AST 224

BASIC PLC COMPONENTS

HOW SWITCHES WORK AND THEIR
STRUCTURE
• Switches are used to facilitate or to interrupt a current flow in an electrical circuit.
Depending on their design, these switches can either be pushbuttons or detenting
switches.
• In the case of a pushbutton, the chosen switching position is only maintained for as
long as the pushbutton is actuated. Pushbuttons are used in doorbells, for example.
In the case of a detenting switch, both switching positions (ON/OFF) are
mechanically latched. Each switching position is maintained until the switch is
actuated again. Light switches in houses are an example of a latching switch in use.
TYPES OF SWITCHES

• Basically, Switches can be of two types. They are:

• Mechanical
• Electronic
• Mechanical Switches are physical switches, which must be activated
physically, by moving, pressing, releasing, or touching its contacts.
• Electronic Switches, on the other hand, do not require any physical contact in
order to control a circuit. These are activated by semiconductor action.
MECHANICAL SWITCHES

• Mechanical switches can be classified into different types

based on several factors such as method of actuation
(manual, limit and process switches), number of contacts
(single contact and multi contact switches), number of
poles and throws (SPST, DPDT, SPDT, etc.), operation
and construction (push button, toggle, rotary, joystick,
etc.), based on state (momentary and locked switches),
etc.
• Based on the number of poles and throws, switches are classified
into following types. The pole represents the number of individual
power circuits that can be switched. Most of the switches are
designed have one, two or three poles and are designated as single
pole, double pole and triple pole.
• The number of throws represents the number of states to which
current can pass through the switch. Most of the switches are
designed to have either one or two throws, which are designated
as single throw and double throw switches.
 SINGLE POLE SINGLE THROW SWITCH
(SPST)
•This is the basic ON and OFF switch consisting of one input contact and one output contact.
•It switches a single circuit and it can either make (ON) or break (OFF) the load.
•The contacts of SPST can be either normally open or normally closed configurations .
SINGLE POLE DOUBLE THROW SWITCH (SPDT)
THIS SWITCH HAS THREE TERMINALS: ONE IS INPUT CONTACT AND REMAINING
TWO ARE OUTPUT CONTACTS.
THIS MEANS IT CONSIST TWO ON POSITIONS AND ONE OFF POSITION.
IN MOST OF THE CIRCUITS, THESE SWITCHES ARE USED AS CHANGEOVER TO
CONNECT THE INPUT BETWEEN TWO CHOICES OF OUTPUTS.
THE CONTACT WHICH IS CONNECTED TO THE INPUT BY DEFAULT IS REFERRED
AS NORMALLY CLOSED CONTACT AND CONTACT WHICH WILL BE CONNECTED
DURING ON OPERATION IS A NORMALLY OPEN CONTACT.
THIS SWITCH CONSISTS OF FOUR TERMINALS: TWO INPUT CONTACTS AND TWO OUTPUT
CONTACTS.
IT BEHAVES LIKE A TWO SEPARATE SPST CONFIGURATIONS, OPERATING AT THE SAME
TIME.
IT HAS ONLY ONE ON POSITION, BUT IT CAN ACTUATE THE TWO CONTACTS
SIMULTANEOUSLY, SUCH THAT EACH INPUT CONTACT WILL BE CONNECTED TO ITS
CORRESPONDING OUTPUT CONTACT.
IN OFF POSITION BOTH SWITCHES ARE AT OPEN STATE.
THIS TYPE OF SWITCHES IS USED FOR CONTROLLING TWO DIFFERENT CIRCUITS AT A
TIME.
ALSO, THE CONTACTS OF THIS SWITCH MAY BE EITHER NORMALLY OPEN OR NORMALLY
CLOSED CONFIGURATIONS.
DOUBLE POLE DOUBLE THROW SWITCH (DPDT)
THIS IS A DUAL ON/OFF SWITCH CONSISTING OF TWO ON POSITIONS.
IT HAS SIX TERMINALS, TWO ARE INPUT CONTACTS AND REMAINING FOUR ARE THE OUTPUT
CONTACTS.
IT BEHAVES LIKE A TWO SEPARATE SPDT CONFIGURATION, OPERATING AT THE SAME TIME.
TWO INPUT CONTACTS ARE CONNECTED TO THE ONE SET OF OUTPUT CONTACTS IN ONE POSITION
AND IN ANOTHER POSITION, INPUT CONTACTS ARE CONNECTED TO THE OTHER SET OF OUTPUT
CONTACTS.
PUSH BUTTON SWITCH
• It is a momentary contact switch that makes or breaks connection as long as pressure is
applied (or when the button is pushed).
• Generally, this pressure is supplied by a button pressed by someone’s finger.
• This button returns its normal position, once the pressure is removed.
• The internal spring mechanism operates these two states (pressed and released) of a push
button.
• It consists of stationary and movable contacts, of which stationary contacts are connected in
series with the circuit to be switched while movable contacts are attached with a push
button.
• Push buttons are majorly classified into normally open, normally closed and double acting
push buttons as shown in the above figure.
• Double acting push buttons are generally used for controlling two electrical circuits.
NORMALLY OPEN CONTACTS

• In the case of a normally open contact (or N/O contact), the circuit is
interrupted when the pushbutton is in its normal position. Actuating the
pushbutton closes the circuit and supplies the consuming device with current.
When the pushbutton is released, spring force returns it to its normal position
and the circuit is interrupted once more.
NORMALLY CLOSED CONTACTS

• In the case of a normally closed contact (or N/C contact), the circuit is closed
by spring force when the pushbutton is in its normal position. Actuating the
pushbutton interrupts the circuit.
CHANGEOVER SWITCHES

