COURSE

Industrial Automation and Control

5th Semester
2022-23
ODD SEM

Faculty:
Mr. MANOJ SAINI
Designation Assistant Professor
Department of Electrical Engineering
Galgotias College of Engineering & Technology
1, Knowledge Park, Phase-II
Greater Noida (UP)-201306
E-mail: manoj.saini@galgotiacollege.edu
Mob No: 9050282545
UNIT - 2
Lecture -1
DETAILED SYLLABUS UNIT-2
INDUSTRIAL AUTOMATION & CONTROL

 Course Outcomes-2: Knowledge Level (K3 – Apply)

Apply Relay logic for automation.

 Unit2: Automation using relay logic

Relay Circuits: Construction & Principle of Operation, Types of
Relays, Relay as a memory element, Contactor Circuits, Advantages
of Contactors over Relay, DOL circuit implementation using
contactor, Automation problems based on relays, PLC Introduction:
History & Current Trends, Basic Block Diagram of PLC,
Classification of PLCs.
 WHAT IS A SWITCH?
 A switch is a device that allows you to stop the flow of current entirely.
 These are usually mechanical devices that separates two bits of metal
(contacts). When the metal doesn't touch, current doesn't flow. When the
metal touches, is called a closed circuit. When the metal doesn't touch, is
called an open circuit. (closed = ON, open = OFF)

Basic Switch Schematic Symbol

S1
SINGLE POLE, SINGLE THROW = SPST
 A simple on-off switch. This type can be used to switch
the power supply to a circuit.

Circuit Symbol Example
SINGLE POLE, DOUBLE THROW =
SPDT
 This switch can be on in both positions, switching on a
separate device in each case. It is often called a
changeover switch. For example, a SPDT switch can be
used to switch on a red lamp in one position and a green
lamp in the other position.
Example
Circuit Symbol
DOUBLE POLE, SINGLE THROW =
DPST
 A pair of on-off switches which operate together (shown
by the dotted line in the circuit symbol).

Circuit Symbol Example
DOUBLE POLE, DOUBLE THROW =
DPDT
 A pair of on-on switches which operate together (shown
by the dotted line in the circuit symbol).

Circuit Symbol Example
 PUSH BUTTON SWITCHES (NO/NC)
 A Normally Open (NO) switch returns to its normally
open (off) position when you release the button.
Circuit Symbol Example

Push-to-make switch

 A Normally Closed (NC) switch returns to its normally

closed (on) position when you release the button.
Circuit Symbol Example
RELAY
 RELAY
Definition: 
 The relay is the device that open or closes the contacts to cause the
operation of the other electric control.
 It detects the intolerable or undesirable condition with an assigned area
and gives the commands to the circuit breaker to disconnect the affected
area. Thus protects the system from damage.
 A Relay is an electro-mechanical or solid-state device, used to control a
device or a circuit electrically by applying a control signal to its coil.
 It is also known by the names auxiliary relay, miniature relay or control
relay.
 Omron, a very reputed manufacturer of relays, medical equipment and
industrial automation systems, defines relay as follows:
 “A relay is a device designed to cause a sudden predicted change in a
single or multiple electrical output circuits when certain conditions are
satisfied by the electrical circuit that contains the relay device”.
 A relay is an electromagnetic switch that is used to turn on and turn off
a circuit by a low power signal, or where several circuits must be
controlled by one signal. 
WHAT IS A RELAY?
 We know that most of the high end industrial application
devices have relays for their effective working.
 Relays are simple switches which are operated both
electrically and mechanically.
 Relays consist of an electromagnet and also a set of
contacts.
 The switching mechanism is carried out with the help of
the electromagnet.
 There are also other operating principles for its working.

 But they differ according to their applications.

 Most of the devices have the application of relays.

 WHY IS A RELAY USED?
 The main operation of a relay comes in places where only a low-power
signal can be used to control a circuit.
 It is also used in places where only one signal can be used to control a lot
of circuits.
 The application of relays started during the invention of telephones.

 They played an important role in switching calls in telephone exchanges.

 They were also used in long distance telegraphy.

