SWITCHES, RELAYS, AND ANNUNCIATORS

I. SWITCHES
- Same operation with on/off control
- They may be operated by hand, actuated by a mechanical signal, or actuated by a process
or electrical signal.
- They may be used for many things including energizing alarms, interlocks, safety systems,
equipment, or other devices when a process condition meets a preset value.

PHYSICAL SWITCH TYPES

A. Toggle Switches
- They consist of a rocker device, usually a lever, that allows a circuit to be powered or
depowered by throwing the switch from the open to closed position or vice versa.
- They can be made exceptionally durable with metal housings.
- They can be made so that they take up very little room and can be installed in great numbers
on panels.
- With the addition of light indicators that show whether they’re on or off, they’re ideal ways to
control large groups of machines.

Advantages: Disadvantages:
 Typically small footprint  Minimal backlighting options available
 Ideal for use with circuit boards  Restricted labeling options
 Easy to seal  Requires a toggle lock washer
 Highly durable

B. Limit Switches
- They are contact sensing devices widely used for detecting the presence or position of objects
in industrial automation systems.
- They can be installed into machinery as control instruments for standard operations or as
emergency devices to prevent machinery malfunction.

Three Key Components of Limit Switches:

1. Actuator Head – The actuator is the part of the switch that makes physical contact with the
object.
2. Switch Body – The switch body is the component containing the electrical contact
mechanism. The contacts within the body open or close the electrical circuit when the
actuator is activated.
3. Receptacle/Terminals – The component containing the terminal screws or screw/clamp
assembly necessary for wiring purposes.
 Advantages:
 Can be used in almost any industrial
environment
 Very precise in terms of accuracy and
repeatability
 Consume little electrical energy
 Can switch loads with high inductance
 Can control multiple loads
Disadvantages:
Not desirable in food application or areas
where repeated touching can damage the
object
Moving mechanical parts will wear out.
Generally restricted to equipment operating at
relatively low speeds

C. Proximity Switches
- They sense the closeness of an object without having to make physical contact.
- These switches are non-contact sensors, using magnetic, electric, or optical means to sense
the proximity of objects.
- They are used to measure the position of machine components, security systems, and in
applications such as detecting the opening of a door.

Four Basic Types of Proximity Switches:

1. Inductive – These switches sense distances to objects by generating magnetic fields. They
are similar in principle to metal detectors.
2. Capacitive – These switches sense distance to objects by detecting changes in electrical
capacitance around it.
3. Infrared – These work by sending out beams of invisible infrared light. A photodetector on
the proximity switch detects any reflections of this light. These reflections allow infrared
proximity switches to determine whether there is an object nearby.
4. Acoustic – These sensors use a transducer to transmit inaudible sound waves at various
frequencies in a preset sequence, then measure the length of time the sound takes to hit a
nearby object and return to a second transducer on the switch.

Advantages:
 They do not cause abrasion or
damage to the object.
 No contacts are used for output, so it
has a longer service life.
 Provide high-speed response
compared with switches that require
physical contact
Disadvantages:
 Unlike switches which rely on physical
contact, proximity sensors are
affected by ambient temperatures,
surrounding objects, and other
sensors.

D. Vibration Switches
- They are devices that recognize the amplitude of the vibration to which it is exposed and
provides some sort of response when this amplitude exceeds a predetermined threshold value.
- They are primarily used for protecting critical machinery from costly destructive failure by
initiating an alarm or shutdown when excessive vibration of the machinery is detected.
 - They can also be utilized to warn the absence of vibration, such as when a conveyer ceases
to function due to a broken drive belt.
- They are commonly used on rotating equipment such as compressors, centrifuges, steam
turbines, and blowers.

Advantages:

 Provides continuous machinery protection

 Electronic and mechanical switches are available.
 Adjustable time delays to avoid false trips during switch power up, equipment startup, and
operational changes

E. Process Variable Switches

- Such switches can be used to sound alarms, indicating that a process variable has exceeded
normal parameters, or they can be used to shut down processes or equipment if these
variables have reached dangerous or destructive levels.

