Level Switches

Types & Applications

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What is a Level Switch?
A level switch is an electrical or mechanical method for
measuring the level of a liquid or powder material. It is
designed to activate an alarm if the material level in a
container passes a predetermined height or depth .

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 Types of Level Switches
1 - Capacitive Level Switch
Capacitive level switches are designed
to measure corrosive liquids, high
temperatures, and liquid levels in
sealed containers. A capacitive level
switch works on the principle of
capacitance. It has an electrode that
changes when the height of the
medium changes and causes its
capacitance, the ratio of its electrical
charge, to change. The sensing
mechanism changes the level or
height of the medium into a current
signal transmitted to a secondary
instrument or computer
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 Types of Level Switches
2 - Conductivity Level Switches
Conductivity level switches have
sophisticated and highly sensitive
sensors that record slight changes
in the level of a liquid. They have
conductive probes that are
completely insulated electrodes
except for their tips to avoid
electrical bridging. The probes
work by the variations of the
electrical resistance between
them, with one electrode being
the reference electrode and the
other being the level control
electrode.
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 Types of Level Switches
3 - Diaphragm Switch
A diaphragm level switch
measures pressure changes
caused by the level of the
material rising or falling. As the
level rises, air pressure gets
higher, and the face of the
diaphragm falls under the
pressure, which activates a micro
switch. When the pressure gets
lower, the diaphragm returns to
its initial position. Diaphragm
level switches have an electrical
contact output and have wide
industrial use
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 Types of Level Switches
4 - Displacer Level Switch
Displacer level switches are
designed to work where there are
high temperatures and pressure.
They have a weight, which is its
displacer, suspended on a spring
that is heavier than the media.
When the media makes contact
with the displacer, buoyancy force
is produced that changes the
weight of the displacer and causes
the spring to retract. As the spring
retracts, it sends a magnet upward
that actuates the switching
element
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 Types of Level Switches
5 - Float Level Switch
A float level switch is a
mechanical switch that floats
on the surface of the media
and moves up or down as the
media rises or falls. They are
commonly used with pumps,
valves, or alarms. Float
switches are a cost effective
and reliable level switch that
can be used with a wide
variety of media.

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 Types of Level Switches
6- Hydrostatic Level Switches
Hydrostatic level switches are a
threshold contact that contains a
pressure switch or pressure
sensor placed in a solid state
NPN or PNP switch. All liquids are
influenced by gravity and
produce hydrostatic pressure,
which is similar to the weight of
a solid object. With liquids, it is
possible to measure the weight
of the liquid in relation to its
level. The weight of the liquid at
different levels is proportional to
a specific level
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 Types of Level Switches
7 - Inductive Level Switches
Inductive level switches are non-contact
switches that respond to a targeted material
when the material comes within the sensing
field. An oscillator resonant circuit uses an open
core coil to produce a concentrated high
frequency electromagnetic field that comes
from the surface of the sensor. If a material
enters the target area, eddy currents are
produced.
When detection is made, the amplitude of the
oscillating unit decreases, and the oscillator is
attenuated. The lower amplitude of the
oscillating unit sends a signal to the electronic
circuit that changes the switching state of the
inductive level switch
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 Types of Level Switches
8 - Laser Sensor
A laser sensor is a non-contact level
switch that takes level readings using the
speed of light. A laser transmitter, at the
top of the container, shoots a short pulse
of light down to the surface of the
process material. The light reflects back
to the detector. Like an ultrasonic level
switch, a timing circuit measures the ToF
to calculate the distance.
The key to lasers is the lack of a beam
spread or false echoes and can be
directed through a very small space.
Laser level switches are very versatile
and can measure vapors and foam
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 Types of Level Switches
9 - Magnetostrictive Level Switch
A Magnetostrictive level switch senses the
level of a fluid by detecting the level of
magnets in the float and sends the data
back to the control system. It uses
buoyancy, magnetostriction, and electronics
to measure levels. A float that travels up
and down due to its buoyancy is mounted
on the level transmitter stem. In the float is
the magnetic element.
An electrical current pulse is sent the length
of the switch through a sensor wire to the
location of the float. A timing circuit
measures the pulse and its return signal.
The signal provides the location of the float
and the level of the media
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 Types of Level Switches
10 - Microwave Level Switches
Microwave level switches are non-
contact level switches that use a
microwave beam that passes from a
sender to a receiver in bursts at 220
times per second. If the bursts are
blocked and fail to connect with the
receiver by being absorbed or reflected
by the material, a relay is activated.
The uses for microwave sensors are in
applications where contact with the
medium will erode or damage a contact
sensor and where there is high
temperature, pressure, and aggregate
material
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 Types of Level Switches
11 - Optical Level Switch
An optical level switch uses the concept of reflection in a
prism and is used for high temperature and pressure
applications
It can be used as a point
level detector and
continuous
measurement level
switch for solids and
liquids. A reflected light
is sent to the receiver of
the sensor and is
refracted by the liquid
being monitored

