PROGRAMMABLE LOGIC

CONTROLLER (PLC) AND

AUTOMATION

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Objective ;

1. Understand automation system

a. Understand type of automation
b. Comparison type of automation

2. Understand relays, contactors, electromechanical

timer and electromechanical counter (symbol,
building diagram, operation and application
examples)
a. Develop simple logical control/ automation
sequence

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The word ‘Automation’ is derived from Greek
words…
“Auto”(self) and “Matos”
(moving)
Automation therefore is the mechanism for
systems that…
“move by itself”

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Automation System

Definition:

Automation is a set of technologies

that results in operation of machines and systems
without significant human intervention
and achieves superior performance to
manual operation.

Automasi didefinasikan sebagai sekumpulan teknologi yang memberikan hasil tertentu pada operasi mesin dan
sistem tanpa campur tangan manusia yang ketara bagi mencapai prestasi unggul berbanding penoperasian secara
manual.

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Automation System
 In the scope of INDUSTRIALIZATION, automation is a step beyond
MECHANIZATION

 Whereas mechanization provided human operators with machinery

to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental
requirements as well

 Type of Automation system :

 fixed/ hardwired automation

 programmable automation

 flexible automation

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BH / EJ501 / JUN 2012 6
Fixed/ Hardwired Automation
 Custom-engineering, special – purpose equipment to automate a
fixed sequence of operations.
 High production rates, inflexible product design

Programmable Automation
 Equipment designed to accommodate a specific class of product
changes.
 Batch production, medium volume

Flexible Automation
 Design to manufactured a variety of product or parts
 Low production rates, varying product design and demand

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 Comparison Types of Automation
Automation When to consider Advantages Disadvantages

Fixed High demand volume, long  maximum efficiency  large initial investment
product life cycle  low unit cost  inflexibility

Programmable Batch production, products  flexibility to deal with  new product requires
with the different options changes in product long set up time
 low unit cost for large  high unit cost relative
batches to fixed automation

Flexible Low production rates,  flexibility to deal with  large initial investment
varying demand, short design variations  high unit cost relative
product life cycles  customized product to fixed or
programmable
automation

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Reasons for automating

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Reasons for automating

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ADVANTAGES OF AUTOMATION

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DISADVANTAGES OF AUTOMATION

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Relays

 Define

 A relay is usually an electromechanical device that is actuated by an electrical current. The

current flowing in one circuit causes the opening or closing of another circuit.

 Relays are like remote control switches and are used in many applications because of their
relative simplicity, long life, and proven high reliability.

 Relays are used in a wide variety of applications throughout industry, such as in telephone
exchanges, digital computers and automation systems.

 Relays are used where it is necessary to control a circuit by a low-power signal (with complete
electrical isolation between control and controlled circuits), or where several circuits must be
controlled by one signal

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Relays

 Define

 Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where
several circuits must be controlled by one signal

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Relays
 Define
 Highly sophisticated relays are utilized to protect electric power systems
against trouble and power blackouts as well as to regulate and control the
generation and distribution of power.

 In the home, relays are used in refrigerators, washing machines and

dishwashers, and heating and air-conditioning controls

 Symbol

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 Building Diagram

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Relay Diagram Bottom View

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RELAY TERMINOLOGY

•Normally-open (NO) contacts connect the circuit when the relay is

activated; the circuit is disconnected when the relay is inactive.

•Normally-closed (NC) contacts disconnect the circuit when the relay is

activated; the circuit is connected when the relay is inactive.

•Double-throw (DT), contacts control two circuits: one normally-open

contact and one normally-closed contact with a common terminal.

•Coil- generates a magnetic field that attracts the armature when an electric
current is passed through it.

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 There are three (3) basic functions of a relay:

 On/Off Control: Example: Air conditioning control, used to

limit and control a “high power” load, such as a compressor.

 Limit Control: Example: Motor Speed Control, used to

disconnect a motor if it runs slower or faster than the
desired speed.

 Logic Operation: Example: Test Equipment, used to connect

the instrument to a number of testing points on the device
under test.

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 How does a relay work?
 All relays contain a sensing unit, the electric coil, which is
powered by AC or DC current.

 When the applied current or voltage exceeds a threshold value,

the coil activates the armature, which operates either to close
the open contacts or to open the closed contacts.

 When a power is supplied to the coil, it generates a magnetic

force that actuates the switch mechanism.

 The magnetic force is, in effect, relaying the action from one
circuit to another.

 The first circuit is called the control circuit; the second is called
the load circuit.

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 Operation

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 Operation

 When no voltage is applied to pin 1, there is no current flow

through the coil.
 No current means no magnetic field is developed, and the
switch is open.
 When voltage is supplied to pin 1, current flow though the coil
creates the magnetic field needed to close the switch allowing
continuity between pins 2 and 4.

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• Type of Relay / Application Examples

This is a Single Pole Single Throw (SPST) relay.

Current will only flow through the contacts when the
relay coil is energized.
This is a Single Pole Double Throw (SPDT) relay. Current will
flow between the movable contact and one fixed contact when the
coil is DEenergized and between the movable contact and the
alternate fixed contact when the relay coil is energized. The most
commonly used relay in car audio, the Bosch relay, is a SPDT
relay.

This is a Double Pole Single Throw (DPST) relay. When the

relay coil is energized, two separate and electrically isolated sets
of contacts are pulled down to make contact with their stationary
counterparts. There is no complete circuit path when the relay is
DEenergized.

