PLC Summer Training Presented by: sarafaraj alam
RELAYS & CONTACTORS
INDUSTRIAL AUTOMATION TRAINING
What is Relay ? Relays ae esse!tial "# a$t#%ati#! syste%s a! "# '#!t#lli!( l#as)
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A elay is a! ele't#%a(!eti' s*it'h #+eate #+eate y a elati-ely s%all ele'ti' ele'ti' '$e!t that 'a! t$! #! # #"" a %$'h la(e ele'ti' '$e!t) The heat #" a elay is a! ele't#%a(!et .a '#il #" *ie that e'#%es a te%+#ay %a(!et *he! ele'ti'ity "l#*s th#$(h it/) •
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Als#, elays elays ae the est est *ay "# i!s$lati#! i!s$lati#! et*ee! et*ee! hi(h a! l#* -#lta(e +#ti#!s +#ti#!s #" a 'i'$it)
Thee ae h$!es #" i""ee!t elay ty+es )
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C#!st$'ti#!
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C#il
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A%at$e
Relay O+eati#! •
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The i!+$t 'i'$it is s*it'he #"" a! !# '$e!t "l#*s th#$(h it $!til s#%ethi!( .eithe a se!s# # a s*it'h 'l#si!(/ t$!s it #!) The #$t+$t 'i'$it is als# als# s*it'he #"") Whe! a s%all '$e!t "l#*s i! the i!+$t 'i'$it, it a'ti-ates the ele't#%a(!et , *hi'h +#$'es a %a(!eti' "iel all a#$! it) The e!e(i0e ele't#%a(!et +$lls the %etal a i! the #$t+$t 'i'$it t#*a it, 'l#si!( the s*it'h a! all#*i!( a %$'h i((e '$e!t t# "l#* th#$(h the #$t+$t 'i'$it) The #$t+$t 'i'$it #+eates a hi(h1'$e!t
Excercise On Relays
1. Make a relay circuit to switch on the lamp when the push utton is presse! an! lamp is o"" when push utton is release!.
E2e'ise13
Me%#y 4$!'ti#! O" Relay
$hat is Contactor % •
A contactor is also a type of relay.
Features of Contactors : A contactor is a relay that is used for switching power. •
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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.
$hat is Contactor % Whe! a elay is $se t# s*it'h a la(e a%#$!t #" ele'ti'al +#*e th#$(h its '#!ta'ts, it is esi(!ate y a s+e'ial !a%e5 contactor .
&esign an! Construction Construction
Li6e a elay, a '#!ta't# als# has 3) C#il 7) S+i!( 8) A%at %at$e 9) M#-i M#-i!( !( '#!t '#!ta' a'tt •
The '#!ta't +at #" the '#!ta't# i!'l$es the +#*e '#!ta'ts as *ell as the a$2iliay '#!ta'ts) The +#*e '#!ta'ts (ai!s the +#*e "# the '#!ta't# a! the a$2iliay '#!ta'ts is $se t# i!( a l##+ *ith the est #" the est #" the e-i'es it is atta'he t#) These '#!ta'ts ae '#!!e'te t# the '#!ta't s+i!(s)
$,-T )S - PLC %
A PLC is a !igital computer use! "or automation o" in!ustrial processes , li6e '#!t#lli!( %a'hi!ey # "a't#y asse%ly li!es) •
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The %ai! i""ee!'e i""ee!'e "#% #the #the '#%+$tes is that :LCs #+eate i! in!ustrial en'ironments .$st, %#ist$e, heat, '#l, Hi(h te%+eat$e a!(es, ele'ti'al !#ise,-iati#! / •
Ha-e %$lti+le i!+$t;#$t+$t ()*O+ terminals.