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 Types of Level Switches
12 - Paddle Level Switch
A paddle level switch has an electric motor that slowly rotates a metal
paddle. When the material in the container reaches the level of the
paddle, the material will place a load on it. A torque switch, attached
to the motor of the switch, activates when a sufficient amount of
torsional stress is placed on the paddle.
The design and purpose of paddle
level switches are to perform
point level detection in dry bulk
materials. The paddle of the
switch is turned by a one rpm
magnet driven motor. As the
product builds up in a container,
the movement of the paddle is
blocked, activating an alarm
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 Types of Level Switches
13 - Potentiometric Level Switches
Potentiometric level switches are
continuous level switches that are
used in metal containers. A low
resistance measuring tube is
immersed in a conductive liquid,
such as an adhesive or paste. A
high frequency current is sent
through the tube. A voltage
reading is taken from the space
between the probe and the tank
wall, which is sent to an amplifier.
The sent reading is proportional to
the tank level

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 Types of Level Switches
14 - Rod Level Switch
Rod level switches have a stainless
steel rod that vibrates or oscillates
at a specific frequency and is
powered by an electronic circuit.
When the media reaches the
vibrating rod, the vibrations stop
and alert the control system. Rod
level switches are a point form of
level switches used as high and low
level indicators or for plugged chute
detection. They are designed and
shaped to resist buildup, which
would send false alarms

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 Types of Level Switches
15 - Tilt Level Switches
Tilt level switches are high level indicators
that are suspended on a cable above the
material. As the media rises and contacts
the switch, the switch tilts to the side. Tilt
level switches are designed to prevent bin
overflow and control levels in open pipes.
They are also used for over or under loads
for conveyor systems.
The sensor activates when it is tilted at an
angle of 17° of a 360° axial arc. The switch
includes a threaded bore for attaching
actuators, which increases sensing
repeatability and protects the switch from
contact with the media.
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 Types of Level Switches
16 - Tuning Fork Level Switch
Tuning fork level switches use
frequency changes to alert of level
changes in a liquid. The switch has two
tuning forks that oscillate in a circuit.
The forks are configured to vibrate at
the frequency of air. All media has a
density greater than air, which causes
the tuning forks to vibrate at a lower
frequency inside the media.
The forks extend from the switch
housing and make contact with the
media. When the media makes contact
with the forks, the feedback resonant
frequency changes indicating a change
in the level of the media.
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 Applications of Level Switches
1- Point Level Detection
A point level detection level
switch is programmed with a
predefined level and activates
when that level is reached. Level
switches used for point level
detection include capacitance,
ultrasonic, rotary paddle, and
tuning fork or rod vibration
switches. In the point level
switch system, there are two
switches with one to measure
the high level and one to
measure the low level

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 Applications of Level Switches
2 - Continuous Level Measurement
Continuous level measurement
level switches monitor the levels
of media and provide a constant
flow of data regarding the
media’s level. They include
microwave, ultrasonic,
capacitive, and float switches.
Continuous level measurement
level switches are more complex
than point level detectors since
they are designed to monitor the
whole system. They are
programmed to check a range of
levels to produce an analog
output of a container's level