 They were used to switch the signal coming from one source to another
destination.
 After the invention of computers they were also used to perform Boolean
and other logical operations.
 The high end applications of relays require high power to be driven by
electric motors and so on.
 Such relays are called contactors.
 WHERE DO WE USE RELAYS?
 Relays have a wide range of application.
 You can find relays everywhere: home appliances,
automobiles, industries, and even in copy machines.
 In some applications, relays are used for switching or
control of circuit (as in timer-based lighting control)
whereas in others they are used to sense and protect
circuits (as in the case of earth fault protection relays).
 Therefore, it is difficult to specify the application area of
relays.
PRINCIPLE OF OPERATION
 Relays are basically classified into two types based on
their working principle as electro-mechanical relays
and solid-state relays.
 The principle of operation of these relays is entirely
different.
 OPERATION OF
ELECTROMECHANICAL RELAYS
 OPERATION OF
ELECTROMECHANICAL RELAYS
 Electromechanical relays transfer signals between its contact through a
mechanical motion.
 It consists of two sections:

 The first is the electromagnet section and

 The other is the armature and mechanical contacts section.

 The electromagnet section consists of a set of coil wound over a magnetic

core.
 When an input voltage (almost equal to the rated voltage of the coil) is
applied to the coil, it gets magnetized and attracts the armature.
 The output contact of the relay is attached to the armature.

 Hence, when the armature is pulled towards the electromagnet, the contact
closes.
 When the input voltage applied to the coil is removed, the armature is
brought back to its original position by the spring release.
 This is how an electromagnetic relay works.
OPERATION OF SOLID-STATE RELAYS
 OPERATION OF SOLID-STATE RELAYS
 Solid-state relays are commonly known as SSRs. Unlike electromechanical
relays, these relays do not have any mechanically moving parts.
 On the other hand, it consists of semiconductor and electronic components within.

 In solid-state relays, the electromagnetic section is replaced by optocoupler and

required driver circuits and the output contact section is replaced by a TRIAC or
transistor plus snubber and driver circuits.
 When the rated voltage is applied to the input section, current flows through the
optocoupler.
 The output of the optocoupler is used to operate the switching circuit of TRIAC or
transistor.
 Switching circuit applies a gate pulse to the TRIAC and the TRIAC starts
conducting.
 Similarly, when the applied input voltage is removed, the optocoupler turns off the
TRIAC switching circuit and which, in turn, stops the gate pulse to the TRIAC and
the TRAIC stops conducting.
 This is how a solid-state relay works.
 CONSTRUCTION -
ELECTROMECHANICAL RELAY
 CONSTRUCTION -
ELECTROMECHANICAL RELAY
 Parts of an electromechanical relay
 A typical electromechanical relay consists of the
following components:
 Electromagnetic coil
 Armature
 Core
 Movable contacts
 Spring return arrangement
 CONSTRUCTION -
ELECTROMECHANICAL RELAY
 Electromagnetic coil
 The electromagnetic coil is the most important part of an
electromechanical relay.
 It consists of a set of copper windings over a magnetic core.
 As you know, the flow of current through the coil produces a
magnetic field.
 Therefore, when voltage is applied to the coil, it becomes an
electromagnet and attracts the armature.
 The reluctance of the magnetic path is kept minimum for making
the circuit more efficient.
 The electromagnet is made up of soft iron, and the coil current is
usually restricted to 5A and the coil voltage to 220V.
 Armature
 An armature is a movable piece of metal, balanced using a pivot
 CONSTRUCTION -
ELECTROMECHANICAL RELAY
 Core
 Core is the metallic part over which the coil is wound.
 Movable contacts and fixed contact
 Contacts are the conducting parts inside the relay, that open or
close when voltage is applied to relay coil.
 The contact that is attracted by the electromagnet is called movable
contact and that is stationary and connected to the terminals are
called fixed contacts.
 The contacts are the most important part of the relay that affects the
reliability.
 The good contact gives limited contact resistance and reduced
contact wear.
 The selection of the contact material depends upon the several factors
like nature of the current to be interrupted, the magnitude of the
current to be interrupted, frequency and voltage of operation.
 CONSTRUCTION -
ELECTROMECHANICAL RELAY
 Spring arrangement
 Spring arrangement is also present in a relay, such as to bring
the armature and the contacts back to the original position
when the coil is de-energized.
 The assembly of an armature with the magnet and the base is
made with the help of spring.
 The spring is insulated from the armature by moulded blocks
which provide dimensional stability.
 The fixed contacts are usually spot welded on the terminal
link
 PARTS OF A SOLID-STATE RELAY
 As discussed earlier, solid-state relays do not have any
movable parts within.
 The internal parts of these relays, are splitted it to the
following sections:
 Input circuit section
 Electrical isolation
 Driver circuitry
 Output section
 PARTS OF A SOLID-STATE RELAY
 Input circuit section
 The input circuit consists of diodes/transistors/gates and resistors
required to drive the optocoupler.
 Electrical Isolation
 Unlike electromagnetic relays, the input and output sections of an SSR
do not have any physical contacts.
 Galvanic separation is provided between them using optocouplers.
 Driver circuit
 Driver circuits consist of components required to turn on the TRIAC or
transistors or thyristors in the output circuit.
 The output of the optocoupler is conditioned and the gate pulse needed
to trigger the transistor is generated.
 Output section
 The output section consists of semiconductor devices such as transistor
or TRIAC or thyristor as an alternative to relay contacts.
HOW TO USE A RELAY IN A CIRCUIT?
 HOW TO USE A RELAY IN A CIRCUIT?
 As stated in the principle of operation, relays have two sections: one is the coil and
the other is the contact section.
 The relay can be controlled by applying a voltage across its coil.

