DR3602 Dual Relay Digital Pressure Switch for High and Low Alarm Control

Why Unnecessary Filter Changes Cost Us $18,000 Annually

During a routine inspection, we noticed the pressure drop across the filter was increasing, but the maintenance schedule indicated it wasn’t due for cleaning yet. This symptom pointed towards an issue that could lead to system downtime and potential safety hazards if not addressed promptly. In fact, we estimated that false trips from pressure spikes were costing us over $18,000 in lost production time each year. As a result, we needed a solution that could handle both high and low pressure alarms independently.

Calendar Days vs Pressure Drop: The $18,000 Difference

Single-relay switches can only provide protection on one side of the pressure range; either high or low, but not both simultaneously. In our facility, this limitation was causing false trips due to start-up pressure spikes, leading to unnecessary shutdowns and increased operational costs. Therefore, it was clear that a solution capable of handling dual setpoints with independent relays was needed. Moreover, traditional switches lacked the flexibility to adjust hysteresis, which is critical for avoiding nuisance trips in systems with transient pressure fluctuations.

How DR3602 Solved Our False Trip Nightmare

We decided to implement the DR3602 Dual Relay Pressure Switch. Equipped with two independent relays for high/low alarm or pump control, this device allowed us to fine-tune our system’s performance by setting distinct pressure thresholds. The 4-digit LED display and optional 4-20mA analog output provided real-time monitoring and easy integration into existing control systems. Additionally, the programmable setpoints and hysteresis enabled us to ignore start-up spikes while still detecting genuine overpressure events. The 24VDC powered design with NEMA 4X/IP65 enclosure ensured reliable performance even under harsh environmental conditions.

Why $18,000 in Savings Changed Our Maintenance Strategy?

The DR3602 swiftly resolved the issue we faced, reducing unnecessary trips from start-up pressures and improving overall efficiency. We estimated a savings of over $18,000 in lost production time annually. Furthermore, the optional RS485 output allowed seamless integration with our SCADA system, providing remote monitoring and data logging capabilities. Consequently, our maintenance team could now focus on predictive maintenance rather than reacting to false alarms.

Key Specifications

• Dual independent relays for high/low alarm
• Programmable setpoints and hysteresis
• 4-digit LED display
• 4-20mA analog output optional
• RS485 output optional
• 24VDC powered
• NEMA 4X / IP65 enclosure

Would you trust your pump control to anything less? Consider how much false trips are costing your facility and whether a dual relay pressure switch could be the solution you need.

Tags: #pressureswitch #adjustablehysteresis #NEMA4Xpressureswitch #DR3602