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Calculate Motor Run Time in PLC Using Hours Counter
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Mar 14, 2025
Learn how to calculate motor run time in PLC systems using an Hours Counter with a detailed programming procedure. #motor #runtime #plc Tags: motor run time calculation, hours counter in plc, motor runtime monitoring, plc programming, industrial automation, motor run time tracking, hours counter logic, automation basics, plc tutorials, motor operating time, hours counter applications, beginner plc programming, industrial plc systems, runtime monitoring in automation, hours calculation in plc, automation training, motor operation time examples, plc runtime tracking, industrial automation tutorials
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0:08
hello everyone myself
0:10
badas in this video I will discuss about
0:14
po counter okay open your PLC software
0:19
on the left side scroll down and go to
0:22
counter category and select ours
0:26
counter and add the comment
0:31
our
0:33
counter
0:38
okay if you see there are 1 2 three
0:42
inputs and one
0:44
output this is very useful in Industries
0:49
okay this block is used to calculate the
0:52
machine run time or motor running time
0:57
pump running time
1:01
okay you can use this block to calculate
1:04
the machine total running
1:07
time we will discuss how this
1:10
works first take three inputs digital
1:15
inputs and one
1:18
output
1:26
connect add comment the first one one is
1:33
reset second one is
1:39
input like
1:41
motor run
1:52
status and third one
1:55
is
1:56
reset all
2:20
okay now go to simulation tools and
2:25
simulation see there are three
2:27
parameters you have to remember for this
2:30
block the first one is m i maintenance
2:34
interval second one is MN time to
2:39
go and third one is OT total time okay
2:44
overall time like
2:46
that if you see these will these are in
2:49
hours and minutes okay Suppose there is
2:53
a pump or a motor okay and we want to
2:58
calculate the total run time of the
3:01
motor how many hours the motor is
3:06
running generally for motor start stop
3:11
trip emergency stop running
3:14
feedback permiss vies Etc signals will
3:17
be
3:20
useful and in this case we need M run
3:25
feedback run status
3:30
that status bit we will connect in this
3:33
enable of this
3:36
block when motor is running this this
3:40
bit will be high this bit will be on so
3:43
I will click this bit
3:46
on so what happens when this bit is
3:49
started this block will note down the
3:52
current
3:53
time and it will calculate the time
3:57
until this bit will be off
4:00
okay for
4:02
example now this motor is in running
4:05
State I will change the time I will
4:08
increase the time I will just increase
4:10
by
4:11
minutes and apply so what happens if you
4:15
see this last one is updated V is now 2
4:21
minutes
4:23
okay the motar is running for 2 minutes
4:27
let's suppose I will add one 1 hour 15
4:33
apply the time is updated so the mot is
4:38
now running for 1 hour 2 minutes
4:41
remember this is simulation for testing
4:44
purpose I am changing the time so that
4:47
we can see the block
4:50
functionality so this block will
4:52
calculate the time and it will update
4:54
the total running time for
4:57
example now the motor is off
5:00
then the status bit will be
5:03
off now this block will not increase the
5:06
time it will save this time 1 Hour 3
5:09
minutes now I will change the time again
5:12
see I will add one more hour 16 and
5:15
apply time is updated see there is no
5:18
change
5:19
here if my bit is again on motor status
5:24
that means motor is running again again
5:27
it will start from this value
5:30
I will add 30 minutes or from some other
5:32
value apply you
5:35
see the time is updated overall running
5:39
time of The
5:42
Machine okay and now we will discuss
5:46
about these two
5:48
bits we'll go to the
5:50
properties if you
5:53
see one option is given maintenance
5:56
interval
5:58
Mi let let's suppose I will add 5
6:02
hours
6:06
okay every machine periodically receives
6:11
maintenance okay every machine needs
6:16
maintenance it may be five every 5 hours
6:19
maintenance is required every 10 hours
6:21
100 hours 500 hours 2,000 hours it
6:25
depends on your process industry on your
6:29
Miss
6:30
model make type UCS Etc remember that
6:35
I'm just using 5 hours for simulation
6:38
purpose now what
