Chapter 3:

Industrial Automation
Synthesis
3.1 Introductory Principles in Designing Automation Circuits
3.1.1 The Latch Principle

 Let’s consider a machine operating with the

help of an electric motor. The motor is a direct
start type and is being controlled by the
utilization of a relay C. It has been analyzed
that the automation circuits are actuating on
the power relays, supplying subsequently the
motors or other industrial devices with the
appropriate electrical power. In this case, the
automation problem can be stated as follows:

 “What automation circuit can we select to Figure 3.1 Elementary manual ON-OFF control of a machine.
Industrial Automation Circuits
energize or de-energize the relay C and thus (a) Permanent stop or operation of a machine C
directly control the operation or non-operation (b) Permanent stop, instantaneous operation of machine C
(c) Permanent operation, instantaneous stop of machine C
of the motor?”
(d) Permanent stop or operation of a machine C
3.1
3.1Introductory
IntroductoryPrinciples
PrinciplesininDesigning
DesigningAutomation
AutomationCircuits
Circuits
3.1.1 The Latch Principle

 Every automation circuit, simple or complex, is secured by a general safety fuse, especially in the cases where
the automation includes control panels for human operators.
 In the case of control panels for human operators, all the automation circuits should be of low voltage in order
to ensure the operator’s safety in case of a short circuit, current leakage, faulty wires, etc.
 The automation circuits are being designed in parallel branches between the R and N lines, while there is no
restriction in their “length”, meaning the total number of branches.
 Every branch of an automation circuit can be simple or complex, which means that it can consist of a series,
parallel, or a mixed type combination of switching contacts.
 Every branch of an automation circuit can contain an unlimited number of switching contacts, but always only
one coil should be able to get energized.
 Industrial
It is never permissible
Automation to have serial connections of relay coils in the same branch, while it is permissible to
Circuits
have a parallel connection of two or multiple coils in the same branch
3.1
3.1Introductory
IntroductoryPrinciples
PrinciplesininDesigning
DesigningAutomation
AutomationCircuits
Circuits
3.1.2 The Principle of “Command”

Industrial Automation Circuits

Figure 3.2 Machine operation (a) manually or (b) automatically via sensor command
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.1 Motor Operation with Thermal Overload Protection

Industrial Automation Circuits

Figure 3.3 Motor operation with thermal overload protection

3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.2 Operation and Fault Indication

Industrial Automation Circuits

Figure 3.4 Signaling of machine operation or faults.

3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.3 Machine Operation with Starting Delay

Example:
A specific category of pumps, called “hydro-
lubricated”, need to be filled with water through a
supporting tank before starting. The water filling of
the tank can be completed in a short time interval of
1–4 minutes. In the case that an automatic operation
of the pump is needed, the following procedure
should be followed:

Figure 3.5 Machine operation with a start-up delay (No.1).

1. In the beginning, the pump water filling mechanism should be set in operation, without the pump needing to be in
operation. Let’s define “T” as the required time interval for completing this process.
2. After the elapse of time T, the pump should be set in operation.
3. In parallel with (2), the operation of the water filling mechanism is terminated
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.3 Machine Operation with Starting Delay

Industrial Automation Circuits

Figure 3.6 Machine operation with a start-up delay (No.2).

3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.3 Machine Operation with Starting Delay

Industrial Automation Circuits

Figure 3.7 Machine operation with a start-up delay (No.3) and (No.4).
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.4 Machine Operation with Stopping Delay

Let’s assume a complex machine is receiving parts in a continuous manner, processing them for a certain
time, and subsequently, placing them on a conveyor belt. If we would like to stop the machine, there are
three possible ways to do so:

1. By pressing the STOP button, the machine will stop independently of the processing stage that it
currently is in. In this case the most likely result would be to have an unfinished part inside the
complex machine.

2. By monitoring the operation of the machine and detecting the termination of a processing cycle for a
part, the STOP button can again be pressed quickly before the start of the next part.

3. The automation
Industrial circuit can be designed in a way that the pressing of the STOP button does not stop
Automation Circuits
the machine directly but will allow the operation to continue until the finalization of the processing
of the current part.
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.4 Machine Operation with Stopping Delay

Industrial Automation Circuits

Figure 3.8 Machine operation with stop delay.

3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.5 Periodic Operation of Machine with Two Time Constants

Industrial Automation Circuits

Figure 3.9 Periodic operation of a machine.

