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Intermediate20 min readIndustrial Manufacturing

Red Lion Controls Structured Text for Motor Control

Learn Structured Text programming for Motor Control using Red Lion Controls Crimson 3.2. Includes code examples, best practices, and step-by-step implementation guide for Industrial Manufacturing applications.

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Platform
Crimson 3.2
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Complexity
Beginner to Intermediate
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Project Duration
1-3 weeks

Implementing Structured Text for Motor Control using Red Lion Controls Crimson 3.2 requires a documented design, applicable standards, and project-specific acceptance criteria. This guide organizes practical checks for code structure, diagnostics, testing, and maintenance.

The example references FlexEdge DA10D-family terminology, but model capabilities vary. Verify the controller manual, the installed Crimson 3.2 version, and any applicable machinery, process, electrical, or functional-safety requirements for the actual project.

Best practices for Motor Control encompass multiple dimensions: proper handling of 5 sensor types, safe control of 5 different actuators, managing soft start implementation, and ensuring compliance with relevant industry standards. The Structured Text approach, when properly implemented, provides powerful for complex logic and excellent code reusability, both critical for beginner to intermediate projects.

This guide presents a reviewable approach to Red Lion Controls Structured Text programming for Motor Control, covering code organization, documentation, test procedures, and maintenance handoff. The sample logic is educational and must be compiled, simulated, peer-reviewed, and tested against the project's acceptance criteria before use on equipment.

Red Lion Controls Crimson 3.2 for Motor Control

Crimson 3.2 is a programming environment associated with Red Lion Controls controller families such as FlexEdge DA10D, FlexEdge DA30D, FlexEdge DA50D. This guide uses Structured Text terminology from the supplied guide dataset, but controller capabilities and language support can change by model, firmware, software edition, and license.

Verify Before You Start:

  • The selected controller supports the required Structured Text constructs

  • The project version matches the installed Crimson 3.2 release

  • Required communications, motion, safety, and simulation options are licensed

  • Firmware and device-description files are compatible with the project

  • The vendor manuals used for the design match the exact hardware revision


Application Planning:

For a Motor Control exercise, map the required inputs and outputs before writing logic. The example considers 5 sensor types, including Current sensors, Vibration sensors, Temperature sensors, and 5 actuator types.

Control Equipment for Motor Control:

  • Motor control centers (MCCs)

  • AC induction motors (NEMA/IEC frame)

  • Synchronous motors for high efficiency

  • DC motors for precise speed control


Controller-family references used in this guide include:

  • FlexEdge DA10D: Confirm CPU, I/O, memory, communications, and Structured Text support in the current selection guide

  • FlexEdge DA30D: Confirm CPU, I/O, memory, communications, and Structured Text support in the current selection guide

  • FlexEdge DA50D: Confirm CPU, I/O, memory, communications, and Structured Text support in the current selection guide

  • Graphite HMI: Confirm CPU, I/O, memory, communications, and Structured Text support in the current selection guide


Hardware Selection Checklist:

  • Count local and remote I/O, including planned expansion

  • Measure the required task and communications update rates

  • Identify memory, data-retention, diagnostics, and cybersecurity requirements

  • Treat safety functions as a separate, standards-led design activity

  • Confirm lifecycle status, regional availability, licensing, and support


Source and Validation Note:

This page does not represent a vendor certification or a hardware acceptance test. Use current Red Lion Controls manuals, release notes, and safety documentation as the authority for product-specific behavior. Validate adapted logic in a simulator or isolated test setup before connecting it to equipment.

Investment Considerations:

For Motor Control projects, compare hardware, software licensing, training, engineering, test equipment, commissioning, spares, and ongoing support. Obtain current pricing and lifecycle information directly from the vendor or an authorized regional supplier.

Understanding Structured Text for Motor Control

Structured Text (ST) is a high-level, text-based programming language defined in IEC 61131-3. It resembles Pascal and provides powerful constructs for complex algorithms, calculations, and data manipulation.

Execution Model:

Code executes sequentially from top to bottom within each program unit. Variables maintain state between scan cycles unless explicitly reset.

