What you should consider about before purchase pressure switches?

What you should consider about before purchase pressure switches?

by | Jun 25, 2017

Contents
2
3

Like many other process measuring instruments, there are many aspects you need to keep in mind before deciding to buy Pressure Switches however, below are the summary of general rules based on our decade’s experience, for you to follow up.

Basic Types

At low pressures (compressed air and very low pressure hydraulics), diaphragm and bellows movements, sometimes Bourdon tube, are most often used. At high pressures, piston and bourdon tube movements are most common. Snap action contacts seem to be universally used except in Pressure Switches with tilting mercury contacts actuated with a Bourdon tube.

Expected Service Life

Expected life is usually limited by the type of pressure sensing mechanism – Bourdon tube, diaphragm, piston, Belleville spring, etc. The snap action contacts are presumed to have greater life than the sensing mechanism.

If the service life (number of cycles the switch is expected to operate) is less than one million, a Bourdon tube or diaphragm type is indicated. If more than a million cycles, a piston type should be used. An exception to this rule is when the pressure change in a system is small (20% or less, of the adjustable range). Under such conditions a Bourdon tube or diaphragm switch can be used up to 2½ million cycles before metal fatigue or contact failure.

Cycle Life and Cycle Rate

The number of times the switches will be activated will have a direct impact on its longevity. Inherent in their design, electromechanical pressure switches have moving parts that are subject to fatigue affected by factors like magnitude of pressure changes and temperature.

Diaphragm switches will typically provide >500k cycles. A piston design switch can typically provide >1 million cycles and is more reliable than a diaphragm design when subjected to frequent large pressure excursions, pressure surges and spikes. With no moving parts, solid state pressure switches wear is reduced, typically allowing >50 million cycles.

The rate at which a pressure switches is cycled will also impact its longevity. An electromechanical switches with a diaphragm works well for applications with a cycle rate of 25 per minute or less. Piston design mechanical switches are usually suitable for up to 50 cycles per minute. With no moving parts to wear out, a solid state switch should be selected for applications requiring rates that exceed 50 cycles per minute.

Accuracy

Accuracy for a pressure switches is defined differently than accuracy for an instrument. Diaphragm and Bourdon tube pressure switches generally have greater accuracy than piston switches, and would be preferred where accuracy is important, provided they meet requirements for service life and speed of cycling.

The predetermined point at which the pressure switches contact opens or closes is the setpoint. For a pressure switches, accuracy is the ability of the switch to repetitively operate at its setpoint. When in doubt, it is always easier to specify the best accuracy available. But one pays a premium for something that may not be needed. Typically, if the switch is used to alarm, 2% accuracy is sufficient. If one is controlling a process where the error of various devices is additive, then 0.25% accuracy may be absolutely necessary. The accuracy of piston and diaphragm-sealed piston switches is 2%, bourdon tube and diaphragm switches are 0.5%, and solid-state switches 0.25%. Remember, accuracy is referenced at the high end of the operating pressure range and decreases at lower pressure.

FYI, we strongly recommend you ESS202 Intelligent Pressure Switch, for details specification, pls click here to check the data sheet.

For an electromechanical pressure switches with a factory set or user adjusted setpoint relative to a known pressure reference, accuracy is a measure of the switch’s ability to repetitively operate at its adjusted setpoint under the same operating conditions. This is referred to as Repeatability in pressure switches specifications.

Because a solid state switch setpoint can be adjusted with calibrated dials, knobs, or a keypad and display, specifications will include both a setting accuracy value and a repeatability value. Pressure switches are typically available with accuracies from 0.25% to 2% and cost increases with accuracy. To avoid paying a premium for unnecessary accuracy, consider the needs of the application. An accuracy of 2% is probably sufficient for a simple alarming application, but controlling a critical process may call for a higher accuracy switch.

Above figure show:  On switches with diaphragm and Bourdon tube movements, greatest accuracy is in the upper 65%, best life factor in the lower 65%, and the best combination is usually in the middle 30% of its working range (Zone A).

Adjustable Range

The term “working range” defines the pressure range a switch may see under normal working conditions. This is normally the adjustable range.

For greatest accuracy the set point should fall in the upper 65% of the adjustable range. But for the most favorable life factor the set point should be in the lower 65% of the adjustable range.

Therefore, the most favorable combination of accuracy and life factor lies in the middle 30% of the adjustable range and this is illustrated in above diagram. This general rule applies to diaphragm and Bourdon tube pressure switches. Piston switches have a more nearly uniform accuracy and life factor over their adjustable range.

