EXPERIMENT No.

0 1
INTRODUCTION TO INDUSTRIAL AUTOMATION,
RELAY AND TIMER OPERATION
PRELAB TASK

OBJECTIVE
The objective of this lab session is to get familiarization with concept ‘automation’, what is it,
what are its uses and how we can apply it in industries and get familiarization with basic
principles of Relays and Timers.
INTRODUCTION
Today industries are going to modernize. As compare to previous today’s industries are working
automatically. In the past man power is needed to done work but now industrial automation
make possible to reduce man power and industries work automatically. Today the development
of technologies made it possible to introduce industry automation systems into almost all
manufacturing fields. Industry automation of production processes enhances labor efficiency and
allows cutting net cost and improving product quality.
THEORY
Earlier the purpose of automation was to increase productivity (since automated systems can
work 24 hours a day), and to reduce the cost associated with human operators (i.e. wages &
benefits). However, today, the focus of automation has shifted to increasing quality and
flexibility in a manufacturing process.
The following are the manufacturing approaches:
1) Automation
2) Flexible manufacturing
3) Quality programs
4) Integration
The following are the types of automation:
1) Fixed
2) Programmable
3) Flexible
The following are the Reasons of automation:
1) To increase labor productivity
2) To reduce labor cost
3) To mitigate the effect of labor shortage.
4) Worker safety
5) Product quality
6) To reduce manufacturing lead time
7) To avoid cost of electric power
Degree of automation:
1) Sequential control
2) Open loop control
3) Closed loop control
Relays are widely used in electronics in automated control systems. Their basic operation is
switching. They are mostly used in CNC machines controlling cards to control working of
different parts. A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such as solid-state
relays. Relays are used where it is necessary to control a circuit by a separate low-power signal,
or where several circuits must be controlled by one signal.
Solid state relays are used in circuits for fast switching reduce switching noise and provide a
good result.
Period during which a system is working in a manner acceptable to its operator or user is called
time operations. There are many devises work on time operations. e.g. Working of CNC
machines grinding, drilling in making guns etc. Many I’C with capacitors and resistors are used
to provide a sufficient required for a particular work. NE555 timer is used to generate time,
AVR, PIC and 80x and 60x microcontrollers generate specific delays, time constants etc.
 LAB SESSION
EQUIPMENT
OMRON TIMER OPERATION KIT
OMRON RELAYS OPERATION KIT

PRECAUTIONS
Follow the lab safety rules and regulations.

EXPERIMANTAL PROCEDURE
In this lab session first of all introduction to automation, reasons for automation, degree of
automation and history of automation is discussed.
Then in second portion relays and timers were discussed briefly, their types, working and
structure is also discussed.
I. Relays:
Relay is a device having two separate circuits and so constructed that a weak current in one of
the circuit controls a strong current in the other circuit. Just as an electrical multiplier. In other
words, a device that opens or closes an auxiliary circuit under pre-determined electrical
conditions in the main circuit. The objective of a relay is generally to act as a sort of electrical
multiplier, that is to say, it enables a comparatively weak current to bring into operation a much
stronger current*. Relays are used to control large current using small amount of current. Relays
are the primary protection as well as switching devices in most of the control processes or
equipments. All the relays respond to one or more electrical quantities like voltage or current
such that they open or close the contacts or circuits. A relay is a switching device as it works to
isolate or change the state of an electric circuit from one state to another. Reclosing relays are
used to connect various components and devices within the system network, such as
synchronizing process, and to restore the various devices soon after any electrical fault vanishes,
and then to connect transformers and feeders to line network. Regulating relays are the switches
that contacts such that voltage boosts up as in the case of tap changing transformers.
 Principle of working of relays:
Working principle of relays as shown in fig. Each relay has a coil wound around an iron
core; a set of movable and stationary relay contacts and the mounting. A switch is used
to start or stop current through the coil. When current flows through the coil, a strong
magnetic field is created. This electromagnet pulls the armature, which, in turn moves
the relay contact down to make electrical connection with the stationary contact. The
physical movement of the armature occurs only when current flows through the coil.

Kit Introduction

G3NA

MK3P-I

G4Q MK2P-I LY4N LY2N

MY2N MY4N
 Relays operational kit
Relays are the basic components of almost all-electrical control panels i.e. conventional
control system and PLC based control system. Relays have different types and have different
working principles depending on their construction. In these operational kits, different relays
are shown in working condition. Relays are used here to represent the function of logic gates.
Logic Gates are the circuit which decide to say “YES”” or “NO” at the output based upon the
inputs. There are three basic type of logic gates i.e.
1) OR GATE
2) AND GATE
3) NOT GATE
AND, OR gates are shown using general-purpose relays i.e. LY, MY series and not gate
using MK series relays. (Below is the discussion of each gate in detail.)

