UT_MOTOR — Motor starter (DOL / contactor / soft starter)

Controls and protects one motor started by a contactor, a soft starter or any
"run relay + run feedback" load (heater bank, fan, conveyor). Built in:
Hand/Off/Auto/Out-of-service, interlocks and permissives, overload, thermistor,
current monitoring, feedback supervision, welded-contactor detection and a
restart/backspin delay. Every protection can recover by itself, retry, or latch.

Pins

Every input is TRUE = active (tripped, pressed). There is no NC setting: wire a
normally-closed contact through NOT at the pin or in the I/O mapping, e.g.
Overload := NOT M1_OL_NC.

Record UT_MOTOR_DATA (shared by every UT_MOTOR* block)

Settings

The reversing, star-delta, two-speed and VSD blocks keep their own settings, commands
and status in a second record of their own (Rev, Sd, Spd, Vsd), so a plain
motor carries none of them. See REV, SD,
2SPD and VSD.

Protections (each a UT_PROTECTION or UT_LEVEL; set each one's response and reset independently)

faultCode has a bit for every protection that is raised, warnings included
(a WARN protection sets its bit as a TRIP one does), and faultId names the
lowest bit set. Bits 8 to 10 are the variants' protections, which live in the
variant's own record.

HMI commands

The reversing and two-speed blocks have their direction and speed commands
(cmdFwd / cmdRev, cmdLow / cmdHigh) in their own record.

Every BOOL command acts once, on its rising edge, and is cleared by the block. One
held TRUE (a Modbus coil left on, a debugger force) acts once: a held cmdStart does
not restart a Hand motor after a stop, and a held cmdReset never turns a MANUAL trip
into an automatic one. Stop always wins: no start in a scan in which cmdStop or
LocalStop reads TRUE, so one held TRUE keeps the motor stopped. A master that
rewrites a command every poll goes through UT_CMD.

Status fields

mode, state, run, running, ready, fault, warning, interlocked,
notPermitted, restartBlocked, restartIn : TIME, current, currentPct,
runTime : TIME (this run), faultCode : DWORD and faultId : UT_FAULT (both cover
warnings too), statusCode : UT_STATUS and statusText : STRING(30) (what it is
doing or what holds it back, see Status), wrnCurrentBad (bit 11),
wrnConfig (bit 12).

Group fields. The motor block writes only isVsd; a group block
(UT_DUTY, UT_PUMP_CASCADE) writes the grp…
fields; you set capacity and jockey:

Added for time visibility and "why it stopped" (at the end of the record):

Why the last run ended (stopReason, the common
stop reasons):

How it works

• Mode (UT_MODE_SELECT): Off → stopped. Hand → cmdStart/LocalStart (rising edge) latch it on,
  cmdStop/LocalStop stop it. A start given while the Permissive is FALSE is
  dropped: the motor does not start later when the permissive returns; the
  operator presses start again (a start waiting out restartDelay is dropped too
  if the permissive goes). Auto → follows AutoCmd, or grpRun while a group (UT_DUTY, UT_PUMP_CASCADE) owns it (grpActive).
  OOS → stopped, protections suppressed, no fault or warning reported.
• Run = requested AND Interlock AND (already running OR Permissive) AND no trip AND
  not restart-blocked. A running motor keeps running if the permissive goes.
• A trip drops Run at once. In Auto, AUTO/RETRY recovery puts it back in service
  by itself if AutoCmd is still on. In Hand a trip drops the hand start, like the
  interlock: once the fault has cleared the operator presses start again. After a
  MANUAL reset of a stopped motor the command must cycle (unless restartAfterReset):
  in Auto, AutoCmd goes off and on; in Hand, the operator presses start again.
• A local stop in Auto stops it; it restarts on the next rising edge of AutoCmd.
• Hand run limit (handMaxRun): a Hand run stops after that long (counted from
  the start, or from the change to Hand of a running motor; status Running: Hand
  with timeLeft counting down, then Hand: max run, press start and stopReason
UT_STOP_MAX_RUN). The operator presses start again for another run.
• In Hand, losing the interlock drops the hand start, so the motor does not restart
  by itself when the interlock returns. In Auto it restarts (its request is still on).
• restartDelay holds back a start until the motor has been off that long; a
  running motor is never stopped by it, nor by the permissive. It counts from
  power-up too, so motors with different delays come back one after the other.
• After a power cut the mode is kept (Off, Hand, Auto, OOS), unless powerUp is
  UT_PU_OFF: then it comes back Off and stays stopped until the operator selects a
  mode again (a conveyor someone must restart on purpose). Auto restarts by
  itself once restartDelay has run. Hand needs a fresh start: a start button held
  through the power cut, or a start command already waiting, is not one. Trips,
  latches and retries are not kept; a fault still there trips again.
• Mode changes are bumpless: Auto → Hand keeps a running motor running.
• State: OOS · FAULT · INTERLOCKED · STARTING (run, no feedback yet) · WARNING ·
  ON · STOPPING (feedback still on after the stop) · OFF.

Status

statusCode, faultId and statusText say the one main thing the motor is
doing, or what holds it back, so a technician can see on the HMI why it is not
running without opening the program. A motor asked to run that is not running
always shows a held, fault or configuration status. The most important reason wins:
configuration > fault > held / waiting > warning > running > idle. A warning shows
over "Running" so it is seen. The time that goes with a status is in timeLeft.
The text is rebuilt only when the status or the fault changes. The numbers are in
conventions.

<fault> is faultId, one of: UT_F_OVERLOAD (overload) · UT_F_MOTOR_HOT (motor
too hot) · UT_F_NO_FEEDBACK (no run feedback) · UT_F_FEEDBACK_LOST (feedback
lost) · UT_F_WELDED (contactor welded) · UT_F_CURRENT_HIGH (current high) ·
UT_F_CURRENT_LOW (current low) · UT_F_DRIVE (drive fault) · UT_F_SPEED_DEV
(speed deviation) · UT_F_CHANGEOVER (changeover) · UT_F_DRIVE_NOT_READY (drive
not ready).
<setting> is one of: UT_F_FLC (full load current) · UT_F_CURRENT_NEEDS_FLC
(current needs FLC) · UT_F_START_MASK (start mask) · UT_F_RESTART_DELAY (restart
delay) · UT_F_HAND_MAX_RUN (hand max run) · a protection's name (its delay,
recover or maxRetries).
The variants add their own statuses and settings, listed in their docs.

Invalid settings

An invalid or out-of-range setting never runs the motor unsafely. Either it falls
back to a safe value and warns (Warning, wrnConfig, faultCode bit 12 "Invalid
setting"), or the motor is kept off with a fault (Fault, wrnConfig, bit 12),
until the setting is fixed. Common to every motor block (warning, fallback):

The variants add their own: REV and 2SPD
negative dead times (warning), SD starTime 0 or negative (kept
off), VSD speed limits and raw scaling (kept off)
and its other settings (warning).

Using it

M1(AutoCmd := Pump1.RunCmd, Feedback := P1_Aux, Overload := P1_OL,
   Interlock := Pump1.Healthy, Permissive := P1Starts.StartPermit, Data := Motor1);
P1_Contactor := M1.Run;