Control Room Equipment
4.1
ANNUNCIATORS AND ALARMS 580
Introduction 581
History 582
Principles of Operation 583
Operating Sequences 583
Annunciator Types 586
Integral Annunciator 586
Remote Annunciator 587
Semigraphic Annunciator 588
Recording Annunciators 589
Vocal Annunciators 590
Relay-Type Annunciators 590
Solid-State Annunciators 593
Annunciator Cabinets 595
Hazardous Area Designs 595
Intrinsically Safe Designs 595
Pneumatic Annunciators 596
Bibliography 597
4.2
CONTROL CENTERS AND PANELS—
TRADITIONAL 598
Introduction 599
Traditional Control Rooms 599
Control Rooms for DCS Systems
Traditional Control Panels 601
Flat Panels 601
Breakfront Panels 601
Consoles 601
© 2006 by Béla Lipták
Traditional Front Panel Layouts 602
Large-Case Instruments 602
Miniature Instruments 602
High-Density Instruments 603
Graphic Panels 603
Back-of-Panel Layout 607
Panel Materials of Construction 607
Panel Specifications 608
Human Engineering 608
Panel Tubing and Wiring 610
Tubing 610
Fittings 611
Panel Wiring 611
Control Center Inspection 615
Panel Shipment 616
Conclusions 616
Reference 616
Bibliography 616
4.3
CONTROL CENTER UPGRADING 618
Baseline Evaluation 619
Original Design Perspective 620
Information Zones and Task Analysis 621
Building a New Control Room 622
Technology Advances 623
Computerized Procedure Systems 626
600 Phased Approach 627
Planning Ahead 630
HMI Standards 630
Maintainability 631
Bibliography 631
575
576 Control Room Equipment
4.4
CONTROLLERS—ELECTRONIC ANALOG
AND DIGITAL 633
Introduction 634
Analog vs. Digital Controllers 634
The Controller’s Function 635
Feature Checklist 635
On/Off and Direct-Connected Controllers
On/Off Relay Outputs 636
Direct-Connected Controllers 636
Analog Controllers 637
Input Variations 638
Control Modes 639
Nonlinear Controllers 640
Special Features 641
Displays 642
Balancing Methods 643
Mounting 644
Servicing 645
Digital Electronic Controllers 645
Advantages and Disadvantages 645
Hardware Components 646
Software Capability 647
Faceplates and Programmers 648
Bibliography 649
4.5
CRT DISPLAYS 650
Introduction 651
Display Options 651
The Total System 653
Data Display Options 654
Keyboard 656
Display Capabilities 657
Refresh Memory 657
Character and Format Control 658
Vector Generator 658
Display Initiation 659
Propagation and Termination 661
Conclusions 662
Bibliography 662
4.6
DCS: BASIC TRENDS AND ADVANCES
Introduction 666
Connectivity and Integration 666
Organizing the Project 667
The Future 669
Control Advances 669
Basic PID Algorithms 669
Auto-Tuning 671
Model-Based Control Algorithms
DCS Bid Package 673
Costs 674
© 2006 by Béla Lipták
Conclusions 674
References 676
4.7
DCS: CONTROL AND SIMULATION
ADVANCES 677
Introduction 677
636 Performance Monitoring 678
Controller Tuning 678
On-Demand Tuning 679
Adaptive Tuning 679
Fuzzy Logic Control 679
Model Predictive Control 681
Neural Network Applications 682
Process and Control Simulation 684
Conclusion 686
Reference 686
Bibliography 686
4.8
DCS: INSTALLATION AND COMMISSIONING 687
Introduction 687
Installation 688
Power and Grounding 688
System Assembly 688
HVAC and Heat Tracing 689
Field Wiring and Checkout 689
Bus Installation 689
Installing HART Networks 690
Commissioning 690
Training and Preliminary Checkout 690
Fieldbus Testing 691
Process Startup 691
Commissioning of Control Loops 692
Advanced Control 692
Conclusion 692
References 692
Bibliography 692
4.9
DCS: INTEGRATION WITH BUSES AND
NETWORKS 693
663 Introduction 693
Bus Integration 693
DCS Fieldbus Support 694
Field Networks 694
Fieldbus Devices 695
Function Blocks 696
Network Integration 697
Recent Integration Trends 698
671 Conclusions 698
References 698
Bibliography 699

4.10
DCS: INTEGRATION WITH OTHER
SYSTEMS 700
Introduction 700
Existing Systems 700
MODBUS Interface 700
OPC Interface 702
Motor Controls 702
Fieldbus Interface 703
Safety Systems 703
Conclusions 705
Reference 705
Bibliography 705
4.11
DCS: MANAGEMENT OF ABNORMAL
CONDITIONS 706
Introduction 706
Abnormal Condition Management 706
Types of Control 707
Need for Operator Intervention 707
Psychological Basis for Intervention 707
Detect Phase 708
Sort/Select and Monitor Phases 709
Plan/Act Phase 709
Response Time 709
Planning the Intervention 709
Types of Operations 709
Managing Abnormal Conditions 710
Control Room Design 711
Operator Training 712
Alarm System Design 712
Graphical User Interface 716
Conclusions 718
Acknowledgments 718
References 718
Bibliography 718
4.12
DCS: MODERN CONTROL GRAPHICS
Introduction 720
Function Block Representation 720
Standard for Process Control 721
Function Block Modes 721
Function Block Types 722
Sequential Function Chart (SFC) 723
Ladder Diagrams 724
Batch S88 725
Safety Logic 725
Conclusions 725
Bibliography 726
© 2006 by Béla Lipták
Contents of Chapter 4 577
4.13
DCS: OPERATOR’S GRAPHICS 727
Introduction 727
Operator Console Equipment 727
Video Display 728
Keyboards 728
Peripheral Devices 729
Remote and Web-Based Stations 729
Remote Clients 729
Web Pages 730
Operator Graphics 730
Types of Displays 731
Overview Graphic Displays 731
Graphic Displays 731
Faceplate with Detailed Display 732
Trend Displays 732
Static Graphic Components 732
Dynamic Elements 732
Dynamos 733
Aliases 734
Display Access 735
Process Performance Monitoring 736
Process Graphic Data Interfaces 736
Conclusion 738
Bibliography 738
4.14
DCS: SYSTEM ARCHITECTURE 739
Introduction 740
Analog Control 740
Direct Digital Control 741
Distributed Control System 741
Functional Components 742
DCS Control Network 742
Operator Console 744
Core Architectural Components 745
International Fieldbus Standards 749
Data Highway Designs 749
Control Network 749
Ethernet Configuration 749
Alarm Management 750
Alert Processing 750
DCS Attributes 752
720
Reliability 753
Mean Time between Failure 753
Pricing 754
Bibliography 755
4.15
DIGITAL READOUTS AND GRAPHIC DISPLAYS 757
Introduction 758
Human Factors 759
Size and Contrast 759
Application Notes 760
578 Control Room Equipment

Mechanical and Electrical Counters 760 4.17

Gas Discharge Displays 761 HUMAN–MACHINE INTERFACE EVOLUTION 790
Cathode Ray Tube Displays 762 Introduction 790
Rear Projection Displays 763 Functions of the Control System HMI 790
Light-Emitting Diode Displays 763 Visualization and Control 791
Liquid Crystal Displays 764 Process Alarming 792
Passive Matrix Liquid Crystal Trending 792
Displays 765 DCS Consoles 793
Active Matrix Liquid Crystal DCS Console Graphic Standards 793
Displays 765 DCS HMI Redundancy 794
Vacuum Fluorescent Displays 767 DCS HMI Chronological Evolution 795
New Trends in Graphic Displays 768 The Open HMI 795
Plasma Displays 768 Open HMI Display Standards 796
Field Emission Displays 768 Documentation 796
Electroluminescent Displays 769 Open HMI Evolution Chronology 796
References 769 Evolution of HMI Architecture 797
Bibliography 769 Evolution of Plant Networking 799
Evolution of Control Rooms 800
Evolution of the Process Operator 801
2005 and Beyond 802
4.16 Distributed and Mobile Control 802
FIELDBUSES AND NETWORK Remote Operation of the Plant 803
PROTOCOLS 770 The Future 803
Introduction 770 References 804
Communications Hierarchy 770
Field Level 771 4.18
Control Level 771 INDICATORS, ANALOG DISPLAYS 805
Operations Level 771 Terminology 805
Enterprise Level 772 Electrical Movements 806
Data Models 772 Indication of Measurements 806
Network Basics 772 Fixed-Scale Indicators 807
OSI Reference Model 772 Movable-Scale Indicators 808
Physical Layer 773 Parametric Indication 809
Data Link Layer 775 Digital Indicators 810
Network Layer 777 Acoustic Indicators 810
Transport Layer 777 Bibliography 811
Application Layer 777
Fieldbus Protocols 778 4.19
AS-i 778 LIGHTS 812
HART 780 Introduction 812
PROFIBUS DP/PROFIBUS PA 781 Light Source Characteristics 813
FOUNDATION Fieldbus 782 Light Selection 814
MODBUS 784 Colors and Flashing 814
ControlNet 785 Lenses and Operating Environments 814
Industrial Ethernet 785 Light Components 814
Netwide Data Exchange 786 Lamp Types 815
OPC Servers 786 Incandescent Lamps 815
XML 787 Neon Lamps 815
FDT/DTM 787 Solid-State Lamps (LEDs) 816
Conclusion 788 Virtual Lights 816
References 788 Checklist 816
Bibliography 789 Conclusions 816
Acronyms 789 Bibliography 817

