Single-Break and Double-Break Switches

Switches can also be classified as SINGLE-BREAK or DOUBLE-BREAK switches. This refers to the number of places in which the switch opens or breaks the circuit. All of the switches shown so far have been single-break switches. A double-break switch is shown in figure 3-5. The schematic symbol shown in figure 3-5(A) shows that this switch breaks the circuit in two places (at both terminals). The upper part of the schematic symbol indicates that these contacts are in the open position and the circuit will close when the switch is acted upon (manually or automatically). The lower symbol shows closed contacts. These contacts will open the circuit when the switch is acted upon

Figure 3-5.—Double-break pushbutton switch

Figure 3-5(B) is a picture of the switch. This switch is called a pushbutton switch because it has a button that must be pushed to change the switch contact connections. Notice that the switch has four terminals. The schematic symbol in figure 3-5(A) shows that when one set of contacts is open, the other set of contacts is closed. This switch is a double-pole, single-throw, double-break switch. The number of poles in a switch is independent of the number of throws and whether it is a single or double break switch. The number of throws in a switch is independent of the number of poles and whether it is a single or double break switch. In other words, each characteristic of a switch (poles, throws, break) is not determined by either of the other characteristics. Figure 3-6 shows the schematic symbols for several different switch configurations.

Figure 3-6.—Schematic symbols of switch configurations.

Rotary Switches A rotary switch is a midcontact switch part of the schematic with the contacts arranged in a full or partial circle. Instead of a pushbutton or toggle, the mechanism used to select the contact moves in a circular motion and must be turned. Rotary switches can be manual or automatic switches. An automobile distributor, the ignition switch on a motor vehicle, and the channel selector on some television sets are rotary switches. The automobile distributor cap and rotor are an example of the simplest form of an automatic rotary switch. Figure 3-7 shows a portion of an automobile ignition system with the distributor cap and rotor shown. The rotor is the portion of this switch that moves (rotates) and selects the circuit (spark plug). The rotor does not actually touch the contacts going to the spark plugs, but the signal (spark) jumps the gap between the rotor and the contacts. This switch has one input (the rotor) and six positions (one for each spark plug). The schematic diagram for this rotary switch is shown below the illustration of the distributor cap.

Figure 3-7.—Rotary switch in automobile ignition system.

The rotor in the distributor rotates continually (when in use) in one direction and makes a complete circle. This is not true for all rotary switches. The ignition switch in an automobile is also a rotary switch. It usually has four positions (accessory, off, on, start). Unlike the rotor, it does not rotate continually when in use, can be turned in either direction, and does not move through a complete circle. Some rotary switches are made with several layers or levels. The arrangement makes possible the control of several circuits with a single switch. Figure 3-8 is an illustration of a rotary switch with two layers. Each layer has a selector and 20 contacts. As this switch is rotated, both layers select a single circuit (contact) of the 20.

Figure 3-8.—Two-layer rotary switch. The channel selector on some television sets is a multilayer rotary switch. It is also called a WAFER SWITCH. In a wafer switch, each layer is known as a wafer. The schematic of the wafer is always drawn to represent the wafer as it would look if viewed from opposite the operating handle or mechanism. If the wafer has contacts on both sides, two drawings are used to show the two sides of the wafer. The two drawings are labeled "front" and "rear." The drawing labeled "front" represents the side of the wafer closest to the operating mechanism.

Figure 3-9(A) shows one wafer of a wafer switch and its schematic symbol. Contact 1 is the point at which current enters the wafer. It is always connected to the movable portion of the wafer. With the wafer in the position shown, contact 1 is connected to both contact 5 and 6 through the movable portion. If the movable portion was rotated slightly clockwise, contact 1 would only be connected to contact 5. This arrangement is known as MAKE BEFORE BREAK because the switch makes a contact before breaking the old contact.

Figure 3-9.—Wafer switch.

Figure 3-9(B) is an illustration of the entire switch and its schematic symbol. Since the switch has two wafers mechanically connected by the shaft of the switch, the shaft rotates the movable portion of both wafers at the same time. This is represented on the schematic symbol by the dotted line connecting the two wafers. The upper wafer of the schematic symbol is the wafer closest to the control mechanism, and is identical to the wafer shown in figure 3-9(A). When switches have more than one wafer, the first wafer shown is always the wafer closest to the operating mechanism. The lower wafer on the schematic diagram is the wafer farthest away from the operating mechanism. Contact 9 of this wafer is connected to the movable portion and is the point at which current enters the wafer. In the position shown, contact 9 is connected to both contact 13 and 16. If the switch is rotated slightly clockwise, contact 9 would no longer be connected to contact 13. A further clockwise movement would connect contact 9 to contact 12. This arrangement is called BREAK BEFORE MAKE. Contact 9 will also be connected to contact 15 at the same time as it is connected to contact 12.

Q9.   Label the switch schematics shown in figure 3-10A through 3-10G.

Figure 3-10.—Switch schematic symbols.

