{"id":1446,"date":"2017-11-08T14:35:33","date_gmt":"2017-11-08T14:35:33","guid":{"rendered":"http:\/\/bryceautomation.com\/?p=1446"},"modified":"2017-11-08T14:35:34","modified_gmt":"2017-11-08T14:35:34","slug":"restart-lockout-logic","status":"publish","type":"post","link":"https:\/\/bryceautomation.com\/index.php\/2017\/11\/08\/restart-lockout-logic\/","title":{"rendered":"Restart Lockout Logic"},"content":{"rendered":"<h2>Introduction to Restart Lockout logic<\/h2>\n<p>Whenever we have a a large motor, a lot of current is required to start the motor.\u00a0 \u00a0 When the motor is pulling a large amount of current, heat is building up in the wingdings of the motor.\u00a0 Hence, we do not want to allow too much heat to build up in the motor.\u00a0 \u00a0 Usually, it&#8217;s important to limit the amount of times an operator can start a motor within a given time period.<\/p><div id=\"bryce-3785460886\" class=\"bryce-afterfirst bryce-entity-placement\"><script async src=\"\/\/pagead2.googlesyndication.com\/pagead\/js\/adsbygoogle.js?client=ca-pub-8316758073402323\" crossorigin=\"anonymous\"><\/script><ins class=\"adsbygoogle\" style=\"display:block;\" data-ad-client=\"ca-pub-8316758073402323\" \ndata-ad-slot=\"7728240895\" \ndata-ad-format=\"auto\"><\/ins>\n<script> \n(adsbygoogle = window.adsbygoogle || []).push({}); \n<\/script>\n<\/div>\n<p>In this instance, we will allow the operator to start a motor 4 times within a 20 second period.\u00a0 \u00a0If the operator attempts a 5th restart within any 20 second window, the operator will be locked out.\u00a0 \u00a0 He cannot restart the motor until an additional 60 seconds has passed.<\/p>\n<p>This code serves as an example only, but yo can modify this code for your own use.\u00a0 On many large motors, the code might be modified for only 2 restarts within an hour.<\/p>\n<h2>Common mistake<\/h2>\n<p>A common mistake when writing this code is to use a 20 second timer, and a counter with a preset of 5.\u00a0 The programmer will start a 20 second timer the first time the operator attempts a start.\u00a0 Then if the counter reaches 5 counts within 20 seconds the operator is locked out for one minute.\u00a0 \u00a0The 20 second timer resets if 5 attempts have not been made.<\/p>\n<p>This method is problematic because the operator could attempt the first start, which would start the 20 second timer.\u00a0 \u00a0The operator could then wait 15 seconds and attempt 3 more restarts.\u00a0 \u00a0When the 20 second timer restarts, the operator could immediately attempt 4 more restarts, say, within 5 more seconds.\u00a0 \u00a0 Because the 20 second timer is resetting, the operator could have then attempted 7 restarts within a 10 second period.<\/p>\n<h2>A better way<\/h2>\n<p>The only true way to write this code is with 5 timers.\u00a0 Each time the operator attempts a start,\u00a0 a new 20 second timer will run.\u00a0 \u00a0In this case, each attempt expires after 20 seconds.\u00a0 \u00a0 If 4 timers are running, and the operator attempts a 5th restart, the 60 second timer will lockout out the output.<\/p>\n<p>Let&#8217;s look at the code:<\/p>\n<p>In the first two rungs, we allow for normal operation of a pump.\u00a0 If you are not familiar with Seals, Latches, and Interlocks, please read up on this first.\u00a0 \u00a0A description of seal circuits can be found <a href=\"https:\/\/bryceautomation.com\/index.php\/2017\/05\/29\/seal-circuits\/\">here<\/a>.<\/p>\n<p><img decoding=\"async\" class=\"aligncenter size-full wp-image-1452 lazyload\" data-src=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/FirstTwoRungs-1.png\" alt=\"FirstTwoRungs\" width=\"573\" height=\"244\" data-srcset=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/FirstTwoRungs-1.png 573w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/FirstTwoRungs-1-300x128.png 300w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/FirstTwoRungs-1-570x244.png 570w\" data-sizes=\"(max-width: 573px) 100vw, 573px\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" style=\"--smush-placeholder-width: 573px; --smush-placeholder-aspect-ratio: 573\/244;\" \/><\/p>\n<p>As long as we are not stopped, and not locked out, we can press the start PB, and the output will seal.\u00a0 \u00a0If your stop button is wired differently, you can change the first instruction.\u00a0 We will assume the PumpRun tag is connected to the real output.\u00a0 We have a PumpRunDelay timer in the second rung.\u00a0 \u00a0This helps to prevent accidental starts.\u00a0 The timer also eliminates a problem with &#8220;Bumping&#8221; the motor starter on a 5th start attempt before the lockout timer shuts the output back off.