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I;O te%i!als '#!!e't the :LC t# se!s#s a! a't$at#s) :LCs #$t+$ts #+eate #+eate ele'ti' %#t#s,
,istory O" PLC % GM !eee the "le2iility #" a '#!t#lle that '#$l e +#(a%%e a! %ai!tai!e y +la!t e!(i!ees> a! *as $((e e!#$(h t# *ithsta! the "a't#y e!-i#!%e!t a! +#-ie easy t#$lesh##ti!()))
Richard E. Morley, an employee of Bedford Associates (Bedford, MA ) involved in the automotive industry, proposed something called a Modular Digital Controller (MODICON) to a major U car manufacturer.
Relay Logic ase! Control Panel
PLC ase! Control Panel
E'olution O" PLC % :LCs *ee *ee i!-e!te i!-e!te as e+la'e%e!ts "# a$t#%ate syste%s that *#$l $se hundreds or thousands of relays, cam timers, and drum sequencers. •
O"te!, a si!(le :LC 'a! e +#(a%%e t# e+la'e th#$sa!s #" elays)
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4ist :#(a%%ale L#(i' C#!t#lles *ee esi(!e a! e-el#+e y Modicon as a relay replacer for GM ) These '#!t#lles eli%i!ate the !ee "# e*ii!( a! ai!( aiti#!al ha*ae "# ea'h !e* '#!"i($ati#! #" l#(i') The !e* syste% asti'ally i!'ease the "$!'ti#!ality #" the '#!t#ls *hile e$'i!( the 'ai!et s+a'e that h#$se the t he l#(i')
The "ist PLC, model 084, *as i!-e!te y Di'6 M#ley i! 3@@) The "ist '#%%e'ial s$''ess"$l :LC, the 84, *as i!t#$'e i! 3@8 *hi'h *as esi(!e y Mi'hael Gee!e()
!hat is a PLC"
The asic lock CP%
#nputs
$utputs
- PRO/R-MM-LE LO/)C CO0TROLLER is a soli! state control system that continuously monitors monitors the status status o" !e'ices connecte! connecte! as inputs. ase! upon a user written program store! in memory it controls the status o" !e'ices connecte! as outputs.
!hat is a PLC"
Ma4or Components o" a Common PLC PO$ER S5PPL6
) 0 P 5 T 8rom SE0SORS
M O & 5 L E
O M
PROCESSOR
Pushuttons contacts limit switches etc.
PRO/R-MM)0/ &E7)CE
5 T P 5 T
O & 5 L E
To O5TP5T Solenoi!s contactors alarms etc.
-!'antages o" PLCs •
Less *ii!()
Wii!( et*ee! e-i'es a! elay '#!ta'ts ae #!e i! the :LC +#(a%)
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Easie a! "aste t# %a6e 'ha!(es)
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T#$le sh##ti!( ais %a6e +#(a%%i!( easie a! e$'e #*!ti%e)
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Reliale '#%+#!e!ts %a6e these li6ely t# #+eate "# yeas e"#e "ail$e)
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#nside a PLC The C:U '#!tai!s a!
C#%%$!i'ate *ith #the e-i'es Othe :LCs, :#(a%%i!( e-i'es, I;O e-i'es, et')
:e"#% H#$se6ee+i!( a'ti-ities Dia(!#sti's, et'
This +#(a% is st#e i!