 Let’s make a circuit, that can be used to switch a lamp whenever something comes
close to it.
 Here we use a proximity sensor to sense the objects close by.

 Whenever something comes close to the sensor, it closes the circuit, allowing current
flow to the coil. 
 The operating voltage of the relay coil and sensor is 24VDC and that of the lamp is
230VAC.
 In the above circuit, whenever some object is brought close to the sensor, 24VDC
from the source is applied across the relay coil.
 A current flows through the coil, the relay coil is magnetized and the contacts are
closed.
 Therefore, the lamp glows.

 When the object moves away from the proximity sensor, it stops conducting and the
relay coil is demagnetized, and the contacts fall back to its original position.
 Current flow to the lamp is interrupted and the lamp stops glowing.
 APPLICATION
 Relays have a wide range of applications starting from
washing machines at homes to the telecommunication
systems at the International space station, relays can be found
everywhere. The following are a few key applications:
 Relays are used in electronic circuits and home appliances for
isolating low voltage or DC circuits from high voltage AC circuits.
 Relays are the backbone of industrial process automation systems.
They are used in combination with PLCs for process control. They
are one of the key components in an automation cabinet.
 Used for signaling and control in railway networks.
 In motor control circuits for motor switching, protection as well as
control.
 In substations and power distribution centers for sensing various
faults and operating the circuit breaker.
 TYPES OF RELAYS
 Relays have a wide range of classifications. Here, we have classified them based on
their application as follows

