Programmable Controllers: Theory and Implementation

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Introduction to PLC Programming and Implementation—from relay logic to PLC logicinclude the use of the overload contacts to monitor the occurrence of anoverload condition. The auxiliary starter contacts (M1 and M2) are notrequired in the PLC program because the sealing circuits can be programmedusing the internal contacts from the motor outputs. Low-voltage protectioncan be implemented using the overload contact input so that, if an overloadoccurs, the motor circuit will turn off. However, after the overload conditionpasses, the operator must push the forward or reverse push button again torestart the motor.L1 L2 L33F1 2 3 1 2 3R23FR2OLT2T1MT3Figure 32. Forward/reverse motor wiring diagram.For simplicity, the PLC implementation of the circuit in Figure 31 includesall of the elements in the hardwired diagram, even though the additionalstarter contacts (normally closed R and F in the hardwired circuit) are notrequired, since the push button interlocking accomplishes the same task. Inthe hardwired circuit, this redundant interlock is performed as a backupinterlocking procedure.Figure 33 shows the field devices that will be connected to the PLC. The stoppush button has address 000, while the normally open sides of the forward andreverse push buttons have addresses 001 and 002, respectively. The overloadcontacts are connected to the input module at address 003. The outputIndustrial Text & Video Company www.industrialtext.com 1-800-752-839834
Introduction to PLC Programming and Implementation—from relay logic to PLC logicL1ForStop Rev R M1FAll OLsL2M1For PL1FM2RM2Rev PL2Figure 33. Real inputs and outputs to the PLC.devices—the forward and reverse starters and their respective interlockingauxiliary contacts—have addresses 030 and 032. The forward and reversepilot light indicators have address 031 and 033, respectively. Additionally,the overload light indicators have addresses 034 and 035, indicating that theoverload condition occurred during either forward or reverse motor operation.The addresses for the auxiliary contact interlocking using the R and Fcontacts are the output addresses of the forward and reverse starters (030 and032). The ladder circuit that latches the overload condition (forward orreverse) must be programmed before the circuits that drive the forward andreverse starters as we will explain shortly. Otherwise, the PLC program willnever recognize the overload signal because the starter will be turned off inthe circuit during the same scan when the overload occurs. If the latchingcircuit is after the motor starter circuit, the latch will never occur because thestarter contacts will be open and continuity will not exist.Table 12 shows the real I/O address assignment for this circuit. Figure 34shows the PLC implementation, which follows the same logic as thehardwired circuit and adds additional overload contact interlockings. Notethat the motor circuit also uses the overload input, which will shut down themotor. The normally closed overload contacts are programmed as normallyopen in the logic driving the motor starter outputs. The forward and reversemotor commands will operate normally if no overload condition existsbecause the overload contacts will provide continuity. However, if anoverload occurs, the contacts in the PLC program will open and the motorcircuit will turn OFF. The overload indicator pilot lights (OL Fault Fwd andOL Fault Rev) use latch/unlatch instructions to latch whether the overloadoccurred in the forward or reverse operation. Again, the latching occursbefore the forward and reverse motor starter circuits, which will turn off dueIndustrial Text & Video Company www.industrialtext.com 1-800-752-839835
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Programmable Controllers: Theory and Implementation

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