Both electromechanical and solid state switches are commonly available to sense vacuum, positive pressures up to thousands of psi, and compound ranges of vacuum to positive pressure.

Electromechanical switches are typically available with a factory setting, or with a blind adjustment capability set by the user relative to an external pressure reference such as a pressure gauge or known pressure value.

Electromechanical switch setpoints can be set to activate upon an increased or decreased pressure. Solid state switch setpoints are set either by calibrated dials, knobs, or entered digitally with a keypad and display.

Deadband

Deadband is the difference in pressure between the switch setpoint and reset point. For example, if a switch is set to activate at 100 psi on an increasing pressure, the switch will close when the pressure rises to 100 psi. When the pressure drops to the reset point of 90 psi, the switch will open. The deadband is 10 psi, the difference between the setpoint (100 psi) and the reset point (90 psi).

For electromechanical switches, deadband can be adjustable but is typically a fixed value, or automatically increases linearly as the setpoint is increased through the adjustable setpoint range.

For solid state switches, the deadband is typically fully adjustable up to 100% of the full operating pressure range. As a general rule a narrow deadband is used in alarm circuits while a wider deadband is better suited for control circuit applications.

Proof and Burst Pressures

Overpressure ratings include proof and burst pressure specifications. Proof pressure is the amount of overpressure that can be applied to the switches without causing damage. The pressure switches can be exposed to pressure reaching the proof pressure rating, and be expected to work properly when the pressure returns to within the rated operating pressure range.

Burst pressure is the amount of overpressure applied at which switches will certainly be damaged. Physical damage to the pressure switches may occur at any point between the proof pressure and burst pressure.

Because proof pressure ratings are determined in a laboratory under controlled conditions including rate of pressure change and temperature, they should be considered a reference value. It is not uncommon for switches in the field to experience pressure surges and spikes that cause damage if a switch with too low of a proof pressure rating was selected. Typically solid state switches have lower proof pressure ratings and are most sensitive to overpressure conditions.

Electromechanical switches with a diaphragm generally have higher overpressure ratings than solid state switches. Piston design switches have very high overpressure ratings and are the most reliable when subjected to pressure surges or spikes, and applications where the normal working pressure is above the nominal range of the switch.

If pressure surges or spikes are anticipated in an application, a pressure switches with a high proof pressure should be selected to avoid damage.

System pressure

Knowing your normal and maximum system pressures will help in selecting a switch with appropriate minimum and maximum operating parameters. Once your set point is established, other factors to consider are vacuum and/or surge pressure that could affect switch operation.

This would involve maximum working pressure, over range pressure, and proof pressure specifications of a pressure switches. The relationship between set point and system pressure has a direct effect on switch performance and life.

Electrical considerations

Micro-switches are available in a variety of configurations. The most common for electro-mechanical switches is 15A, 480VAC SPDT (single pole, double throw). The advantage of a SPDT micro-switch is that it offers wiring flexibility to either open or close on pressure change. Other micro-switches available include 1A with gold contacts, useful when working with a PLC, or at the upper end, 30A when switching certain high voltage heaters or motors.

Adjustable micro-switches help with deadband adjustment. A DPDT (double pole, double throw) micro-switch would provide two simultaneous functions off of one micro-switch. If a low-high limit alarm and shutdown were required, there are pressure switches that include two SPDT micro-switches that are independently settable.

An electronic switch would use solid-state relays to change states. Like an electro-mechanical switch, the electronic switch can be programmed to open or close on rising or falling pressure. There are different capacities for switching voltage and current depending upon the application requirements.

Electrical Characteristics

Electromechanical pressure switches harness the pressure of the medium being sensed to mechanically operate a snap-acting switch – no external power supply is required for the pressure switches to operate. Typically, electromechanical pressure switches are provided with SPDT or DPDT contacts rated for 3 to 15 amps and voltages from 120VAC to 480VAC. With solid state switches, an external power supply, usually 24VDC, is necessary to power the electronic circuitry inside the switch. The outputs of solid state switches are typically normally-open and normally-closed transistor switching outputs rated for about 500mA and 30VDC.

 Process media and wetted parts

The pressure connection and sensor are known as wetted parts since they come into direct contact with the process media. Sensor material is either elastomer (i.e. Buna-N, Teflon®) or metallic (i.e. Brass, Stainless Steel) with metallic or composite pressure connections.

The process media must be compatible with the wetted parts material. Process media temperature should also be considered as each of the different wetted materials would have differing operating properties.

For both electromechanical and solid state switches, determining the chemical compatibility of switches with the medium sensed is a critical element in the longevity of the pressure switches.

