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Relays are switches that open and close circuits electromechanically or


electronically. Relays control one electrical circuit by opening and closing contacts in another
circuit. As relay diagrams show, when a relay contact is normally open (NO), there is an open
contact when the relay is not energized. 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 switches that open and close circuits electromechanically or electronically.
Relays control one electrical circuit by opening and closing contacts in another circuit.
As relay diagrams show, when a relay contact is normally open (NO), there is an open
contact when the relay is not energized. When a relay contact is Normally Closed (NC),
there is a closed contact when the relay is not energized. In either case, applying
electrical current to the contacts will change their state.
Relays are generally used to switch smaller currents in a control circuit and do not
usually control power consuming devices except for small motors and Solenoids that
draw low amps. Nonetheless, relays can "control" larger voltages and amperes by
having an amplifying effect because a small voltage applied to a relays coil can result in
a large voltage being switched by the contacts.
Protective relays can prevent equipment damage by detecting electrical abnormalities,
including overcurrent, undercurrent, overloads and reverse currents. In addition, relays
are also widely used to switch starting coils, heating elements, pilot lights and audible
alarms.

A relay is nothing more than a remote switch that uses an electromagnet to close a set of
contact points. ... Relays are often used in circuits to reduce the current that flows through the
primary control switch. A relatively low amperage switch, timer, or sensor can be used to turn a
much higher capacity relay on and off.

PLCs perform the same function as relays, but can do so much more. They can be put to
great use when old relay panels need to be modernized, or when new systems need an
elegant means of control.

If the electrical control system has only a few inputs and outputs and the logic
requirements are simple ON/OFF control, then relays can do the job just fine without a
PLC. But if a dozen or more digital I/O are required (and maybe even some analog
signals), then PLCs are the way to go. Each electrical device (input or output signal) is
wired its own terminal point.

And PLCs can be networked into a SCADA system so that an operator can use a
computer or touch screen to easily see what's going on with the process or to observe
historical trending saved to a database.

The cool thing about PLCs is their ability to be "re-wired" with programming. The
programming decides which outputs need to be turned on based on the status of the
inputs presented to the logic. Modifications are easy. To make a change in the
functionality, just use a computer terminal to edit the ladder logic programming (which
looks like a wiring diagram):

Keep in mind, if you look inside a control panel that has a PLC installed in it, you might
see a bunch of relays wired up. So what gives? Isn't the idea to eliminate relays? Not
always... Sometimes relays are used as an interface between the PLC inputs/outputs and
the field devices. This adds a layer of protection for the PLC or is a means of changing
voltage levels or controlling a big load with a small current. The relay wiring is
simplified and does not play a significant role in the control logic which is done in the
PLC program.

So relays are sometimes used along side PLCs for interfacing the signals.

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