SWITCHES

Switches
Flow Switch
• In industrial processing, flow is the movement of liquids,
steam, and gases through a processing system. Flow
rate measurement is used to measure the volume of
fluid process media passing through a specific cross-
sectional area per unit of time. Monitoring flow rate
measurements is essential in controlling the safe
movement of fluid within an industrial system. The
monitoring and control of flow is a requirement for all
industries that process fluid media.
Flow switch
• flow switches are used to monitor and control the flow
rate of fluid within an industrial process system.
Automated industrial systems that process fluid media
rely heavily on flow switches to ensure safe and optimal
flow rates. Flow switches respond to pre-set flow rate
levels and perform two functions when those levels are
reached: namely, closing its contacts and turning a
specific piece of equipment ON, or opening its contacts
and turning a specific piece of equipment OFF.
Flow sensor and Flow switch
• While flow switches and flow sensors both can be used
to monitor media flow within a system, the difference
between a flow switch and a flow sensor is that a flow
sensor can only monitor and display information – flow
switches monitor flow and send trip signals and trigger
specific actions from machines within the system.
.
• There are a variety of different types of flow switches on the
market today – functioning in a variety of different ways –
but what all flow switches have in common is that when the
flow rate reaches a switch’s set-point, it can either open or
close the circuit which triggers an action: whether it’s
turning a pump on or off or it’s actuating an alarm.

Flow switches are either configured to be Normally Open

(NO) or Normally Closed (NC). This refers to the default state
of the switch. With a NO switch, the circuit is open (OFF)
until triggered otherwise. With a NC switch, the circuit is
closed (ON) until triggered otherwise
Paddle Flow switch
• The paddle design flow switch is constructed with a
hinged or spring-mounted paddle, which makes direct
contact with the media flowing through the pipe. The
paddle is held in position when the media is flowing at
the target rate (or setpoint). An increase or a decrease
in the flow rate will move the paddle from its setpoint,
which, in turn, throws a small switch triggering the
specified action.
Level Switch
• Liquid level switches detect liquid levels or interfaces
between liquids such as oil and water, or liquid and solid
interfaces. Liquid level switches are used in a number of
liquid container monitoring applications including flow
line monitoring, heaters and furnaces, as well as other
household appliances, automotive applications, and
control technology.
• Principle: This is a simple limit switch based level
switch. When the float moves with the raise in level
then the output contact changes & it indicates the level
position.
• They are used as a measurement device, a monitoring control, or warning alarm,
such as when to turn a mechanism on or off. Level switches are equipped with a
mechanical or electrical output, depending on their design, and can be open or
closed.
• Types of Level Switches
• Capacitance type
• Inductive type
• Paddle type
• Float type
• Diaphragm type
• Displacer type
 Temperature Switch
Temperature
Switch has a vapour filled
flexible sensing element
actuates a micro switch
by means of a piston
when temperature
reaches the setpoint. The
set point is adjusted by
means of a compressible
spring or a adjustable
screw installed in the
switch.
• Fluid in the sensing bulb reacts to the
temperature variations and increase
the pressure in the bellows element
when the temperature rises. A rise in
the bulb temperature compresses the
bellows and moves the spindle
upwards until spring force and
bellows pressure are in equilibrium.
This movement of the spindle is
transferred to the switch and causes
on-off action.
• Bimetallic Temperature
switch
Pressure Switch
• A pressure switch is a simple electromechanical device
that is triggered by pressure to turn an electrical circuit
on or off. The pressure point that activates the switch is
called its set point, and the pressure threshold that
deactivates the switch is called the cut out point. A
pressure switch consists of the following key
components:
• A diaphragm that acts as the pressure detection
element. It is typically made of a pliable material that is
sensitive to pressure.
• An adjustment spring to vary the set or cut out
points. Some switches have separate springs for
• A pressure switch is a passive device since the presence
or absence of pressure is all that is necessary for it to
function. The pressure on the diaphragm compresses a
calibrated spring. When the spring tension reaches or
exceeds the set point, it will move the contacts from open
to closed in a NO switch or closed to open in an NC switch.
• Compressed air systems. Pressure switches turn on
or turn off the compressor at the set point.
• Process equipment. Fluid and gas flow control
equipment use pressure switches to maintain a steady
rate of flow.
Vibration Switch
• Mechanical Vibration Switches provide vibration
protection for low- to medium-speed machinery. An
inertia sensitive mechanism activates a snap-action
switch.
• The mechanical vibration switch contacts can be used
to activate an alarm or initiate equipment shutdown as
per our requirement.
Electromechanical Relay
• Electromechanical Relay
• An electromechanical relay is a type of relay which function
using a magnetic field produced by an electromagnetic coil
when a control signal is applied to it. It is called as
electromechanical since it has moving contacts in the output
circuit which are operated by applying an electrical signal.