<\/p>\n<h2>Request Timers<\/h2>\n<p>Now, let&#8217;s take a look at the next two rungs:<\/p>\n<p><img decoding=\"async\" class=\"aligncenter size-full wp-image-1449 lazyload\" data-src=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/NextTwoRungs.png\" alt=\"Next Two Rungs\" width=\"451\" height=\"184\" data-srcset=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/NextTwoRungs.png 451w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/NextTwoRungs-300x122.png 300w\" data-sizes=\"(max-width: 451px) 100vw, 451px\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" style=\"--smush-placeholder-width: 451px; --smush-placeholder-aspect-ratio: 451\/184;\" \/><\/p>\n<p>If a request has been made, we will set the flag.\u00a0 \u00a0We have the OneShot instruction, because we do not want to hold this request flag high.\u00a0 \u00a0We just want to indicate that a request has been made to start the pump.<\/p>\n<p>In the next rung, if the flag is set, and this timer has not been started, we will start the timer and put the flag down.\u00a0 \u00a0This indicates that we have acted on the event.\u00a0 \u00a0The first time the operator attempts a start, the first timer will begin to run, and will time for 20 seconds.<\/p>\n<p>Similarly, we will do this for the next three start attempts.\u00a0 If the first timer was already running, then the PumpRequest flag is still high&#8230;.\u00a0 Therefore the next timer will start, and so on.<\/p>\n<p><img decoding=\"async\" class=\"aligncenter size-full wp-image-1450 lazyload\" data-src=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/next3rungs.png\" alt=\"Next three rungs\" width=\"457\" height=\"444\" data-srcset=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/next3rungs.png 457w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/next3rungs-300x291.png 300w\" data-sizes=\"(max-width: 457px) 100vw, 457px\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" style=\"--smush-placeholder-width: 457px; --smush-placeholder-aspect-ratio: 457\/444;\" \/><\/p>\n<h2>Lockout Timer<\/h2>\n<p>Finally, if all four timers are running, and the operator attempts a fifth attempt, the lockout timer will start running:<\/p>\n<p><img decoding=\"async\" class=\"aligncenter size-full wp-image-1451 lazyload\" data-src=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/LockoutTimer.png\" alt=\"Lockout Timer\" width=\"571\" height=\"207\" data-srcset=\"https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/LockoutTimer.png 571w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/LockoutTimer-300x109.png 300w, https:\/\/bryceautomation.com\/wp-content\/uploads\/2017\/11\/LockoutTimer-570x207.png 570w\" data-sizes=\"(max-width: 571px) 100vw, 571px\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" style=\"--smush-placeholder-width: 571px; --smush-placeholder-aspect-ratio: 571\/207;\" \/><\/p>\n<p>Recall that from the first rung:\u00a0 \u00a0If the lockout timer is timing, the pump cannot energize.\u00a0 In this instance, after 60 seconds, the operator will be able to energize the rung again.<\/p>\n<p>&nbsp;<\/p>\n<p>&#8212; Ricky Bryce<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<div id=\"bryce-1030884394\" class=\"bryce-after-content bryce-entity-placement\"><script async src=\"\/\/pagead2.googlesyndication.com\/pagead\/js\/adsbygoogle.js?client=ca-pub-8316758073402323\" crossorigin=\"anonymous\"><\/script><ins class=\"adsbygoogle\" style=\"display:block;\" data-ad-client=\"ca-pub-8316758073402323\" \ndata-ad-slot=\"4667596182\" \ndata-ad-format=\"auto\"><\/ins>\n<script> \n(adsbygoogle = window.adsbygoogle || []).push({}); \n<\/script>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>Introduction to Restart Lockout logic Whenever we have a a large motor, a lot of current is required to start the motor.\u00a0 \u00a0 When the motor is pulling a large amount of current, heat is building up in the wingdings of the motor.\u00a0 Hence, we do not want to allow too much heat to build <a class=\"moretag btn btn-primary\" href=\"https:\/\/bryceautomation.com\/index.php\/2017\/11\/08\/restart-lockout-logic\/\">Read More \u00bb<\/a><\/p>\n","protected":false},"author":1,"featured_media":1450,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[4],"tags":[11,97],"class_list":{"0":"post-1446","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-controllogix","8":"tag-controllogix","9":"tag-restart-lockout","10":"czr-hentry"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>ControlLogix restart lockout logic using the TON instruction.<\/title>\n<meta name=\"description\" content=\"After 5 start attempts for a motor within 20 seconds, we will lock the operator out for 60 seconds. 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