Class : T. E.

Instrumentation and Control Course : Control System Components

Experiment No. : ....

Title : ……………………………………………………………………

Name : ……………………………………………………………………

Class : …………………………………

Roll No. : ……………

Batch : ……………

Date : ……………

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Class : T. E. Instrumentation and Control Course : Control System Components

Figure 1.1 : Relay construction and Symbol

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Class : T. E. Instrumentation and Control Course : Control System Components

Experiment No : 1

Relay Logic Circuits

Aim : Study of relays and implementation of relay logic circuits for applications like
latching, sequencing, interlocking and direction control of DC motor.
Components required:

Sr. No. Components Short specifications Quantity

SPDT, 1 changeover, 12Vdc 01
01. Relay
DPDT, 2 changeover, 12Vdc 01
Push-to-ON, NO, 12Vdc, 2A 01
02. Pushbuttons
Push-to-OFF, NC, 12Vdc, 2A 01
03. Lamps 230 Vac, Green and Red colour 02
04. Motor 12 Vdc, Geared 01
12 Vdc, 3A 01
05. Power Supply
230 Vac, 5A power chord 01
06. Digital Multimeter For continuity test 01
07. Connecting wires Multistrand As required

Theory :
Introduction : Relays are used to switch high power circuit, which is connected to the load
using a lower power circuit. In other words, it is an electrically powered device that
mechanically switches high power electric circuits.
Types of Relays: Relays are classified as:
1. According to construction: a) Electromechanical Relay (EMR) b) Reed relay c)
Hermetically Sealed Relay d) Solid State Relay e) Timing Relay f) Latching Relay g)
Pneumatic Relay
2. According to Number of contacts: 1-change over (1-c/o) to 6-change over (6-c/o)

Electromechanical Relay (EMR) :

An electromechanical relay is a device that uses an electromagnetic field (force) to close or
open the switch contacts. Relay contacts come in two basic configurations:
a) Normally opened contacts (NO), which are closed in the energized state and open when
the relay coil is de-energized.
b) Normally closed contacts (NC), which are closed in the de-energized state and open when
the relay coil is energized.
By convention, the relay symbol shows the contacts in the unenergized state. See Fig. 1.1.
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Class : T. E. Instrumentation and Control Course : Control System Components

Figure 1.2 : Relay Terminal Identification

Figure 1.3 : Testing of Relay

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Class : T. E. Instrumentation and Control Course : Control System Components

Specifications of Relay:
Type of relay : EMR
Contact configuration : 1c/o, 2 c/o…..
Coil: Voltage rating : 6 V DC, 12V DC, 24V DC…..
Current rating : Inrush / sealed
Power rating : 200 mW
Resistance : 600 Ω
Contacts:
Contacts rating
Inrush current (max.) = 15A AC / 5 A DC
Voltage (max.) = 250 V AC / 110 V DC
Power rating = 2500 VA/300 Watts
Resistance = On-state = 30 mΩ
Insulation > 1000 MΩ
Electrical life = 30*104 operations (for silver contacts)
Operation time = 10 ms
Release time = 10 ms
Clearance (Gap) = 8 mm
Insulation between:
Contact and contact = 1kV
Contact and coil = 4.5kV
Pole and pole = 2.5kV
Power consumption = 200 mW
Enclosure = Plastic Cap
Mounting = PCB / Socket
Temperature Range = -20 o C to +70 oC
Vibration = 55 Hz
Shock = 100 g

Applications : As relay is switches contact having rating 230 Vac, 5A, it is used to
operate devices like motors, heaters, lamps, blowers, etc. It is also used to develop logic
circuits for applications like latching of pushbutton, sequencing of lamps, interlocking of
motors and direction control of DC motor.

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Class : T. E. Instrumentation and Control Course : Control System Components

Figure 1.4 : Latching the Pushbutton

Figure 1.5 : Sequencing of Lamps having same rating

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Class : T. E. Instrumentation and Control Course : Control System Components

Implementation of Relay Logic Circuits:

Precaution : Great care must be taken while using 230 V AC power supply. Do not touch
at any points in the power circuit to prevent electric shock because these are at high
potential.

1. Relay Terminal Identification: Before connecting a relay in a circuit, it is

required to find its terminals. SPDT relay having five terminals: Two coil terminals
and three contacts terminals (C, NO, NC). If relay is open or having transparent
enclosure on it, then it is easy to find its terminals. But if relay is enclosed in metallic
case or non-transparent case, then terminal of relay are identified by continuity test
using digital multimeter. See Figure 1.2.

2. Testing of Relay : In this section working of relay is demonstrated. Use SPDT

relay. Connect Push-to-ON and Push-to-OFF switches in control circuit of relay as
shown in Figure 1.3. Use lamp in power circuit by connecting it to NO terminal of
the relay. Give 12 Vdc supply to control circuit and 230VAC supply to power circuit.
When Push-to-ON switch (acts as a START) is pressed, then lamp turns on. When
Push-to-OFF switch (acts as a STOP) is pressed, then lamp turns off. Thus a relay is
used to make a lamp on and off. Here it is required to hold Push-to-ON switch for
continuous lamp on otherwise this switch become open and lamp turns off. This
shows a need of latching the Push-to-ON pushbutton.

