Help me do this better, switches/ATO

[iReefer12]

I have a large 200 gallon ATO reservoir. I have 4 float switches, low, 80 left, 160 left, and Full.

I have had this setup for a year, but my low sensor suddenly crapped out on me. So I investigated and realized water had got behind the seal and had eroded the copper wire (double bad!!!) not sure how much of this copper was then leaching into the top off, but either way, not good.

Anyone come up with a better solution to place the float sensors in big containers like this?

 

[iReefer12]

The strategy I had was to use 1/2 PVC and thread the cable down the pipe, solder the float switch and then cement the cap on, this clearly wasn’t water tight.

Corrosion on the wire in the last pic.

 

[iReefer12]

Perhaps if I do the same thing, but to finish it off, I fill the cap with silicone and let it set? Thoughts anyone?

 

[Red_Beard]

If you don’t mind getting a little technical, optical/infared liquid level sensors are pretty robust. But you will need a raspberry pi or arduino or something to interface with it. Another cool no contact option is ultrasonic. That will tell you exactly how full the tank is, but, is another tech solution.

I think your previous idea would work too, but you’d need to seal the threads as that was likely the point of ingress. Unless you had a faulty float. I would use ptfe tape, either the thick gray oatey stuff or blue monster. The white cheep Chinese stuff is useless. And be careful not to over tighten . Good luck either way, that stinks!

 

[Rundmc2016]

Question. What do you do with the information that the different float switches tell you? Just curious. If you don't take any action until it is almost empty then the avast barrel tender will get you a copper free refill method, but that will only start filling at low and turn off when full. If you really need the information at 80 / 160 gallons you can add avast pressure switches.

https://www.avastmarine.com/products/barrel-tender
https://www.avastmarine.com/products/pressure-switch

 

[Dburr1014]

Where I solder the wires I have shrink tubing filled with rtv. Shrink the wire and the rtv spills out so I know it's filled.

Or are you saying the point where the company filled the wires on the float switch failed?