--Switches and Photoelectric Devices Module 12209

Instrument Trainee Task Module 12209

SWITCHES AND PHOTOELECTRIC DEVICES

Objectives
Upon completion of this module, the trainee will be able to: 1. State the purpose of a switch. 2. Given pictures, samples or specification sheets, identif commonl used switches. !. "escribe the major parts of a switch. #. $lassif switches usin% wirin% s mbols accordin% to the number of poles and the number of throws. &. "efine a photoelectric device. '. Given pictures, samples or specification sheets, identif commonl used photoelectric devices. (. State the electrical characteristics of a photocell. ). State the form of electroma%netic radiation that tri%%ers motion detectors. 9. State the electrical characteristics of a solar cell. 10.State the purpose of an S$*.

+rere,uisites
Successful completion of the followin% -as. Module/s0 is re,uired before be%innin% of this -as. Module1 2$$3* $ore $urricula4 2$$3* -as. Module 12201, Craft-Related Mathematics; 2$$3* -as. Module 12202, Instrumentation Drawings & Documents II; 2$$3* -as. Module 1220!, Principles of Welding; 2$$3* -as. Module 1220#, Process Control Theory

*e,uired Student Materials

1. Student Module 2. *e,uired Safet 3,uipment

5nstrument -rainee -as. Module 12209

$ourse Map 5nformation

-his course map shows all of the Wheels of !earning tas. modules in the second level of the 5nstrument curricula. -he su%%ested trainin% order be%ins at the bottom and proceeds up. S.ill levels increase as a trainee advances on the course map. -he trainin% order ma be adjusted b the local -rainin% +ro%ram Sponsor.

$ourse Map1 5nstrument, 6evel 2 63736 2 $OM+63-3

Switches and +hotoelectric "evices 8 Module 12209

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Section Topic . Page 1.0.0 5ntroduction to Switches and +hotoelectric "evices <<<<<<<.. & 2.0.0 "efinition, $lassification, and "escription <<<<<<<<<<<<< & 2.1.0 Switch "efinition <<<<<<<<<<<<<<<<<<<<<<<<<< & 2.2.0 Switch $lassifications

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<<<<<<<<<<<<<<<<<<<<<<<.. ' 2.2.1 Switch $ontacts <<<<<<<<<<<<<<<<<<<<<<<<<<.. ' 2.2.2 +ole of a Switch <<<<<<<<<<<<<<<<<<<<<<<<<<.. ( 2.2.! -hrows of a Switch <<<<<<<<<<<<<<<<<<<<<<<<< ( 2.!.0 Switch "escriptions <<<<<<<<<<<<<<<<<<<<<<<<.. ) 2.!.1 Sin%le=+ole Switch <<<<<<<<<<<<<<<<<<<<<<<<<. ) 2.!.2 -hree=>a Switch <<<<<<<<<<<<<<<<<<<<<<<<<. 9 2.!.! "ouble=+ole Switch <<<<<<<<<<<<<<<<<<<<<<<<.. 9 2.!.# ;loat Switch <<<<<<<<<<<<<<<<<<<<<<<<<<<<.. 10 2.!.& +neumatic Switch <<<<<<<<<<<<<<<<<<<<<<<<<.. 10 2.!.' 6imit Switch <<<<<<<<<<<<<<<<<<<<<<<<<<<<.. 11 2.!.( 3lectronic Switch <<<<<<<<<<<<<<<<<<<<<<<<<< 1! !.0.0 +hotoelectric "evices <<<<<<<<<<<<<<<<<<<<<<<< 1# !.1.0 +hotocell Switch <<<<<<<<<<<<<<<<<<<<<<<<<<.. 1# !.2.0 Solar $ells <<<<<<<<<<<<<<<<<<<<<<<<<<<<<.. !.2.1 5nfrared "evices <<<<<<<<<<<<<<<<<<<<<<<<<<. 1) !.2.2 Motion "etectors <<<<<<<<<<<<<<<<<<<<<<<<<< 1) #.0.0 +ro?imit Switch <<<<<<<<<<<<<<<<<<<<<<<<<<. 20