Types of Process Variable What process variable does

Sensing Element
Switches it detect?
Pressure Switches Presence of fluid pressure Diaphragms or bellows
Level of liquid or solid in a
Level Switches Floats
vessel
Temperature Switches Temperature of an object Bimetallic strips
Flow Switches Flow of fluid through a pipe Paddles

SYSTEM RESPONSES DUE TO SWITCH ACTION

A. Alarm Switches
- They are used to notify when a process variable enters an abnormal range. The switch triggers
an alarm that informs the process technician of the condition.

“Hard” vs. “Soft” Alarms

Hard alarms
They are hard-wired into the process.
They are not exposed to the adverse effects of
a common-mode failure because they maintain
complete independence from the DCS or PLC.
Basic Alarm Trip Functions
Soft alarms
They are software-implemented alarms found
within a Distributed Control System (DCS) or a
Programmable Logic Controller (PLC).
They can be susceptible to failures that could
disable all soft alarms in the system.
Trigger
 High and Low Limit Alarms
Rate-of-Change Alarm
Self-Diagnostic Alarm
Average Alarms
Differential Alarms
Window Alarm
When the value of the variable being measured
exceeds a preset high or low alarm trip point
When the input rate-of-change exceeds a user-
selected rate over a user-selected time period
Some limit alarm trips continuously monitor
their own status during operation, and trip if
they are not operating properly.
When the average of two or three input signals
exceeds a pre-selected high or low trip point.
When the difference between two input signals
exceeds a specific value
When the process variable is outside of the
low/high trip point ranges.

Alarm Trips with Multiple Relay Outputs Mechanism

 A status change of a single high alarm
occurs when the input rises above the trip
point.
High Alarm  The status will return to a non-alarm
condition when the input falls below the
deadband.

 This alarm accepts one input, but has two

high relays, each with its own trip point.
 When the input rises above Trip Point 1 (the
lower trip point), the first set of contacts will
High/High Alarm change status merely to serve as a warning;
however, should the input rise above Trip
Point 2 (the higher trip point), the second set
of contacts change status, which may initiate
an emergency shutdown.

 The alarm condition of a single low alarm

occurs when the input falls below the trip
point. The status will return to a non-alarm
condition when the input rises above the
Low Alarm deadband.
 A typical application of a low alarm is warning
of a low tank level to avert problems with a
pump running dry.

 A dual low alarm accepts one input, but has

Low/Low Alarm two relays, each with its own independent
trip point.
  When the input falls below Trip Point 1, the
first set of contacts will change status merely
to serve as a warning. Should the input fall
below Trip Point 2, the second set of
contacts change status, possibility initiating a
shutdown of the process.
 A typical application includes monitoring the
low extreme temperature of a cryogenic tank
to avoid over-cooling.
 A dual high/low alarm accepts one input and
High/Low Alarm has two relays, each with a separate trip
point.

B. Shutdown Switches
- They are used to actuate a circuit that shuts down a process. In fail-safe situations, they can
be used to deactivate a circuit or detect an open circuit to shutdown part of the process.

C. Autostart Switches
- They trigger an auto start sequence when predetermined process conditions are met.

D. Bypass Switches
- They allow the user to override (bypass) the normal operation of a system or device in cases
of high inrush or fault conditions.
- Static bypass switches allow the normal uninterruptible power supply (UPS) operation to
be circumvented in cases of an overload or fault situation without loss of power to the load.
- An external maintenance bypass is attached to the outside of UPS and is sometimes
referred to as a wraparound bypass. It allows the engineer to completely remove power
from the system for servicing or removal, without any load interruption.