Core Advantages for Motor Control:

  • Powerful for complex logic: Critical for Motor Control when handling beginner to intermediate control logic

  • Excellent code reusability: Critical for Motor Control when handling beginner to intermediate control logic

  • Compact code representation: Critical for Motor Control when handling beginner to intermediate control logic

  • Good for algorithms and calculations: Critical for Motor Control when handling beginner to intermediate control logic

  • Familiar to software developers: Critical for Motor Control when handling beginner to intermediate control logic


Why Structured Text Fits Motor Control:

Motor Control systems in Industrial Manufacturing typically involve:

  • Sensors: Current transformers for motor current monitoring, RTD or thermocouple for motor winding temperature, Vibration sensors for bearing monitoring

  • Actuators: Contactors for direct-on-line starting, Soft starters for reduced voltage starting, Variable frequency drives for speed control

  • Complexity: Beginner to Intermediate with challenges including Managing starting current within supply limits


Programming Fundamentals in Structured Text:

Variables:
- declaration: VAR / VAR_INPUT / VAR_OUTPUT / VAR_IN_OUT / VAR_GLOBAL sections
- initialization: Variables can be initialized at declaration: Counter : INT := 0;
- constants: VAR CONSTANT section for read-only values

Operators:
- arithmetic: + - * / MOD (modulo)
- comparison: = <> < > <= >=
- logical: AND OR XOR NOT

ControlStructures:
- if: IF condition THEN statements; ELSIF condition THEN statements; ELSE statements; END_IF;
- case: CASE selector OF value1: statements; value2: statements; ELSE statements; END_CASE;
- for: FOR index := start TO end BY step DO statements; END_FOR;

Best Practices for Structured Text:

  • Use meaningful variable names with consistent naming conventions

  • Initialize all variables at declaration to prevent undefined behavior

  • Use enumerated types for state machines instead of magic numbers

  • Break complex expressions into intermediate variables for readability

  • Use functions for reusable calculations and function blocks for stateful operations


Common Mistakes to Avoid:

  • Using = instead of := for assignment (= is comparison)

  • Forgetting semicolons at end of statements

  • Integer division truncation - use REAL for decimal results

  • Infinite loops from incorrect WHILE/REPEAT conditions


Typical Applications:

1. PID control: Directly applicable to Motor Control
2. Recipe management: Related control patterns
3. Statistical calculations: Related control patterns
4. Data logging: Related control patterns

Understanding these fundamentals prepares you to implement effective Structured Text solutions for Motor Control using Red Lion Controls Crimson 3.2.

Implementing Motor Control with Structured Text

Motor control systems use PLCs to start, stop, and regulate electric motors in industrial applications. These systems provide protection, speed control, and coordination for motors ranging from fractional horsepower to thousands of horsepower.

This walkthrough demonstrates practical implementation using Red Lion Controls Crimson 3.2 and Structured Text programming.

System Requirements:

A typical Motor Control implementation includes:

Input Devices (Sensors):
1. Current transformers for motor current monitoring: Critical for monitoring system state
2. RTD or thermocouple for motor winding temperature: Critical for monitoring system state
3. Vibration sensors for bearing monitoring: Critical for monitoring system state
4. Speed encoders or tachometers: Critical for monitoring system state
5. Torque sensors for load monitoring: Critical for monitoring system state

Output Devices (Actuators):
1. Contactors for direct-on-line starting: Primary control output
2. Soft starters for reduced voltage starting: Supporting control function
3. Variable frequency drives for speed control: Supporting control function
4. Brakes (mechanical or dynamic): Supporting control function
5. Starters (star-delta, autotransformer): Supporting control function

Control Equipment:

  • Motor control centers (MCCs)

  • AC induction motors (NEMA/IEC frame)

  • Synchronous motors for high efficiency

  • DC motors for precise speed control


Control Strategies for Motor Control:

1. Primary Control: Industrial motor control using PLCs for start/stop, speed control, and protection of electric motors.
2. Safety Interlocks: Preventing Soft start implementation
3. Error Recovery: Handling Overload protection

Implementation Steps:

Step 1: Calculate motor starting current and verify supply capacity

In Crimson 3.2, calculate motor starting current and verify supply capacity.

Step 2: Select starting method based on motor size and load requirements

In Crimson 3.2, select starting method based on motor size and load requirements.

Step 3: Configure motor protection with correct thermal curve

In Crimson 3.2, configure motor protection with correct thermal curve.

Step 4: Implement control logic for start/stop with proper interlocks

In Crimson 3.2, implement control logic for start/stop with proper interlocks.

Step 5: Add speed control loop if VFD is used

In Crimson 3.2, add speed control loop if vfd is used.

Step 6: Configure acceleration and deceleration ramps

In Crimson 3.2, configure acceleration and deceleration ramps.


Red Lion Controls Function Design:

Crimson projects use reusable 'programs' (Crimson's unit of logic code) with parameters. Library management is more basic than in mainstream IEC ecosystems; OEMs typically maintain private project templates and copy-adapt rather than importing shared libraries. FlexEdge DA's IEC PLC portion follows standard IEC 61131-3 function-block reuse patterns.

Common Challenges and Solutions:

1. Managing starting current within supply limits

  • Solution: Structured Text addresses this through Powerful for complex logic.


2. Coordinating acceleration with driven load requirements

  • Solution: Structured Text addresses this through Excellent code reusability.