OTHER TYPES OF SWITCHES You have learned that switches are classified by the number of poles, throws, and breaks. There are other factors used to describe a switch such as the type of actuator and the number of positions. In addition, switches are classified by whether the switch has momentary contacts or is locked into or out of position and whether or not the switch is snap-acting.

Type of Actuator In addition to the pushbutton, toggle, and knife actuated switches already described, switches can have other actuators. There are rocker switches, paddle switches, keyboard switches and mercury switches (in which a small amount of mercury makes the electrical contact between two conductors).

Number of Positions Switches are also classified by the number of positions of the actuating device. Figure 3-11 shows three toggle switches, the toggle positions, and schematic diagrams of the switch. Figure 3-11(A) is a single-pole, single-throw, two-position switch. The switch is marked to indicate the ON position (when the switch is closed) and the OFF position (when the switch is open). Figure 3-11(B) is a single-pole, double-throw, three-position switch. The switch markings show two ON positions and an OFF position. When this switch is OFF, no connection is made between any of the terminals. In either of the ON positions, the center terminal is connected to one of the outside terminals. (The outside terminals are not connected together in any position of the switch.) Figure 3-11(C) is a single-pole, double-throw, two-position switch. There is no OFF position. In either position of this switch, the center terminal is connected to one of the outside terminals.

Figure 3-11.—Two- and three-position switches.

Momentary and Locked Position Switches

In some switches, one or more of the switch positions are MOMENTARY.  This means that the switch will only remain in the momentary position as long as the actuator is held in that position. As soon as you let go of the actuator, the switch will return to a non-momentary position. The starter switch on an automobile is an example of a momentary switch. As soon as you release the switch, it no longer applies power to the starter. Another type of switch can be LOCKED IN or OUT of some of the switch positions. This locking prevents the accidental movement of the switch. If a switch has locked-in positions, the switch cannot be moved from those positions accidentally (by the switch being bumped or mistaken for an unlocked switch). If the switch has locked-out positions, the switch cannot be moved into those positions accidentally. Figure 3-12 shows a three-position, locking switch.

Figure 3-12.—Three-position locking switch. Snap-Acting Switches

A SNAP-ACTING switch is a switch in which the movement of the switch mechanism (contacts) is relatively independent of the activating mechanism movement. In other words, in a toggle switch, no matter how fast or slow you move the toggle, the actual switching of the circuit takes place at a fixed speed. The snap-acting switch is constructed by making the switch mechanism a leaf spring so that it "snaps" between positions. A snap-acting switch will always be in one of the positions designed for that switch. The switch cannot be "between" positions. A two-position, single-pole, double-throw, snap-acting switch could not be left in an OFF position. Accurate Snap-Acting Switches.

An ACCURATE SNAP-ACTING SWITCH is a snap-acting switch in which the operating point is pre-set and very accurately known. The operating point is the point at which the plunger causes the switch to "switch." The accurate snap-acting switch is commonly called a MICROSWITCH. A microswitch is shown in figure 3-13.

Figure 3-13.—Accurate snap-acting switch (microswitch).

The full description of the microswitch shown in figure 3-13 is a two-position, single-pole, double-throw, single-break, momentary-contact, accurate, snap-acting switch. Notice the terminals marked C, NO, and NC. These letters stand for common, normally open, and normally closed. The common terminal is connected to the normally closed terminal until the plunger is depressed. When the plunger is depressed, the spring will "snap" into the momentary position and the common terminal will be connected to the normally open terminal. As soon as the plunger is released, the spring will "snap" back to the original condition. This basic accurate snap-acting switch is used in many applications as an automatic switch. Several different methods are used to actuate this type of switch. Some of the more common actuators and their uses are shown in figure 3-14.

Figure 3-14.—Common actuators and their uses for accurate snap-acting switches.

Q10.   What classification of a switch is used when you describe it as a rocker switch?

Q11.   In describing a switch by the number of positions of the actuator, what are the two possible configurations for a single-pole, double-throw switch?

Q12.   What type of switch should be used to control a circuit that requires a temporary actuation signal?

Q13.   What type of switch is used if it is necessary to guard against a circuit being accidentally turned on or off?

Q14.   What is the common name used for an accurate snap-acting switch?

SWITCH RATING Switches are rated according to their electrical characteristics. The rating of a switch is determined by such factors as contact size, contact material, and contact spacing. There are two basic parts to a switch rating-the current and voltage rating. For example, a switch may be rated at 250 volts dc, 10 amperes. Some switches have more than one rating. For example, a single switch may be rated at 250 volts dc, 10 amperes; 500 volts ac, 10 amperes; and 28 volts dc, 20 amperes. This rating indicates a current rating that depends upon the voltage applied.

CURRENT RATING OF A SWITCH The current rating of a switch refers to the maximum current the switch is designed to carry. This rating is dependent on the voltage of the circuit in which the switch is used. This is shown in the example given above. The current rating of a switch should never be exceeded. If the current rating of a switch is exceeded, the contacts may "weld" together making it impossible to open the circuit.

