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Reed Switch - Level Switch and Float Switch Electrical Considerations
Electrical Considerations for Reed Switch Devices

The life of the reed switch is typically 106 - 109 operations, dependent upon load conditions. The special reed blade material is selected to ensure a mechanical life of at least 3 x 109 operations.

Contact Protection: The specified value of switching current and/or voltage must never be exceeded, even for very short periods. It is strongly recommended that contact protection be used whenever there are capacitive or inductive loads (long leads and relay loads). High inrush loads caused by filament lamp switching or capacitances may be compensated for by using current limiting resistors. These should limit the current to that acceptable to the reed switch.

Electrical current overload is a common cause of failure for liquid level switches utilizing reed switch technology. Reed switches are rated for a steady-state current. Devices such as motors, solenoids or coils can produce capacitive or inductive electrical loads. When power is applied or removed from these devices, it can produce a current spike from 4 to 10 times the switch's steady-state current. This spike in the current can arc across the contacts of the reed switch, causing the contacts to fuse together or stick. When this occurs, the switch may fail or appear unreliable. To prevent this type of failure, a circuit can be wired in conjunction with the switch to protect it from the current overload caused by capacitive or inductive devices. A resistor/capacitor network or varistor can be used for AC loads, and a diode can be used for DC loads.

When trying to switch loads (capacitive or inductive) that exceed the maximum steady-state current rating of the reed switch (see UL Current & Voltage Rating Chart below), Madison recommends the use of general-purpose/isolation relays or controllers to protect the switch from current overload. This will prevent the contact of the reed switch from fusing together, thereby increasing the lifespan and reliability of the switch. Madison offers the R1 general-purpose DPDT relay for switching simple loads, as well as the R2 controller to perform pump-up or pump-down control when used with at least two levels. Keep in mind that any relay or controller that you use should be rated to handle your supply voltage and have a current rating greater than your maximum supply current.

Current and Voltage Rating of Liquid Level Switches

UL Rating of Level Switch Madison Calculation
Nominal VA Amperes
(resistive)
at 240 VAC
Amperes
(resistive)
at 120 VAC
Amperes
(resistive)
at 120 VDC
Amperes
(resistive)
at 24 VDC
Amperes
(resistive)
at 12 VDC
360 1.50 3.00 0.75 3.00 3.00
100 0.40 1.00 0.40 1.00 2.00
60 0.40 0.50 0.20 0.50 0.70
30 0.14 0.28 0.07 0.28 0.56
25 0.28 0.28 0.28
15 0.12 100 VDC / 0.10 0.30 0.30

Above ratings are for resistive loads only.
Maximum voltage ratings: SPST Switches – 240 VAC; SPDT Switches – 120 VAC

Please note: Nominal VA is Volts x Amps and is the term used for Apparent Power in AC circuits. It is simply the product of voltage and current, without taking into account the type of load (resistive or inductive). In this chart we use the Nominal VA with resistive load in conjunction with the applied AC voltage to determine the current – we are stating currents with a resistive load. Watts and VA can be used interchangeably in the charts above.

We recommend that switches stay below these ratings for non-resistive loads.

Current and Voltage ratings are for resistive loads only. For inductive loads, maximum life will be achieved if appropriate arc suppression is used.

Maximum voltage ratings: SPST Switches — 240 VAC; SPDT Switches — 120 VAC

Each switch has a power rating in watts. These power ratings are for resistive loads that are at a steady state and are calculated as Power (Watts) = Voltage (AC/DC) * Current (Amps-resistive load). Most devices have other things to consider, such as current or voltage spikes caused when powering up or shutting down. Common devices such as pumps, coils and light bulbs can create these types of spikes. For these more complex cases, one must remember to stay within the maximum current and voltage ratings of the switch regardless of the power rating.

For example, our 30-watt standard switches have a maximum switching current of 1 Amp and a carrying current of 2.5 Amps. If the switch is connected to a 12 V circuit that spikes to 2 Amps and runs at a steady state of 1 Amp, the power spike exceeds the switch rating although the steady state running power is 12 Watts. Due to the heat and type of power dissipated during the spike, the contact may be damaged or even welded together, causing switch failure.

Custom designs have other elements to consider and even alternative ground paths that may affect the power delivered to a switch. It is important to consult your engineering department before assuming the system's power requirements. Contact the factory for additional assistance.

Tank Level Control

For Pump-Up Applications For Pump-Down Applications
For Pump-Up Applications For Pump-Down Applications
Madison has extensive experience in the design and production of tank level controls. Level switches with two or more floats are often used as part of a control system for pumps and other filling devices. For single-phase devices, such as solenoids and pumps with fractional horsepower motors, a single relay circuit may be incorporated in an enclosure for either filling or draining operations. For larger pumps, where three-phase operation is required, the same relay circuit can be used to control the three-phase contactor in the motor control circuit. Consult Madison's fluid control engineers for assistance with these applications. Typical circuits for this type of control are illustrated here.

Wire Color Guide

Wire Colors for Full-Size Multi-Point Switches
with SPDT Switches

Note: Maximum of four levels with SPDT switches
Number of
Switches
Color Code
(Top to Bottom)
1 C - Black, NO - Green, NC - Yellow
2 C - Blue, NO - White, NC - Red
C - Black, NO - Green, NC - Yellow
3 C - Blue, NO - White, NC - Red
C - Brown, NO - Orange, NC - Violet
C - Black, NO - Green, NC - Yellow
4 C - Blue, NO - White, NC - Red
C - Brown, NO - Orange, NC - Violet
C - Grey, NO - Red/White, NC - Yellow/White
C - Black, NO - Green, NC - Yellow
Wire Colors for
Full-Size and Miniature
Multi-Point Switches
with SPST Switches
Number of
Switches
Color Code
(Top to Bottom)
2 Red
Black
3 Red
White
Black
4 Red
White
Blue
Black
5 Red
White
Blue
Green
Black
6 Red
White
Blue
Green
Yellow
Black
Wire Colors for
Standard Switches
Wire
Color
Switch Material
or Model No.
White Polypropylene
Black Stainless Steel,
Brass/Buna-N, PBT
Yellow Kynar
Brown M3326
Red M3326-NO
Note: Custom wire colors are available at customer request.
 
Madison Company | 27 Business Park Dr., Branford, CT 06405, 1.800.466.5383, Tel: 203.488.4477, Fax: 203.481.5036
Madison Europe | Tel: +31(0)548 659 034, Fax: +31(0)548 659 010