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Regular maintenance is key to avoiding float switch problems. In a harsh wastewater environment, floats can foul up quickly, so you should implement a routine schedule:
Inspection and Cleaning: Check the floats and their cables at least quarterly (every 3 months) in industrial lift stations. Many operators do a visual check monthly and a thorough cleaning quarterly. Pull the float up and rinse/scrape off any grease, sediment, or growth. Pay special attention to the pivot points or tether points where debris can lodge. By keeping the float clean and free-moving, you prevent most failure modes
Functional Testing: When you inspect, also manually test each float’s operation (using a test switch on the panel or a hooked pole to lift the float). Ensure the pump kicks on and off at the right points and that alarms function. This testing makes sure the float hasn’t failed since the last cycle. It’s especially important for alarm floats which might not activate often – you need to know they’ll work in an emergency.
Cable and Attachment Checks: Look over the float cables for any signs of wear – cuts, nicks, or deteriorated insulation. In a wastewater pit, cables can rub and eventually expose wires. If damage is spotted, replace the float or at least tape/seal the area as a temporary fix. Also verify that clamps or ties holding the floats are secure. Sometimes, vibration from pumps can loosen clamps over time, altering the float tether length. Keep a log of float positions and periodically confirm they haven’t slipped.
Preventive Measures: Consider periodic flushing of the sump or wet well to reduce solids buildup that could entangle floats. In very greasy systems, some facilities use degreasers or enzymes to minimize grease accumulation on floats (ensure any additive is compatible with your system and environmental regulations). If a particular float requires frequent cleaning, it might be worth upgrading to a different design (for example, a shielded float switch or an ultrasonic level sensor as a replacement). Preventive maintenance might also include keeping spares: having an extra float switch on hand is cheap insurance so you can swap it out quickly if one fails.
Documentation: Keep a maintenance log – note the dates of float cleaning, any adjustments made, and when floats were replaced. This can help predict when a float is nearing end-of-life. Some industrial floats can last for many years if maintained, but others might show recurring issues in which case a different product should be tried. Regular maintenance not only extends the life of the float switches but also ensures the overall