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PLC與繼電器控制的主要區別有以下幾點：
（1）組成器件不同
繼電器控制線路是由許多真正的硬件繼電器組成的。而PLC是由許多“軟繼電器”組成的，這些“繼電器”實際上是存儲器中的觸發器，可以置“0”或置“1”。
（2）觸點的數量不同
硬繼電器的觸點數有限，一般只有4至8對；而“軟繼電器”可供編程的觸點數有無限對，因為觸發器狀態可取用任意次。
（3）控制方法不同
繼電器控制是通過元件之間的硬接線來實現的，因此其控制功能就固定在線路中了，因此功能專一，不靈活；而PLC控制是通過軟件編程來解決的，只要程序改變，功能可跟著改變，控制很靈活。又因PLC是通過循環掃描工作的，不存在繼電器控制線路中的聯鎖與互鎖電路，控制設計大大簡化了。
（4）工作方式不同
在繼電器控制線路中，當電源接通時，線路中各繼電器都處于受制約狀態，該合的合，該斷的斷。而在PLC的梯形圖中，各“軟繼電器”都處于周期性循環掃描接通中，從客觀上看，每個“軟繼電器”受條件制約，接通時間是短暫的。也就是說繼電器在控制的工作方式是并行的，而PLC的工作方式是串行的。

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