• The changeover switch combines the functions of an N/C contact and an N/O
contact in one device. They are used to close one circuit and open another
one with a single switching operation. Both circuits are briefly interrupted
during the changeover.
TOGGLE SWITCH

• A toggle switch is manually actuated (or pushed up or down) by a mechanical handle,

lever or rocking mechanism. These are commonly used as light control switches.
• Most of these switches come with two or more lever positions which are in the
versions of SPDT, SPST, DPST and DPDT switch. These are used for switching high
currents (as high as 10 A) and can also be used for switching small currents.
• These are available in different ratings, sizes and styles and are used for different type
of applications. The ON condition can be any of their level positions, however, by
convention the downward is the closed or ON position.
LIMIT SWITCH

• The control schemes of a limit switch are shown in above figure , in which
four varieties of limit switches are presented.
• Some switches are operated by the presence of an object or by the absence of
objects or by the motion of machine instead of human hand operation. These
switches are called as limit switches.
• These switches consist of a bumper type of arm actuated by an object. When
this bumper arm is actuated, it causes the switch contacts to change position.
FLOAT SWITCHES
• Float switches are mainly used for controlling DC and AC motor pumps according to the
liquid or water in a tank or sump.
• This switch is operated when the float (or floating object) moves downward or upward based
on water level in a tank.
• This float movement of rod or chain assembly and counterweight causes to open or close
electrical contacts. Another form of float switch is the mercury bulb type switch that does not
consist of any float rod or chain arrangement.
• This bulb consist of mercury contacts such that when the liquid level rises or falls, the state of
contacts also changes.
• The ball float switch symbol is shown in the above figure. These float switches can be
normally open or normally closed type.
FLOW SWITCHES
• These are mainly used to detect the movement of liquid or air flow through a pipe or duct. The
air flow switch (or a micro switch) is constructed by a snap-action.
• This micro switch is attached to a metal arm .To this metal arm, a thin plastic or metal piece is
connected.
• When a large amount of air passes through the metal or plastic piece, it causes the movement of
metal arm and thus operates the contacts of the switch.
• Liquid flow switches are designed with a paddle that inserted across the flow of liquid in a pipe.
When liquid flows through the pipe, force exerted against the paddle changes the position of the
contacts.
• The above figure shows the switch symbol used for both air flow and liquid flow. The flag
symbol on the switch indicates the paddle which senses the flow or movement of liquid.
• These switches again normally open or normally closed type configurations.
PRESSURE SWITCHES
• These switches are commonly used in industrial applications in order to
sense the pressure of hydraulic systems and pneumatic devices.
• Depends on the range of pressure to be measured, these pressure switches are
classified into diaphragm operated pressure switch, metal bellow type
pressure switch and piston type pressure switch.
• In all these types, pressure detection element operates a set of contacts
(which can be either double pole or single pole contacts).
• This switch symbol consist a half-circle connected to a line in which flat part
indicates a diaphragm. These switches may be either normally open or
normally closed type configurations.
TEMPERATURE SWITCHES
• The most common heat sensing element is the bimetallic strip that operates
on the principle of thermal expansion.
• The bimetallic strips are made with two dissimilar metals (that are having
different thermal expansion rates) and are bonded with each other.
• The switch contacts are operated when the temperature causes the strip to
bend or wrap. Another method of operating the temperature switch is to use
mercury glass tube.
• When the bulb is heated, mercury in the tube will expand and then generates
pressure to operate the contacts.
JOYSTICK SWITCH
• Joystick switches are manually actuated control devices used mainly in
portable control equipment.
• It consists of a lever which moves freely in more than one axis of motion.
• Depending on the movement of the lever pushed, one or more switch
contacts are actuated.
• These are ideally suited for lowering, raising and triggering movements to
the left and right.
• These are used for building machinery, cable controls and cranes. The
symbol for the joystick is shown below.
ROTARY SWITCHES
• These are used for connecting one line to one of many lines.
• Examples of these switches are range selectors in electrical metering
equipment, channel selectors in communication devices and band selectors in
multi-band radios.
• It consists of one or more moving contacts (knob) and more than one
stationary contact.
• These switches are come with different arrangement of contacts such as
single pole 12-way, 3-pole 4-way, 2-pole 6-way and 4-pole 3-way.
RELAYS AND CONTACTORS
• A relay is a kind of switch that is electrically driven. It receives a signal from
the source to open and close the contact. Relays built into electrical
appliances transmit electrical signals to other equipment by turning a switch
on and off.
APPLICATIONS OF RELAYS

• Relays are used in electropneumatic control systems to:

• • multiply signals,
• • delay and convert signals,
• • link information,
• • separate the control and main circuits.
• They are also used in purely electrical control systems to separate the DC and
AC circuits.
STRUCTURE OF A RELAY

• A relay is an electromagnetically-actuated switch where the control circuit and the controlled
circuit are electrically separated from each other. It essentially consists of a coil with an iron
core (see (3)(1)
in Figure 3.12), an armature as a mechanical actuating element (4), a return spring (2) and
switch contacts (6). When a voltage is applied to the solenoid coil, an electromagnetic field is
generated. This causes the movable armature to move towards the coil core. The armature acts
upon the relay contacts that are either closed or opened, depending on the arrangement. If the
flow of current through the coil is interrupted, a spring returns the armature to its initial
position.
A relay coil can be used to switch one or more contacts.
In addition to the relay type described above, there are
also other designs of electromagnetically-actuated
switches, for example the remanence relay, the time relay
and the contactor.