1(

Switches and +hotoelectric "evices 8 Module 12209

-rade -erms 5ntroduced 5n -his Module

Anode: -he positive terminal of an electrical device. Cathode: -he ne%ative terminal of an electrical device. Circ it: -he complete path of an electric current. Diode: 9n electronic device which allows current to flow in one direction onl . Edd! C rent": $urrents induced into a metal b transformer action. In#rared: 5nvisible heat waves havin% wavelen%ths lon%er than those of red li%ht. O$er%oad: 9 circuit operatin% at %reater than rated current. O&idation: -he process where o? %en combines with another element. Point": 9 set of electrical contacts. SCR: Silicon controlled rectifier. Short Circ it: 9 circuit which is accidentl or intentionall placed in operation with ver little resistance.

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One of the most common electrical devices in commercial installations is the switch. 7irtuall ever piece of electrical e,uipment or s stem has switches of some t pe. +hotoelectric devices such as motion sensors and photocells are also becomin% ver popular. :ecause there are so man t pes and name brands of switches and photoelectric devices, the trainee is encoura%ed to learn the principals of operation of the most popular t pes of switches and photoelectric devices and then appl this .nowled%e to other devices encountered in the field. -he aim of this module will be to describe in sufficient detail the characteristics, description, and operation of the most popular t pes of switches and photoelectric devices such that proper e,uipment can be selected and installed for satisfactor service in commercial installations.

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9n electrical switch is a device used to ma.e or brea. an electrical circuit that is operatin% within the rated current and volta%e of the switch. Standard electrical switches should not be used to interrupt a circuit under short circuit or overload. ;uses or circuit brea.ers should be used to prevent such conditions. NOTE: >hen selectin% and installin% switches, pa to the volta%e and current ratin%s. special attention

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Switches can be classified in man different wa s. 1. 9ccordin% to the number of poles. a. Sin%le pole b. "ouble pole c. -riple pole 2. 9ccordin% to the number of closed positions. a. Sin%le throw b. "ouble throw /two position0 c. -hree position !. 9ccordin% to the method of insulation. a. 9ir b. Oil c. Gas #. 9ccordin% to the method of operation. a. Manual /push button, .nife0 b. +neumatic /air0 c. A draulic d. Ma%netic &. 9ccordin% to function. a. -imer b. "immer c. -hree wa d. ;our wa e. Momentar contact f. Safet disconnect %. %. 3lectronicBsolid state

2.2.1 Switch $ontacts

-he contacts of a switch are used to ma.e or brea. the electrical circuit. One set of contacts are stationar and the other set are movable. 5n all switches, the electrical contact is formed b pressin% the movable contact a%ainst the stationar contact. @suall a sprin% is emplo ed to help ensure constant pressure is maintained between the two contacts. -he two most common t pes of contacts are the C.nife blade contactsC and the Cbutt contactsC, see "igure # Man times the contacts will be silver coated to prevent oxidation and to ensure a low resistance contact point.

Switches and +hotoelectric "evices 8 Module 12209

;i%ure 1. /90 Dnife Switch $ontacts /:0 :utt $ontacts

-he contacts of a switch, especiall burnt or charred contacts, will need to be burnished, filed, or even replaced periodicall to maintain a low resistance contact point.

2.2.2 +ole of a Switch

-he pole of a switch is where the contacts are attached. -he poles in conjunction with the contacts are used to ma.e and brea. the electrical circuit. 3ach pole is electricall insulated from one another. 9 sin%le pole switch will ma.e and brea. onl one conductor or le% of a circuit, whereas a two pole switch will ma.e and brea. two le%s of a circuit, and so on. See the schematic dia%ram in "igure $

;i%ure 2. +oles of a Switch

2.2.! $losed +ositions or -hrows of a Switch

9 sin%le=throw switch will onl ma.e a closed circuit when the switch is in one position. 9 double=throw switch will ma.e a closed circuit when placed in either of two positions, "igure !. >hen more than two closed positions are needed, special multiple throw switches should be emplo ed.

