STUDY GUIDE for Module 7: Relay Circuit, Programmable Logic Controller (PLC), and

Ladder Diagram.

Relay - a simple electromechanical switch up of an electromagnet and a set of contacts.

Constructions of RELAY

1. Electromagnet

2. Armature that can be attracted by the electromagnet

3. Spring

4. Set of electrical contacts

Definition of Relay

• Relays Transform a Control Signal into a Control Action

• Relays Provide:

1. Isolation Between Input and Output

2. Leverage (Small Signal Can Control Large Action)

3. Automation (Minimize Human Interaction with a Control Process)

Types of RELAY

1. Control relays

2. Power relays or contactors

3. Magnetic motor starters

4. Reed relays

5. Overload relays (Thermal or Magnetic)

A Relay consists of the coil and the contact:

Contacts:

a. Normally open -| |-

b. Normally closed -|/|-

d. Negative transition sensing -|N|-

Coil:

a. Coil -( )-

b. negative coil -(/)-

c. Set Coil -(S)-

d. Reset Coil -(R)-

Relays can be Designed to Perform Many Functions:

• Detect Out of Limit Conditions on Voltages and Currents

• Start Motors

• Prevent Motors from Over Heating

• Control Assembly Lines

• Adjust Lighting

Notes:

• In general, the point of a relay is to use a small amount of power in the electromagnet to
move an armature that is able to switch a much larger amount of power.

• For example, you might want the electromagnet to energize using 5 volts and 50
milliamps (250 milliwatts), while the armature can support 120V AC at 2 amps (240
watts).

• Relays are quite common in home appliances where there is an electronic control turning
on something like a motor or a light.

• They are also common in cars, where the 12V supply voltage means that just about
everything needs a large amount of current.

• In places where a large amount of power needs to be switched, relays are often cascaded.

• In this case, a small relay switches the power needed to drive a much larger relay, and
that second relay switches the power to drive the load.
Programmable Logic Controllers (PLCs)

– Were introduced in 1968

– Were primarily intended to replace relay devices

– Similar to a Microcontroller:

• Microprocessor Based

• Onboard Memory for Storing Programs

• Special Programming Language: Ladder Logic

• Input/Output Ports

– Dissimilar to Microcontrollers

• Intended for Industrial Applications

• I/O Designed to interface with Control Relays

• Emphasis on Maximum Reliability

Programmable Logic Controllers (PLCs)

– Widely applied in every industry

–Developed to simplify the implementation of control automation systems in plants and

– Designed to minimize the number of control relays in a process and maximize the ways
relays can be used

– First applied to automobile industry in the late 1960’s

– Flexible, Reliable and Low Cost

PLC Components

1. Processor

– The processor (CPU) scans the status of the input peripheral , examines the control logic to see
what action to take , and then execute the appropriate output response.
2. Memory

– The control program and the peripheral status are stored in the memory.

Examples of Memory components are the following:

• ROM( Read Only Memory )

• RAM (Random Access Memory)

• PROM (Programmable Read Only Memory)

• EEPROM (Electric Erasable Programmable ROM)

• EPROM (Erasable Programmable Read Only Memory)

• EAPROM (Electronically Alterable Programmable Read Only Memory)

3. Input/Output

• modular plug-in periphery

• Ac voltage input and output

• Dc voltage input and output

• Low level analog input

• High level analog input and output

• Special purpose modules

4. Power Supply

– AC power

5. Peripherals

• Hand-Held Programmer ( HHP)

• CRT programmer

• Operator console

• Printer

• Simulator

• EPROM loader
 • Graphics processor

PLC IO Modules

– Input Modules: Input Signals can be AC or DC, Analog or Digital

– Output Modules: Outputs are either AC or DC Analog Signals

– Modern PLC’s have Expansion Ports to Increase the Number of Available Inputs and Outputs

PLC Programming

• Ladder Diagram - most common

• Structure Text Programming (ST)

• Functional Block Programming (FB)

• Instruction List (IL)

• Sequential Function Chart (SFC)

Ladder Diagram

• is a means of graphically representing the logic required in a relay logic system.

• a special type of wiring diagram developed for relay-and-switching control circuits.

• is a symbolic and schematic way of representing both the system hardware and the
process controller.

• It is called a ladder diagram because the various circuit devices connected in parallel

• across the ac line form something that looks like a ladder.

Ladder Diagram – Control Circuit

This circuit is used to control industrial electronics circuits using relays and contacts:

Ladder or line diagram – The schematic diagram

Rails – Two vertical lines, for potential difference

Rungs – The horizontal lines where contacts and components where placed

Branch – Part of rung where conditional circuit is made

Rungs

– It contain both input and output instructions

– Input instructions perform a comparison or test and set the rung state based on the outcome.

– Output instructions examine the rung state and execute some operation or function.

Series Vs. Parallel Operations

– Ladder Diagram input instructions perform logical “AND” and “OR” operations

– Input instructions connected in series must all be true for outputs to execute “AND”

– Input instructions connected in parallel must all be true for outputs to execute “OR”

– Paralleling outputs allows multiple operations to occur on the same input criteria

Ladder Logic Execution

– Rungs of Ladder diagram are usually solved from left to right, and top to bottom

– Branches within rungs are usually solved top left to bottom right

Ladder Diagram Rules:

– The vertical lines represents power lines AC or DC.

– Left rail is designated as L1 and the active line for AC or + terminal for DC.

– Right rail as designated as L2 and the neutral line for AC or – terminal for DC.

– Rungs are labeled in numerical order from top to bottom.

– To read the diagram: left to right, top to bottom

– The vertical lines represents power lines AC or DC.

– The components are shown in their normal condition (de-energized).

– Contacts will always have the same letter and number designation as the device that controls
them, and it includes timers, switch, coils, relays, and motor starters.

– A normally open contact closes when the device that controls it is energized.

– A normally closed contact opens when the device that controls it is energized
Counters

– Counter Relays must “Count” a pre-determined number of events before changing contact
status

– Can Count Up (UpCounter) or Count Down (DownCounter)

– An UpCounter is set to 8 and is programmed to detect every occurrence of a 5 Volt pulse.

– Great for making Real-Time Clocks, etc

Timers and Counters

Timers:

a. Retentive on delay -(RTO)-

b. Retentive off delay -(RTF)-

c. Reset -(RST)-

Counter:

a. Counter up -(CTU)-

b. Counter down -(CTD)-

c. Counter reset -(CTR)-

Time Delay Symbol

– Counter Relays must “Count” a pre-determined number of events before changing contact
status

– given ladder diagram is for Delay Motor Start While Alarm Sounds for Safety.

References:

• Boylestad, Robert L. et. al. 2014. Electronic Devices and Circuit Theory 11th ed. United
States: Prentice Hall.

• Floyd, Thomas L. 2012. Electronic Devices 9th ed. United States: Prentice Hall.

• Anand, M. L. 2016. Electronic devices and circuits III (power electronics). New Delhi :
S. K. Kataria& Sons.
• Northrop, Robert B. 2014. Introduction to instrumentation and measurements. Boca
Raton : CRC Press, Taylor & Francis Group.

• Gupta, J. B. 2015.Electronics measurements and instrumentation. New Delhi : S. K.

• Goyal, Shweta 2015. Industrial electronics and control devices. New Delhi : S. K.
Kataria& Sons