Wetted parts are the parts of the switches that actually come in direct contact with the medium being sensed, and their material composition is identified in switches specifications. The wetted parts will include the pressure sensing port of the switch, the diaphragm, bellows, bourdon tube, or piston and any O-ring seals.

Chemical resistance charts and databases are readily available on the Internet and may be used to determine the compatibility of switches wetted parts with the chemicals encountered in the measured medium.

A switch with a brass pressure sensing port and elastomeric diaphragm (such as Buna N or Viton) may work well for some applications but will not last as long as a pressure switches with the chemical resistance of a weld-sealed stainless steel diaphragm and sensing port in many industrial applications.

Pressure switches mounting

If the unit is to be installed directly onto the process, there are many methods of installation.

Typically a 1/8”, 1/4”, or 1/2” NPT (national pipe thread taper) connection is used with a mating fitting to secure the pressure switches to the process. There are also straight threaded (SAE, BSPT) connections, flush mount connections, and sanitary connections.

Check details about Thread Types for process connection.

The switches may be mounted directly in the process line using the threaded connection, a manifold, or flange; or the enclosure could be bolted to a mounting plate or other plane to secure it. If heavy vibration is present, you may choose to use a remote diaphragm seal with the pressure switches. The diaphragm seal mates with the process connection while the switches enclosure is mounted securely away from the vibration.

Process environment

It is important to know what type of environment the switches would be installed in – hazardous or ordinary location; indoors or outdoors; exposed to salt air; inside a control panel; in high ambient temperature. These are just some of the factors to consider so the right enclosure type is chosen. Enclosure types come in many shapes, sizes, and materials. They also conform to various industry and third-party approval standards.

Electronic switches can be used to replace electro-mechanical switches when SIL is needed for safety applications.  There are also electro-mechanical switches without enclosures; typically used in OEM, non-hazardous locations where the environment is benign.

Types of Switch Action

Standard switches sense a single pressure source and open or close a single set of contacts. Differential switches have two connections and sense the pressure difference across a circuit.

Dual switches sense a high and low limit on the same pressure source, and actuate two sets of electrical contacts. Wide range dual pressure sensing can be accomplished with two standard switches. See diagram below.

Additional Posts which may be of interest

Which Pressure Switch is suitable for you?

Which Pressure Switch is suitable for you?

by | May 26, 2017

The Guide abut Pressure Switch
THE GUIDE IN 2017
Contents
2
3

What is Pressure Switch

Pressure switches are one of the most commonly used fluid control components. We use them at home, in our refrigerators, dishwashers and washing machines. Whenever we handle a gas or liquid we almost always need to control the pressure.

Our home appliances do not demand high accuracy nor do they experience high cycle rates. By contrast, the pressure switches used in industrial machinery and systems must be rugged, dependable, accurate, and have a high lifecycle.

Most of the time we never think about pressure switches. They just show up with such machinery as paper machines, air compressors or pump sets. In this type of equipment, we depend upon pressure switches to act as safety devices, alarms, or as the control element within the system. But in most cases we give little consideration to this component when we make a purchase.

The basic function of a pressure switch is to detect a pressure change and convert it into an electrical signal function – typically on/off or off/on. Although there are many different types, pressure switches fall under two basic classifications:

  1. Electromechanical
  2. Electronic/solid state.

And while each may have its advantages, arriving at the correct pressure switch for your application is the same.

If you want to know what are the difference between pressure switch and pressure transducer, you can check our post of Pressure Switches V.S Pressure Transducer

Electromechanical pressure switches

Electromechanical pressure switches have a sensing element which responds to changes in pressure and mechanically operates a snap-acting switch in response to the pressure changes. Different types of sensing technologies are used in the design of electromechanical pressure switches.

  • Diaphragm switches use an elastomeric or weld-sealed metal diaphragm which deflects with pressure changes; they act directly, or via a push-rod, on a snap-acting switch.
  • With a bellows or bourdon tube switch, the movement of the bellows, or sealed metal bourdon tube, is caused by pressure changes; this movement mechanically operates a snap-acting switch.
  • A piston switch design uses an O-ring sealed piston that moves in response to pressure changes, and directly or via a push-rod, actuates the electrical snap-acting switch.
FIGURE Selection of adjustable range for electromechanical pressure switches
 
TypesRangeAccuracyLife cyclesCost
Bourdon Tube50 ~ 18,000 psi±0.5%Less than 25 cycles/minHigh
Diaphragm150 psi and vacuum±0.5%Less than 25 cycles/minMedium
Diaphragm Sealedfrom vacuum to 1600 psi±2% accuracy2.5 million cyclesLow
Piston0~12,000 psi±2% accuracy2.5 million cyclesMedium
 

Solid state pressure switch

Solid state pressure switches use the same technology found in analog pressure transmitters to sense changes in pressure. A weld-sealed metal diaphragm or O-ring sealed ceramic diaphragm with a piezoresistive strain gage-based sensing element is used to measure changes in pressure. Rather than harnessing the energy of the pressure changes to mechanically operate a switch (as with electromechanical pressure switches), solid state pressure switches electrically measure pressure changes and internal electronic circuitry is used to activate one or more solid state switched outputs.