6:41
happens we entered Mi value which is 5
6:45
hours I
6:47
need my motor maintenance after running
6:51
5
6:52
hours there is no need to run motor
6:55
continuously for 5 hours today it may
6:58
run for 2 hours tomorrow it may run for
7:00
1 hour like that after reaching 5
7:03
hours then I want to do the
7:07
maintenance in that
7:09
case I need one status or I need one
7:13
output from the PLC I need one alarm or
7:17
notification from the PLC that this 5
7:20
hours is completed you have to do the
7:23
maintenance okay this is optional please
7:28
remember if you need this type of option
7:30
we can use otherwise you can ignore
7:34
this how this works
7:36
is the total time is already calculating
7:39
by the block which is W now it is 1 hour
7:42
38 minutes our maintenance interval is 5
7:46
hours right so what it will do it
7:50
will it will calculate the difference
7:53
between Mi and
7:55
OT so 5 hours minus 1 hour 39 minutes
8:00
this is the result 3 hours 21
8:03
minutes if the machine is running and
8:07
ran for 1 hour I will increase 1 hour
8:11
mission time
8:13
apply see what
8:21
happens
8:25
okay
8:28
17 so what happens My overall time run
8:33
uh running time of The Machine V is
8:35
updated it is increased and
8:41
similarly the M1 value time to go value
8:45
is also
8:47
updated I will increase
8:49
further 18 one more
8:52
hour overall time is
8:54
increased MN time to go is decreasing
8:57
like that it will work
9:05
20 14 apply see 5 hours is
9:12
completed MN is equal to Z remember when
9:17
M1 is equal to Z output will be turned
9:20
on that is why q1 is on here that means
9:26
your maintenance interval 5 hours is
9:30
completed you please do the maintenance
9:32
signal will be given by the
9:35
PLC it will not stop the motor or it
9:39
will not stop the counting of the total
9:41
run time this is only notification only
9:45
an alarm it will give to us we have to
9:49
decide whether to continue to run the
9:51
motor or we have to stop the motor as
9:54
per your
9:56
requirement okay let's suppose I I'm
9:59
continuously running the
10:01
motor for 1 more
10:03
hour 21 apply what happens maintenance
10:08
bit is still on output is still on but
10:12
the OT total time of the motor running
10:15
time is
10:17
increasing okay this is
10:20
how the total time will be
10:24
calculated for
10:26
example now I told turned of the motor
10:31
and maintenance is
10:33
completed
10:34
okay again I turned on the
10:38
motor still my q1 is on output is
10:43
on but maintenance is completed so what
10:47
I have to do is we have to activate or
10:50
press the first input which is
10:53
reset okay what it will do it will reset
10:57
the
10:57
output and it it will update the MN
11:01
again
11:03
see input is activated and again
11:07
normal MN is equal to 5 again 5
11:11
hours output is
11:14
off M1 M1 means time to go is 5 hours
11:18
means again after 5 hours again output
11:21
will be
11:22
on again we have to do the maintenance
11:25
in simulation case generally this value
11:27
will be high 100 hours 200 hours th000
11:30
hours like that okay in
11:35
Industries I will increase one more hour
11:38
just see our 2 hours
11:42
23
11:48
apply so like this it will work for
11:51
example I want to reset all the fields
11:55
output Mi MN all then I have to give
11:59
reset all I'm activating reset
12:03
all W uh main output and W will be reset
12:07
M MN are fixed values taken from the
12:11
properties if you no need for this you
12:13
just enter 0
12:15
0
12:17
okay or you can enter some big
12:24
value
12:25
okay mainly this V is important
12:29
total time of the
12:31
machine for
12:33
maintenance we have to know how many
12:36
hours each motor is running after
12:40
running for specific hours we have to do
12:43
the
12:43
maintenance then again they can use the
12:46
motor for the process
12:49
operations in this case we discussed
12:51
about motor run status we can use this
12:55
type of application for any machine
13:00
if you have any experience in
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Industries share with us how you are
13:04
using this type
13:06
of
13:07
counter and what is the parameters and
13:11
applications are type of the counters
13:14
you using in the industries share with
13:17
us through the comment section thank you
13:20
I will meet you in the next session
#Factory Automation
#Industrial Materials & Equipment
#Industrial Measurement & Control Equipment