3. Latching the Pushbutton : To latch the pushbutton there is need of DPDT or 2-

changeover relay. Connect Push-to-ON and Push-to-OFF switches in control circuit
of relay as shown in Figure 1.4. Use lamp in power circuit by connecting it to NO
terminal of the relay. Connect additional terminals (C and NO) available in relay in
parallel with Push-to-ON switch. Give 12 Vdc supply to control circuit and 230VAC
supply to power circuit. When Push-to-ON switch (acts as a START) is pressed,
then lamp turns on. There is no need to hold Push-to-ON switch for continuous lamp
on. If you remove finger from START button, then circuit remain closed through
these additional terminals (C and NO). When Push-to-OFF switch (acts as a STOP)
is pressed, then lamp turns off.

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Class : T. E. Instrumentation and Control Course : Control System Components

Figure 1.6 : Sequencing of Lamp and Motor having different rating

Figure 1.7 : Interlocking of Lamps having same rating

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Class : T. E. Instrumentation and Control Course : Control System Components

4. Sequencing of Lamps : Sequencing of lamps means to make lamps on one

after. If there are two lamps and when first lamp is on, immediately or after some
delay (if timer is used) second lamp is also on. If first lamp is off then immediately or
after some delay (if timer is used) second lamp is also turn off.
In this section, two circuits are demonstrated. First with two outputs having same
voltage and current rating and second with two outputs having different ratings.
If ratings of two outputs (lamps) are same i.e. 230 VAC, 5A, then these two lamps
are connected in parallel in power circuit of SPDT relay as shown in Figure 1.5. Use
only Push-to-ON switch (acts as a START) in control circuit. Give 12 Vdc supply to
control circuit and 230VAC supply to power circuit. When Push-to-ON switch is
pressed, then both lamps turn on. When Push-to-ON switch is not pressed, then both
lamps turn off. Thus a SPDT relay is used for sequencing of lamps.
If ratings of two outputs (lamp and dc motor) are different i.e. 230 VAC-5A, and
12VDC-1A, then these two outputs are connected in different power circuit of DPDT
relay as shown in Figure 1.6. Use only Push-to-ON switch (acts as a START) in
control circuit. Give 12 Vdc supply to control circuit and 230VAC supply to first
power circuit (lamp) and12 Vdc supply to second power circuit (dc motor). When
Push-to-ON switch is pressed, then both lamp and dc motor turn on. When Push-to-
ON switch is not pressed, then both lamp and dc motor turn off. Thus a DPDT relay
is used for sequencing of outputs having different ratings.

5. Interlocking of Lamps : Interlocking of lamps means to make lamps on

alternately. If there are two lamps and when first lamp is on, immediately or after
some delay (if timer is used) second lamp should be off. If first lamp is off then
immediately or after some delay (if timer is used) second lamp should be turn on.
In this section, two circuits are demonstrated. First with two outputs having same
voltage and current rating and second with two outputs having different ratings.
If ratings of two outputs (lamps) are same i.e. 230 VAC, 5A, then one lamp is
connected to NO terminal and second lamp to NC terminal of SPDT relay as shown
in Figure 1.7. Use only Push-to-ON switch (acts as a START) in control circuit. Give
12 Vdc supply to control circuit and 230VAC supply to power circuit. When Push-
to-ON switch is pressed, then the lamp connected to NO terminal turns on.

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Class : T. E. Instrumentation and Control Course : Control System Components

Figure 1.8 : Interlocking of Lamp and Motor having different rating

Figure 1.9 : Direction Control of DC Motor using DPDT relay

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Class : T. E. Instrumentation and Control Course : Control System Components

When Push-to-ON switch is not pressed, then the lamp connected to NC terminal
turns on. Thus a SPDT relay is used for interlocking of lamps.
If ratings of two outputs (lamp and dc motor) are different i.e. 230 VAC-5A, and
12VDC-1A, then these two outputs are connected in different power circuit of DPDT
relay as shown in Figure 1.8. Lamp connected to first NO terminal and dc motor is
connected to second NC terminal of DPDT relay. Use only Push-to-ON switch (acts
as a START) in control circuit. Give 12 Vdc supply to control circuit and 230VAC
supply to first power circuit (lamp) and12 Vdc supply to second power circuit (dc
motor). When Push-to-ON switch is pressed, then lamp turns on and dc motor turns
off. When Push-to-ON switch is not pressed, then lamp turns off and dc motor turns
on. Thus a DPDT relay is used for interlocking of outputs having different ratings.

6. Direction Control of DC Motor : Direction of rotation of dc motor can be

changed by interchanging the polarities of dc power supply given to it. To change the
polarities DPDT relay is used. Connect dc motor in power circuit as shown in Figure
1.9. Use only Push-to-ON switch in control circuit. Give 12 Vdc supply to control
circuit and 12 Vdc supply to power circuit (dc motor). When Push-to-ON switch is
pressed, then dc motor rotates in forward direction. When Push-to-ON switch is not
pressed, then dc motor rotates in reverse direction. Thus a DPDT relay is used to
change the direction of dc motor. (Try it using SPDT relay!).

Conclusion: Write down new things / concepts you learnt from this experimentation.

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