Husnen Rupani:

Hi, I’m Hus. In this video, we’ll recreate the stop-start circuit operation from our previous video, but this time using the Zelio programmable relay on the control circuit Pracbox. Let’s get started.

Before we start programming the Zelio and connecting the circuit, let’s first look at the stop-start operation using the contactor that we’re trying to recreate. This is our previous circuit. Let’s quickly test it. Start, stop, start, emergency stop. When emergency stop is activated, nothing works. Start again. If the active cable disconnects, the circuit stops. Start again. If the stop-wire disconnects, the circuit stops as well and doesn’t re-energize. But if everything is working, then it operates normally.

Let’s now connect the circuit using the Zelio programmable relay. This is the circuit diagram that we will follow. Let’s quickly understand all the components on the circuit. So first we have an emergency stop, which is connected to a 24-volt positive rail. That 24-volt positive rail is also powering the Zelio programmable relay. We have a stop push button. We have a start push button. And all of these three push buttons are going to I1, I2 and I3. The negative or the common connection of the Zelio programmable relay is going to the zero volts. On the other side, we have the contactor coil getting powered through the programmable relay contact, going through our active, which is AC. And one of the contacts of that contactor is then going to power up our pilot lamp. Let’s connect the circuit.

The components that we’ll use for this circuit will be our power supply, our E-stop, stop start, contactor pilot lamp, and the Zelio programmable relay. And we’ll also use this 24-volt DC power supply for our inputs. There are a couple of things that are internally connected, so I’ll mark that off. So, our 24-volt supply is connected directly to the Zelio, and the common terminal is also connected, so we won’t need to do those connections. So now, let’s start by connecting our positive 24-volts to the E-stop. And then from the E-stop, we go to the input I3.

Now we’ll connect our stop push button. We’ll go from after the E-stop to our stop push button and then go to the input I2. Now we’ll connect our start push button. We’ll go from the E-stop to our start push button, which is normally open to I1. Now we’ll connect our relay. We’ll go from active of our AC power supply to the Q1 contact. And then from the other side of the Q1 contact, we’ll go to A1 of our contactor coil and then A2 of the contactor coil will go to neutral.

Now we’ll connect our active wire to one of the contacts of the contactor. From that contact, we’ll go to the pilot lamp and then connect the other side of the pilot lamp to neutral.

Now we have completed our circuit connections. Let’s now write a program for our Zelio programmable relay and then test the circuit.

We’ll program the Zelio programmable relay using the ZelioSoft software. It’s a free download that you can get from the Schneider’s website. When you first start using it this is the screen you will get, or we’ll go to create new program and then choose our module. Our module is SR2B121BBD. There are no other connections to this relay. We’ll choose ladder diagram, and here we have a canvas for our program. First, I will label all our inputs.

Our relay Q1 is here, and I’m going to label that as the contactor. Let’s now place all the components onto the canvas.

We can see that we have an E-stop. Then we go to stop push button, then to the start push button. Let’s now create a holding circuit using our key Q1 contact. Now we have a stop start circuit with a holding. I’ll put a couple of comments, so I know what exactly this program does.

Let’s now run a quick simulation of how this program will operate. The simulation button is hidden behind my picture, but I might move that down here so we can see that, so if I run the simulation, let me close, so it’s not running yet, but we’re in a simulation mode and we will click run. So now our simulation is running. Since our E-stop and stop push buttons are normally closed, we know that I2 and I3 will be engaged all the time till we press it. I1 on the other hand, is our start push button, so when I press it momentarily, the circuit should operate. Let’s try that. If I press it momentarily, we can see that our coil engaged Q1 and Q1 contact turned on, and that’s our holding circuit complete and the circuit is operational. If I momentarily press our stop button, we can see that the Q1 disengages.

Let’s now download this program and see if the circuit works. To download this program to our Zelio programmable relay, I have connected our programming cable from the laptop to the programmable relay. From my software, I will go to transfer just to confirm if our communication is working, and that looks like it’s successful. Let’s now transfer the program, so PC to module, which is download in this case.

Now that we have downloaded our program, I will disconnect our Zelio cable. And we can see here it says that it’s already in run mode. From the input screens, I can see that two and three or inputs two and three are activated, which is our E-stop and our stop button. Let’s now turn on the power supply and test our circuit operation. So first, we’ll test our normal operation, start, stop. While it’s running, we will press the emergency stop, and we can see that our buttons aren’t active anymore. Once we reset, it starts working. If the power cable or the cable going to our control circuit is disconnected, we can see that that also disengages our contactor. If our stop push button is disconnected, our contactor disengages as well. We can see that our circuit is operating as expected.

I hoped you enjoyed this video of stop-start circuit operation using the Zelio programmable relay. If you have any questions or feedback, please feel free to contact us. Thanks for watching.