3. Protecting motors from frequent starting (thermal cycling)

  • Solution: Structured Text addresses this through Compact code representation.


4. Handling regenerative energy during deceleration

  • Solution: Structured Text addresses this through Good for algorithms and calculations.


Safety Considerations:

  • Proper machine guarding for rotating equipment

  • Emergency stop functionality with safe torque off

  • Lockout/tagout provisions for maintenance

  • Arc flash protection and PPE requirements

  • Proper grounding and bonding


Performance Metrics:

  • Task and I/O timing: Record minimum, average, and maximum values under a defined test load

  • Accuracy: Define an acceptable tolerance and compare it with calibrated reference measurements

  • Throughput: Count completed cycles over a fixed interval and record rejected or incomplete cycles

  • Fault response: Measure detection, safe-state, alarm, and recovery behavior for each test case

  • Resource use: Record memory, communications load, and diagnostic-buffer behavior

Red Lion Controls Diagnostic Tools:

Crimson 3.2 integrated debugger with tag monitoring and simulation mode,Built-in data-logging diagnostics with local and network-export options,Integrated communication analyzer for every supported driver (300+ protocols),FlexEdge webserver for remote HMI mirroring and device-level diagnostics,Visual logic debugger for Crimson logic (event-driven rather than scan-based),Real-time tag watch with filtering and grouping,Database import/export for tag-database migration and diffing,N-Tron managed switch diagnostics integrated with FlexEdge ecosystem,Red Lion US-based technical support,Crimson help system with protocol-specific driver documentation inline

Use the monitoring and diagnostic functions available in your Crimson 3.2 version, and record the software, firmware, hardware, workload, and test procedure with every result.

Red Lion Controls Structured Text Example for Motor Control

Illustrative Structured Text example for Motor Control using Red Lion Controls terminology. Adapt the syntax to your Crimson 3.2 release, compile it, and verify it in an isolated test environment before use on equipment.

(* Red Lion Controls Crimson 3.2 - Motor Control Control *)
(* Structured Text Implementation for Industrial Manufacturing *)
(* Red Lion projects use Crimson's tag database with typed tags and descr *)

PROGRAM PRG_MOTOR_CONTROL_Control

VAR
    (* State Machine Variables *)
    eState : E_MOTOR_CONTROL_States := IDLE;
    bEnable : BOOL := FALSE;
    bFaultActive : BOOL := FALSE;

    (* Timers *)
    tonDebounce : TON;
    tonProcessTimeout : TON;
    tonFeedbackCheck : TON;

    (* Counters *)
    ctuCycleCounter : CTU;

    (* Process Variables *)
    rCurrentsensors : REAL := 0.0;
    rMotorstarters : REAL := 0.0;
    rSetpoint : REAL := 100.0; (* Illustrative value; replace with a reviewed requirement *)
END_VAR

VAR CONSTANT
    (* Industrial Manufacturing Process Parameters *)
    C_DEBOUNCE_TIME : TIME := T#500MS;
    C_PROCESS_TIMEOUT : TIME := T#30S; (* Illustrative value; verify for the process *)
    C_BATCH_SIZE : INT := 50; (* Illustrative value; replace with a reviewed requirement *)
END_VAR

(* Input Conditioning *)
tonDebounce(IN := bStartButton, PT := C_DEBOUNCE_TIME);
bEnable := tonDebounce.Q AND NOT bEmergencyStop AND bSafetyOK;

(* Main State Machine - Pattern: State machines in Crimson are typically  *)
CASE eState OF
    IDLE:
        rMotorstarters := 0.0;
        ctuCycleCounter(RESET := TRUE);
        IF bEnable AND rCurrentsensors > 0.0 THEN
            eState := STARTING;
        END_IF;

    STARTING:
        (* Ramp up output - Gradual start *)
        rMotorstarters := MIN(rMotorstarters + 5.0, rSetpoint);
        IF rMotorstarters >= rSetpoint THEN
            eState := RUNNING;
        END_IF;

    RUNNING:
        (* Motor Control active - Motor control systems use PLCs to start, stop, and *)
        tonProcessTimeout(IN := TRUE, PT := C_PROCESS_TIMEOUT);
        ctuCycleCounter(CU := bCyclePulse, PV := C_BATCH_SIZE);

        IF ctuCycleCounter.Q THEN
            eState := COMPLETE;
        ELSIF tonProcessTimeout.Q THEN
            bFaultActive := TRUE;
            eState := FAULT;
        END_IF;

    COMPLETE:
        rMotorstarters := 0.0;
        (* Log production data - Data logging uses Crimson's built-in Logger — configured periodic or event-triggered records written to local SD card, networked SFTP, or cloud endpoints in CSV or JSON format. Integration with database historians is supported through standard protocols. For FlexEdge, integration with N-Tron switches and the wider Red Lion data ecosystem supports site-wide aggregation. *)
        eState := IDLE;