SWITCH SYMBOLS
Component Circuit Symbol Function of Component
Push Switch A push switch allows current to flow
(push-to- only when the button is pressed. This
make) is the switch used to operate a
doorbell.
Push-to-Break This type of push switch is normally
Switch closed (on), it is open (off) only when
the button is pressed.
On-Off Switch SPST = Single Pole, Single Throw.
(SPST) An on-off switch allows current to flow
only when it is in the closed (on)
position.
2-way Switch SPDT = Single Pole, Double Throw.
(SPDT) A 2-way changeover switch directs the
flow of current to one of two routes
according to its position. Some SPDT
 switches have a central off position
and are described as 'on-off-on'.
Dual On-Off DPST = Double Pole, Single Throw.
Switch A dual on-off switch which is often
(DPST) used to switch mains electricity
because it can isolate both the live and
neutral connections.
Reversing DPDT = Double Pole, Double Throw.
Switch This switch can be wired up as a
(DPDT) reversing switch for a motor. Some
DPDT switches have a central off
position.

Relay An electrically operated switch, for

example a 9V battery circuit connected
to the coil can switch a 230V AC mains
circuit.
NO = Normally Open,
COM = Common,
NC = Normally Closed.

II. RELAYS
 They assist in signal transfer by increasing (boosting), passing, or maintaining a signal. It is a
device that initiates action in a circuit in response to some change in conditions in that circuit
or in some other circuit.
 When applied to pneumatic (computational) devices, relays are analog instruments handling
continuously variable signals.
 When applied to electrical devices, relays are discrete, on/off devices.

Types of Relays
A. Pneumatic and Hydraulic
- Used to perform mathematical operations, signal conditioning, and selection or
modification operations.
 Pneumatic Relays – are those which are attached to circuits that conduct compressed
air rather than flow of electrons; however, the principle is the same.
 Hydraulic Relays – this relay uses compressed liquid instead of air.

a. Electronic (on/off Control)

- Used to control one or more circuits that are not normally part of the control circuit.

Advantages of Electronic Relay: Disadvantages of Electronic Relay:

 They require low maintenance.
 The relay has fast response time.
 They decrease the burden on the
instrument transformer.
 The high-tension supply is required for
their operation.
 The power consumption in the
electronic relay is very high.
 The relay has the short lifespan.
 b. Timing
- May be electrical, mechanical, electromechanical that is used to determine the elapsed
time between the start and stop of related operations or events (e.g. a timing relay may be
used to start an agitator 15 seconds after the pump starts).
- Examples are pneumatic timers, electronic timers, and motor-driven timers.

c. Pneumatic Booster
- Contains a high-pressure or volume source that increases the signal value or volume.
- Advantages:
 Quick response with increased actuator stroking speeds
 Maintains correct actuator positioning at high stroking speeds
 Adjustable by pass valve provides good operational sensitivity
 High stability which allow normal slow actuator response to slow signal changes
 Capable of using high pressure plant air supply
 Different Booster sizes available to suit wide range of actuator sizes
 Main internal air supply valve with soft seat insert for tight shut off

d. Selection
- Can take two or more inputs and chose a predetermined value (e.g. high, medium, low).

Relay Applications
 Refrigerator – This appliance has motors and fans. Relays are responsible in controlling these
parts so that refrigerator work and produce cold temperature.
 Controlling traffic lights – They can be operated remotely with the use of a switching
component.
 Automatic garage door –The door’s movement and direction are the ones being controlled.
 Long telegraph lines – The weak signal received at an intermediate station could control a
contact, regenerating the signal for further transmission.

III. ANNUNCIATORS
 They are instruments that provide audible and/or visual alarms in reference to some measured
variable.
 They can be standalone panel board devices or configured as part of a distributed control
system (DCS).
 The purpose of an alarm system (annunciator) is to bring attention to an abnormal or unsafe
operating condition in the plant. Traditional annunciators used discrete alarm modules for this
purpose.
 They are used in installations where simplicity is desired or where separation from the basic
process control system is required for safety reasons.
 The annunciator system consists of multiple alarm points. Each alarm circuit includes a
problematic contact (alarm switch), a logic module and a visual indicator. The problem contact
is an alarm switch that monitors a particular process variable and is activated when the variable
exceeds the preset limits.
 Examples of Annunciators:
o Audible Annunciators – bell, chime, horn, loudspeaker, and sire
o Visible Annunciators – indicator light, strobe light, and rotating beacon