© 2006 by Béla Lipták


4.20
RECORDERS, OSCILLOGRAPHS, LOGGERS,
TAPE RECORDERS 818
Introduction 819
Sensor Mechanisms 819
Galvanometric Recorders 820
Light-Beam Recorders (Oscillographs)
Potentiometric Recorders 820
Open Loop Recorders 821
Linear Array Recorders 821
Recording Methods 822
Ink-Writing Systems 822
Inkless Systems 822
Paperless Systems 822
Charts and Coordinates 822
Circular Chart Recorders 823
Strip-Chart Recorders 824
Multiple Recorders 824
X–Y Recorders 825
Event Recorders 826
Tape Recording 826
Data Loggers 827
Bibliography 828
4.21
SWITCHES, PUSHBUTTONS, KEYBOARDS
Introduction 830
Switch Designs and Operation 830
Switching Action 831
Contact Arrangements 831
Switching Elements and Circuits 831
Grades of Switching Devices 833
Types of Switching Devices 833
Pushbuttons 833
Toggle Switches 836
Rotary Switches 837
Thumbwheel Switches 838
Application and Selection 839
Human Factors 839
Display Movement 841
Error Prevention 842
Mechanical Features 844
Environmental Considerations 844
Bibliography 844
4.22
TOUCH-SCREEN DISPLAYS 845
Introduction 845
Touch Technology 845
Advantages 845
Touch-Screen Designs 845
Evaluating Touch Technologies 848
© 2006 by Béla Lipták
Contents of Chapter 4 579
Overall System Design 851
Mechanical Considerations 851
Physical Attributes 851
Programming Considerations 852
Bibliography 853
820
4.23
UNINTERRUPTIBLE POWER AND VOLTAGE
SUPPLIES (UPS AND UVS) 854
Introduction 854
Uninterruptible Voltage Sources (UVS) 855
Uninterruptible Power Supply (UPS) Features 856
Networks and Buses 856
Power Failure Classifications 857
Source Failure 857
Equipment Failure (Inverter) 858
Common Bus Branch (Load) Failure 860
System Components 861
Rotating Equipment 861
Batteries 862
Static Inverters 863
Bus Transfer Switches 865
Protective Components 865
Standby Power Supply Systems 865
829 Multicycle Transfer System 865
Sub-Cycle Transfer System 866
No-Break Transfer System 866
System Redundancy 866
Specifications 866
Bibliography 867
4.24
WORKSTATION DESIGNS 868
Classification of Workstations 868
Hardware Architecture 868
Function 869
Hardware Components 870
Software Features 871
Selection of Correct Platform 871
Comparing Various Operating Platforms 872
Cost 872
Reliability 872
Manageability and Administration 873
Scalability 873
Security 873
Error Handling 873
Integration of Software and Hardware 873
Openness 874
Conclusions 874
Glossary 874
Bibliography 875
4.1 Annunciators and Alarms LAL Low level
alarm

TAH High temperature

alarm
J. A. GUMP (1972, 1985) B. G. LIPTÁK (1995, 2005)

E. M. MARSZAL (2005) PAHL High and low

pressure alarm

Flow sheet symbol

Types: A. Audiovisual Annunciators: integral, remote, and semigraphic systems with audible
and visual display and electromechanical (relay) or solid-state (semiconductor)
designs
B. Recording Annunciators: integral, solid-state systems with recorded printout
C. Bargraphs
D. Vocal Annunciators: integral, solid-state systems with audible command message

Cost per Alarm Point: Integral cabinet costs $75 to $175; remote system, $125 to $250; semigraphic system,
$125 to $250; recording annunciator or annunciator with communications will add
about 30% to the cost per point. These figures are budgetary in nature (± 20%), and
a number of variables can affect the price. These factors include system size, window
size, number of alarm points per board, field contact voltages, type of lamp, com-
munications options, and required certifications (e.g., Class I, Div. 2, etc.).

Partial List of Suppliers: 4B Components Ltd. (A) (www.go4b.com)

Acromag Inc. (A) (www.acromag.com)
Adaptive Micro Systems Inc. (A) (www.adaptivedisplays.com)
Advotech Inc. (D) (www.advotechcompany.com)
Ametek Power Instruments (A, B, mosaic graphic) (www.ametekpower.com)
Barnett Engineering Ltd. (A) (www.barnett-engg.com)
Beta Calibrators div. Hathaway Process Instrumentation Corp. (A, B) (www.the-esb.com)
CAL Controls Inc. (www.cal-controls.com)
CEA Instruments Inc. (www.ceainstr.com)
Cole-Parmer Instrument Co. (www.coleparmer.com)
CTC Parker Automation (www.ctcusa.com)
Daytronic Corp. (A) (www.daytronic.com)
Devar Inc. (A) (www.devarinc.com)
Draeger Safety Inc. (www.draeger.com/gds)
Druck Inc. (www.pressure.com)
Fisher Controls International Inc. (A) (www.fisher.com)
Flow Tech Inc. (www.flowtechinc.com)
Fluid Components International (www.fluidcomponents.com)
Foxboro Co. (A) (www.foxboro.com)
GE Kaye div. General Electric Co. (A)
General Monitors (www.generalmonitors.com)
Graybar Electric Co. (www.graybar.com)
Honeywell Industry Solutions (www.iac.honeywell.com)
ImageVision Inc. (www.imagevisioninc.com)
Mauell Corp. (A) (www.mauell-us.com)
Matrikon Inc. (www.matrikon.com)
Metrix-PCM/Beta (A) (www.metrix1.com)
Moore Industries Inc. (www.miinet.com)
North American Manufacturing Co. (A) (www.namfg.com)
Oceana Sensor (www.oceanasensor.com)
Phonetix Inc. (www.sensaphone.com)
Powers Process Control, A Unit of Mark Controls Corp. (A)
(www.powerscontrols.com)
Precision Digital Corp. (www.predig.com)

580

© 2006 by Béla Lipták

 4.1 Annunciators and Alarms 581

ProSys Inc. (www.prosysinc.com)

Puleo Electronics Inc. (A) (www.annuciator.com)
Raco Manufacturing and Engineering (www.racoman.com)
Robicon div. High Voltage Engineering Corp. (A) (www.robicon.com)
Ronan Engineering Co. (A, B, mosaic graphic) (www.ronan.com)
Schneider Electric/Square D (www.squared.com)
Scott Aviation div. Tyco Inc. (A) (www.tycoelectronics.com)
Seekirk Inc. (D) (www.seekirk.com)
Sierra Monitor (www.sierramonitor.com)
Swanson Engineering & Manufacturing (A) (www.amtonline.org)
Texmate Inc. (A) (www.texmate.com)
Thermo Brandt Instruments (www.brandtinstruments.com)
Tips Inc. (www.tipsweb.com)
Transmation Inc. (D) (www.transmation.com)
Trip-A-Larm (A) (www.modicon.control.com)
Visi-con div. Visicomm Industries (A) (www.alarmpanels.com)
Vorne Industries Inc. (A) (www.vorne.com)
Western Reserve Control (www.wrcakron.com)
White Electronic Designs Corp. (C) (www.motionnet.com)
Wilkerson Instrument Co. (A) (www.wici.com)
Zetron Inc. (A) (www.zetron.com)

