Automatic Water Refill System for Chemical Dosing Tanks Using Float Sensors and Microcontroller

Abstract

This paper presents the development of an intelligent water refill system designed for a chemical dosing tank using a microcontroller-based electronic circuit. The system is equipped with four strategically placed float sensors that monitor the water level within the tank. A water pump, controlled by the microcontroller, regulates the flow of distilled water into the tank. When the water level drops to the lower float, the system activates the pump to begin refilling. Once the upper float is reached, the pump is automatically shut off to prevent overfilling. Additionally, the lowest float functions as a critical low-level alarm, and the highest float serves as a high-level alarm, both triggering LED and buzzer warnings. This design automates manual processes, improves system reliability, and minimizes human intervention. The integration of electronic controls ensures timely refills and safeguards against tank dry-out, which is essential for consistent chemical dosing performance. The system also includes a manual override switch for pump control in the event of automation failure. Its compact design and low cost make it suitable for industrial and laboratory environments where water level management is critical.