VOLTAGE RATING OF A SWITCH The voltage rating of a switch refers to the maximum voltage allowable in the circuit in which the switch is used. The voltage rating may be given as an ac voltage, a dc voltage, or both. The voltage rating of a switch should never be exceeded. If a voltage higher than the voltage rating of the switch is applied to the switch, the voltage may be able to "jump" the open contacts of the switch. This would make it impossible to control the circuit in which the switch was used.

Q15.   What is the current rating of a switch?

Q16.   What is the voltage rating of a switch?

MAINTENANCE AND REPLACEMENT OF SWITCHES Switches are usually a very reliable electrical component. This means, they don’t fail very often. Most switches are designed to operate 100,000 times or more without failure if the voltage and current ratings are not exceeded. Even so, switches do fail. The following information will help you in maintaining and changing switches.

CHECKING SWITCHES There are two basic methods used to check a switch. You can use an ohmmeter or a voltmeter. Each of these methods will be explained using a single-pole, double-throw, single-break, three-position, snap-acting, toggle switch. Figure 3-15 is used to explain the method of using an ohmmeter to check a switch. Figure 3-15(A) shows the toggle positions and schematic diagrams for the three switch positions. Figure 3-15(B) shows the ohmmeter connections used to check the switch while the toggle is in position 1. Figure 3-15(C) is a table showing the switch position, ohmmeter connection, and correct ohmmeter reading for those conditions.

Figure 3-15.—Table of correct readings.

With the switch in position 1 and the ohmmeter connected to terminals 1 and 2 of the switch, the ohmmeter should indicate (¥). When the ohmmeter is moved to terminals 2 and 3, the ohmmeter should indicate zero ohms. With the ohmmeter connected to terminals 1 and 3, the indication should be (¥). As you remember from chapter 1, before the ohmmeter is used, power must be removed from the circuit and the component being checked should be isolated from the circuit. The best way to isolate the switch is to remove it from the circuit completely. This is not always practical, and it is sometimes necessary to check a switch while there is power applied to it. In these cases, you would not be able to use an ohmmeter to check the switch, but you can check the switch by the use of a voltmeter. Figure 3-16(A) shows a switch connected between a power source (battery) and two loads. In figure 3-16(B), a voltmeter is shown connected between ground and each of the three switch terminals while the switch is in position 1. Figure 3-16(C) is a table showing the switch position, voltmeter connection, and the correct voltmeter reading

Figure 3-16.—Table of correct readings.

With the switch in position 1 and the voltmeter connected between ground and terminal 1, the voltmeter should indicate no voltage (OV). When the voltmeter is connected to terminal 2, the voltmeter should indicate the source voltage. With the voltmeter connected to terminal 3, the source voltage should also be indicated. The table in figure 3-16(C) will show you the correct readings with the switch in position 2 or 3.

REPLACEMENT OF SWITCHES When a switch is faulty, it must be replaced. The technical manual for the equipment will specify the exact replacement switch. If it is necessary to use a substitute switch, the following guidelines should be used. The substitute switch must have all of the following characteristics.

· At least the same number of poles.

· At least the same number of throws.

· The same number of breaks.

· At least the same number of positions.

· The same configuration in regard to momentary or locked positions.

· A voltage rating equal to or higher than the original switch.

· A current rating equal to or higher than the original switch.

· A physical size compatible with the mounting. In addition, the type of actuator (toggle, pushbutton, rocker, etc.) should be the same as the original switch. (This is desirable but not necessary. For example, a toggle switch could be used to replace a rocker switch if it were acceptable in all other ways.) The number of poles and throws of a switch can be determined from markings on the switch itself. The switch case will be marked with a schematic diagram of the switch or letters such as SPST for single-pole, single-throw. The voltage and current ratings will also be marked on the switch. The number of breaks can be determined from the schematic marked on the switch or by counting the terminals after you have determined the number of poles and throws. The type of actuator, number of positions, the momentary and locked positions of the switch can all be determined by looking at the switch and switching it to all the positions.

PREVENTIVE MAINTENANCE OF SWITCHES As already mentioned, switches do not fail very often. However, there is a need for preventive maintenance of switches. Periodically switches should be checked for corrosion at the terminals, smooth and correct operation, and physical damage. Any problems found should be corrected immediately. Most switches can be inspected visually for corrosion or damage. The operation of the switch may be checked by moving the actuator. When the actuator is moved, you can feel whether the switch operation is smooth or seems to have a great deal of friction. To check the actual switching, you can observe the operation of the equipment or check the switch with a meter.

Q17.   What two types of meters can be used to check a switch?

Q18.   If a switch must be checked with power applied, what type of meter is used?

Q19.   A double-pole, double-throw, single-break, three-position, toggle switch is faulty. This switch has a momentary position 1 and is locked out opposition 3. The voltage and current ratings for the switch are 115 volt dc, 5 amperes. No direct replacement is available. From switches A through I, in table 3-1, indicate if the switch is acceptable or not acceptable as a substitute. Of the acceptable switches, rank them in order of choice. If the switch is unacceptable, give the reason.

Q20.   What should you check when performing preventive maintenance on a switch?

Table 3-1.—Replacement Switches and Their Characteristics