circuits using
pick-and-place equipment. While designing the CT05 or CT10
Fig. 2 Reed switch - R 2R resistor ladder diagram. switches into a sensor, it’s useful to note that every switch that
leaves the Coto factory is tested for operate and release sen-
sitivity AFTER lead cropping and encapsulation, ensuring that
Figure 3 shows a still from such an animation. Since the flux these sensitivities are known accurately. In contrast, other reed
density required to operate a switch of a given closure sensi- switch manufacturers test the operate and release sensitivity
tivity is known for every switch leaving the Coto factory, it is before lead cropping and molding, and can only make a rough
possible to predict the minimum distance the switches should estimate of the sensitivity of the shipped product.
be spaced in order to ensure that only one switch is turned on
Relationship between Amp-Turn (AT) operate and release
at any given time.
sensitivity, and required operate and release field.
Choice of reed switch
The CT05 and CT10 series reed switches are specified in terms
Figure 1 shows a bare glass reed switch in order to visualize of the range of operate AT. For example, the CT10-1030-G1
the reed switch blades. However, bare glass reed switches are switch has a range from 10 to 30 AT. In other words, Coto war-
fragile, and a better choice is a plastic encapsulated reed switch rants that the operate sensitivity of a switch randomly selected

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 APPLICATION NOTE
AN1602-1

from a batch of CT10-1030-G1 switches will operate in a field of

between 10 amp-turns and 30 amp-turns measured in Coto’s Bare Switch
factory test coil. (The specification for this coil is available on
request.) However, most CT series switch users expect to use a
permanent magnet to operate the switch. What magnetic field
strength is needed to operate a 10 AT switch? There is a simple CT05 Molded Switch
rule of thumb to figure this. It is:

4 AT = 1 mT Bare Switch

In other words, divide the switch AT by 4 to get the required

field strength in milliTeslas (mT). So the 10 AT switch will
operate when immersed in a field of approximately CT10 Molded Switch
10/4 = 2.5 mT (25 Gauss in the older CGS units.)
Correspondingly, a 30 AT switch will close at 7.5 mT. Fig. 4 bare glass reed switches are fragile, and a better choice
is a plastic encapsulated reed switch such as Coto Technology’s
CT05 or CT10 series. They consist of a high-quality reed switch
Other level sensor design considerations encapsulated in a hard epoxy resin, which effectively “splints”
the reed switch, protecting it from shock, vibration and environ-
Considerations for designing reed switch level sensors include mental damage.
the following:

1. What is the nature of the fluid being monitored? the best choice compared to the CT10, after taking into
Though the switch will be installed inside a protective account the smaller reservoir volume that can be used,
tube of plastic or non-magnetic metal, the float and and the reduced space needed in the engine compart-
possibly the magnet will be directly exposed to the fluid, ment. Plus of course, the lower weight and volume of
so highly corrosive or flammable fluids are probably not brake fluid needed, and the resultant reduction in the
suitable. carbon footprint of the vehicle.

2. Design the system so it is fail safe. Consider what 6. What are the environmental conditions? When
condition will be registered if the leads to the sensor are looking at alternative fluid level sensing technologies
severed, and place the reed switch in the appropriate (and there are many, as a quick Google search will show),
position relative to the float position of the magnet. consider shock, vibration, high temperatures and even
G-forces. Reed float sensors using ring magnets make
3. Is continuous or discrete level monitoring needed?
great brake fluid sensors even during high-G cornering,
Reed float sensors can’t provide continuous (step-free)
since the float movement is constrained by the tube
monitoring, though as we have shown, multiple reed
containing the reed switch or switch ladder.
switches can be used to provide a series of discrete lev-
els.) 7. Consider the cost. Reed float sensors are simple, reli-
able, inexpensive and consume no power. Exotic tech-
4. Consider reliability. The CT05 and CT10 series switches
nologies such as radar, ultrasonic and magnetostrictive
have contact life expectancy between 100 million and
level sensors may be overkill for a simple level sensing
5 billion contact closure cycles while switching a signal
application. Look at all the positives and negatives be-
level load. They are also highly shock and vibration re-
fore starting your sensor design, and lean on Coto if you
sistant. It’s likely the equipment they are installed in will
need the best applications support in the industry!
wear out long before the switches do.
5. Consider the space available. Space (and weight) For further information contact [email protected]
cost money, especially in automobile applications. The For detailed data sheets on the CT05 and CT10 series switches,
smaller and slightly more expensive CT05 switch may be visit www.cotorelay.com

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