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;i%ure !. Sin%le and "ouble=-hrow Switches

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-o%%le switches or wall switches are used to control li%hts, appliances, and fractional horsepower motors. -he most common switch is the sin%le=pole sin%le=throw switch which is used to control li%hts or e,uipment from one location onl . -his switch has two brass colored screw terminals for wire connections, see "igure %

;i%ure #. Sin%le=+ole Sin%le=throw Switch

Switches and +hotoelectric "evices 8 Module 12209

2.!.2 -hree=>a Switch

-he three=wa switch is used in pairs to control a li%ht or piece of e,uipment from two locations. 5t has three screw terminals for wire connections4 one blac. or copper and two brass or silver colored. -he three wa switch is a sin%le pole double=throw switch, see "igure &.

;i%ure &. -hree=>a /Sin%le=pole "ouble=throw0

2.!.! "ouble=+ole Switch

-he double=pole switch shown in "igure & is normall used to control 2#0 volt e,uipment. -his switch has four brass colored screw terminals for wire connections. -he terminals on the left side of the switch are connected throu%h one set of contacts and the terminals on the ri%ht side of the switch are connected throu%h another set of contacts.

;i%ure '. "ouble=+ole Sin%le=-hrow Switch

2.!.# ;loat Switch

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-he raisin% and lowerin% of a float which is mechanicall attached to electrical contacts ma start motor driven pumps to empt or fill tan.s. -he float switch contacts ma be either normall open contacts /2O0 or normall closed contacts /2$0 and the cannot be submer%ed. -hese rod=operated float switches are also commonl close solenoid valves to control fluids, "igure ' used to open or

;i%ure (. *od=Operated ;loat 7alve >ith >irin% S mbol

2.!.& +neumatic Switch

+neumatic or pressure switches are used to control the pressure of li,uids and %ases b startin% and stoppin% motors and compressors at the proper time. 9ir compressors, for e?ample are started directl or indirectl on a call for more air b a pressure switch. NOTE: >hen selectin% pressure switches, pa particular attention to the pressure ratin% of the switch and the operatin% pressure of the s stem. 2ever e?ceed the switch ratin%s.

+ressure switches use mechanical motion from pressure chan%es to operate one or more sets of contacts. 9 t pical pressure switch usin% a bellows as the pressure sensin% element is shown in "igure ( Other common sensin% elements are the diaphra%m and bourdon tube. Most pressure switches have an adjustment screw to adjust the setpoint.

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;i%ure ). - pical +ressure Switch

Man times pressure switches come with two sets of contacts, one 2O set and one 2$ set. >hen the pressure reaches the setpoint, one set of contacts will open and the other will close. 5n selectin% a pressure switch for a particular application, each of the followin% should be ta.en into consideration. -he adjustable ran%e. -his is the span of pressures within which the pressure sensin% element can be set to actuate the contacts of the switch. ;or e?ample, a pressure switch ma have a ran%e of 20 to 100 psi. -he adjustable differential pressure. -his is the span of pressure between the hi%h pressure limit which actuates the contacts, and the low pressure limit which resets the contacts to their normal position. 9 pressure switch ma have an adjustable ran%e between 20 and 100 psi with a differential adjustable pressure of onl & to 1& psi. -he ratin% of the switch and contacts. -he ratin% includes the t pe of switch used such as sin%le=pole sin%le=throw, sin%le=pole double=throw, etc. 5t also includes the amount of current and volta%e that the contacts can safet switch. -he accurac of the switch refers to the abilit of the switch to repeatedl actuate at the setpoint. -his value is t picall stated as a percent /E0 of the ma?imum operatin% pressure of the switch /i.e. F 2E of ma?imum operatin% pressure0.

2.!.' 6imit Switch

6imit switches are desi%ned such that the can be activated b the motion of machiner . -he repeat accurac of the switches must be reliable and the response virtuall instantaneous. 5n %eneral, the operation of a limit switch be%ins when the movin%

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machine or movin% part of a machine stri.es an operatin% lever which activates the limit switch, "igure )

;i%ure 9. 6imit Switch >ith >irin% S mbols

6imit switches can be used either or as emer%enc switches to e,uipment. -he contacts ma be /2$0 and the ma be momentar t pes.

as control devices for re%ular operation prevent the improper functionin% of normall open /2O0 or normall closed /sprin% returned0 or maintained contact

-he installation of limit switches involves pic.in% the best actuator and then mountin% the1 limit switch in the correct position in relationship to the movin% part. 5t is important that the limit switch not be operated be ond the manufacturerGs recommended specifications of travel. 9 mechanical stop as shown in "igure #* should be used to ensure the switch is not dama%ed b the motion of the machine it is supposed to be controllin%.

