Commission the variable-speed infeed conveyor drive

The brief

Work order

WO-PS-701

Job

Commission the variable-speed infeed conveyor drive

Difficulty

Advanced

Type of work

Commissioning

Detail

33 wires, lockout, meter checks and a PLC program

Harbour Spice Co.. Infeed conveyor IC-701 (motor 1.5 kW, 415 V, 3.6 A) needs an adjustable speed from a potentiometer on the door, with FWD and REV buttons through the PLC. The drive V1 (2.2 kW) is mounted in the panel with its settings loaded: 3 s up, 4 s down, 0 to 10 V on AI1, safe torque off enabled. The panel +D701 has arrived with the supply to F2, the 24 V supply and the PLC supply wired. The drive wiring is yours.

What you do

1. Lock out the panel at the main isolator Q1: switch OFF, apply your lock and your tag.
2. Prove it dead with the meter, live-dead-live. Include the drive's DC bus test points DC+ and DC-: on a real drive the capacitors stay charged for minutes after switch-off, so read the discharge time on the drive's plate and measure before you touch.
3. Wire the 33 conductors of the wiring schedule. Power first: F2 goes to the drive's L1 L2 L3 and the motor comes off U V W, never the other way round. Protective earth to both PE terminals. The drive's own earth leakage is high, so the earth connection is fixed and sound.
4. There is no contactor in the motor cable, by design. A normal stop is the run command going away so that the drive ramps down. The E-STOP removes torque through STO1 (S2 11-12) and STO2 (S2 21-22): two separate channels.
5. The PLC gives run forward (DI1) and run reverse (DI2). The speed is not in the program: RV1 gives the drive 0 to 10 V on AI1 (10V → RV1 3, RV1 2 → AI1, RV1 1 → AGND). The drive's fault relay goes to I0.4.
6. Restore power: tick the checklist, remove your tag and lock, switch Q1 ON, put the PLC in RUN.
7. Test: set the speed with RV1, run FWD and REV, STOP, the E-STOP and a drive fault (use TEST on the drive, then RESET). Then run the FAT.

What the test checks

The factory acceptance test is marked against the panel you built. The level sets out:

• 33 conductors in the wiring schedule
• 7 dead checks before you touch the panel

In this lab

• Lock out and prove dead, live-dead-live
• Wire the backplate from the schematic
• Meter, tester, clamp and insulation tester