In addition to this section, safety alarm systems are discussed More sophisticated annunciator designs can incorporate
in several other parts of this handbook, particularly in connec- bargraph-type displays, color computer graphics, and event-
tion with DCS and CRT systems in Chapter 4 and PLCs in recording or data-logging systems. Much of the new devel-
Chapter 5. The subject of process alarm management is sepa- opment in annunciator system designs involves enhanced
rately covered in Section 1.6. This section concentrates on methods of communication and reporting. As a consequence,
dedicated, conventional annunciators and other alarm devices. annunciator status can be logged and used for tasks such as
alarm management and abnormal event analysis.
Graphic displays can be dynamic, where flow in pipes is
INTRODUCTION shown by actual movement, and CRT displays can concen-
trate large amounts of information into a single display.
The purpose of an alarm system (annunciator) is to bring Figure 4.1a illustrates such a display, where the CRT displays
attention to an abnormal or unsafe operating condition in the
plant. Traditional annunciators used discrete alarm modules
for this purpose. These dedicated hardware units are dimin-
ishing in numbers yet are still used in installations where 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
simplicity is desired or where separation from the basic pro- A
cess control system is required for safety reasons. B
In some installations where traditional units have been C
replaced by PLC- or DCS-based annunciators, the recogni- D
tion of and response to alarm conditions have deteriorated E
F
because on computer screens they are not very visible and
G
can go unnoticed. In addition, because of the low incremental H
cost of adding new alarm points, excessive numbers of alarms I
been configured. Because of the floods of alarms, an impor- J
tant new component of safety system design is alarm ratio- K
nalization and alarm management (Section 1.6). L
It is possible to connect conventional annunciators as front-
end devices to DCS systems through various communication Area 3-H of plant layout Color code:
links. There is a wide variety of such links available, ranging is flashing in coded color 1-Combustibles 5-CO
2-Smoke 6-SO2
from serial links employing MODBUS protocol to Ethernet 3-Fire 7-Vinyl chloride
links utilizing Object Linking and Embedding (OLE) for Pro- 4-High pressure
cess Control (OPC). This hybrid solution adds the visibility,
reliability, and built-in redundancy of dedicated annunciators FIG. 4.1a
to the flexibility and record-keeping convenience of DCS- The overall safety status of the plant can be displayed on a single
based systems. CRT.

© 2006 by Béla Lipták

582 Control Room Equipment
the plot plan of the plant as the background. Such a plot plan
can be separated into small square segments, so that if an
unsafe condition is detected in a particular segment, the cor-
responding square can start flashing in the color that corre-
sponds to the type of safety problem detected. This type of
annunciator display is easily and quickly comprehended and
can provide a summary report on a large number of safety
conditions in an efficient manner.
HISTORY
The term “drop” was initially applied to individual annunci-
ator points, from which we may infer that annunciator sys-
tems developed from paging systems of the type used in
hospitals and from call systems used in business establish-
ments to summon individuals when their services are needed.
These systems consisted of solenoid-operated nameplates
that dropped when deenergized. The drops were grouped at
a central location and were energized by pressing an electrical
pushbutton in the location requiring service. The system also
included an audible signal to sound the alert.
Similar systems were used for fire and burglar alarms. The
drops were operated either by manual switches or by trouble
contacts that monitored thermal and security conditions in
various building locations. The use of these systems in the
chemical processing industry was a logical development when
alarm switches became available.
This development, however, was preceded by explosion-
proof, single-station annunciators that were designed to oper-
ate in the petroleum and organic chemical process plants
constructed immediately before, during, and after World War
II. They were usually installed on control panels located
either outdoors near the process unit or in local control
houses. A drop-type system could not be used in these loca-
tions because they were electrically hazardous.
By the late 1940s, centralized control rooms were
introduced. Drop-type annunciators were suited for these
Optional pressure loss alarm switch
or electrical power control unit
Supplier
Installer
Venturi orifice
Rapid exchange
pressure gauge
Purging
gas supply
Rapid exchange pressure
control filter regulator
FIG. 4.1b
Local annunciators were available in explosion-proof designs or were mounted in air-purged enclosures when mounted in Class 1 areas.
(Courtesy of Bebco Industries.)
© 2006 by Béla Lipták
general-purpose central control rooms. However, more
compact, reliable, and flexible annunciators were subse-
quently introduced.
In the early 1950s, the plug-in relay annunciator was devel-
oped. Instead of utilizing solenoid-operated drops, it used elec-
trical annunciator circuits with small telephone-type relays to
operate alarm lights and to sound a horn when abnormal con-
ditions occurred. The alarm lights installed in the front of the
annunciator cabinets were either the bull’s-eye type or back-
lighted nameplate designs.
The annunciators were compact, reliable, and because of
the hermetically sealed relay logic modules, they could also
be mounted in certain hazardous areas in addition to the
general-purpose control rooms. In order to be mounted in
Class 1 explosion-proof areas, they required purging
(Figure 4.1b). Miniaturization of instruments and the use of
graphic control panels initiated the development of remote
annunciator systems, consisting of a remotely mounted relay
cabinet connected to alarm lights installed at appropriate
points in the graphic or semigraphic diagram.
Solid-state annunciator systems with semiconductor
logic modules were developed in the late 1950s. These
permitted additional miniaturization and lowered both the
operating power requirements and the amount of heat
generated. The semigraphic annunciator was introduced
in the late 1960s and fully utilized the high-density capa-
bilities of solid-state logic. It has permitted the designs of
very compact and flexible semigraphic displays in control
centers.
With the spread of digital communication networks and
microprocessor-based smart instruments, the number of
alarm points increased, their management as a function of
importance (Section 1.6) became a separate field, and their
displays were further miniaturized. These days, with the
greater availability and reliability of integrated circuit logic
components, alarms can be displayed on handheld tools in
the field, on computer screens at workstations, or on CRTs
in DCS systems.
Enclosure
pressure indicator Required enclosure
protection vent
Reference out
Rapid exchange Enclosure
control valve warning
nameplate
Supply in
Protected
Enclosure pressure enclosure
control valve

PRINCIPLES OF OPERATION
The annunciator system consists of multiple alarm points. Each
alarm circuit includes a trouble contact (alarm switch), a logic
module, and a visual indicator (Figure 4.1c). The individual
alarm points are operated from a common power supply and
share a number of annunciator system components, including
an audible signal generator (horn), a flasher, and acknowledge
and test pushbuttons. In normal operation the annunciator sys-
tem and individual alarm points are quiescent.
The trouble contact is an alarm switch that monitors a
particular process variable and is actuated when the variable
exceeds preset limits. In electrical annunciator systems it is
normally a switch contact that closes (makes) or opens
(breaks) the electrical circuit to the logic module and thereby
initiates the alarm condition. In the alert state, the annunciator
turns on the visual indicator of the particular alarm point, the
audible signal, and the flasher for the system. The visual
indicator is usually a backlighted nameplate engraved with
an inscription to identify the variable and the abnormal con-
dition, but it can also be a bull’s-eye light with a nameplate.
The audible signal can be a horn, a buzzer, or a bell.
The flasher is common to all individual alarm points and
interrupts the circuit to the visual indicator as that point goes
into the alert condition. This causes the light to continue to
flash intermittently until either the abnormal condition
returns to normal or is acknowledged by the operator.
The horn acknowledgment pushbutton is provided with
a momentary contact: when it is operated, it changes the logic
module circuit to silence the audible signal, stop the flasher,
and turn the visual indicator on “steady.” When the abnormal
condition is corrected, the trouble contact returns to normal,
and the visual indicator is automatically turned off.
The lamp test pushbutton with its momentary contact tests
for burned-out lamps in the visual indicators. When activated,
Power supply
Common system
Audible
components
Horn
acknowledge
signal
generator
(horn)
Flasher
alarm points
Individual
Trouble Logic Visual
contacts modules indicators
(process alarm
switches)
FIG. 4.1c
The main components of a traditional annunciator system.
© 2006 by Béla Lipták
4.1 Annunciators and Alarms 583
the pushbutton closes a common circuit (bus) to each visual
indicator in the annunciator system, turning on those lamps
that are not already on as result of an abnormal operating
condition.
Operating Sequences
A wide variety of sequences are available to define the oper-
ation of an individual alarm point in the normal, alert,
acknowledged, and return-to-normal stages in the annuncia-
tor sequence. The five most commonly used annunciator
sequences are shown in Table 4.1d, identified by the original
code designation of the Instrumentation, Systems, and Auto-
mation Society (ISA). These sequences were specified by the
ISA-recommended practice RP-18.1, which has since been
revised and updated into standard ISA 18.1.
Because the old sequence designations are still used in
some plants, some of their more common versions are listed
in Table 4.1d and also described below. The sequence desig-
nations of the present standard ISA 18.1 will also be discussed
below.
The Old ISA Sequence Designations ISA Sequence 1B, also
referred to as flashing sequence A, is the one most frequently
used. The alert condition of an alarm point results in a flashing
visual indication and an audible signal. The visual indication
turns off automatically when the monitored process variable
returns to normal.
ISA Sequence 1D (often referred to as a dim sequence)
is identical to Sequence 1B except that ordinarily the visual
indicator is dim rather than off. A dimmer unit, common to
the system, is required. Because all visual indicators are
always turned on—for dim (normal), flashing (alert), or
steady (acknowledged)—the feature for detecting lamp fail-
ure is unnecessary.
ISA Sequence 2A (commonly referred to as a ring-back
sequence) differs from Sequence 1B in that following
acknowledgment the return-to-normal condition produces a
dim flashing and an audible signal. An additional momen-
tary contact reset pushbutton is required for this sequence.
Lamp
test Pushing the reset button after the monitored variable has
returned to normal turns off the dim flashing light and silen-
ces the audible signal. This sequence is applied when the
operator must know if normal operating conditions have been
restored.
ISA Sequence 2C is like Sequence 1B except that the
system must be reset manually after operation has returned
to normal in order to turn off the visual indicator. This
sequence is also referred to as a manual reset sequence and,
like Sequence 2A, requires an additional momentary contact
reset pushbutton. Sequence 2C is used when it is desirable
to keep the visual indicator on (after the horn has been
silenced by the acknowledgment pushbutton) even though
the trouble contact has returned to normal.
ISA Sequence 4A, also known as the first-out sequence,
is designed to identify the first of a number of interrelated
584 Control Room Equipment

