PLC Summer Training
Presented by:
sarafaraj alam
RELAYS & CONTACTORS
INDUSTRIAL AUTOMATION TRAINING
ABES ENGINEERING COLLEGE , GHAZIABAD
What is Relay ?
Relays are essential for automation systems and for controlling loads.
A relay is an electromagnetic switch operated by a relatively small electric current that can
turn
on or off a much larger electric current. The heart of a relay is an electromagnet (a coil of wire
that becomes a temporary magnet when electricity flows through it).
Also, relays are the best way for insulation between high and low voltage portions
of a circuit.
There are hundreds of different relay types .
Construction
Coil
Armature
Contacts ( NO & NC )
Relay Operation
The input circuit is switched off and no
current flows through it until something
(either a sensor or a switch closing) turns it
on. The output circuit is also switched off.
When a small current flows in the input
circuit, it activates the electromagnet , which
produces a magnetic field all around it.
The energized electromagnet pulls the metal
bar in the output circuit toward it, closing the
switch and allowing a much bigger current to
flow through the output circuit.
The output circuit operates a high-current
appliance such as a lamp or an electric
Excercise On Relays
1. Make a relay circuit to
switch on the lamp when
the push button is pressed
and lamp is off when push
button is released.
Exercise-1
Memory Function Of Relay
What is Contactor ?
A contactor is also a type of relay.
Features of Contactors :
A contactor is a relay that is used for switching power.
They usually handle very heavy loads like an electric motor, lighting
and heating equipments and so on.
Though their output is used for switching very high loads, they are
controlled by a circuit with very less power.
According to the loads they handle, they vary in sizes from a small
device to as huge as a yard.
Though they are used for switching purposes, they do not interrupt a
short-circuit current like a circuit breaker.
They have ratings ranging from a breaking current of a few amperes
What is Contactor ?
When a relay is used to switch a large amount of electrical power
through its contacts, it is designated by a special name: contactor.
Design and Construction
Like a relay, a contactor also has
1. Coil
2. Spring
3. Armature
4. Moving contact
The contact part of the contactor includes the power contacts as
well as the auxiliary contacts. The power contacts gains the power
for the contactor and the auxiliary contacts is used to bring a loop
with the rest of the rest of the devices it is attached to. These
contacts are connected to the contact springs.
WHAT IS A PLC ?
A PLC is a digital computer used for automation of industrial processes, like controlling machinery or
factory assembly lines.
The main difference from other computers is that
PLCs operate in industrial environments (dust, moisture, heat, cold, High temperature ranges,
electrical noise,vibration )
Have multiple input/output (I/O) terminals.
I/O terminals connect the PLC to sensors and actuators. PLCs outputs operate electric motors,
pneumatic or hydraulic cylinders, relays or solenoids, and analog outputs.
History Of PLC ?
GM needed the flexibility of solid state; a controller that
could be programmed and maintained by plant engineers;
and was rugged enough to withstand the factory
environment and provided easy troubleshooting...
Richard E. Morley, an employee of Bedford
Associates (Bedford, MA ) involved in the
automotive industry, proposed something called
a Modular Digital Controller (MODICON) to a
major US car manufacturer.
Relay Logic Based Control
Panel
PLC Based Control Panel
Evolution Of PLC ?
PLCs were invented as replacements for automated systems that would use
hundreds or thousands of relays, cam timers, and drum sequencers.
Often, a single PLC can be programmed to replace thousands of relays.
First Programmable Logic Controllers were designed and developed
by Modicon as a relay replacer for GM .
These controllers eliminated the need for rewiring and adding additional
hardware for each new configuration of logic.
The new system drastically increased the functionality of the controls while
reducing the cabinet space that housed the logic.
The first PLC, model 084, was invented by Dick Morley in 1969.
The first commercial successful PLC, the 184, was introduced in 1973
which was designed by Michael Greenberg.
What is a PLC?
The Basic Block
CPU
Inputs
Outputs
A PROGRAMMABLE LOGIC CONTROLLER is a solid state control system that
continuously monitors the status of devices connected as inputs. Based upon a
user written program, stored in memory, it controls the status of devices
connected as outputs.
What is a PLC?
Major Components of a Common PLC
POWER
SUPPLY
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
I
N
P
U
T
M
O
D
U
L
E
O M
PROCESSOR
PROGRAMMING
DEVICE
U O
T D
P U
U L
T E
To
OUTPUT
Solenoids,
contactors,
alarms
etc.