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;i%ure 10. 6imit Switch 5nstallations

2.!.( 3lectronic Switch /S$*0

Silicon $ontrolled *ectifiers or SCR+s are electronic devices that normall operate in the O2 or O;; state ver much li.e a switch does. S$*Gs are used e?tensivel in motor controls and power supplies, see "igure ##

;i%ure 11. Silicon $ontrolled *ectifier /S$*0

-he basic purpose of the S$* is to function as a switch that can turn on and off lar%e amounts of power. 5t performs this function with no movin% parts that wear out and no points or contacts that re,uire replacin%. -he S$* can be used in 9$ and "$ circuits but it will onl allow current to pass in the forward direction /from anode to cathode0. 5t has an anode /positive0 lead, a cathode /ne%ative0 lead, and a %ate lead. 2o current will flow throu%h the S$* until the %ate lead receives an electrical si%nal. Once the %ate receives a si%nal, the S$* is li.e a closed switch and it conducts current easil in the forward direction /anode to cathode0. -he %ate si%nal

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can now be removed but conduction will not stop until1

the current tries to reverse direction, or the current drops to near Hero.

Once conduction has stopped, the S$* will be li.e an open switch and no current will flow. 9 new %ate si%nal must be applied before the S$* will conduct a%ain. -he S$* is similar to a diode in that it will onl allow current to flow in the forward direction /anode to cathode0 and never in the reverse direction /cathode to anode0.

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6i%ht sensitive devices, sometimes called photoelectric transducers, alter their electric characteristics when e?posed to visible or infrared li%ht. 6i%ht sensitive devices include photocells, solar cells, motion detectors, and phototransistors. Such li%ht sensitive devices can tri%%er man different .inds of circuits for the control of alarms, li%hts, motors, rela s, and other actuators. Some of the more common photoelectric devices and their principal of operation will be discussed in this section.

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+hotocells are also called man other names includin% photoconductive cells, li%ht dependent resistors /6"*Gs0, and photoresistors. :asicall , photocells are variable resistors with an e?tremel wide ran%e of resistance values which depends upon the amount of li%ht that falls on them. -he resistance of the photoconductive material shown in "igure #$ varies inversel with the amount of li%ht that shines on it. 5n other words, the more li%ht that hits the photocell, the lower the resistance of the photoconductive material. -he photoconductive material is usuall made of $admium Sulfide /$dS0 or $admium Selenide /$dSe0 and is placed directl between the two terminals of the photocell. 5n bri%ht li%ht, the resistance between the terminals can be as low as &0I, and in dar.ness as hi%h as & MI.

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;i%ure 12. $utawa 7iew of a +hotocell or 6i%ht="ependent *esistor /6"*0

-he most common use for photocells is the photocell switch used to control li%hts between dus. and dawn. 3ssentiall , the photocell switch shown in "igure 1!, acts as a sin%le=pole sin%le=throw /S+S-0 switch that closes when it %ets dar. and opens when it %ets li%ht. +hotocell switches as in "igure 1! can be rated for up to !00 watts and can directl control a set of floor li%hts rated !00 watts or less.

;i%ure 1!. +hotocell Switch and - pical 9pplication

+hotocell switches can also be used in control circuits b usin% a li%ht beam and a photoreceiver to scan across an area to detect the presence of an object. >hen the li%ht beam is bro.en, the photocell or photoreceiver responds b sendin% a "$ si%nal to the control circuit. "igure #% shows the direct scan method of photoelectric detection. -he li%ht source and the photoreceiver are positioned directl opposite each other, so that li%ht from the source shines directl at the receiver. >hen the roll of paper %ets bi% enou%h to bloc. the li%ht beam, the photoreceiver sends a si%nal to the controller which will load a new spool on the paper spindle.

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NOTE:

Deep the sensor and reflector lenses clean to ensure proper operation of detectors.