Kit Operation
There are six different relays on the Kit in working conditions and two three relays for just
display. Each relay coil is operated by 24VDC coil. The kit is operated by 220VAC.The kit
can be switched ON/OFF through a power switch. There is a 5Amp fuse for over current
protection. For 24VDC voltage, a power supply provides 24VDC voltage to all components.
When the power is switched on, green indication will turn ON. Green indication means that
output of the power supply is ok. Now let us discuss the function of each gate.

I. OR GATE

OR GATE is based on the OR law of the Boolean algebra. The function of two inputs OR
Gate can be stated, as “The output Y is HIGH if any of the two inputs is HIGH and the
output is low if both the inputs are LOW.

Logic Symbol and Truth Table

The logic expression for OR gate is
Y=A+B

Logic Symbol Of
OR Gate
 Truth Table of OR gate
INPUTS OUTPUT

A B Y

0 0 0

0 1 1

1 0 1

1 1 1

The electrical representation of two-inputted OR GATE can be shown as in the following fig.

Operation
The basic idea of the OR GATE is that when both the switches “A” or “B” are Open
then the lamp ‘Y’ will be OFF .When any one switch “A” or “B” is Closed then the
output led “Y” will turn ON. Also, when both switches A, B are closed then the output
led “Y” will be ON.

There are two toggle switches “A” or “B” on the kit. The LED represents the output
status. The output follows Boolean law Y=A+B for OR GATE. Relays (LY2N, LY4N)
are turned ON/OFF through these toggle switches. When the toggle switch “A” is turned,
ON the LED is connected with the NO (Normally Open) contact of both relays in
parallel.
II. AND GATE

AND GATE is a logic circuit that performs AND operation of Boolean algebra. The
function of two input AND gate can be stated as
“For Two input AND gate the output ‘X’ is only HIGH if both the inputs ‘A’ and ‘B’ are
HIGH and its output is LOW if any of the two inputs is LOW.

Symbol and Truth Table

The truth table and logic symbol of AND gate is given below.

Logic Symbol Of AND Gate

The logic expression for AND gate is X = A.B

Truth Table of AND gate

INPUTS OUTPUT

A B Y = A.B

0 0 0

0 1 0

1 0 0

1 1 1
 Electrical circuit of AND Gate

Operation
This operational kit comprises of TWO switches to act as input signals. Two relays
(MY2N and MY4N) are used to achieve AND operation. A LED indicator finally
displays the logic level of the output. When both the switches are closed, both relays are
activated or energized and NO contacts are closed which completes the path for the load
current. Thus, the indicator turns ON. If either of the relays is not activated, i.e. the
switches are open, the load current path remains open and the output indicator remains
OFF.

Here we explain how the relays and switches are mutually connected to act as an AND
GATE. Both relays are connected to 24VDC voltage source through two switches such
that when switches are closed the relays are energized. 24VDC positive terminal is
connected to the common terminal of relay 2. The common of relay 1 is connected to the
NO contact of relay 2. The output indicator is connected to the NO contact of Relay 1.
Thus when both switches are closed 24VDC is coupled to the output indicator and it turns
ON. If either switch is, open that relay will be de-energized and the indicator will be
OFF.

III. NOT GATE

The NOT Gate is based on the complementation law of the Boolean algebra. The
operation of the NOT gate can be stated as “ the output Y will be high if input A is low
and output Y will be low if the input A is High.”
Symbol and Truth table
The symbol and truth table of the inverter is given in the figure below.

Logic Symbol of NOT Gate

Truth Table of OR gate

INPUT OUTPUT

A Y

0 1

1 0

The Boolean equation of NOT GATE is given as

X= (A) `
Operation
If the switch is closed, logic high is received at the gate input. As a result, the output goes
low. If the switch is open logic, low is received at the input of the gate that results in
logic high at the output.