Today, there are a wide variety of solid-state pressure switches having one to four or more switch points, digital displays, analog and digital outputs, and full programmability.

In addition to opening or closing the pressure switch circuit(s), they provide a proportional analog 4-20 mA signal or digital output. The analog signal can interface with PLCs (Programmable Logic Controls), DCSs (Distributed Control Systems) and computers.

Solid-state pressure switches provide a number of advantages over electromechanical switches, including:

  • Much longer cycle life
  • Improved accuracy to ±0.25%
  • High resistance to shock and vibration
  • The ability to handle a wide range of system pressures
  • Broad frequency response
  • Excellent long-term stability

ESS201 Series Intelligent Pressure Switch adopts the solid-state sensing technology and the major advantage lies in cycle life. Solid-state switches routinely have an operational life of 100 million cycles.

One concern with solid-state switches used in industrial and process settings is electromagnetic interference which can corrupt signal data. One should select a solid-state pressure switch that is in compliance with approved electronic standards. Additionally, a solid state switch requires an input power source to function. EMI/RFI does not affect electromechanical switches because the circuit is a mechanical switch that is either open or closed.

Even with their list of attributes, however, the initial comparatively high price may probably prevent many users from upgrading to this technology. If one is designing a new system, the selection of a solid-state switch may, in fact, be the most cost-effective solution.

When a system requires multiple switch points, a local gauge and transmitters using a solid-state pressure switch can reduce the installed cost by one-half.

Which Application need Pressure Switch

Pressure switches are commonly used in various applications where monitoring and controlling pressure levels is critical. Some of the applications that require pressure switches include:

1. HVAC Systems:

Pressure switches are used in heating, ventilation, and air conditioning (HVAC) systems to monitor and control the pressure of refrigerant or air. They help ensure proper system performance and prevent damage due to excessive pressure.

2. Pump Systems:

Pressure switches are used in pump systems to monitor the pressure and control the operation of the pump. They can detect low or high-pressure conditions and trigger the pump to turn on or off accordingly.

3. Compressed Air Systems:

Pressure switches are used in compressed air systems to monitor the pressure levels and control the compressor operation. They help maintain optimal pressure for efficient operation and prevent overpressure situations.

4. Hydraulic Systems:

Pressure switches are used in hydraulic systems to monitor and control the pressure of hydraulic fluid. They can trigger alarms or shut down the system if the pressure exceeds safe limits or falls below required levels.

5. Water Systems:

Pressure switches are used in water systems, such as water pumps and water tanks, to monitor and control water pressure. They ensure consistent water pressure and can activate pumps or valves to maintain desired pressure levels.

6. Industrial Processes:

Pressure switches are used in various industrial processes where pressure control is critical. They can be found in applications such as steam systems, chemical processing, oil and gas pipelines, and manufacturing processes.

Click below link to find more details about Eastsensor Pressure Switch products

Additional Posts which may be of interest

Pressure Switch V.S Pressure Transducer, what’s the difference?

Pressure Switch V.S Pressure Transducer, what’s the difference?

by | Dec 31, 2016

Contents
2
3

Last month, we posted article to explain the relationship between pressure transducer and pressure transmitter, if you are not very clear and intent to learn the details, please check transducer v.s transmitter v.s sensor.  Or we are wrapping things up below for your short review.

  • Common points: Both pressure transmitter and transducer (sometime even pressure switch) are generically referred to pressure sensor; they generate/modify an electrical signal (except pressure switch) in proportion to medium or measuring variables.
  • Pressure transmitter: Output signal is current loop such as 4-20mA or 0-20mA, which can be transmitted over very long distances with same current flow in all parts of the loop.
  • Pressure transducer: Output signal is voltage (sometime mill volt) such as 0-10Vdc, 0/1-5Vdc, 8-24Vdc/ac, 11-30Vdc/ac etc. however we’d admit volt drops and interference can have an effect on accuracy especially when long distance measuring come into consideration.