$ountin% products is a common application of photoelectric controls. $ountin% batches or %roups of cans or other items prior to pac.a%in% or %roup processin% is also common.

-he siHe of a paper or fabric roll can be controlled b positionin% a li%ht source and a photoreceiver so the roll diameter bloc.s the beam. ;i%ure 1#. "irect Scannin% Methods

*eflective scan is another popular scannin% method used to detect movin% objects. 5n GG reflective scan, the li%ht source and the photoreceiver are mounted in the same housin% and on the same side of the object to be detected, see "igure #, -his method is used when there is limited space or when mountin% restrictions prevent aimin% the li%ht beam directl at the photoreceiver. 9s shown in "igure #,- the li%ht source reflects off of the reflector and is absorbed b the scannerBreceiver. >hen the li%ht beam is bro.en b the bottles, there is no reflection and the photodetector si%nals the capper to appl the bottle cap.

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;i%ure 1&. *eflective Scannin% Method @sed to $ount and $ap :ottles

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Solar cells, also called photovoltaic detectors, %enerate a "$ volta%e which is proportional to the amount of li%ht that is absorbed b the cell. 9 t pical cell, as shown in "igure #&- onl %enerates about 1B2 volt "$. -herefore, cells are often arran%ed in series and parallel combinations to obtain the desired output volta%e and current levels. $ells are joined to%ether to ma.e1 a solar module4 a solar panel4 and, a solar arra . "igure #' shows the components of a photovoltaic arra s stem that could be used to char%e a batter ban. or power a piece of "$ e,uipment.

;i%ure 1'. - pical solar $ell

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;i%ure 1(. +hotovoltaic 9rra $omponents

!.2.1 5nfrared "evices

9n object not at a temperature of absolute Hero /=#'0J ;ahrenheit0 will emit invisible electroma%netic radiation in the form of Infrared *adiation /5*0. Since infrared radiation is a form of ener% , a detector can pic. up this transmitted ener% and produce an electrical si%nal proportional to the amount of 5* radiation detected. -his si%nal can then be used to control other devices. 5* detectors are commonl used for motionBpeople detectors, -7 remote control detectors, 5* scanners which detect hot spots in electrical e,uipment, etc. : far, the most common application is the motionBpeople detector.

!.2.2 Motion "etectors

Motion detectors are t picall used in a securit s stem of some t pe. -he securit s stem ma be an elaborate Hone controlled s stem that incorporates motion detectors, door switches, smo.e detectors, moisture sensors etc., or it ma be as simple as a set of motion detector floodli%hts mounted above the %ara%e. -he basic operation of the detector is the same in all cases. "igure #( shows a set of floodli%hts controlled b an 5* motion detector switch. Man times a photocell switch is added to the li%ht controller which automaticall turns the li%hts off durin% da li%ht hours. 9lso, the li%ht

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controller usuall comes e,uipped with a manual override method which can be used to turn the li%hts on at an time.

;i%ure 1). Motion "etector ;lood 6i%hts

>hen the li%ht controller contains both the photocell switch and an 5* detector switch, it operates as if there were three S+S- /sin%le=pole sin%le= throw0 switches involved, see "igure 19. -he photocell switch and the motion detector switch are in series such that have to be closed for the li%ht to come in. -he third switch is the manual b pass switch which is in parallel with the series motion detector and photocell switches. 2ormall for the li%ht to come on, there must be motion detected and it must be dar.. "igure $* shows a t pical application and wirin% dia%ram for a popular 5* motion detector with photocell li%ht controller. :esides controllin% li%hts, the same detector could be used to sound a siren, open an automatic %ate, or perform some other automatic function.

;i%ure 19. sin%le=6ine dia%ram of Motion "etector >ith +hotocell 6i%ht $ontroller

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;i%ure 20. t pical application of an 5* Motion "etector 6i%ht $ontroller

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+ro?imit switches are used to detect the presence or absence of an object without ever touchin% it. -he are becomin% increasin%l popular for industrial applications because the are versatile, safe, reliable, and can be used in place of mechanical limit switches. - pical pro?imit switches are shown in "igure $#

;i%ure 21. - pical +ro?imit Switches

-he most popular t pe of pro?imit switch is the inductive *; oscillator t pe which operates on the 3dd $urrent Dilled Oscillator /3$DO0 principle. -he oscillator consists of an inductorBcapacitor /6$0 tuned tan. circuit which %enerates an 9$ ma%netic flu? as it oscillates and emits this field from the face of the switch, see "igure $$ >hen a metal object is placed near the ma%netic lines of flu?, eddy currents are induced in the metal object which in turn disrupts the tunin% of the 6$ tan. circuit and the oscillations die out or are .illed. >hen the oscillations die the inte%rator si%nals the tri%%er to switch the output of the pro?imit switch.