• Electromechanical Relay: Working Principle
• An electromechanical relay transfers signals between its
contacts through a mechanical movement. It has three sections
viz. input section, control section and output section.
• The input section consists of input terminals where a small control signal is
to be applied. The control section has an electromagnetic coil which gets
energised when control input signal is applied to the input terminals and
the output section consists of an movable armature and mechanical
contacts – movable and stationary, the movement of the armature makes or
breaks the electrical circuit.
• When an input control voltage is applied to the electromagnetic coil, it gets
magnetised and the armature is attracted by the magnetic field produced by
the coil. The movable mechanical contacts are attached to the armature,
thus when the armature moves towards the electromagnet, the contacts
closes, making the output circuit switched on. When the control signal is
removed, the armature comes back to its original position by the force of
spring, making output circuit off.
• Classification of EMRs based on their applications
• General Purpose Relays – Such as miniature relays, latching relays, timer
relays, contactors, machine tool relays, hybrid relays, smart relays, signal relays,
automobile relays and PCB relays etc.
• Protection Relays – Such as thermal overload relays, earth fault relays, under
or over voltage relays, under or over current relays,differential relays, distance
protection relays, sequence protection relays, electronic relays etc.
• Classification of EMRs based on contact configurations
• Single-Pole Single-Throw (SPST)
• Single-Pole Double-Throw (SPDT)
• Double-Pole single-Throw (DPST)
• Double-Pole Double-Throw (DPDT)
EMR Specifications
• Pole Type
• AC/DC Coil Voltage
• Throw(Single/Double)
• NO/NC Type
• Maximum Current
• Coil Resistance
• Make time
• Break time
• Operating Temperature
Applications
• The typical applications of electromechanical relays include
motor control,
• automotive applications such as an electrical fuel pump,
• industrial applications where control of high
voltages and currents is intended, controlling large power loads,
Solid state relays(SSR)
• Solid state relay (SSR) is an electronic switching device made
of semiconductors that switch (On & Off) a high voltage circuit
using a low voltage at its control terminals.
• Unlike EMR (Electromagnetic relay) that has a coil &
mechanical switch (physical contacts), the SSR relay uses
Optocoupler to isolate the control circuit from the controlled
circuit.
• SSR relay has two sets of terminals i.e input terminals & output terminals.
• These two terminals are the input control terminal. It is connected to a low power circuit
that controls its switching.
• The control input of an SSR relay is designed for DC or AC circuit separately.
• The output terminals of SSR relay switches on and off depending on the control input.
• Normally, the electrical connection between these terminals remains open. When the
relay activates, these terminals connect together providing a closed path.
• The output terminals are specifically designed for either AC or DC circuit. Unlike EMR
relay, an SSR relay cannot switch both AC & DC signal using the same terminals.
• The input of the SSR relay activates the optocoupler which
switches the Load circuit. The optocoupler has no physical
connection & it isolates the low voltage circuit from the high
voltage circuit.
• Optocoupler has an LED at its input which emits infrared light
when a voltage is applied. These IR waves are received by
the photo-sensor (Photo-transistor, photodiode etc.) on its
output end. The Photo-sensor converts the light signal into an
electrical signal & switches on the circuit.
• Advantages
• SSR switching time is much faster than EMR (Electromechanical relay) relay.
• It has no physical contacts.
• There is no issue of contacts spark & wear out.
• They have a longer lifespan than EMR relays.
• SSR relay Switch off at 0 AC load current which prevents any arch or electrical noise.
• Vibrations or movement does not affect its operation.
• It has very low power consumption as compared to EMR relay.
• SSR relay is very easily controlled by logic circuits(microcontrollers)
• Disadvantages
• It has a complex design as compared to EMR relay
• There is a voltage drop across its load terminals.
• It has a leakage current during off state.
• SSR relays dissipate too much heat.
• It cannot switch low voltages as compared to EMR relay.
• SSR relay switching depends on the voltage of the controlled circuit.
Applications
• Generally, SSR relay are used for switching purpose i.e. ON/OFF
control of AC Power.
• It is used to control the power i.e. motor speed control, light and
fan dimming, power switching etc.
• They are also use to drive electric heaters to control the
temperature.
• SSR can be used as a latch which is useful in case of kettles.
• In communication lines, photocoupler SSR relay are used to
eliminate relay driving current flowing through it.
• Solid state relay are mostly used in High load switching
Interposing Relay
• An interposing relay is simply an auxiliary relay that is
used to isolate two different systems or devices from
one another.
• In Industrial Automation,
generally when people say
'interposing relay' it means
a relay that is used for
interposing, meaning to
separate or put a barrier
between two circuits.
• It normally consists of a coil
that is energised by either
AC or DC power and
activates contacts that are
used to trigger another
circuit.
• Construction of a relay.
