In modern facilities governed by Building Automation Systems (BAS), the problem is often digital rather than purely mechanical. These systems rely on level sensors—typically ultrasonic, capacitance, or conductive probes—to relay data to the control panel. If a sensor becomes fouled with biological growth (biofilm) or scale, it may report a "low level" reading when the basin is actually full. Consequently, the automation system commands the makeup valve to open, causing an overflow event. This highlights the critical need for regular sensor calibration and cleaning; a dirty sensor is not just inaccurate, it is financially wasteful.
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Link a water flow switch on the overflow line to your alarm system. This provides immediate notification the moment water begins to exit the system improperly. In modern facilities governed by Building Automation Systems
Inspect valves and sensors monthly. Remove scale buildup from probes and ensure mechanical arms move freely. innovek
Does it overflow or only when the pumps turn off ? What is the approximate age of the unit?
You aren't just losing water; you are losing the expensive corrosion inhibitors, biocides, and scale dispersants added to that water. This leaves your internal piping vulnerable to rust and biofouling.
💡 If your tower overflows every time it shuts down, your basin level is likely set too high. Try lowering the float by two inches to create a "buffer zone" for water returning from the pipes.