TABLE 4.1d
The Old ISA Designations of Annunciator Sequences
ISA Code for Annunciator Process Variable Condition
the Sequence Condition (Trouble Contact) Visual Indicator Audible Signal Use Frequency

IB Normal Normal Off Off 55%

Alert Abnormal Flashing On
Acknowledged Abnormal On Off
Normal again Normal Off Off
Test Normal On Off
ID Normal Normal Dim Off 1%
Alert Abnormal Flashing On
Acknowledged Abnormal On Off
Normal again Normal Dim Off
2A Normal Normal Off Off 4%
Alert Abnormal Flashing On
Acknowledged Abnormal On Off
Return to normal Normal Dim flashing On
Reset Normal Off Off
Test Normal On Off
2C Normal Normal Off Off 5%
Alert Abnormal Flashing On
Acknowledged Abnormal On Off
Return to normal Normal On Off
Reset Normal Off Off
Test Normal On Off
4A Normal Normal Off Off 28%
Alert Abnormal
Initial Flashing On
Subsequent On Off
Acknowledged Abnormal
Initial On Off
Subsequent On Off
Normal again Normal Off Off
Test Normal On Off
All others 7%

variables that have exceeded normal operating limits. An sequence A. The sequence designations in ISA 18.1 use the
off-normal condition in any one of a group of process vari- following letter codes:
ables will cause some or all of the remaining conditions in
the group to become abnormal. The first alarm causes flash- A = Automatic Reset
ing, and all subsequent points in the group turn on the steady M = Manual Reset
light only. This sequence monitors interrelated variables. R = Ringback
The visual indication is turned off automatically when con- F = First-out
ditions return to normal after acknowledgment.
Therefore, using the ISA 18.1 sequence designations A-13
The New ISA Sequence Designations In the updated annu- means that the annunciator has automatic reset and is pro-
nciator standard ISA 18.1, the sequence designations are vided with Option 13, which suggests the presence of a dim
different, as shown in Table 4.1e. The most widely used lamp monitor. For definitions of less frequently used
sequence, the basic flashing sequence, is now designated as sequences, refer to ISA 18.1.

© 2006 by Béla Lipták

 4.1 Annunciators and Alarms 585

TABLE 4.1e
The New ISA Designations of Annunciator Sequences as Defined by ISA Standard ISA 18.1
Condition-sensing Return to
Signal Returns to Normal Condition-sensing Normal
Sequence Device Normal Alert Before Acknowledge Acknowledge Returns to Normal Reset Remarks

A Visual Off Flash Flash On Off — Flasher memory

Audible Off On On Off Off —
A-5 Visual Off On On On Off — Memory
Audible Off On On Off Off —
A-4 Visual Off Flash Off On Off — Flasher
Audible Off On Off Off Off —
A-4-5 Visual Off On Off On Off —
Audible Off On Off Off Off —
A-13 Visual Dim Flash Flash On Dim — Memory—flasher
Audible Off On On Off Off — Continuous lamp test

Optional Operating Features Annunciator sequences may
be initiated by alarm switch trouble contacts that are either
open or closed during normal operations. These are referred
to as normally open (NO) and normally closed (NC)
sequences, respectively, and the ability to use the same logic
module for either type of trouble contact is called an NO-NC
option. It is important because some alarm switches are avail-
able with either an NO or an NC contact but not with both,
and therefore without the NO-NC option in the logic module
two types of logic modules would be required. The logic
module is converted for use with either form of contact by a
switch or wire jumper connection.
The relationship between the NO and NC sequences
required in the logic module to match the various trouble
contacts and analog measurement signal actions is shown in
Figure 4.1f. A high alarm in a normally closed annunciator
Off-normal limit High
Annunciator sequence NC
Sensor action Direct Reverse Direct Reverse
system requires a normally closed trouble contact operated
by a direct-acting analog input.
If an increase in the measured variable results in an
increased output signal, the detector is direct acting; if the
output signal is reduced, it is a reverse-acting sensor. If the
trouble contacts in all alarm switches in the plant are standard-
ized such that normal operating conditions will cause all trouble
contacts to be NC (or NO), the required annunciator sequence
is also NC (or NO), and Figure 3.1f need not be consulted.
Annunciator systems are fail safe or self-policing if they
initiate an alarm when the logic module fails because of relay
coil burnout. The feature is standard for most NO and NC
annunciator sequences; annunciators using NC trouble con-
tacts are also fail safe against failures in the trouble contact
circuit.
The lock-in option locks in the alert condition initiated
by a momentary alarm until the horn acknowledgment button
is pushed, preventing loss of a transient alarm condition until
the operator can identify it. The logic module is usually
changed from lock-in to non-lock-in operation by either addi-
tion of a wire jumper or operation of a switch. The lock-in
NO feature is useful for monitoring unstable or fluctuating process
variables.

Test and Repeater Features The test feature in a standard

Trouble contact-“on shelf” NC NO NO NC
High alarm
annunciator serves only to test for burned-out lamps in the
visual indicators. The operational test feature provides a test
Off-normal limit Low of the complete annunciator system, including logic modules,
lamps, flasher, audible signal, and acknowledgment circuits.
Annunciator sequence NC NO
The operational test circuit usually requires an additional
momentary contact pushbutton, which can replace the regular
Sensor action Direct Reverse Direct Reverse
lamp test pushbutton.
Trouble contact-“on shelf” NO NC NC NO The logic module of relay-type annunciators may have
Low alarm spare (electrically isolated) auxiliary contacts that can operate
shutdown and interlock systems when alarm conditions
FIG. 4.1f occur. The auxiliary contacts are wired to terminal blocks in
Logic trees for the NO and NC annunciator sequences. the annunciator cabinet for connection to external circuitry.

© 2006 by Béla Lipták

586 Control Room Equipment

Repeater lights may be located away from the common
logic module and serve to alert operators in other areas.
Annunciator cabinet terminals for connecting these repeater
lights in parallel with the annunciator visual indicator are
available.
It may also be desirable to actuate a horn in more than
one location. The electrical load of multiple audible signals
requires an interposing relay, called a horn-isolating relay,
operated by the logic modules. This relay has contacts of
adequate capacity to operate multiple audible signals. Horn-
isolating relays may be installed either in the annunciator
cabinet or in a separate assembly.
Annunciator systems can be used for several operational
sequences without changing system wiring, and many logic
modules can supply more than one operational sequence.
This multiple sequence capability is sometimes useful when
the sequence has not yet been determined.
ANNUNCIATOR TYPES
The audiovisual annunciator can be packaged as an integral,
remote, or semigraphic annunciator.
Integral Annunciator
The integral annunciator, a cabinet containing a group of
individual annunciator points wired to terminal blocks for
connection to external trouble contacts, power supply, horn
and acknowledge and test pushbuttons, is the most econom-
ical of the various packaging methods available in terms of
cost per point. It is also the simplest and cheapest to install.
Two methods of packaging integral annunciators are illus-
trated in Figure 4.1g. In the nonmodular type, plug-in logic
modules are installed inside the cabinet and connected to
alarm windows on the cabinet door through an interconnecting
wiring harness; in the modular type, individual plug-in alarm
point assemblies of logic module and visual indicator are
grouped together.
The nonmodular and modular cabinet styles are both
designed for flush panel mounting with the logic modules
and visual indicators accessible from the front. Electrical
terminals for the external circuitry are located in the rear of
the cabinet and are accessible from the back.
Integral annunciators are used on nongraphic and on
semigraphic control panels in which physical association of
the visual indicators with a specific location in the graphic

Back lighted
name plates
Pushbutton
stations

Relay type
Front view-door closed
logic modules

Solid state
alarm module
Lamp module
Window bezel

Front view Mounting

Alarm point clamp
terminals
Front view with
door open

Visual
indicators

Filter
(1) Nonmodular (2) Modular type module Power and system
Rear view of terminal enclosure function terminals
Rear view with cover removed

FIG. 4.1g
Integral annunciator cabinets are available in modular (right) and nonmodular (left) construction.