)*O Mo!ule The I;O i!te"a'e se'ti#! #" a :LC '#!!e'ts it t# e2te!al "iel e-i'es) The %ai! +$+#se #" the I;O i!te"a'e is t# '#!iti#! the -ai#$s si(!als e'ei-e "#% # se!t t# the e2te!al i!+$t a! #$t+$t e-i'es) #nput modules '#!-ets si(!als "#% is'ete # a!al#( i!+$t e-i'es t# l#(i' le-els a''e+tale t# :LCs +#'ess#) $utput modules '#!-ets si(!al "#% the +#'ess# t# le-els 'a+ale #" i-i!( the '#!!e'te is'ete # a!al#( #$t+$t e-i'es)
)*O Circuits Dis'ete I!+$ts Ci'$its #" this ty+e ae $se t# se!se the stat$s #" li%it s*it'hes, +$sh $tt#!s, a! #the is'ete se!s#s) N#ise s$++essi#! is #" (eat i%+#ta!'e i! +e-e!ti!( "alse i!i'ati#! #" i!+$ts t$!i!( #! # #"" e'a$se #" !#ise) A!al#( I;O Ci'$its #" this ty+e se!se # i-e a!al#( si(!als) A!al#( i!+$ts '#%e "#% e-i'es, s$'h as the%#'#$+les, the%#'#$+les, stai! (a(es, # +ess$e se!s#s, that +#-ie a si(!al -#lta(e # '$e!t that is ei-e "#% the +#'ess -aiale) Sta!a A!al#( I!+$t si(!als5 917%A> 13 A!al#( #$t+$ts 'a! e $se t# i-e e-i'es s$'h s $'h as -#lt%etes, F1Y e'#es, se-#%#t# i-es, a! -al-es th#$(h the $se #" ta!s$'es) Sta!a A!al#( O$t+$t si(!als5 917%A> 1> 13
Dis'ete I!+$t A is'ete i!+$t als# e"ee as i(ital i!+$t is a! i!+$t that is eithe ON # O44 ae '#!!e'te t# the :LC i(ital i!+$t) I! the ON '#!iti#! it is e"ee t# as l#(i' 3 # a l#(i' hi(h a! i! the O44 '#!iti#! %aye e"ee t# as l#(i' # # l#(i' l#*)
N#%ally O+e! :$sh$tt#! N#%ally Cl#se :$sh$tt#! N#%ally O+e! s*it'h N#%ally Cl#se s*it'h N#%ally O+e! '#!ta't N#%ally 'l#se '#!ta't 8
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O88 Logic ;
PLC )nput Mo!ule 23 7 !c
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O88 Logic 1
PLC )nput Mo!ule 23 7 !c
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&igital Output A is'ete #$t+$t is eithe i! a! ON ON # O44 '#!iti#!) S#le!#is, '#!ta't#s '#ils, la%+s ae e2a%+le #" e-i'es '#!!e'te t# the Dis'ete # i(ital #$t+$ts) Bel#*, the la%+ 'a! e t$!e ON # O44 y the :LC #$t+$t it is '#!!e'te t#) O5T
PLC
La%+ &igital Output Mo!ule
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-nalog )nput A! a!al#( i!+$t is a! i!+$t si(!al that has a '#!ti!$#$s si(!al) Ty+i'al i!+$ts %ay -ay "#% t# 7%A, 9 t# 7%A # t#3) Bel#*, a le-el ta!s%itte %#!it#s the le-el #" li$i i! the ta!6) De+e!i!( De+e!i!( #! the le-el T2, the si(!al t# the :LC 'a! eithe i!'ease # e'ease as the le-el i!'eases # e'eases)
Le-el Ta!s%itte
Ta!6
)0
PLC -nalog )nput Mo!ule
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-nalog Output A! a!al#( #$t+$t is a! #$t+$t si(!al that has a '#!ti!$#$s si(!al) Ty+i'al #$t+$ts %ay -ay "#% t# 7%A, 9 t# 7%A # t#3) Electric to pneumatic trans!ucer O5T
PLC -nalog Output Mo!ule
; to 1;7
E
P
Supply air
Pneumatic control 'al'e
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I!+$t M#$les 79 #lt DC Syste% Terminal block this is where wires from the field devices are connected Field device this is showing a simple switch
+ ! "olts - ! "olts
Input Module 3 A ; 7 D ' # 8 ! 9 e s i# ! @ 3 COM
To PLC
)*O Mo!ule &C )0P5T MO&5LE IS NEEDED TO5 :e-e!t -#lta(e ta!sie!ts "#% a%a(i!( the +#'ess#) Hel+s e$'e the e""e'ts #" ele'ti'al !#ise
USE TO DRO: THE OLTAGE TO LOGIC LEEL
8ROM )0P5T &E7)CE
C$e!t Li%iti!( Resist#
OPTO> )SOL-TOR
B$""e, 4ilte, hysteesis Ci'$its
TO PROCESSOR
:N: ; N:N SENSORS WIRING 4OR DC IN:UTS
$hat is the !i""erence etween P0P an! 0P0 when !escriing < wire connection o" a sensor% •
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Most in!ustrial proximity proximity sensors (in!ucti'e capaciti'e capaciti'e ultrasonic an! an! photo electric+ are soli! state.
