> Programmable Logic Controller (PLC) help?

Programmable Logic Controller (PLC) help?

Posted at: 2015-01-07 
A stop button circuit should always be 'normally closed', so a fault forces a stop rather than preventing a stop.





Using a normally open allows many possible faults that would disable the stop circuit.







An Emergency Stop system should also always be based on NC contacts, and if there is any possibility at all of an injury being caused by a machine the ES system should be a hardware type separate from the PLC, so PLC problems cannot disable it.





ES systems should also be self-testing to ensure no single fault can disable the ES system.



In machinery that can cause significant injury, the ES system should be 'double loop', using two NC contacts on each switch and two separate circuits, so a complete failure of one ES loop/circuit does not prevent the ES operating.







A normally open contact in to a PLC would be extremely unsafe & could be disabled by bad connections or wiring faults.





It would not be legal on any machine that actually needed an Emergency Stop function.

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If there's a fault, the off switch won't work. Fill in your own scenario of killer robots, rotating shears etc.

Ask yourself how would you complete a circuit if one of the wires was broken or if you didn't have a battery?

Can anyone identify and briefly explain the dangers posed by the 2 following scenarios?





The stop button on a plc motor program has been set up using an XIO instruction as the stop bustton has been installed using a normally open contact. During normal production when the motor is running, a fault develops which causes the fuse supplying 24Vdc to the PLC input card to blow





An E stop is wired as a normally open contact to a PLC input. Over a period of time vibration in the production area has caused the cable between the E stop and the PLC input to become disconnected.





Any help would be much appreciated.