UT_MOTOR_SD — Star-delta starter

Main, star and delta contactors with a timed (or current-confirmed) star stage and
an open-transition dead time, so star and delta are never on together. Modes,
interlocks, protection, faults and restart rules are as UT_MOTOR.

Pins

Always wire the star and delta contactors' NC auxiliaries as a hardware interlock as
well. The block never turns both on, but only the wiring stops a welded contactor.

Record UT_MOTOR_SD_DATA (pin Sd)

Everything else (modes, protections, commands, status) is in the motor record Data.

How it works

• Sequence: star and main together → starTime (or the early change on
  current) → star off → transitionTime → delta. Main stays on throughout, so
  Running and the run-feedback protections follow the main contactor.
• Main confirmed first: with useFeedback the change to delta waits until the
  main contactor's feedback is in: star is held past starTime, and delta is held
  off in the transition, while main is not confirmed. If main never confirms,
  noFeedback acts; if it drops, feedbackLost acts. Delta never comes on with
  main unconfirmed. In simulate the simulated feedback confirms it; without
  useFeedback there is no wait.
• Invalid settings: starTime zero or negative would start the motor straight
  in delta, so the motor is kept off with a fault (wrnConfig, faultCode bit 12
  "Invalid setting"). A negative transitionTime (0 is used), and a starCurrentPct
  that is negative, not a number, or set without a valid fullLoadCurrent (only
  starTime is used) warn (Warning, wrnConfig) and the motor runs.
• The early change on current needs the current to have reached
  starCurrentPct first, so the zero reading before the contactors make is not taken
  as "up to speed". NaN or no fullLoadCurrent: the star time is used.
• Stopping at any point (stop, interlock, trip, Off, OOS) turns all three off at
  once. A start again goes into star, with a full star time. Star never comes on
  within transitionTime of delta going off, so a quick restart after running in
  delta waits for the dead time (the core is held, so no feedback fault is counted).
• After a power-up the first start waits transitionTime.
• With useStarDeltaFb (not in simulate): delta waits for the star aux to show
  open, and a start waits for the delta aux to show open. The changeover
  protection (changeover, bit 9, TRIP · MANUAL by default) trips when star and
  delta both show closed; when delta shows closed in star, or star shows closed in
  delta; when star or delta still shows closed stuck.delay after it went off (a
  welded contactor: delta is withheld, main stays on alone until the trip); or when
  the star or delta aux has not confirmed noFeedback.delay after its contactor came
  on.
• Always a gap: there is always at least one scan with neither star nor delta
  on, even with transitionTime at 0.

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).
This block adds the settings UT_F_TRANSITION_TIME (transition time) · UT_F_STAR_CURRENT (star current %) · UT_F_STAR_NEEDS_FLC (star % needs FLC) · UT_F_STAR_TIME (star time, zero or negative: UT_ST_CONFIG, kept off), and uses UT_F_CHANGEOVER for its changeover protection.
The rows marked (this block) come from its own sequence and show from the scan after it changes.

Using it

Crusher(AutoCmd := Seq.Run3, FeedbackMain := KM_Aux, FeedbackStar := KY_Aux, FeedbackDelta := KD_Aux,
        Overload := Crusher_OL, Current := Crusher_Amps, Interlock := PullCord.Healthy, Data := CrusherData,
        Sd := CrusherSd);
KM := Crusher.Main;
KY := Crusher.Star;
KD := Crusher.Delta;