Kaw Area Technical School

Chapter 11 Control Devices

Industrial Technology

Kaw Area Technical School

Chapter 11 Control Devices

Electrical Control Systems I

Richard E. Stephens
CET Sr.

PowerPoint Presentation

Chapter 11
Control Devices
Industrial Pushbuttons Selector Switches Joysticks Limit Switches Foot Switches Daylight Switches Pressure Switches Temperature Switches Flow Switches Smoke/Gas Switches Level Switches Wind Metering Automated Systems Troubleshooting Control Devices Smart (Intelligent) Input Devices

Chapter 11 Control Devices

An industrial pushbutton consists of a legend plate, an operator, and one or more contact blocks (electrical contacts).

Chapter 11 Control Devices

An operator is the device that is pressed, pulled, or rotated by the individual operating the circuit.

Chapter 11 Control Devices

Contact blocks include normally open (NO), normally closed (NC), or both NO and NC contacts.

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A pushbutton station is an enclosure that protects the pushbutton, contact block, and wiring from dust, dirt, water, and corrosive fluids.

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A two-position selector switch allows the operator to select one of two circuit conditions.

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A three-position selector switch allows the operator to select one of three circuit conditions.

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Contact position on a selector switch may be illustrated using truth tables (target tables) or solid lines, dashed lines, and a series of small circles.

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A joystick is used to control many different circuit operations from one location.

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Limit switches are used to convert a mechanical motion into an electrical signal.

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Arcing or welding of the contacts may occur from a possible short circuit if the contacts are connected to opposite polarity.

Chapter 11 Control Devices

A relay, contactor, or motor starter must be used to interface the limit switch with the load if the load current exceeds the contact rating.

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An actuator is the part of a limit switch that transfers the mechanical force of the moving part to the electrical contacts.

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Limit switches should not be operated beyond the manufacturers recommended travel specifications.

Chapter 11 Control Devices

A cam-operated limit switch must be installed to prevent severe impact and allow a slow release of the lever.

Chapter 11 Control Devices

Limit switches using push-roller actuators must not be operated beyond their travel limit.

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Limit switches should be mounted to avoid accidental activation, accumulated materials, and excessive heat.

Chapter 11 Control Devices

A foot switch is used to allow hands-free control or an additional control point.

Chapter 11 Control Devices

A daylight switch is a switch that automatically turns lamps ON at dusk and OFF at dawn.

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A pressure switch is a control switch that detects a set amount of force and activates electrical contacts when the set amount of force is reached.

Chapter 11 Control Devices

Pressure switches use different sensing devices to detect the amount of pressure.

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Deadband is the amount of pressure that must be removed before the switch contacts reset for another cycle after the setpoint has been reached and the switch has been actuated.

Chapter 11 Control Devices

Pressure switches are used to maintain a predetermined pressure in a tank or reservoir, or sequence the return of pneumatic or hydraulic cylinders.

Chapter 11 Control Devices

A low-range pressure switch may be used with a metal tubing arrangement in a fluidic sensor to determine the presence of a material in process.

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In a heating system, heat is produced when the temperature switch contacts cool and close.

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In a cooling system, cool air is produced when the temperature switch contacts heat and close.

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The different sensors used to activate electrical contacts in response to temperature changes include bimetallic, capillary tube, thermistor, and thermocouple.

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Thermistors are available that monitor the temperature of liquid, air, or a surface temperature.

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A flow switch is a control switch that detects the movement of a fluid.

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Both NO and NC electrical contacts are used with flow switches.

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A flow switch may be used to determine if sufficient air is flowing across the heating elements of an electric heater.

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A flow switch may be used to advance a clogged filter when restricted airflow is sensed.

Chapter 11 Control Devices

A flow switch may be used to advance a clogged filter when restricted airflow is sensed.

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A smoke switch (smoke detector) is a switch that detects a set amount of smoke caused by smoldering or burning material and activates a set of electrical contacts. A gas switch (gas detector) is a switch that detects a set amount of a specified gas and activates a set of electrical contacts.

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A mechanical level switch uses a float, which moves up and down at the level of the liquid and activates electrical contacts at a set height.

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A magnetic level switch uses a magnetically operated reed switch and a moving magnet to detect the level of a liquid.

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A conductive probe level switch uses liquid to complete the electrical path between two conductive probes.

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A capacitive level switch detects the dielectric variation when the product is in contact with the probe and when the product is not in contact with the probe.

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Optical level switches use a photoelectric beam to sense the liquid.

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Level switches detect and respond to the level of a material in a tank.

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The distance controlled in one-level control is small. Any distance may be controlled in two-level control.

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A temperature and level control may be combined to control the temperature and level of a fluid.

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In a solar heating system, the circulation pump is activated by the temperature differential between T1 and T2.

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A wiring diagram is used to properly install the control circuit of the solar heating system.

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An air pollution detector uses a logic module and an air pollution sensor to measure the pollutants in the air and compare them to a set level.

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Windmills are used to harness the wind to generate power.

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Anemometer and wind velocity relay specifications are given in manufacturer data sheets.

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A wind vane and a wind direction relay are used to control the yawing function of a windmill.

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An automated system includes manual, mechanical, and automatic control devices that are interconnected to provide the required inputs to make the system function as designed.

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Contact protection may be added when switching large DC and AC inductive loads to prevent or reduce arcing at the switch contacts.

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A pressure relief valve may be added to a circuit to protect a pressure switch from excessive pressure.

Chapter 11 Control Devices

Allow a distance of at least three pipe inside diameters (ID) on each side of the flow switch when mounting a flow switch.

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A DMM set to measure voltage is used to test the operation of a switch.

Chapter 11 Control Devices

A DMM set to measure voltage is used to measure the voltage into and out of a two-wire solid-state switch.

Chapter 11 Control Devices

A DMM set to measure voltage is used to measure the voltage into and out of a three-wire solid-state switch.

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Hard wiring requires a large number of control wires to interconnect a system.

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A smart device uses a communication protocol that allows individual devices to communicate with each other over a single cable.

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Smart devices may be connected using screw connectors or quick connectors.