The NOT function in this kit is achieved by using single relay. The output indicator is
connected to NC contact of the relay. When the switch is closed, the relay is energized
and NC contact gets open. Thus, the path of the current is cut and the indicator turns
OFF. When the switch is open NC, relay is de-energized and NC contact remains close
ensuring complete path to the load current. Thus, the indicator stays ON. In this way, the
basic inversion function is achieved.
II. Latching Relay

Latching relay is designed specially to keep the output set or reset after coil voltage
is removed. When voltage is applied to the coil, relays ‘NO’ point changes to ‘NC’
and ‘NC’ point changes to ‘NO’. Output remains set even the voltage is removed
from the coil.
Latching Relay in Operational Kit:
G4Q-2125 is used in operational kit as latching relay. Single pushbutton either
sets the output or reset it. Push to ON push to OFF concept is achieved by Using
Latching Relay

III. Solid State Relay

Solid-state relay are used in some application instead of electro magnetic relay. It
differs from EMRs in that the SSR uses a thyristor to do the switching.An SSR has no
moving parts.
Solid State Relay in Operational Kit
G3NA-205B Solid state Relay is Used in operational kit. Although it is not in
operational form, it is displayed to familiarize student.
IV. Wiring Diagram And Dimensions
This lab is
performed on
device (OMRON
TIMERS
OPERATION
KIT). There are five
timers on it. First
two are analog and
remaining
three are digital
controlled.
This device sets
the time according to the user demand. Function of every timer is different.

Timers
Timers are devices that activate or deactivate a device after a preset time. Timers have external
relay with normally open ’NO’ and normally closed ’NC’ contacts. The output relay is energized
and de energized according to the timer operation.

Types Of Timer

Three basic groups of timers are:

1. Electromechanical timers (EM )
EM timers have a motor and mechanical timing element. Outputs for such timers are mechanical
contact devices, such as relays or miniature switches. They are usually preferred for very long
timing ranges, such as 30- 50 hours.
2. Pneumatic Timers
These timers measure time by admitting air into an evacuated chamber through an adjustable
orifice. When the chambers reaches a certain pressure, it triggers the timers output.
They are typically used in short time ranges and when precision accuracy is not needed. They do
not require electric power for the timing cycle, a useful feature in many applications.
3. Solid State Timers
These timers offer extreme accuracy and long time ranges. they reset about ten times faster than
EM timers. They can be easily installed in places where space is critical.
Modes Of Timers

A: ON-delay
B: Flicker OFF start
B2: Flicker ON start
C: Signal ON/OFF-delay
D: Signal OFF-delay
E: Interval
J: One-shot*
Kit Introduction:

The kit is designed that all features, modes and possible functions of timers can be explained
on a single kit. This Timer kit is equipped with toggle switches, push buttons and LED’s for
completed control operation of the timers. There are five timers used on the kit and each one
have different mode selected. The selected mode of the timers is also given on the kit in
printed form. Each timer can be selected through their respective toggle switch. Control
button are common to the all timers, so that only one timer can be operated at one time.
Power supply to kit is 220VAC and control of the timers is 24VDC. All Input/Output is
operated on the 24VDC, so there is also a 220VAC to 24VDC power supply on the kit. For
over-current protection a 5Amp fuse is used.
This is a simple and comprehensive kit for the beginner level training and can also be used
for the professional level.
Timer Operational Kit

I. Quick Start to Use this Operational Kit:

To use the timer kit fellow these steps:

A) Give power supply i.e. 220VAC to kit through a power plug from any external
source.
B) Then turn ON the “Power” switch, it will glow.
C) After power up, green LED on the 24VDC Power supply will turn ON. It means
that 24VDC is available on its terminals.
D) Select the timer which to use through the “Timer Slection” toggle switches.
E) Let’s select first timer i.e. Timer 1
F) Timer 1 is already set in “Mode A”
G) Then press the “Start” button in the control inputs
H) Timer 1 i.e. H3CR-A will start timing for Set Vaue (SV) of time.
I) Time on the H3CR-A can be set through the knob on the timer.
J) There is also slection of “Sec”, “Min” and “Hour” on the timer.
K) After completing the set value time, the output LED will turn ON,mean that Set
time is completed.
L) There are two more buttons i.e. “Reset” and “Gate” in the control inputs which have
a different tasks.
M) “Gate” switch is basically a pause function switch. If Gate signal is given to the
timer, it will pause the timing and after removing the Gate signal, timer will resume
the timing from that point again.
N) “Reset” button will reset the timing of the timer to the initial position at any time
during the operation.
 O) The same procdure can be followed for all timers.

II. Kit Operation:

The timer operational kit consists of three different type of timer’s i.e.
1) H3CR
2) H8GN
3) H5CX
There are five different mode of timer; Mode-A, Mode-B, Mode-C, Mode-D and Mode-
E, whose timing diagram is given on the timer kit. Operation of each mode is given as:

1) Timer 1: H3CR-Mode-A

Operation
First of all power up the kit. Now select Timer1 through the timer selection box,
using the toggle switch. The power LED will turn ON. Mode of Timer1 is mode A. in
this mode when power is turned on or is applied to the coil of timer and then start
signal is applied the timer will start timing for the set value SV time. At first the
output LED will be OFF and when the time is completed the output LED will turn
ON after the set time.

