PLC Program to Count Running Hours of any Equipment

This is a PLC Program to count running hours of any equipment using bit instructions, math instructions, and counters.

PLC Running Hours

In industry, it is sometime necessary to count running hours of any equipment (pumps, compressors, motors) to maintain its efficiency, equipment life as well as periodic maintenance. By using PLC instruction we can prepare a PLC program to count the running hours of any equipment.

PLC Running Hours

PLC Programming

Here is the PLC program to count the running hours of any equipment.

Network 1:

PLC Pump Running Hours

This network adds the 1 second at every 1-second pulse when there is running feedback of equipment and there is no reset bit.

Network 2:

converts seconds into hour in plc

This is the network that converts seconds into the hour.

Network 3:

mod instruction in plc

In this network, we are getting the remaining second by mod instructions and then convert it into minutes.

Network 4:

converts minute into second in plc

This network converts minute into seconds.

Network 5:

CMP instruction in plc
Reset Logic for pump Run Hours

These two networks are for reset logic. When there are 1000 hours in the count it will add count up by 1 and reset all the counting by just moving 0 to an hour, minute and second.

Author: Hiral Patel

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2 thoughts on “PLC Program to Count Running Hours of any Equipment”

  1. In case of HT equipment’s, while commissioning after annual overhaul, the motor circuit will be frequently switched on & Off under testing position and this will boost the actual running hours of machines.

    Hence we have corrected this logic instead from motor ON contact, motor current > … Amps will initiate the counter circuit please.

    Thanks for sharing what,why,where concepts of instrumentation to Knowledge World. Congrats.


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