© 2006 by Béla Lipták

 4.1 Annunciators and Alarms 587

(5)

(1)
(3)

(6)

(2) (4)

(7)

FIG. 4.1h
Integral annunciator window configurations. 1. Modular single-point annunciator. 2. Modular double-point annunciator. 3. Modular triple-
point annunciator. 4. Modular quadruple-point annunciator. 5. Nonmodular single-point. 6. Nonmodular triple-point. 7. Nonmodular single-
point with small nameplate.

process flow diagram is not required. Integral annunciator They are used with full and semigraphic control panels and
cabinets occupy more front but less rear panel space than the in nongraphic applications in which an integral annunciator
equivalent remote designs. The electrical terminals are in a cabinet may require too much front panel space. Figure 4.1i
general-purpose enclosure at the rear of the cabinet, and trouble
contacts can be wired directly to them, thus eliminating the
need for and resultant costs of intermediate terminal blocks
for trouble contact wiring.
An advantage of the modular-type cabinet is that it can
be expanded by enlargement of the panel cutout and by the
addition of modular alarm point assemblies. Nonmodular cab-
inets cannot be expanded, and new cabinets must be installed
to house additional alarm points. Consequently, one should
include more spare points when specifying the cabinet size
for a nonmodular system. The modular cabinet is also more
compact, takes up less panel space, and has a greater visual
display area per point than the nonmodular design.
Figure 4.1h illustrates various configurations of visual
(1) Chassis with general purpose enclosure
indicators that can be supplied with integral annunciator cab-
inets. Many of these groupings are also available in single-
unit assemblies for remote annunciator systems.

Remote Annunciator

The remote annunciator differs from the integral annunciator

in that the visual indicators are remote from the cabinet or (2) Chassis
chassis containing the logic modules. Remote annunciators
were developed to allow the visual indicators to be placed in FIG. 4.1i
their actual process location in the graphic flow diagram. General purpose, remote annunciator cabinets.

© 2006 by Béla Lipták

588 Control Room Equipment

illustrates a remote annunciator chassis with optional cabinet
enclosure. The chassis contains spare positions for plug-in logic
modules and a system flasher. Auxiliary system modules, such
as horn-isolating relays, may also be plugged into the logic
module chassis positions.
The chassis and cabinet enclosure are designed for wall
or surface mounting behind the control panel. Each chassis
position has terminal points for connecting the visual indi-
cator and trouble contact. In addition, the chassis has a system
terminal block for connecting electrical power, horn, flasher,
and acknowledge and test pushbuttons.
The disadvantages of remote annunciators include higher
equipment and installation costs and an increased require-
ment for back panel space. In addition, the wiring connec-
tions from field trouble contacts must be made to intermediate
terminal blocks rather than directly to the cabinet terminals,
as with the integral annunciator.
These terminal blocks, the terminal enclosure, and the
required wiring result in higher installation costs and extra
space requirements. Finally, the remote annunciator is diffi-
cult to change, and modification costs of remote systems are
substantially higher than those of the integral type, partially
because spare visual indicators cannot be installed initially.
Semigraphic Annunciator
The semigraphic annunciator developed in the late 1960s
combines some of the advantages of the integral annunciator
with the flexibility to locate visual indicators at appropriate
points in a graphic flow diagram. Figure 4.1j illustrates a
semigraphic annunciator.

Replaceable
translucent Removable transparent
drawing sheet plastic protective panel

Lamp
nesting
Aluminum
panel
housing

Main bus Main bus

terminals terminals
(Accessory) (Power)

S15 S14 S13 S12 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S1 FC FC FC FC FC FC F2 F1 FR R K T C (+) HV CN (−) LC L2 L1

POS.
1-15
1-14
1-13
1-12
1-11

1-10
1-9
1-8
1-7
1-6
1-5
1-4
1-3
1-2
1-1

Terminals located
Knockouts G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 FC FC FC
under rear cover
Annunciator logic-rack,
S15 S14 S13 S12 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S1 FC FC FC FC FC FC F2 F1 FR R K T C (+) HV CN (−) LC L2 L1
plug-in modules and power supplies
POS.
2-15
2-14
2-13
2-12
2-11

2-10
2-9
2-8
2-7
2-6
2-5
2-4
2-3
2-2
2-1

G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 FC FC FC

Lamps
S15 S14 S13 S12 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S1 FC FC FC FC FC FC F2 F1 FR R K T C (+) HV CN (−) LC L2 L1
POS.

Window position numbers

3-15
3-14
3-13
3-12
3-11

3-10
3-9
3-8
3-7
3-6
3-5
3-4
3-3
3-2
3-1

(4 high by 15 wide)
G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 FC FC FC
12 10 8 12 10 8 12 10 8 12 10 8 12 10 8 Pin numbers of socket
A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
POS.
4-15
4-14
4-13
4-12
4-11

4-10

To signal terminals
4-9
4-8
4-7
4-6
4-5
4-4
4-3
4-2
4-1

Detailed view of the grid of row 4 wired for

(lamp nesting panel) B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 transformers
11 8 7 11 9 7 11 9 7 11 9 7 11 9 7

Pin numbers of socket

Rear view showing terminal block arrangement

FIG. 4.1j
Construction of a typical semigraphic annunciator, showing the plug-in modules,the lamp nesting panel, and the arrangement of the terminal
blocks on the rear of the unit.

© 2006 by Béla Lipták


A T
Integral Remote
FIG. 4.1k
Control panels with integral, remote, and semigraphic annunciators.
It consists of a cabinet containing annunciator logic mod-
ules wired to visual indicators placed in a 3/4-inch (18.75-mm)
lamp insertion matrix grid forming the cabinet front. The
semigraphic display is placed between the lamp grid and a
transparent protective cover plate, and the visual indicators
are positioned to backlight alarm name plates located in the
graphic display.
The protective cover and lamp grid are either hinged or
removable to provide access to the logic module and lamp
assemblies. The lamp assemblies are connected to intermedi-
ate terminals located behind the lamp grid, and the terminals
in turn are connected to the logic modules. Terminal points
for trouble contact wiring are in the back of the cabinet.
The semigraphic annunciator is flexible, and changes in
the annunciator system, graphic display, and related panel
modifications can be made easily and cheaply. It is practical
to prepare the graphic displays in the drafting room or
model shop, thus protecting proprietary process information
of a confidential nature.
The graphic display has little or no effect on completing
either the annunciator or the control panel because it can be
installed on site or at any time. The semigraphic annunciator
has a high density of 40 alarm points per linear foot (0.3 m)
and a solid-state rather than relay-type logic design. Power
supplies are self-contained in the semigraphic annunciator
cabinet.
Front panel layouts illustrating integral, remote, and
semigraphic annunciators are shown in Figure 4.1k. Integral
systems similar to the one shown at the left in the figure are
normally specified on nongraphic control panels. The
graphic panel in the center contains a remote annunciator
© 2006 by Béla Lipták
4.1 Annunciators and Alarms 589
T A
Semigraphic
with backlighted nameplates (shaded rectangles) and pilot
lights (shaded circles) for visual indication. The remote sys-
tem may also be used with miniature lamps in a semigraphic
display similar to the one shown at the right.
Recording Annunciators
Solid-state, high-speed, recording annunciators are available
to amend or substitute a printed record of abnormal events
for only visual and/or audible alarms. These systems print
out a record of the events and identify the variable, the time
at which the alarm occurs, and the time at which the system
returns to normal. They can also discriminate among a num-
ber of almost simultaneous events and print them out in the
time sequence in which they occurred. A number of optional
features, including secondary printers at remote locations,
supplementary visual indication, and computer interfacing,
are also available. The typical unit consists of logic, control,
and printer sections.
The input status is continuously scanned. If a change in
the trouble contacts has occurred since the preceding scan
cycle, the central control places the exact time, the alarm
point identification, and the new status of the trouble contact
(normal or abnormal) into the memory and initiates the oper-
ation of the output control unit (Figure 4.1l).
The output control unit accepts the stored information
and transfers it to the printer, which logs the event. Following
this, the memory is automatically cleared of the data and is
ready to accept new information. In addition to or in place
of the printer (if a permanent record is not required), a CRT
display can serve as the event readout. Trouble contacts are
590 Control Room Equipment