Now pressing the start button will begin the timing and indicator of the power on
timer will start blinking. It means that timing is in progress. When Timer H3CR-A
complete its set value the output indicator on the timer will turn ON. The output
LED1 on the timer H3CR on the kit will turn ON. The output LED1 will remain ON
until it is reset by the Reset button in the control inputs. If the gate signal is applied to
the timer through the toggle switches, the timing of the timer will stop at time T1.i.e
the timing will be paused. When the gate signal is removed the timer will resume
timing. Now the set time will be T1+T2. The output will turn ON after the combine
time. This mode is called ON-Delay timer Mode. When timer is already running, the
start button will have no effect on the operation.
2) Timer 2: H3CR-Mode-B2

Operation
Select timer2 through the toggle switch2 from the time selection box on the kit. This
will energize the timer2 and will be ready for the operation. The timer2 i.e. the H3CR
is used in mode B2, the flicker OFF Start Mode. It means that when the start button is
pressed the timing will be started and the output will turn OFF for that time and will
be turn ON for that time.
When the start button is pressed the timing will be started for the set time and power
indicator on the H3CR timer will start blinking. After completing the time, the output
indicator on the timer will turn ON. At the same time the output LED2 will also turn
ON, because the LED is connected to NO contact of the timer. After turning on the
output Led, the timing will start again for the set value time (SV).This process will
repeat until reset by the Reset Push Button. The gate signal will pause the timing of
the timer and after removing the gate signal the timer will resume timing from the
accumulated time.

3) Timer 3: H8GN-Mode-D

Operation
The third timer i.e. H8GN on this operational kit is a dual timer/counter. It means that
H8GN can be used as a timer and as a counter. But here we have used this as a timer
in Mode D. i.e. Signal OFF Delay Timer.
 In this mode as described before when start signal is given to the timer, the output
will turn ON and the timer will start timing. After removing the start signal the timer
will start timing for the set value of time and after the value is reached the output will
turn OFF. On the operational kit, first of all select the required timer i.e. timer 3 from
the timer selection box. This will select H8GN timer and will be ready to operate.
Now pressing Start Button from the control input box will turn ON the output Led 3.
Releasing the start button will start the timing and after the set value is achieved the
output Led3 will turn OFF.
The gate signal in the control inputs will pause the timing at any stage and after the
removal of the gate signal the timing will be resumed from the accumulated time. The
reset signal will reset the timing to zero and will set the timer to the initial position.

4) Timer 4: H5CX-Mode-E

Operation
The fourth timer on the kit is H5CX timer. This timer is used in mode E i.e. in
interval mode. Select timer 4 from the timer selection box. This will ready the timer
for operation. Now pressing the start button begins the timing of the timer. The output
Led4 will turn, when the start button is pressed and also the timer will start timing for
the set value of time. After completing the timing the output Led will turn off. The
timing chart of mode E is given on the operational kit. The gate and reset button will
pause and reset the timing of the timer at any stage.

5) Timer 5: H5CX- Mode-F

Operation
The last and fifth timer is H5CX timer in mode F i.e. one shot and flicker mode. In
this mode when timer is ready for operation, and the start signal is given to the timer,
the timer will start timing for the set value of time and after completing the timing for
the set time the output will turn ON. And timer will again start timing for the set time.
After completing the timing the output will turn OFF. After completing on cycle of
 ON/OFF the timer will reset and will be ready to operate again on arrival of start
signal. The timing chart of mode F is given on the kit.
Select timer 5 from the timer selection box. This will ready the timer 5 for operation.
Pressing the start button will start the timing of the timer and after completing the set
value time, the output led will turn ON. The timer will again start timing up to the set
value. And after completing the time the output Led will turn off. This will complete
one cycle for the output.
The reset button will reset the timing of the timer at any stage during operation. The
gate signal will pause the timing of the timer and after removing the signal the timing
will be resumed.

Wiring diagram

6 10 11 12 4 2
_
OV NO

H5C X A D

Reset Start Gate NC Pole +

S TA R T 7 8 9 5 3 1

R ES ET 6 3 8 10 12 2
OV Start NO Pole +
r
H8GN
 LAB REPORT

LAB REPORT
Conclusion:
Summary:

Questions
Q1: Timing diagram of ON-delay timer.
Q2: Timing diagram of OFF-delay timer.
Q3: Implement NOR, XNOR, XOR and NAND gate (circuit diagram with relay logic).
Q4. Draw Timing Diagram of all Timers including Lab and other than Lab?
Q.5 Draw Schematic/Circuit Diagram using Relay Logic for Conveyor Belt?
Bibliography

[1] http://www.ia.omron.com/products/category/relays/.