The term soli! state re"ers to the type o" components use! within the sensor. Soli! state electronic components such as transistors are use! to switch the output o" the sensor upon !etection o" an o4ect.
Two speci"ic types o" < wire sensors are a'ailale? P0P an! 0P0. The !i""erence is a result o" the internal circuit !esign an! type o" transistors use!.
- key point to oser'e is that P0P an! 0P0 has nothing to !o with whether the sensor is normally open (0*O+ or normally close! (0*C+ i.e. a P0P sensor may e either 0*O or 0*C as can an 0P0 e either 0*O or 0*C.
$hy two types% •
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The sele'ti#! #" a :N: se!s# -eses a! N:N se!s# is ete%i!e y the !at$e #" the 'i'$it the e-i'e is t# e $se i!) Whe! $se i! a taiti#!al elay ty+e '#!t#l 'i'$it, it is !#%ally +#ssile t# $se eithe the :N: # the N:N ty+e #" se!s# as sh#*! el#*) :N: se!s#s te! t# e %#e '#%%#!ly $se)
Usi!( :N: ; N:N Se!s#s *ith :LC •
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Whe! sele'ti!( a se!s# t# e $se *ith a :LC, it is -ey i%+#ta!t that the se!s# %at'hes the ty+e #" :LC i!+$t 'a t# e $se) T*# ty+es #" i!+$t 'as e2ist, e2ist, th#se that Ksi!6K '$e!t .als# 6!#*! as +#siti-e +#siti-e l#(i'/ a! th#se that Ks#$'eK '$e!t ' $e!t .als# 6!#*! as !e(ati-e l#(i'/) It is thee"#e i%+#ta!t t# ie!ti"y the ty+e #" se!s# t# e $se *ith the :LC 'a ase #! the :LC %a!$"a't$eKs #'$%e!tati#! a! ; # *ii!( ia(a%s)
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&'in(in) *+P+ pro-ides a path to 0 ./C */C
&'ourci n) n) *P+P pro-ides a path to 124 ./C *1/C
)*O Mo!ule -C )0P5T MO&5LE IS NEEDED TO5 :e-e!t -#lta(e ta!sie!ts "#% a%a(i!( the +#'ess#) Hel+s e$'e the e""e'ts #" ele'ti'al !#ise
CONERTS THE AC IN:UT TO DC AND DRO:S THE OLTAGE TO LOGIC LEEL
8ROM )0P5T &E7)CE
Re'ti"ie, Resist# Net*#6
OPTO> )SOL-TOR
B$""e, 4ilte, Hysteesis Ci'$its
TO PROCESSOR
!hat are #nputs" &)/)T-L @ Switches an! Pushuttons Sensing &e'ices Limit Switches Photoelectric Sensors Proximity Sensors
Con!ition Sensors Pressure Switches Le'el Switches Temperature Switches
Enco!ers
-0-LO/@ RT&s
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O$t+$t M#$les Terminal block &utput Module
From PLC
D ; A C # ! e s i# !