Overload relay
• An overload relay, also referred to as a relay switch, is a device that opens the circuit
in the event of an electrical, thermal or power overload. When mounted with a
contactor they create a motor starter. Overload relays are normally closed, meaning
they only open if they experience an overload. They are used to protect motors from
damage in a number of applications across industrial and commercial sectors, among
others. They are available in a number of current ratings which can be adjustable on
some models.
• Common types of overload relays.
• Overload relays are typically one of two types: thermal relays or electrical relays. The
overload mechanism inside thermal relays consists of a bimetallic strip in conjunction
with a heating element. When the heating element experiences an excessive current,
the bimetallic strip bends and opens the normally closed contact, thus interrupting
the circuit. These have adjustable current ratings to meet a variety of application
requirements. On the other hand, electronic relays rely on electrical components
which measure the current flowing through. While these are more accurate and are
available across more current ratings, thermal relays can be more cost-effective.
Contactor
• A contactor is an electrical device which is used for switching an electrical circuit on or
off. It is considered to be a special type of relay. However, the basic difference between
the relay and contactor is that the contactor is used in applications with higher current
carrying capacity, whereas the relay is used for lower current applications. Contactors can
be field mounted easily and are compact in size. Generally, these electrical devices
feature multiple contacts. These contacts are in most cases normally open and provide
operating power to the load when the contactor coil is energized. Contactors are most
commonly used for controlling electric motors.
• There are various types of contactors, and each type has its own set of features,
capabilities, and applications. Contactors can break current over a wide range of currents,
from a few amperes to thousands of amperes, and voltages from 24 VDC to thousands of
volts. In addition, these electrical devices come in varying sizes, from hand-held
dimensions to sizes measuring a meter or yard on one side (approximately).
• The most common application area of the contactor is high-current load. Contactors are
known for their capability to handle currents of over 5000 amperes and high power over
100 kW. Heavy motor currents produce arcs when being interrupted. These arcs can be
reduced and controlled using a contactor.
 1.Coil or Electromagnet: This is the most crucial component of a
contactor. The driving force that is required to close the contacts is
provided by the coil or electromagnet of the contactor. The coil or
electromagnet and contacts are protected by an enclosure.
2.Enclosure: Just like the enclosures used in any other application,
contactors also feature an enclosure, which provides insulation and
protection from personnel touching the contacts. The protective
enclosure is made from different materials, such as polycarbonate,
polyester, Nylon 6, Bakelite, thermosetting plastics, and others.
Generally, the open-frame contactor features an additional enclosure,
which protects the device from bad weather, hazards of explosion,
dust, and oil.
3.Contacts: This is yet another important component of this electrical
device. The current carrying task of the contactor is done by the
contacts. There are different types of contacts in a contactor namely,
contact springs, auxiliary contacts, and power contacts. Each type of
Operating
contact hasPrinciple of a role
an individual Contactor:The
to play. current passing through the contactor
excites the electromagnet. The excited electromagnet produces a magnetic field,
causing the contactor core to move the armature. A normally closed (NC) contact
completes the circuit between the fixed contacts and the moving contacts. This permits
the current to pass through these contacts to the load. When current is removed, the
coil is de-energized and opens the circuit. The contacts of the contactors are known for
their rapid open and close action.
• 1. Load Capacity
• Relays are generally classified as carrying loads of 10A or less, while a contactor would be used for loads
greater than 10A,
• 2. Open/Closed Contact Standards
• Contactors are almost exclusively designed to operate with normally open (Form A) contacts. Relays on the
other hand can and often are both Normally Open and/or Normally Closed depending on the desired function.

• 3. Safety Features (Spring-Loaded Contacts)

• Because contactors are typically carrying high loads, they often contain additional safety features like spring-
loaded contacts to help ensure the circuit is broken when de-energized. This is important because in high load
situations contacts can weld themselves together. This can create the dangerous situation of a circuit being
energized when it is supposed to be off. Spring-loaded contacts help to reduce this chance, as well as ensure
all circuits are broken at the same time. Since relays are typically for lower power, spring-loaded contacts are
much less common.
• 4 Safety Features (Arc Suppression)
• Another safety feature commonly included in contactors, due to the high loads they
typically carry, is arc suppression. Magnetic arc suppression works by extending the path
an arc would have to travel. If this distance is extended further than the energy can
overcome, the arc is suppressed. Since relays aren’t designed for high loads, arcing is less
of a concern and arc suppression is much less common on relays.
• 5. Safety Features (Overloads)
• Lastly, contactors are commonly connected to overloads that will interrupt the circuit if the
current exceeds a set threshold for a selected time period, usually 10-30seconds. This is to
help protect the equipment downstream of the contactor from damage due to current.
Overloads are much less common on relays.