Armature Form
d
nte Spacer B
m ou C
ld r N Form
Fie O ole
N ub
s A
trontact
co
ut
Inp us Coil
t at Coil
s c
i
log
Spring Armature
an A B
Sc ol
tr
con
Permanent magnet
al
ntr
Ce trol Coil
con NS Coil

ry
mo
Me

al Glass
g it Pivot
Di k & C D
capsule
c
clo ndar r
e te
c al in
Pr FIG. 4.1m
t
tpu Standard electro-mechanical relay structures include: A) the clapper-
Ou trol
con type, B) the phone-type, C) the balanced-force, and D) the Reed
relay.

when the point becomes abnormal. The verbal message may

FIG. 4.1l
Functional block diagram of a digital, recording annunciator with
its printer, which can be replaced by a CRT.
connected to terminal points in the logic cabinet, and a cable
connects the cabinet and the printer.
A recording annunciator can perform more sophisticated
monitoring than an audiovisual annunciator and is correspond-
ingly more expensive on a per-point basis. System cost per
point decreases as the system size increases. Higher equipment
cost, however, is offset in part by savings in control panel space
and in installation costs. Recording annunciators are frequently
used by the electrical power generating industry but may be
applied to advantage in any industrial process that must mon-
itor large numbers of operating variables and analyze abnormal
events efficiently.
Vocal Annunciators
Vocal annunciators are unique in the type of abnormal audible
message they produce. The audible output is a verbal message
identifying and describing the abnormal condition when it
occurs and repeating the message until the operator acknowl-
edges the difficulty. The system continuously scans the trou-
ble contacts, and when an abnormality is found, it turns on
a flashing visual indicator and selects the optional proper
verbal message for broadcast.
The visual indicator is turned off by the system when the
point returns to normal. The control unit also arranges the
messages to be broadcast in the order in which the difficulties
occur. In the event of multiple alarms, the second message
is played only after the first has been acknowledged. The
flashing visual indicator for each point, however, turns on
be broadcast simultaneously in the control room and related
operating areas, thus permitting personnel at the operating
unit to correct the problem immediately.
Relay-Type Annunciators
The basic element of this annunciator is an electrical relay
wired to provide the logic functions required to operate a
particular sequence. Figure 4.1m illustrates some of the basic
relay designs.
At least two relays per logic module are necessary for
most sequences. The relays are installed and wired in a plug-
in assembly, which is the logic module for a single alarm
point. The plug-in module assembly is usually hermetically
sealed in an inert atmosphere to prolong the life of the relay
contact. The sealing also makes the logic module acceptable
in certain hazardous electrical areas.
Figure 4.1n is a semischematic electrical circuit for a
remote system with sequence operation according to old ISA
Sequence 1B (new Sequence A): Two logic modules are
shown; one is in normally closed operation and the other is
in normally open operation. The remote visual indicators for
each alarm point, the horn, the flasher, and the acknowledge
and test pushbuttons common to the system are also shown.
Each logic module has two relays, A and B, shown in their
deenergized state according to normal electrical convention.
The operation of these circuits during the various stages of
sequence operation is as follows:
Normal The trouble contact of the NC alarm point is wired
in series with the A relay coil at point terminals H and NC.
In the normal condition, the trouble contact is closed, relays

© 2006 by Béla Lipták

 4.1 Annunciators and Alarms 591

Operational sequence
Trouble Signal Audible
Condition “A” relay “B” relay
contact lamps signal
Normal Normal Off Off Energized Energized
Alert Abnormal Flashing On Deenergized Energized
Audible silenced Abnormal Steady−on Off Deenergized Deenergized
(acknowledged)
Normal again Normal Off Off Energized Energized
Lamp test Normal Steady−on Off Energized Energized

Flasher Logic module Logic module

F2 A5 B5 A5 B5

Internal
F1 A B A B
wiring
of A1 A7 B6 B3 B4 A1 A7 B6 B3 B4
plug-in
B1 A6 B2 A2 A3 A4 B1 A6 B2 A2 A3 A4
M

9 6 4 7 8 10 11 9 2 1 5 7 4 3 6 8 10 11 9 2 1 5 7 4 3 6

Resis-
tor
R R

K K K
Internal N N N
chassis F F F
wiring T T T
R R R
C C C
H H H

Main bus Typical set of

SL H NC NO L B A SL H NC NO L B A
terminals point terminals
Lock-in No auxiliary
jumper contact No trouble
terminals contact
Lock-in
NC Trouble jumper
contact L Remote lamp L
Field
wiring “H” wire common
to all
Audible silence signal
T R C
(acknowledge) lamps
Lamp Audible
test signal

N
Power supply
H

FIG. 4.1n
Semischematic diagram of a relay-type annunciator designed for ISA new sequence A (old sequence 1B), which sequences are described
in Tables 4.1d and 4.1e.

A and B are energized, and all A and B relay contacts are in and jumper to the neutral side of the line N. Relay B is also
the state opposite that shown. energized from H through the normally closed acknowledge
Relay A is energized from power source H through the pushbutton to terminal C, closed contact A2, and relay coil
closed trouble contract, relay coil A, resistor R, terminal K, B, to N. Relay B is locked in by its own contact B2, which

© 2006 by Béla Lipták

592 Control Room Equipment
closes when relay B is energized. The visual indicator is
turned off by open contact A5. The audible signal and the
flasher motor are turned off by open contacts A3 and B4 in
the same circuit.
Alert The trouble contact opens, deenergizing relay A and
returning all A relay contacts to the state shown in Figure 4.1n.
The visual indicator is turned on, flashing through circuit H,
lamp filament, terminal L, closed contacts A5 and B6, bus F,
and flasher contact F1, to N. The flasher motor is driven
through circuit C, closed contacts A3 and B3, R bus, and the
flasher motor to N, and the audible signal is turned on by the
same circuit.
Acknowledged Relay B is deenergized by operating (open-
ing) the momentary contact horn acknowledgment pushbutton
and is locked out by open contact A2. All B relay contacts
are returned to the state shown in Figure 4.1n. The visual
indicator is turned on steady through closed contact B5 to N
and is disconnected from flasher contact F1 by open contact
B6. The flasher motor and audible signal are turned off by the
horn acknowledgment pushbutton and remain off as a result
of open contact B3.
Normal Again When the variable condition returns to nor-
mal, the trouble contact closes to energize relay A, the visual
indicator is turned off by open contact A5, relay B is ener-
gized by closed contact A2, and all circuits are again in the
state described under normal.
Lamp Test The lamp test circuit operates the visual indi-
cators of only those alarm points that are in the normal
condition. The circuit is completed through power source H,
lamp filament, terminal L, closed contact A6, bus T, and
normally open momentary contact lamp test pushbutton, to
N. Closing the lamp test pushbutton to N completes the
circuit and lights the visual indicators. Alarm points that are
in the off-normal condition (either alert or acknowledged) do
not operate because their A relays are deenergized and the
A6 contact is open. The visual indicators of these abnormal
alarm points are already turned on (either flashing or steady)
through the operation of the alarm sequence.
Lock-In The lock-in feature operates to prevent an annun-
ciator alert condition (caused by a momentary alarm) from
returning to normal until the horn acknowledgment button is
pushed. Point terminals H and SL are jumpered to provide
the lock-in feature (see Figure 4.1n). When the trouble con-
tact opens, the A relay is deenergized, and power source H
is applied to the N side of the relay through closed contacts
A1 and B1.
The power is dissipated through resistor R, terminal K,
and jumper to N. If the trouble contact returns to normal,
relay A will remain deenergized because potential H is on
both sides of the coil. If the acknowledgment button is
pushed before the trouble contact closes again, relay B will
© 2006 by Béla Lipták
be deenergized, opening contact B1 and the lock-in circuit,
thus permitting the system to return automatically to normal
when the trouble contact closes.
If the acknowledgment button is pushed after the trouble
contact has reclosed, contact B1 opens momentarily, allowing
the A relay to reenergize. Contact A1 opens, and the circuits
are reestablished in their normal operating state.
Operational Test Full operational test is incorporated in the
annunciator sequence shown by replacement of the jumper
connection between main bus terminals K and N with a
normally closed momentary contact pushbutton, which when
pushed opens all annunciator circuits, thus initiating the alert
condition of all alarm points in the normal condition.
Auxiliary Contacts Normally closed contact A7 connected
to point terminals A and B is available for auxiliary control
functions.
Relay Fail-Safe Feature Two parallel circuits, one consist-
ing of closed contact A3 and open contact B3 and the other
of open contact A4 and closed contact B4, operate an alert
signal when there is a failure of either the A or the B relay
coil. A failure of the former initiates a normal alert in the same
way as the trouble contact. A failure of the B relay turns on
the audible signal through closed contacts A4 and B4.
Normally Open Trouble Contacts The annunciator sequence
and features described for NC trouble contacts operate in
essentially the same way when NO contacts are used. In the
NO system, however, the trouble contact is wired in parallel
with the A relay coil to point terminals H and NO, and a wire
jumper is installed between point terminals H and NC. Nor-
mally, the trouble contact is open and the A relay is energized
from terminals H and jumper to terminal NC. In the alert
condition, the trouble contact closes to deenergize the A relay
by applying power source H to the N side of the relay.
Electromechanical relays are available for use with a
variety of AC and DC voltages, but 120 AC, 50 to 60 Hz,
and 125 DC are the most popular. Power consumption of the
logic modules is normally less than 10 voltamperes (AC) and
10 watts (DC). Special low-drain and no-drain logic modules
are available; these consume no power during normal oper-
ation. Visual indicators consume different amounts of power,
depending on the type. Small bull’s-eye lights and back-
lighted nameplates use approximately 3 watts, whereas large
units require 6 to 12 watts, depending on whether one or two
lamps are used.
Electromechanical annunciator systems are reliable and
may be used at normal atmospheric pressures and ambient
temperatures in the 0 to 110°F (–17.8 to 43.3°C) range. They
are not position sensitive. They will generate a substantial
amount of heat during plant shutdown when a large number
of points are askew, and therefore power should be discon-
nected during these periods. The principal disadvantages of