However increasingly, we’ve been questioned many times because our customers have confused pressure switch and pressure transducers also the difference between them.

Consideration must be given to the fact that in many cases both definitions are interchangeable but they are significant difference when it comes to functionality and safety performance they provide.

Understanding the differences can help you know when to use a pressure switch versus a pressure transmitter and vice versa.

Difference on conclusion (to stop here to get a rough idea about the difference if no sufficient time)

Pressure switch

  • Far more simplistic than pressure transducer
  • Can make contact or break contact which moving into one of two positions.
  • Not highly accurate if compare to pressure transducer
  • Need to be tested manually if want to make sure whether it work properly.
  • Easy to install

Pressure transducer

  • More advanced and sophisticated than pressure switch
  • Far more accurate and repeatable than pressure switch
  • Can provide digital display
  • Can be tested automatically many times every second
  • Always connect to logic board to improve safety performance

Difference in details (more specific details set forth below for your further interesting)

Pressure Switch

A pressure switch is a device that can measure pressure electromechanically in a process, pressure switch can complete the function of “on” and/or “off” when a pressure reaches the given limited high or low points that predefined, in case of that the switch can open or close/contact or break a circuit and move into one of two positions by the pressure of medium it measured.

Pressure switch provide a simple mechanical switch linked to an on/off valve or pump which can effectively and reliably control the process at hand, keeping a tank from running dry or a temperature from climbing too high.

The accurate of pressure switch is not very high, let’s make a small example, the current most popular type of pressure switch range is 0-220bar with accuracy of 5% FS.

Once given a certain pressure for example 80bar, which means the trigger condition can be alarmed anywhere between 69-91bar (5% of 220 =11, 80+11=91, 80-11=69) and the alarm may trigger at a different pressure within this range every time.

Another drawback of pressure switches is that the only way to know if the switch is working properly is to test it.  This requires that the pressure switch must be physically disconnected from the pipeline to allow the pressure to fall below the low pressure alarm set point and, if it’s a high/low switch, connected to a pump which raises the pressure above the high pressure set point.

This type of testing must be done manually and is typically only done during a periodic (in most cases annual) inspection.

Pressure Transducer

A pressure transmitter or pressure transducer, on the other hand, is also an electromechanical device which continuously measure and communicate their assigned process variables over a range of values however, instead of signaling a switch, pressure transducer sends a read-out signal of what the specific pressure value is to a remote location.

The function of pressure switch is simple, so it always is deployed at some critical environment to implement  key safety task, for example, oil wellhead can occur extreme high pressure spikes which probably lead to heavy blowout when pressure touch the limitation.

In case of that a pressure switch can function well in this application to prevent it by triggering contact or break at predefined points.

On the contrary, pressure transmitter can be produced to more sophisticated. Via pre-installed software, the pressure transmitter can interpret the given pressure reading and transmit signal to logic board or remote device.

It can be extremely helpful for measuring efficiencies of pressure systems and can control many industrial functions, such as inlets and outlets, chemical or fuel mixtures, or can even act as a safety switch itself depending on how the software is set up to control the system.

Wrapping up

When choosing between pressure switch and pressure transmitter, you’d better ask below questions yourself.

  • In the case of normal process, can the operation variable be allowed to vary between lower and/or upper limits or is more precise setpoint range required? If the variable can vary from one to another point, then pressure switch is needed, or pressure transmitter is good choice to implement continuous communication between a predefined pressure ranges.
  • On top of control functionality, is local display needed or is there any need for remote communication and the alarming of process variable in question?Just how precisely the process variable must be measured – and controlled – will determine how accurate (i.e., how expensive) the transmitter will need to be.
  • If there is a need to display or communicate the process variable in question, application of a transmitter also is indicated. A switch by its very nature does not provide a measurement signal output to drive a local display or remote communications. It simply changes state when its threshold is crossed, initiating a discrete (on/off) control action.
  • What are the consequences if the process variables move outside its intended range? Does that lead to device damage, excessive downtime or an unsafe condition ensue?
  • If adverse consequences such as equipment damage, excessive downtime or an unsafe condition are likely to ensue if the process variable moves beyond its intended range, risk analysis and safety considerations come to the forefront. In these types of applications, the transmitter holds one advantage over the switch in that it’s easier to tell if a transmitter is not working.
  • This is both because of its continuous communications output and the extensive self-diagnostics built into today’s electronic transmitters. While normally quite reliable, there’s no obvious or automatic way to tell if a switch deployed in a protective (non-control) application has failed.

Additional Posts which may be of interest