3 7 8 9 @ 3 COM
this is where wires from the field devices are Field device connected -Motor starter# controlling an $C motor%
OUT:UT MODULES ARE O4 THREE TY:E .3/Relay Ty+e .AC # DC l#a/ .7/DC Ty+e # Ta!sist# Ty+e # M#s"et Ty+e .8/Tia' Ty+e .#!ly a' l#a/
)*O Mo!ule &C * -C O5TP5T MO&5LE IS NEEDED TO5 :e-e!t -#lta(e ta!sie!ts "#% a%a(i!( the +#'ess#) Hel+s e$'e the e""e'ts #" ele'ti'al !#ise
8ROM PROCESSOR
TTL Ci'$its
OPTO> )SOL-TOR
A%+li"ie RELAY TRIAC FSISTOR
TO O5TP5T &E7)CE
SINING OUT:UT WIRING DIAGRAM
SOURCING OUT:UT WIRING DIAGRAM
!hat are $utputs" 7al'es Motor Starters Solenoi!s -ctuators Control Relays ,orns B -larms Stack Lights 8ans Counter*Totali Counter*Totalier er Pumps Printers
!hat are $utputs"
MO&5L-R B ST-0& -LO0E PLCs MO&5L-R PLC @ CP5 )nputs Outputs 0etwork -!apters are a'ailale as separate mo!ules that "its into the chassis slots.
Stan! -lone PLC @ CP5 )nputs B Outputs points are a'ailale in a single package. ,as "ixe! no. o" )*Os
The ackplane pro'i!es a communication path etween the )*O mo!ules an! either the processor mo!ule or the )*O a!apter mo!ule.
'*ample of a modular based PLC% The PLC slides into the chassis along with other modules )lide modules into available slots
'*ample of a PLC that plugs into adacent modules to form a backplane with no chassis re,uired 'ach module plugs into the one to the left
'*ample of a PLC with the modules built in% Comes as one block
Connections for the built in I(&
y
I;O Syste%s Local I(& I(& adapter Input module - distributed I(& PLC
)witch-input I(& network
PLC Sie 3) SMALL
1 it '#-es $!its *ith $+ t# 37 I;Os a! %e%#ies $+ t# 7 ytes) 1 these :LCs ae 'a+ale #" +#-ii!( si%+le t# a-a!'e le-els # %a'hi!e '#!t#ls)
7) MEDIUM 1 ha ha-e $+ $+ t# t# 7 79 I;O I;Os a! a! %e %e%#i ie es $+ $+ t# 87 ytes)
8) LARGE
1 the %#st s#+histi'ate $!its #" the :LC "a%ily) They ha-e $+ t# 3@7 I;Os a! %e%#ies $+ t# ytes) 1 'a! '#!t#l i!i-i$al i!i-i$al +#$'ti#! +#$'ti#! +#'esses # e!tie +la!t)
ai#$s Ba!s #" :LCs
-llen ra!ley
5S-
Si Siemens
/ermany
Mo!icon Mo
8rance
Mi Mitshuishi
apan
/E 8anuc
5S-
Omron Om
apan
Selecting a PLC Criteria F
N$%e #" l#(i'al i!+$ts a! #$t+$ts)
Me%#y
N$%e #" s+e'ial I;O %#$les
S'a! Ti%e
C#%%$!i'ati#!s
S#"t*ae
#nside a PLC Communications Port
I n p u t
C i r c u i t s
O u t p u t
Central Processor 5nit (CP5+
,igh 7oltage
)solation arrier
MEMOR6
)solation arrier
!ata
program
&C Power Supply Low 7oltage -C Power Supply
or
C i r c u i t s
&C PO$ER S5PPL6
CR
,igh 7oltage
Alle! Baely :LCs
Wii!( ia(a% #" i!+$t a! #$t+$t
PLC -PPL)C-T)O0S :a :a'6a(i!(
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B#ttli!( & Ca!!i!(
Mateial Ha!li!(
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Ma'hi!i!(
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:#*e Ge!eati#!
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HAC; B$ili!( A$t#%ati#!
Se'$ity Syste%s
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A$t#%ate Asse%ly
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:ai!t Li!es
Wate teat%e!t
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INDUSTRY Ce%e!t
A$t#%#ile
Che%i'als
Metals
:a+e
4&B
:lasti's
G. -ny application in any in!ustry that reHuires electrical electrical control
THANK YOU