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• Type of Relay / Application Examples

This relay is a Double Pole Double Throw

(DPDT) relay. It operates like the SPDT relay but
has twice as many contacts. There are two
completely isolated sets of contacts.

This is a 4 Pole Double Throw (4PDT) relay. It

operates like the SPDT relay but it has 4 sets of
isolated contacts.

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 Figure : Relay Contact Configuration

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EXAMPLE OF CONTROL

Figure : Wiring of relay

Pin no 1 – Common
Pin no 2 – NC
Pin no 3 – NO

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EXAMPLE OF CONTROL
 When the relay is at
rest, the switch is not
actuated and the relay
coil is not energized.
The normally close
contact will remain close
and light will be lit.
 when the switch is
closed, the relay coil will
be energized and its
associated contacts will
switch. The normally
open contact, now
closed. Light will turn off
as its contact are open,
and Motor will operate
through its normally
open contacts, which
are closed.
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EXAMPLE OF CONTROL

 If a relay is connected as
shown in figure 3, it will
become 'latched' on when
the coil is energized by
pressing the Trigger
button.  The only way to
turn the relay off will then
be to cut the power
supply by pressing the
Reset button (which must
be a push-to-break type).

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Contactors
 Define
Contactors are used to indicate an open or closed path of
current flow. Contacts are shown as normally open (NO) or
normally closed (NC). Contacts shown by this symbol require
another device to actuate them.

 Symbol

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Contactors
 Define
•A contactor is an electrically controlled switch used
for switching a power circuit, similar to a relay except
with higher current ratings.

•contactor is controlled by a circuit which has a much

lower power level than the switched circuit.

•Contactors are used to control electric motors, lighting,

heating, capacitor banks, and other electrical loads.

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 Building Diagram

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 Building Diagram
•A contactor is composed of three different items:
Power/Main Contact
Auxiliary Contact
Coil Input

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 POWER/MAIN CONTACT
Main contact
generally only
normally open
contacts.
It is used for open
and closed power
circuits.

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 AUXILIARY CONTACT
There are two basic auxiliary contact types:
those that are closed in the non-activated
state or those that are open.
These are known as normally closed (N/C) and
normally open (N/O) contacts.

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 AUXILIARY CONTACT
Uses of auxiliary contacts:
i-electrical retainer circuit
ii-remote status and trip indication.

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 COIL INPUT
 Driven by either an AC or DC supply
depending on the contactor design.
 The coil may be energized at the same
voltage as the motor, or may be separately
controlled with a lower coil voltage better
suited to control by programmable
controllers and lower-voltage pilot devices.
 Coil is used to produce electromagnet when
power is supplied.

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 BASIC CONTACTOR OPERATION
 Contactors operate utilizing
electromagnetic principles.
 When a DC voltage is applied to
the wire, the iron becomes
magnetic.
 When the DC voltage is removed
from the wire, the iron returns
to its nonmagnetic state

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 CONTACTOR OPERATION
 There are two circuits
involved in the operation of a
contactor:
 control circuit
 power circuit.
 The control circuit is
connected to the coil.
 The power circuit is
connected to the stationary
contacts.

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 CONTACTOR OPERATION
 When power is supplied to the coil from the
control circuit, a magnetic field is produced
and magnetizing the electromagnet.
 The magnetic field attracts the armature to
the magnet, which in turn closes the
contacts.
 With the contacts closed, current flows
through the power circuit from the line to
the load.
 When the electromagnet’s coil is de
energized, the magnetic field collapses and
the movable contacts open under spring
pressure.
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 Operation Normally Open Contact

•In the following illustration the circuit is

first shown in the de-energized state.

•The contacts are shown in their normally

open (NO) state.

•When the relay is energized, the

contacts close, completing the path of
current and illuminating the light.

•The contacts have been highlighted to

indicate they are now closed.

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 Operation

Normally Close Contact

•In the following illustration the contacts

are shown as normally closed (NC),
meaning the contacts is closed when
the relay is de-energized.

•A complete path of current exists and

the light is on.

•When the relay is energized, the

contacts open turning the light off.

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 APPLICATION

3-PHASE MOTOR STARTER - DOL

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 CONTACTOR CONTROL CIRCUIT

Start/stop station controlling magnetic starter

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 CONTACTOR CONTROL CIRCUIT

Start/stop station controlling two magnetic starter with

emergency stop.

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  CONTACTOR CONTROL CIRCUIT

Start/stop station with pilot light indicate device deactivation .

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Electromechanical Timer
Define

 Electromechanical timers are used to start or stop a machine

or other device at preset or delayed intervals.

 They consist of both electrical and mechanical components,

and often feature an electric motor that drives one or more
gears. 

 They typically accept electric or electronic inputs to operate a

mechanical output such as rotating wheels or knobs.

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  Symbol Electromechanical Timer

Contact symbols determine the time of timer action:-

On-delay action - TR energized, contacts change state after set time interval
Off-delay action - TR de-energized, contacts change state after set time
interval

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Electromechanical Counter
Define

 Electromechanical counters are used to detect, totalize, and

indicate a sequence of events.

 They typically accept electric or electronic inputs to operate

mechanical outputs such as rotating wheels or knobs.

 These devices may count UP and/or DOWN, support multiple

functions, and provide reset capabilities.

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 Symbol Electromechanical Counter

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Simple Logical Control/ Automation Sequence

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 Contactor

Relay

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3ph Starter/1ph Motor

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