Classification of
Relays

General Purpose
Protection relays
relays
 TYPES OF RELAYS
 General purpose relays
 Miniature relays
 Latching relays
 Timer relays
 Contactors
 Machine tool relays
 Hybrid relays
 Smart relays
 Signal relays
 Automobile relays
 PCB relays
 TYPES OF RELAYS
 Protection relays
 Thermal overload relays
 Distance protection relays
 Earth fault relays
 Under / over voltage relays
 Under / over current relays
 Under / over speed relays
 Frequency protection relays
 Differential relays
 Electronic relays
 Buchholz relays
TYPES OF RELAYS - GENERAL PURPOSE RELAYS
 Auxiliary relays/ Miniature relays
 These relays are used in the control circuits to switch any device/circuit when some condition is
satisfied.
 It is the basic form of relays, with a coil and a set of contacts for switching.
 These relays are available in various contact configurations.
 Latching relays
 Latching relays hold the position of contacts indefinitely even if the supply to the coil is removed.
 It consists of two separate coils, one to latch and others to release.
 When current flows through the first coil (Coil A), the York gets magnetized and the armature is
attracted towards the core.
 The York is made up of a special magnetic material that keeps the armature attracted even if the voltage
applied to the coil is removed.
 In order to bring back the armature to its original position, voltage is applied to the second coil(Coil B).
 The second coil is wound over the York in such a way that the current flow through the coil generates
magnetic flux opposite to the existing field.
 This weakens the existing magnetic field and the armature is released. Hence the contacts fall back to its
original position
 TYPES OF RELAYS - GENERAL PURPOSE
RELAYS
 Timer relays
 Delay timers are the example of timer relays.
 They are made in such a way that the contacts operates in a short time after the coil is
energized.
 Contactors
 Contactors are used for the switch of electric motors, capacitors, lighting loads and other
high-power applications that a relay cannot handle.
 The principle of operation of contactors are same as that of the relays.
 They are designed to carry more current than the relays.
 They have specially designed arc chutes to mitigate the electric arcs formed during the
switching of high current loads.
 Machine tool relays
 These relays are used for logic control in machinery.
 These are electro-mechanical relays with a large number of contacts.
 These relays are obsolete now and are replaced by PLCs.
 Hybrid-relays
 Hybrid-relays combine both a static-relay and a mechanical-relay in parallel, marrying the
low voltage-drop of a relay to the high reliability of silicon devices.
TYPES OF RELAYS - GENERAL PURPOSE
RELAYS
 Smart relays
 Relays monitor voltages, currents and frequency in the electrical system and send control signals to
protective devices such as circuit breakers or switches.
 Smart relays can store measurement data and process that data to provide utilities with complex
information about power system conditions.
 The settings of smart relays can be adjusted automatically or remotely in response to changing
conditions and control instructions.
 Signal relays
 Signal relays are mainly used for lower than 2A load switching, and can be used in various
applications such as telecom & network devices, test and measurement equipment, and security
devices.
 Automotive relays
 Automotive relays are the common type of electromechanical relay that are used in all types of
vehicles, like car, trucks, vans and trailers.
 They enable a small current flow circuit to control and operate a higher current circuit in vehicular
applications.
 Printed circuit board (PCB) relays
 Printed circuit board (PCB) relays are compact relay devices used for power management in control
system designs which require the relay to be mounted directly on the printed circuit board
 TYPES OF RELAYS - PROTECTION
RELAYS
 Thermal overload relays
 Thermal overload relays are protective devices.
 They are designed to cut power if the motor draws too much current for an
extended period of time.
 To accomplish this, thermal overload relays contain a normally closed (NC) relay.
 When excessive current flows through the motor circuit, the relay opens due to
increased motor temperature, relay temperature, or sensed overload current,
depending on the relay type. 
 Distance protection relay
 Since the impedance of a transmission line is proportional to its length, for distance
measurement it is appropriate to use a relay capable of measuring the impedance of
a line up to a predetermined point (the reach point).
 The basic principle of distance protection involves the division of the voltage at the
relaying point by the measured current.
 The apparent impedance so calculated is compared with the reach point impedance.
 If the measured impedance is less than the reach point impedance, it is assumed
that a fault exists on the line between the relay and the reach point.
 TYPES OF RELAYS - PROTECTION
RELAYS
 Earth leakage relay
 An Earth leakage relay is used to protect a device or a circuit from earth faults and
human being from electric shocks.
 It senses the current leakage to the earth and helps safely isolating the circuit or
device.
 The contacts of earth leakage relay are connected to trip circuit of a circuit breaker.
 The earth leakage relay activates the trip circuit as soon as the leakage current goes
over the preset value and opens the circuit breaker.
 Under /Over Voltage Relay
 Under /Over Voltage Relay is used to provide a signal that the incoming power supply
voltage is outside of a predetermined range.
 This signal can be used to trigger an alarm or shut down sensitive equipment in an
orderly manner to prevent permanent damage.
 It is designed to develop a low-voltage and high-voltage tripping mechanism to protect
a load from any damage.
 Differential relay
 A differential relay is defined as the relay that operates when the phasor difference of
two or more similar electrical quantities exceeds a predetermined amount
 TYPES OF RELAYS - PROTECTION
RELAYS
 Electronic relay
 The electronic relay is a type of an electronic switch that opens or
close the circuit contacts by using electronic component without any
mechanical operation.
 Buchholz relay
 Buchholz relay is an oil actuated relay.
 It gives an alarm or trips the input supply based on the level of oil
inside it.
 It also responds quickly to the unusual oil flow from the transformer
main tank to the oil conservator.
 It is a protection and monitoring equipment not only for transformers
but also for oil-immersed chokes with an oil conservator.
 It protects a transformer from short circuits happening inside the
main tank.