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;i%ure 22. 3dd $urrent Dilled Oscillator /3$DO0 Sensor

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@nderstandin% the classifications and operation of switches and photoelectric devices is ver important to an one wor.in% in the electrical field. >ithout such .nowled%e, the selection, installation, or maintenance of electrical e,uipment and circuits will be ver difficult if not impossible. Switches are classified accordin% to the number of poles, the number of throws /S+S-, S+"-0, and accordin% to their function /i.e. pressure, temp.0. -heir operation depends mostl upon the t pe of contacts involved and the method of operatin% the contacts. Overloadin% is the most fre,uent cause of switch failures. +hotoelectric devices on the other hand are %enerall classified onl accordin% to their function /photocell switch0. -he operation of these devices usuall depends upon complicated electronics which are not readil accessible to the user. ;or photoelectric devices, overloadin% and improper wirin% connections are the most common causes for failure.

*eferences
;or a more advanced stud of topics covered in the -as. Module, the followin% wor.s are su%%ested1 .lectric Motor Control- -hird 3dition, >alter 2. 9lerich. /merican .lectricians+ 0and1oo2- -welfth 3dition, -errell $roft, >ilford 5. Summers. 3ational .lectric Code - #))* 0and1oo2- ;ifth 3dition, 2ational ;ire +rotection 9ssociation.

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S36;=$A3$D *3753> B +*9$-5$3 M@3S-5O2S

1. Switches are normall used to ma.e or brea. an electrical circuit that is operatin%1 a. >ithin the rated volta%e of the switch. b. @nder an overload condition. c. >ithin the rated current of the switch. d. >ithin rated volta%e and current ratin%s of the switch. Switch contacts are silver coated to prevent NNNNNNNNNNNNNNN. -he NNNNNNNNNNNNNNof a switch, in conjunction with the contacts, are used to ma.e and brea. the electrical circuit. 9 double pole switch is t picall used to control1 a. 120 volt circuits or e,uipment. b. 2#0 volt circuits or e,uipment. c. -hree phase circuits or e,uipment. d. 9ll of the above. 6abel the switches below accordin% to the number of poles and the number of throws.

2. !. #.

&.

'.

NNNNNNNNNNNN switches are desi%ned such that the can be activated b the motion of machiner . a. +ressure. b. 6imit. c. ;loat. d. +hotoelectric.

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(.

9n a. b. c. d.

S$* is an electronic device that NNNNNNNNNNNNN. 5s tri%%ered b infrared radiation. $an turn on and off lar%e amounts of power. @ses four leads durin% normal operation. >ill conduct current in the forward and reverse direction.

). 9. 10.

-he NNNNNNNNNNNof a photocell varies dependin% upon the amount of li%ht that shines on the cell. 9 solar cell uses converts NNNNNNNNNNNNNNinto electrical power. 9 motion detector switch uses a detector to sense motion. a. 7ibration. b. -emperature. c. 5nfrared. d. 9ll of the above.

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5dentif and select various t pes of switches which are on displa . Step 1 5dentif b name each switch that is displa ed on a table. Step 2 $lassif each switch accordin% to the number of poles and throws. Step ! 3?plain the operation of selected switches. 5dentif and select various t pes of photoelectric devices which are on displa . Step 1 5dentif each device on displa . Step 2 3?plain the operation of each device.

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1. a 2. o?idation !. poles #. b &. a. Sin%le=pole "ouble=throw /S+"-0 b. "ouble=pole Sin%le=throw /"+S-0 c. Sin%le=pole Sin%le=throw /S+S-0 '. b (. b ). resistance 9. li%ht 10. c

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