Level 1 — Guided Motor Starter

Field Wiring

Lock out the main disconnect first (panel below). Then click one terminal, then another, to install a wire.

100%

WORK ORDER Commission the M1 transfer-pump starter. Lock out and verify the panel dead, land the 3-wire control circuit, restore power, program the PLC, switch it to RUN, and bring the pump online. Job CT-101

Main Disconnect — 3-Phase Line In

3-phase power IN → factory-fed to the motor branch. Its load side also feeds control transformer T1 (mounted above this panel), which supplies the 24 V supply’s 120 V control power.

🔒 Lockable disconnect — the LOTO energy-isolating device (OSHA 1910.147). Lock this out to service the machine; a Stop button, the E-Stop, or the contactor is never the means of de-energization.

Nameplate: 600 V, 30 A, 3Φ · panel SCCR 5 kA · per NEC 409.110 marking

24 VDC Power Supply

L / N = 120 V control power X1 / X2, pre-wired from control transformer T1 above this panel. Opening the main disconnect removes it.

Start PB — NO

Stop PB — NC

Overload — NC

95–96 = NC (wire these) · 97–98 = NO (spare)

PLC — Allen-Bradley MicroLogix 1400

E-Stop — NC Safety Contact

21–22 = NC safety contact · hardwired in series with the coil

Emergency stop pushbutton with normally-closed safety contact

Contactor line, coil, auxiliary, and load terminals

Contactor M1

T1–T2–T3 (load) → wire to motor T1–T2–T3

3 Phase Motor

STOPPED

Motor receives 3-phase power from contactor M1 · PE = green/yellow equipment ground bonds the frame

Machine — M1 Transfer Pump

The starter you wire drives this pump. Bring the motor online to fill the day tank.

M1 transfer pump stopped — clear pipes, no flow to the day tank

Ladder Logic Editor

Build the program yourself. The PLC executes the rungs from top to bottom.

PLC MODE PROGRAM

Instruction palette Select a rung first, then add an instruction.

Tag	Address	Type
Start_PB	I:0/0	Input
Stop_PB	I:0/1	Input
Motor_OL	I:0/2	Input
Motor_Run	O:0/0	Output

Scan Count0

Last Scan Time0.0 ms

I/O Status

Address	Tag	State
I:0/0	Start_PB	OFF
I:0/1	Stop_PB	ON
I:0/2	Motor_OL	ON
O:0/0	Motor_Run	OFF

Goal

Switch the PLC to RUN, then press Start. The output should seal itself in. Press Stop or trip the overload to drop the motor out.

Safety Circuit

The E-Stop is a normally-closed contact hardwired in series with the contactor coil (O:0/0 → E-Stop 21, E-Stop 22 → M1 A1). Pressing it drops the contactor no matter what the PLC program is doing — the safety stop does not depend on the ladder logic. Twist to release, then Start again to recover.

Training simplification: in this simulator, releasing the E-Stop does not restart the motor — a new Start press is needed. On a real machine the PLC program can only drop its run seal if the PLC can see the E-Stop (a second E-Stop contact wired to a PLC input, or a safety relay). This drawing leaves that connection out.

Complete Level 1

When your machine operates correctly, check your completion requirements.

Finish the wiring and successfully run the motor before completing this level.