the relay-type annunciator are size, power consumption, and
heat generation.
Solid-State Annunciators
A solid-state logic module consists of transistors, diodes, resis-
tors, and capacitors soldered to the copper conductor network
of a printed circuit board supplying the required annunciator
logic functions. The modules terminate in a plug-in printed
circuit connector for insertion into an annunciator chassis; they
may also contain mechanical switching or patching devices to
provide lock-in and NO-NC options.
Figure 4.1o is a semischematic electrical circuit for a
remote system with ISA Sequence 1B. The logic module
shown is in normally closed operation. Remote lamps for two
points and a flasher-audible module, speaker, and acknowl-
edge and test pushbuttons common to a system are also
included. Switch S1 is the NO-NC option switch and is shown
in the NC operating position. Switch S2 is the lock-in option
switch and is shown in the lock-in position. The following
description uses negative logic, i.e., a high equals a negative
voltage, whereas a low is approximately 0 volts.
Normal The trouble contact of the NC alarm point is con-
nected to an input filter circuit consisting of resistors R13
and R50 and capacitor C1. This provides transient signal
suppression as well as voltage dropping. The slide switch S1
connects the trouble contact and filter network to resistor-
R14. In this state transistor T1 is conducting, causing the full
negative voltage to be dropped across resistor R17, resulting
in a low voltage at the bottom end of resistor R20. Transistors
T2 and T3 are the active elements of the input memory and
are roughly equivalent to the A relay of an electromechanical
module (see Figure 4.1n).
The base of T2 has four inputs, including resistor R20,
either directly from the trouble contact in NO operation or
from the collector of T1 in NC operation; resistor R19 with
a locking signal from the alarm memory transistor T5; resis-
tor R28 and capacitor C2, which form a regenerative feed-
back from T3; and resistor R15 from the test circuit. The
base of T3 has one input, resistor R29 from the collector of
T2. In normal operation, all four inputs to the base of T2 are
low, T2 is not conducting, and T3 is conducting. Conversely,
when a high signal is present at any one of the four inputs
to the base of T2, T2 conducts and T3 turns off.
Transistors T4 and T5 are the active elements of the alarm
memory and are approximately equivalent to the B relay of
an electromechanical module. T4 and T5 together with bias
resistors R30 and R33 and cross-coupling resistors R31 and
R32 form a bi-stable (flip-flop). In normal operation T4 is off
and T5 conducts. The upper end of capacitor C4 is connected
to the collector T2. When T2 is off, its collector is at a high
and capacitor C4 will change from top to bottom, minus to
plus. Transistor T7 is a high-capacity lamp amplifier and T6
is its preamplifier. In normal operation the base of T6 is high
and T6 is on, T7 is off, and the visual indicator is off.
© 2006 by Béla Lipták
4.1 Annunciators and Alarms 593
Before completion of the description of the normal con-
dition, the operation of the flasher-audible module in
Figure 4.1o will be described. The module has two oscillators.
The first is a 3-Hz unit generating a signal that is amplified
and supplied to the logic modules through the Fl bus. The
second is a 700-Hz oscillator generating a signal that is ampli-
fied and supplied to the audible signal through the R bus.
The audible signal is a permanent magnet-type trans-
ducer (speaker) that converts the electrical energy into
sound. Initiated by an audio oscillator, the active elements
of which are transistors T1 and T2, these transistors together
with passive components (capacitors C1 and C2 and diodes
D3 and D4) form an unstable multivibrator when an input
is present on the FR bus. In the normal conditions there is
no FR signal, the voltage necessary to turn on transistor T1
is missing, and the oscillator will not operate. This is the
normal, or quiescent, condition.
Alert The trouble contact opens and the base of T1
becomes low, turning off T1. This action produces a high on
the base of T2 through R20, which turns on T2 and turns off
T3. The negative end of C4 is clamped to common through
T2, causing a positive pulse at the base of T5 through diode
D12, turning T5 off and T4 on. With T2 conducting, the base
of T6 becomes low through resistor R6, and with T5 off the
clamp on the flasher signal is removed through diode D4 at
the junction of R1 and R2. The flasher source provides an
alternating high and low voltage at the Fl bus, which turns
T6 on and off, which in turn turns T7 and the light off and on.
The flasher signal is generated by transistors T8 and T9,
which are the active elements of an unstable multivibrator
used as an on/off signal to the output driver stage. Resistor
R24 and capacitor C6 decouple the oscillator from the power
lines so that its frequency is not affected by that of the other
oscillators. The output driver stage consists of transistors T10
and T11, a switching inverter, and an emitter follower stage,
which produces an alternating high and low voltage of F1
bus through R23. Transistor T11 is a high-current transistor
capable of driving a multiple lamp load.
The audible signal is initiated by a high on the FR bus,
which turns on an audio oscillator, the elements of which are
transistors T1 and T2. The audio oscillator output is amplified
in an audio amplifier stage composed of transistors T3, T4,
T5, and T6 connected in two pairs—one T3 and T5; the other
T4 and T6.
The input components to the stage from the audio oscil-
lator are opposite each other, i.e., whenever one is high (neg-
ative voltage) the other is low (near zero), causing only one
pair of transistors to conduct at a time. When T5 is off, T6
is on and the capacitor is discharged. This alternating action
causes an alternating current to flow in the speaker coil,
giving an audible signal.
Acknowledged A negative voltage is applied to the base of
T5 through resistor R40 by closing the acknowledge push-
button. This turns T5 on and T4 off, and the FR bus becomes
 594
Control Room Equipment
T K FR C F1 (+)
Main bus
Logic module Flasher−audible module terminals

D5 (+) Resistors

R20
R13

R23
R22
R24

R19

R17
R18
R9
R3
R5
R4
**

R32
R20
T
R10

R28
R24

R31
R25
R19

R15
D4 S2 T3 K
T5 C2 C

R21
T11

R8
R41 D4
T7 (−)

R12
R14
D12 D14 C3 C4
R2
R6

* C2 C4

R34
R35
R17
D3 C1
R14

S1 T6 T10
Capacitors
T6

R7
T4 R10 T8 (1) filter

R43
R29
T1 T2 T3 T4
R48

D2 T5 network
D2 T1 T2 T9
required
R50
R13

R16
R15

R11
R9

R2
R1

R1

R6
D1 C1 D1 D6 per chassis
R21

R30

R40
R33
R23 C5
D3

6 11 12 1 2 3 5 7 10 9 8 1 2 3 9 11 5 8 12
* S1 Shown for NC field contacts
S2 Shown for ‘lock-in’ on
* * momentary alarms
R S G
Τ
Κ
FR
C
F1
(+)
(−)
F2
Typical set of
point terminals Main bus
L1 S G terminals R S G F2 CN (−)

NC trouble No trouble
Operational sequence
contact contact
Trouble Nameplate Audible T1 T1 T2 T3 T4 T5 T6 T7
To Condition Signal lamps
Remote lamps L L
Contact Signal NO NC
additional Normal Normal Off Off Off On Off On Off On On Off
LC Alert
signal Abnormal Flashing On Off Off On Off On Off On/Off Off/On
lamps Audible silenced Abnormal Steady-on Off Off Off On Off Off On Off On
R T C (Acknowledged) Off On Off On Off On On Off
Normal again Normal Off Off
Off On On Off On Off On/Off Off/On
Capacitor Functional test Normal Flashing On
Speaker
Audible
Volume Symbols: PNP NPN
Functional silence
control − Collector
test (acknowledge)
Resistor Diode Pad Base Transistors
+
no.
Capacitors Emitter
CN

FIG. 4.1o
Semischematic diagram of a solid-state annunciator designed for ISA new sequence A (old sequence 1B), which sequences are described in Tables 4.1d and 4.1e.