3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.6 Machine Operation with Automatic or Manual Control

Industrial Automation Circuits

Figure 3.10 Machine operation with: (a) a selectable auto-manual mode, and (b) with a time relay.
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.7 Operation of Two Machine with a Common Manual Command or Separate Automatic Commands

Industrial Automation Circuits

Figure 3.11 Operation of two machines with selectable common manual commands or separate automatic
commands. (a) Automation based on additional contacts of a switch, (b) automation based on an auxiliary relay .
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.8 Operation of Two Machine with a Common Automatic Command or Separate Manual Commands

Industrial Automation Circuits

Figure 3.12 Operation of two machines with selectable common automatic commands or
separate manual command.
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.9 Operation of a Machine from Two or More Points

Industrial Automation Circuits

Figure 3.13 Machine manipulation from multiple control panels (without operation signaling
3.1
3.1Step-by-Step
IntroductoryBasic
Principles
Automation
in Designing
Examples
Automation
SynthesisCircuits
3.2.10 Control Panel for Operating n-Machines

Figure 3.14 Control panel for n machines:

(a) Centralized control panel for 1 machine
(b) Decentralized control panel for 1 machine
(c) Decentralized automation for n-machines
(d) Console for the decentralized automation of n-machine

Industrial Automation Circuits

3.3
3.1The
Introductory
Meaning of
Principles
the Electrical
in Designing
and Mechanical
Automation
Latch
Circuits

Industrial Automation Circuits

Figure 3.15 Automation circuit with relays under electric and mechanic latching
3.3
3.1The
Introductory
Meaning of
Principles
the Electrical
in Designing
and Mechanical
Automation
Latch
Circuits
3.3.1 Sequential Start – Latch of Machines (Chain Latch)

Industrial Automation Circuits

Figure 3.16 Sequential start-up of 4 machine Figure 3.17 Sequential start-up of 4 machine with
with chain electric latching chain electric latching without reoperation in case of
overload relay trip-reset
3.3
3.1The
Introductory
Meaning of
Principles
the Electrical
in Designing
and Mechanical
Automation
Latch
Circuits
3.3.2 Motor Operation with Power Supply from Two Different Networks

 In large industrial units it is

possible, for safety and cost
reasons, to have the ability to
select the supply from a different
power network, instead of the one
commonly provided. In this case,
switching to a different power
Industrial Automation Circuits
network is ideal

Figure 3.18 (a) Power and (b) Automation circuits of a

motor connect in two different supply networks
3.4 Automation Circuits for Motor
3.4.1 Motor with Inversion in Rotation

Industrial Automation Circuits

Figure 3.19 Power circuit of a motor with two Figure 3.20 Automation circuits for (a) permanent or(b)
directions of rotation. instant operation of motor with two directions of rotation.
3.4 Automation Circuits for Motor
3.4.2 Motor with a Star-Delta (Y-Δ) Start

Figure 3.21 (a)Power circuits, (b) windings

connection, and (c) Automation circuit of a
motor with Y-Δ start-up
3.5 Automation Circuits with Sensors
3.5.1 Starting a Machine with Canceling Ability

Figure 3.22 Example of a pump which stops Figure 3.23 (a) Automation circuit for pump operation with
if there is no fluid flow cancellation possibility and time graph of basic components,
without flow (b), and with flow (c)
3.5 Automation Circuits with Sensors
3.5.1 Starting a Machine with Canceling Ability

Figure 3.24 Automation circuit for pump operation with cancellation possibility and
complete signaling
3.5 Automation Circuits with Sensors
3.5.2 Pump Operation Based on Level Control

Figure 3.25 Automated filling of a tank

3.5 Automation Circuits with Sensors
3.5.3 Operation of Two Pumps According to Demand

 Two pumps are supplying a water tank

from a natural source of water, and
subsequently, the tank supplies a
consumer with a random demand. Ideally,
the automatic operation of the two pumps
is as follows

Figure 3.26 Automatic operation of two pumps according to

the demand

1. If the level of the tank is below a certain level (E1), both pumps should be in operation.
2. If the level of the tank is between the levels E1 and E2 , one pump should be in operation.
3. If the level is greater than level E2 , none of the pumps should be in operation.
3.5 Automation Circuits with Sensors
3.5.4 Automation of a Garage Door

Figure 3.27 An electrically driven gate

with sensors for automatic operation
Figure 3.28 Automation circuit of the
electrically driven gate
3.6 Automation Circuits Design Regulations