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Advantages of PLCs
Less wiring.
Wiring between devices and relay contacts are
done in the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming
easier and reduce downtime.
Reliable components make these likely to operate
for years before failure.
Inside a PLC
The CPU contains an Executive program that tells the PLC
how to:
Execute the control Instructions
Users Program
Communicate with other devices
Other PLCs, Programming devices, I/O devices, etc.
Perform Housekeeping activities
Diagnostics, etc
This program is stored in nonvolatile memory
Meaning that the program will not be lost if power is removed
I/O Module
The I/O interface section of a PLC connects it to external field
devices.
The main purpose of the I/O interface is to condition the various
signals received from or sent to the external input and output
devices.
Input modules converts signals from discrete or analog input
devices to logic levels acceptable to PLCs processor.
Output modules converts signal from the processor to levels
capable of driving the connected discrete or analog
output devices.
28
I/O Circuits
Discrete Inputs
Circuits of this type are used to sense the status of limit switches, push buttons, and
other discrete sensors. Noise suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.
Analog I/O
Circuits of this type sense or drive analog signals.
Analog inputs come from devices, such as thermocouples, strain gages, or pressure
sensors, that provide a signal voltage or current that is derived from the process variable.
Standard Analog Input signals: 4-20mA; 0-10V
Analog outputs can be used to drive devices such as voltmeters, X-Y recorders,
servomotor drives, and valves through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V
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Discrete Input
A discrete input also referred as digital input is an input that is either ON or OFF are
connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a
logic high and in the OFF condition maybe referred to as logic o or logic low.
Normally Open
Pushbutton
Normally Closed
Pushbutton
Normally Open switch
Normally Closed switch
Normally Open contact
Normally closed contact
30
IN
OFF
Logic 0
PLC
Input
Module
24 V dc
IN
OFF
Logic 1
PLC
Input
Module
24 V dc
31
Digital Output
A discrete output is either in an ON or OFF condition. Solenoids,
contactors coils, lamps are example of devices connected to the
Discrete or digital outputs. Below, the lamp can be turned ON or OFF
by the PLC output it is connected to.
OUT
PLC
Lamp
Digital
Output
Module
32
Analog Input
An analog input is an input signal that has a continuous signal. Typical
inputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level
transmitter monitors the level of liquid in the tank. Depending on the
level Tx, the signal to the PLC can either increase or decrease as the
level increases or decreases.
Level Transmitter
Tank
IN
PLC
Analog
Input
Module
33
Analog Output
An analog output is an output signal that has a
continuous signal. Typical outputs may vary from 0 to
20mA, 4 to 20mA or 0 to10V.
Electric to pneumatic transducer
OUT
PLC
Analog
Output
Module
0 to 10V
Supply air
Pneumatic control valve
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Input Modules
24 Volt DC
System
Field device this is showing
a simple switch
+ 24
Volts
- 24
Volts
Input
Module
1
2
3
4
5
6
7
8
9
10
COM
A/D conversion
Terminal block this is where wires
from the field
devices are
connected
To PLC
I/O Module
DC INPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise
USE TO DROP
THE VOLTAGE
TO LOGIC LEVEL
FROM INPUT
DEVICE
Current
Limiting
Resistor
OPTOISOLATOR
Buffer, Filter,
hysteresis
Circuits
TO
PROCESSOR
36
PNP / NPN SENSORS WIRING
FOR DC INPUTS
What is the difference between PNP and NPN when describing 3 wire
connection of a sensor?
Most industrial proximity sensors (inductive, capacitive, ultrasonic and photo
electric) are solid state.
The term solid state refers to the type of components used within the sensor.
Solid state electronic components such as transistors are usedto switch the
output of the sensor upon detection of an object.
Two specific types of 3 wire sensors are available; PNP and NPN. The difference
isa result of the internal circuit design and type of transistors used.
A key point toobserveis thatPNPand NPNhas nothing to do with whether the
sensor isnormally open (N/O) or normally closed (N/C), i.e. a PNP sensor may be
eitherN/O or N/C as can an NPN be either N/O or N/C.
Why twotypes?
The selection of a PNP sensorverses an NPN sensoris determined by the nature
of the circuit thedevice is to be used in.
When used in a traditional relay type control circuit, it is normallypossible touse
either the PNP or theNPN type of sensor as shown below.
PNP sensors tend to be more commonly used.
Traditional relay type control circuit
Using PNP / NPN Sensors with PLC
When selecting a sensor to be used with a PLC, it is very important that the sensor
matches the type of PLC input card to be used.