• Contactor vs Relay Applications
• Contactors are typically built for and used in 3-phase applications where a relay is more
commonly used in single phase applications. A contactor joins 2 poles together, without a
common circuit between them, while a relay has a common contact that connects to a
neutral position. Additionally, contactors are commonly rated for up to 1000V, while relays
are usually rated to only 250V.
• When selecting between the two, some very general rules you
can follow to help
• When to Use a Relay:
• 10A or less current
• Up to 250VAC
• 1 phase
• When to Use a Contactor:
• 9A or more current
• Up to 1000VAC
• 1 or 3 phase
Starter
• Are used to start a motor
• It is a protecting device
• Initial current is very high to limit the current starters are employed.
• A push button switch is a small, sealed mechanism that
completes an electric circuit when you press on it. When it's
on, a small metal spring inside makes contact with two wires,
allowing electricity to flow. When it's off, the spring retracts,
contact is interrupted, and current won't flow. The body of the
switch is made of non-conducting plastic.
• Toggle switches are actuated by moving a lever back and forth to open
or close an electrical circuit. There are two basic types: maintained
contact and momentary contact.
• Maintained contact toggle switches maintain the position to which they
are moved or actuated. Momentary contact toggle switches do not.
• Rotary switch is a switch that controls the opening and
closing of the main contact by rotating the handle.
• The working principle of the rotary switch is: change the
resistance value within a range, and then there is a
contact switch. This is the switch for the old TV and
radio. The current electric fan has several gears, and
several sets of lead wires connected to the fan winding.
The speed is changed by changing the number of coils.
The principle is similar to that of a potentiometer.
• A DIP switch is a dual in-line package switch, meaning
that it consists of a series of switches in a single unit. It
is an electromechanical device requiring a user to
manually move the actuator so that a different
electronic circuit is activated or deactivated. Commonly
mounted on a PCB or breadboard, DIP switches allow
users to quickly preconfigure or toggle an electronic
device between a variety of settings or operating
modes.
Limit switch
• The main function of a limit switch is to observe
and control the physical movement of any
machine.
• A limit switch is an electromechanical device operated by a
physical force applied to it by an object. Limit switches are
used to detect the presence or absence of an object.
• The limit switch is used extensively in the control
system. The limit switch also has a different role in
automating our machine. Limit switches are commonly
overused in CNC machine robotics and motor control
functions. Apart from this, the limit switch is also used
for safety purposes
• The lever of a limit switch is also called an actuator. This
limit is located on the outside of the switch and is attached
to the header. The lever always works up and down. When
anything presses the lever of this limit switch, the contact
inside the switch operates and the switch starts working.
• the lever of the limit switch is mounted on top of this
operating header, due to which this operating header
operates whenever there is any movement in the lever.
• the lever is fitted in the limit switch. And when the device
comes in touch with it, this lever displaces. As it moves,
the mini switch inside the limit switch operates.
• The advantages of the limit switch are Limit
switches are quite accurate
• Limit switches operate at very low power.
• The cost is much lower compared to sensors.
• The limit switch can also be used in open spaces
• disadvantages of the limit switch :
• If it works for a long time, it is very likely to break down.
• It is necessary to come in direct contact with the working of the
limit switch.
• If a device is moving fast then it becomes difficult to detect that
device at that time.
• Where is the limit switch used?
• The presence or absence of any object can be detected.
• In speed detection.
• In automation.
• To know the position or travel limit.
• So why do we need to isolate different devices in the first place. Let’s consider a scenario where
we have the need operate a device that requires 120VAC, but the PLC in which we need to control
this device can only output 24VDC. There is no way to accomplish this output control without the
use of a “interposing relay” The relay… in this case, would us a 24VDC coil that would open or
close a contact on that relay that is rated for the 120VAC needed for the device we want to
operate. Simply put, we use a small amount of voltage to control a high voltage device. Another
benefit of using a relay in this manor, is that if a spike in voltage or current occurs on the device
we are operating, the relay will act as a “buffer” between the PLC and the higher voltage device.
Because of this, the relay also provides some protection to the PLC. So, the worst case scenario
is… we may have to replace a relay that has become damaged, but the PLC will remain
undamaged. This logic can also apply to inputs that need to be read by the PLC, but don’t input at
the proper voltage or current. So what other scenarios do you see this type of isolation method
being used? It is very common to see interposing relays being using in the automotive industry.
One of the most common applications is the starter motor in our vehicle. In order to start our car,
we need to initiate some kind of start command or control, which is why we turn the key… this is
our start command. However, the starter motor in our cars draws a lot of current. It would be
unsafe and very impractical to have the key switch that amount of current. Instead, a solenoid
relay (which acts like an interposing relay) is used to switch a relatively safe of amount of current,
that in turn switches a much higher amount of current in a safer location within the vehicle to
provide the amperage that is needed to crank the starter motor.