Figure 3.29 Symbols of Switch Contacts and

Automation Divices
3.6 Automation Circuits Design Regulations

Figure 3.30 Meaning of Letters in Automation

Circuits
3.6 Automation Circuits Design Regulations

1. We number all the vertical branches of

the automation circuit.
2. Under each relay, we create a small table
with two columns, with the notations
“O” and “C” representing the number of
open and closed contacts, respectively.
3. In every column, we denote the number
of the branch where a closed or an open
contact exists, respectively, and this is
happening for all the existing contacts of
the relay.
4. We repeat step (3) for all of the
remaining relays. Figure 3.31 An alternative automation circuit for the Y-Δ start-up of a
motor, and example of the localization manner of switching contacts
and relays
3.7 Automation Circuits Design Regulations

Overall, it should be mentioned that the development of an

industrial automation system involves the following stages:

1. Collection of the operational requirements for the complex machine or

production line
2. Design of the automation circuit based on the gathered regulations
Calculation of the circuit components (e.g., power relays, thermal overload
relays, auxiliary relays, wires, power supplies, operating voltages, etc.)
3. Manufacturing of the electrical industrial switchgear Installation of the
industrial switchgear, which includes:
– Placement of the switchgear
– Power wirings (e.g., motors)
– Low-power wirings (e.g., sensors, actuators, signaling devices, control
buttons and switches in control panels, etc.)
– Testing of the whole system and tuning of sensors (e.g., position tuning Figure 3.32 Example of an industrial switchgear
of the limit switches, photo cells, etc.) implementation including both power and
4. Implementing and programming, where the automation or parts of the automation circuits.
automation in PLCs are needed and perform the necessary wiring
connections from and to the PLC and the rest of the automation equipment,
as described previously
3.8 Applications
3.8.1 Machine Operation Control from Multiple Positions

Figure 3.33 Use of pule relay for the ON-OFF Figure 3.34 The automation circuit of Figure 3.31 in
manual control of a machine from multiple control oder not present the reoperation feature
panels with a two-wire interconnection
3.8 Applications
3.8.2 Operation Control of a Power Transformer

1. For the four kinds of error types, a separate light indication

should exist.
2. For the two alert signaling errors (SPST contacts) of the
Buchholz device and the thermometer, a sound signaling
(horn) should exist.
3. The second error signal from the Buchholz device should
create a breaking of the medium power automatic switch.
4. The second error signal from the temperature sensor should
create a breaking of the main low voltage switch.
5. The horn should be able to be muted, while the fault
continues to exist.
6. A testing capability of the proper operation (without fault) of
the light indications and the horn should be provided.
7. When the fault is created by any kind of operation breaking,
the light indications should exist even after the event of
Figure 3.35 General view of a transformer power
breaking
station.
3.8 Applications
3.8.3 Operation of Two Pumps with a Cyclic Alteration, Based on a Low-High Demand 1. The automation circuit should provide the
ability to choose between the manual and the
automatic operation of each pump separately.
2. If the base pressure sensor is energized, the
based pump should be activated.
3. If the base pump is in operation and the peak
pressure sensor is energized, then the peak
pump should be set into operation. If the peak
pressure sensor is de-activated, then the
operation of the peak pump should also be
stopped.
4. If the base sensor pressure is de-activated, the
based pump should stop. However, as soon as
the base pressure sensor is activated again, the
peak pump should be put in operation and
considered as the new base pump, and the
previously considered base pump should be
considered now as the new peak pump (cyclic
operation). The same procedure of changing
the consideration among the current base and
peak pumps should be followed for every
operational cycle, until the end of the overall
operation where we would desire the complete
Figure 3.36 (a) Automation circuit for transformer station safety operation, and operation stop for both pump
(b) change over of power supply of the automation circuit
3.8 Applications
3.8.3 Operation of Two Pumps with a Cyclic Alteration, Based on a Low-High Demand 1. The automation circuit should provide the
ability to choose between the manual and the
automatic operation of each pump separately.
2. If the base pressure sensor is energized, the
based pump should be activated.
3. If the base pump is in operation and the peak
pressure sensor is energized, then the peak
pump should be set into operation. If the peak
pressure sensor is de-activated, then the
operation of the peak pump should also be
stopped.
4. If the base sensor pressure is de-activated, the
based pump should stop. However, as soon as
the base pressure sensor is activated again, the
peak pump should be put in operation and
considered as the new base pump, and the
previously considered base pump should be
considered now as the new peak pump (cyclic
operation). The same procedure of changing
the consideration among the current base and
peak pumps should be followed for every
operational cycle, until the end of the overall
operation where we would desire the complete
Figure 3.37 Automaiton circuit for a two-pump operation with cyclic alteration operation stop for both pump
3.8 Applications
3.8.4 Operation of Three Air Compressors with Predefined Combination

Figure 3.37 Automation circuit for a two-pump operation Figure 3.38 Air compressor operation according to
with cyclic alteration selector switch position.