© 2006 by Béla Lipták


low, thus silencing the audible signal. When the point is
acknowledged, T5 conducts; this restores the clamp at R1
and R2, which removes the flash source voltage. T6 is off all
the time, T7 is on all the time, and the light is on steady.
Normal Again When the variable condition returns to nor-
mal, the trouble contact closes and the base of T1 becomes
high, turning T1 on. This produces a low on the base of T2,
which turns T2 off and T3 on. All circuits are again in the
state described under the normal condition.
Lamp Test No separate lamp test is normally provided.
One initiates a full operational test by pushing the test button,
which applies an alternate input signal through resistor R15
to the base of transistor T2. This turns T2 on, initiating a full
operational test of the system as already described.
Lock-In The lock-in feature is provided by a switch S2. If
the switch is in the lock-in position (see Figure 4.1o), when
T5 turns off (on the alarm condition), a high at the collector
of T5 is coupled to the base of T2 through R19, which keeps
T2 turned on even if the trouble contact returns to normal.
Transistor T5 will remain off and keep T2 turned on until the
acknowledgment button is pushed.
If the switch is in the non-lock-in position, the circuit
between the collector of T5 and the base of T2 is open; there-
fore, T2 will turn off if the trouble contact returns to normal
before acknowledgment and return all circuits to normal.
Operational Test See description under lamp test.
Auxiliary Contacts Auxiliary contacts are not supplied as
part of the logic module. Adapter assemblies consisting of
relays operated by the semiconductor logic, however, are
available.
Relay Fail-Safe Feature Not available in solid-state circuits.
Normally Open Trouble Contacts The annunciator sequence
and features already explained for NC trouble contacts operate
in essentially the same way for NO contacts. The NO-NC
option switch bypasses inverter stage transistor T1. When the
contact closes on an abnormal condition, it turns on T2 though
R20 and the sequence operation proceeds exactly as described
for the NC operation.
Solid-state annunciators are for use with DC voltages rang-
ing from 12 to 125 DC. Power consumption of the logic mod-
ules ordinarily is less than 5 watts. Visual indicators consume
different amounts of power, depending on the type. Bull’s-eye
lights use approximately 1 watt, whereas back-lighted name-
plates use from 1 to 6 watts, depending on the number and
wattage of lamps.
Solid-state annunciators are very reliable and are not posi-
tion sensitive. They offer the advantages of compactness, low
power consumption, and little heat generation, factors that
make them particularly useful in large integral annunciators.
© 2006 by Béla Lipták
4.1 Annunciators and Alarms 595
The per-point cost of solid-state systems is slightly higher
than that of their relay-type equivalent, due to the cost of
power supplies and interfacing accessories that may be
required with solid-state systems. The cost of the logic mod-
ules, visual indicators, and cabinets themselves is not exces-
sive. Integrated circuit components using recently developed
microcircuits will most likely reduce size, power consump-
tion, and heat dissipation of annunciator systems.
ANNUNCIATOR CABINETS
Annunciator systems are installed in areas ranging from gen-
eral purpose to hazardous. Annunciator cabinets are installed
indoors and outdoors in a variety of dusty, moisture-laden,
and other adverse environments. Industrial annunciator cab-
inets are usually designed for general-purpose, dry indoor
use. Special cabinets and enclosures are used in hazardous,
moist, and outdoor locations.
Hazardous Area Designs
The requirements of Class 1, Division 2 hazardous locations
as defined in Article 500 of the National Electric Code (NEC)
are satisfied by the visual indicators and logic modules (either
relay or solid state) of most annunciator systems. A manually
operated or door-interlocked power disconnect switch is used
with annunciator cabinets in those locations to turn off power
when logic modules are relamped or changed.
Annunciator equipment for Class 1, Division 1 areas is
installed in cast steel or aluminum housings approved for the
hazardous environment. The housings are expensive to pur-
chase and install. These annunciators are available in both
integral and remote configurations. The remote type is gen-
erally wired to explosion-proof bull’s-eye lights. Annunciator
power must be disconnected either manually or automatically
before the enclosures are opened to prevent an accidental arc
or spark when logic modules are relamped or changed.
One can weatherproof annunciator cabinets installed in
either general-purpose or hazardous areas (class 1, division
2) either by housing them in a suitable enclosure or by cov-
ering the exposed cabinet front with a weatherproof door.
Housings that comply with class 1, division 1 requirements
are also weatherproof. Figure 4.1p illustrates several weath-
erproof and hazardous-area enclosures. For the design of
purging systems, refer to Figure 4.1b.
Intrinsically Safe Designs
Annunciators are classified as intrinsically safe if they are
designed to keep the energy level at the trouble contact below
that necessary to generate a hot arc or spark. Care must also
be taken in installing the system to place wiring so as to
prevent a high-energy arc or spark at the trouble contact
caused by accidental short circuit or mechanical damage.
Thus, general-purpose trouble contacts may be used with
596 Control Room Equipment

Front view
NC NO

Slotted-knurled (5) (6)

(8)
thumbscrew NC I O I O (7)
3–15 PSIG S S
(4)
(0.2 –1.0 bar) I O
Backlighted nameplate (3)
From LT-9 S
Enclosure window
O NO: supply (S) connected to
(1) I (2) output (O)
Pushbuttons
NC: (S) blocked to (O)
Audible signal 80–100 PSIG(0.6–0.69 MPa)
Air supply
Condition Relay (4) Relay (5) Relay (6) Horn (7) Indicator (3)
Normal Closed Closed Open Off Off
Annunciator cabinet Alert Open Closed Open On On
in weatherproof enclosure Acknowledge Open Open Closed Off On
Normal again Closed Closed Open Off Off

FIG. 4.1q
The tubing configuration and components of a pneumatic annunci-
ator circuit.

Power supply to the system is instrument air at 80 to

Annunciator cabinet
with weatherproof door
Integral annunciator
for class1 division 1
hazardous area
FIG. 4.1p
Annunciator enclosures for weatherproof and hazardous areas.
intrinsically safe annunciator systems even though they are
installed in a hazardous area.
The annunciator logic modules and visual indicators,
however, must conform to the electrical classification of the
area in which they are installed. (For more on intrinsically
safe designs, see Section 7.2 in Volume 1 of this handbook.)
PNEUMATIC ANNUNCIATORS
Pneumatic annunciators consist of air-operated equivalents
of the trouble contact, logic module, and visual indicator
stages of an electrical annunciator system. A single-point
system furnishing high tank level monitoring is shown in
Figure 4.1q.
100 PSIG (0.6 to 0.69 MPa), which is reduced to the required
operating pressure by pressure regulator (1). The operating
pressure is indicated on pressure gauge (2). A 3 to 15 PSIG
(0.2 to 1.0 bar), an analog input signal from a direct-acting
level transmitter (LT-9) enters high-pressure limit relay (4),
which is normally closed and set to open when the high level
limit is exceeded. When this happens (alert condition), an
input at supply pressure from (4) turns on a pneumatic visual
indicator (3), and a normally open high-pressure limit relay
(6) allows supply air flow to air horn (7), turning it on.
Simultaneously, the air output from (4) enters normally
closed high-pressure limit relay (5) and momentary contact
pushbutton (8), which is a normally open acknowledgment
pushbutton for the system. In the alert condition, the pneu-
matic indicator and horn are both on.
One acknowledges the alert condition by pushing button
(2), closing it, and thereby opening high-pressure limit relay
(5). Supply air pressure from (5) closes high-pressure limit
relay (6), which cuts off the operating air to the horn, thereby
turning it off. Simultaneously, operating air pressure from (5)
is fed back to the inlet of (5).
The feedback pressure locks up (5) so that it will not
close when the acknowledgment pushbutton (8) is released.
In the acknowledged condition, the pneumatic indicator is on
and the horn is off. The system returns to normal when the
3- to 15-PSIG (0.2- to 1.0-bar) analog input falls below the
setpoint. This closes high-pressure limit relay (4) which turns
off the pneumatic indicator (3). It also closes high-pressure
limit relay (5) by venting the lock-in circuit through relay (4).
Pneumatic annunciators are used when one or two alarm
points are needed but electrical power is not readily available
and in hazardous electrical areas where an electrical annun-
ciator might not be practical. Pneumatic annunciators require

© 2006 by Béla Lipták


a substantial amount of installation space and are expensive
to manufacture.
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