    FAULT:
        rMotorstarters := 0.0;
        (* Alarm handling uses Crimson's built-in Alarm Manager — configured alarm conditions with severity, message text, logging, and HMI display behaviour. The alarm engine handles detection, acknowledgement, and history without custom code. Integration with email, SMS, or external alarm aggregators is configured via Crimson's notification features. *)
        IF bFaultReset AND NOT bEmergencyStop THEN
            bFaultActive := FALSE;
            eState := IDLE;
        END_IF;
END_CASE;

(* Safety Override - Always executes *)
IF bEmergencyStop OR NOT bSafetyOK THEN
    rMotorstarters := 0.0;
    eState := FAULT;
    bFaultActive := TRUE;
END_IF;

END_PROGRAM

Code Explanation:

  • 1.Enumerated state machine (State machines in Crimson are typically implemented using tag-based state variables with event-driven logic checking the state on each event. The event-driven model maps naturally to state-transition logic. FlexEdge DA's IEC PLC portion uses standard CASE-based state machines in ST when PLC-side sequencing is required.) for clear Motor Control sequence control
  • 2.Constants use clearly marked illustrative values that must be replaced with reviewed project requirements
  • 3.Input conditioning with debounce timer prevents false triggers in industrial environment
  • 4.STARTING state implements soft-start ramp - prevents mechanical shock
  • 5.Process timeout detection flags a possible stuck condition for investigation
  • 6.The final override illustrates a software permissive only; it is not a safety-rated function and must not replace a validated safety system

Best Practices

  • ✓Follow Red Lion Controls naming conventions: Red Lion projects use Crimson's tag database with typed tags and descriptive nam
  • ✓Red Lion Controls function design: Crimson projects use reusable 'programs' (Crimson's unit of logic code) with par
  • ✓Data organization: Crimson tag databases hold typed tags with scope (Global, Alarm, Report, etc.) a
  • ✓Structured Text: Use meaningful variable names with consistent naming conventions
  • ✓Structured Text: Initialize all variables at declaration to prevent undefined behavior
  • ✓Structured Text: Use enumerated types for state machines instead of magic numbers
  • ✓Motor Control: Verify motor running with current or speed feedback, not just contactor status
  • ✓Motor Control: Implement minimum off time between starts for motor cooling
  • ✓Motor Control: Add phase loss and phase reversal protection
  • ✓Debug with Crimson 3.2: Use Crimson 3.2's simulation mode to test HMI and logic before deployi
  • ✓Safety: Proper machine guarding for rotating equipment
  • ✓Use a compatible simulator or isolated test rig to test Motor Control logic before deployment

Common Pitfalls to Avoid

  • ⚠Structured Text: Using = instead of := for assignment (= is comparison)
  • ⚠Structured Text: Forgetting semicolons at end of statements
  • ⚠Structured Text: Integer division truncation - use REAL for decimal results
  • ⚠Red Lion Controls common error: Crimson version-to-firmware compatibility issues after hardware firmware upgrade
  • ⚠Motor Control: Managing starting current within supply limits
  • ⚠Motor Control: Coordinating acceleration with driven load requirements
  • ⚠Neglecting to validate Current transformers for motor current monitoring leads to control errors
  • ⚠Insufficient comments make Structured Text programs unmaintainable over time

Related Certifications

🏆Red Lion Crimson Certified Engineer
🏆Red Lion Specialist Training
🏆Advanced Red Lion Controls Programming Certification

Applying Structured Text to Motor Control using Red Lion Controls Crimson 3.2 requires understanding the platform, the process, and the project's acceptance criteria. This guide has covered implementation structure, an illustrative code example, verification practices, and common pitfalls for a beginner to intermediate Motor Control exercise.

Use the practices outlined here to create a design that can be reviewed and tested. Define performance targets in the project requirements and confirm them with repeatable measurements.

Next Steps:

1. Check Sources: Read the current Crimson 3.2 help, controller manual, release notes, and relevant standards
2. Practice Safely: Adapt the example in a simulator or isolated training setup
3. Review: Have the I/O map, state behavior, faults, and recovery steps reviewed
4. Test: Record normal, boundary, fault, restart, and communications test results

Structured Text Foundation:

Structured Text (ST) is a high-level, text-based programming language defined in IEC 61131-3. It resembles Pascal and provides powerful constructs for...

Project duration depends on scope, reviews, hardware availability, software and firmware versions, testing, commissioning, and site constraints. Remember: Verify motor running with current or speed feedback, not just contactor status

For further learning, explore related topics including Recipe management, Fan systems, and Red Lion Controls platform-specific features for Motor Control optimization.