Two types of input cards exist, those that 'sink' current (also known as positive
logic) and those that 'source' current (also known as negativelogic).
Itis therefore important to identify the type ofsensor to be used with the PLC card
based on the PLCmanufacturer's documentation and /or wiring diagrams.
Sinking (NPN) provides a path to 0 VDC (-DC)
Sourcing (PNP) provides a path to +24 VDC (+DC)
I/O Module
AC INPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise
CONVERTS THE AC INPUT
TO DC AND DROPS THE
VOLTAGE TO LOGIC LEVEL
FROM INPUT
DEVICE
Rectifier,
Resistor
Network
OPTOISOLATOR
Buffer,
Filter,
Hysteresis
Circuits
TO
PROCESSOR
42
What are Inputs?
DIGITAL :
Switches and Pushbuttons
Sensing Devices
Limit Switches
Photoelectric Sensors
Proximity Sensors
Condition Sensors
Pressure Switches
Level Switches
Temperature Switches
Encoders
ANALOG:
RTDs
Thermo couple
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Output Modules
Terminal block Output
Module
D/A Conversion
From
PLC
1
2
3
4
5
6
7
8
9
10
COM
this is where wires
from the field
devices are Field device
connected
-Motor starter,
controlling an
AC motor.
OUTPUT MODULES ARE OF THREE TYPE
(1)Relay Type (AC or DC load)
(2)DC Type or Transistor Type or Mosfet Type
(3)Triac Type (only ac load)
I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise
FROM
PROCESSOR
TTL
Circuits
OPTOISOLATOR
Amplifier
RELAY
TRIAC
XSISTOR
TO
OUTPUT
DEVICE
47
SINKING OUTPUT WIRING DIAGRAM
SOURCING OUTPUT WIRING DIAGRAM
What are Outputs?
Valves
Motor Starters
Solenoids
Actuators
Control Relays
Horns & Alarms
Stack Lights
Fans
Counter/Totalizer
Pumps
Printers
What are Outputs?
MODULAR & STAND ALONE PLCs
MODULAR PLC :
CPU , Inputs , Outputs , Network
Adapters are available as
separate modules that fits into
the chassis slots.
Stand Alone PLC :
CPU , Inputs & Outputs points
are available in a single package.
Has fixed no. of I/Os
The backplane provides a communication path between the I/O
modules and either the processor module or the I/O adapter module.
Example of a modular
based PLC. The PLC slides
into the chassis along with
other modules
Slide modules into
available slots
Example of a PLC that plugs
into adjacent modules to
form a backplane with no
chassis required
Each module plugs
into the one to the
left
Example of a PLC with the
modules built in. Comes as
one block
Connections for the
built in I/O
I/O Systems
Local I/O
I/O adapter
Input module - distributed
I/O
PLC
Switch-input
I/O network
PLC Size
1. SMALL
- it covers units with up to 128 I/Os and
memories up to 2 Kbytes.
- these PLCs are capable of providing simple to
advance levels or machine controls.
2. MEDIUM - have up to 2048 I/Os and memories up
to 32 Kbytes.
3. LARGE
- the most sophisticated units of the PLC family.
They have up to 8192 I/Os and
memories up to
750 Kbytes.
- can control individual production processes or
entire plant.
55
Various Brands of PLCs
Allen Bradley
USA
Siemens
Germany
Modicon
France
Mitshubishi
Japan
GE Fanuc
USA
Omron
Japan
Selecting a PLC
Criteria
Number of logical inputs and outputs.
Memory
Number of special I/O modules
Scan Time
Communications
Software
Inside a PLC
Communications
Port
I
n
p
u
t
C
i
r
c
u
i
t
s
Central
Processor
Unit
(CPU)
High
Voltage
O
u
t
p
u
t
Isolation
Barrier
MEMORY
Isolation
Barrier
data
program
DC Power Supply
Low Voltage
AC Power Supply
or
C
i
r
c
u
i
t
s
DC POWER SUPPLY
CR
High
Voltage
Allen Bradely PLCs
Wiring diagram of input and output
PLC APPLICATIONS
Packaging
Bottling & Canning
Material Handling
Machining
Power Generation
HVAC/ Building Automation
Security Systems
Automated Assembly
Paint Lines
Water treatment
INDUSTRY
Cement
Metals
Automobile
Paper
Chemicals
F&B
Plastics
. Any application in any industry that requires electrical control
THANK YOU