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 Applications of Level Switches
3 - Contact Level Switches
Contact level switches come in contact
with the measured product or material
and include floats, conductive, and
vibrating or tuning fork level switches.
They are a very cost effective and
straightforward tool for measuring
process levels. Unlike non-contact level
switches, contact level switches have
fewer features and a simplistic design. An
important concern for contact level
switches is the configuration of the
material they will measure, such as
corrosive, acidic, or highly reactive.
Though contact level switches are less
expensive, they have to be chosen
carefully to match the medium
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 Applications of Level Switches
4 - Non-Contact Level Switches
Contact level switches come in contact with the measured
product or material and include floats, conductive, and
vibrating or tuning fork level switches.
They are a very cost effective and
straightforward tool for measuring
process levels. Unlike non-contact
level switches, contact level
switches have fewer features and a
simplistic design. An important
concern for contact level switches is
the configuration of the material
they will measure, such as corrosive,
acidic, or highly reactive. Though
contact level switches are less
expensive, they have to be chosen
carefully to match the medium
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 Choosing a Level Switch

1- Level Switch Material

Level switches are made from every type of material conceivable. When
determining what level switch to buy, it is important that the level switch be
compatible with the material it will be monitoring. Manufacturers make level
switches from brass, stainless steel, and various forms of plastic. All of these
materials can be used with wet materials that are non corrosive.
The chemical impact from the media being measured can impact the
performance of a level switch. This consideration is also a factor in deciding if
the level switch will be the immersion type, such as a displacer or float level
switch.

2- Electrical Requirements
For a level switch to work properly, its electrical connection must match its
power supply. Insufficient power supply or over supply can lead to poor
performance of the level switch or non-activation

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 Choosing a Level Switch

3- Switch Mounting
As simple as this may seem, the mounting of a level switch has a great to do
with its performance and capabilities. Fundamentally, level switches can be
mounted horizontally or vertically, which are the most basic descriptions of
level switch mounting.
Included in the mounting configurations are the size of hole through which
the level switch will be mounted, positioning on the container such as the
side, top, or bottom, threaded or unthreaded attachment, hanging or wall
mounted, and several other factors each of which must be decided in
advance of purchasing a level switch.
4 -Container Size
All level switches can be easily carried by hand and are small and compact
devices. Though this is common to all level switches, some types are easier to fit
in certain containers than other types. Of the many factors regarding the
selection process, this particular one is the most obvious but is often overlooked
due to the general size of level switches
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 Choosing a Level Switch
5 - Measurement of a Switch
This factor is the reason for purchasing a level switch. It must be decided in
advance what type of data required and the method of measurement. All
level switches are designed to take accurate readings. The types of readings
are determined by how the level switch will be used. Most applications
require two level switches, with one to measure the empty level and the
other to measure overfill.
It is important to determine what the lowest allowable level will be and how
close to the top of the container the contents should be allowed to rise.
Some of these factors are decided by the size of the container and its
volume.

6 - Material Pressure
All materials produce pressure due to their weight. When choosing a level
switch, it is important to understand if the materials being monitored will
place pressure on the level switch. If that is the case, there are level
switches designed from materials capable of withstanding high pressure
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 Choosing a Level Switch
7 -Temperature Withstanding
In the case of temperature, not all level switches are created equal. The
base material of a level switch and its type of wiring will determine the level
of temperatures that it can endure. Though all level switches can be used
for a variety of applications, only ones that are specially designed are
capable of withstanding high temperatures of 1000° C or higher.

8 - Switch Output
Level switches can produce different types of output, which can be a relay,
analog, or digital. The type of output has to match the controller that will be
receiving the data. The selection includes the type of time delay that can
differentiate between using parallel or serial output.

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Conclusion
✓ A level switch is an electrical or mechanical method for measuring the
level of a liquid, powder, or granule material.
✓ Level switches are an essential part of production operations and are
used in harsh conditions with extremes in temperature, pressure, and
vibrations.
✓ There is a type of level switch to fit any type of product or application.
They are used as a measurement device, a monitoring control, or as a
warning alarm, such as when to turn a mechanism on or off.
✓ A level switch is designed to serve a single purpose, which is to notify or
alert controllers when there is the detection of a problem with a
product's level or presence. It signals the system when the measured
level is outside the programmed parameters.
✓ Level switches are an economical method for monitoring, controlling,
and regulating the levels of bulk materials and fluids or liquids

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Thanks…

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