Commission the variable-speed infeed conveyor drive

What you will build

Work order WO-PS-701. Your site team, Commission the variable-speed infeed conveyor drive.

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 will learn

• Lock out and prove dead, live then dead then live
• Land 33 control conductors from a wiring schedule
• Read the supplied PLC program and match it to your wiring
• Restore power safely, test, and run the FAT

How it goes

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.

Parts in the panel

• Main isolator, 4-pole, 63 A

  Switches all three phases and neutral. The incoming cable lands on 1, 3, 5, 7: those terminals stay live when it is OFF.

• MCB 2-pole, 6 A, C curve: control supply

  Feeds the 24 V power supply with 230 V (L1 and N).

• MCB 3-pole, 10 A, C curve: drive input

  Protects the supply cable of the drive against short circuits. The drive protects the motor against overload.

• Variable frequency drive 2.2 kW, 415 V 3~ in and out, 5.8 A, with STO

  Mains in on L1 L2 L3 at the top, motor out on U V W at the bottom. Run forward DI1, run reverse DI2, reset DI3, torque off STO1 and STO2 (both need 24 V), speed reference AI1 (0 to 10 V), fault relay RC-RNO. Settings are loaded: 3 s up, 4 s down.

• Power supply 230 V AC to 24 V DC, 5 A

  Its 0 V (−) is bonded to PE at the factory, so 0 V and earth are the same potential.

• PLC: compact CPU, 8 DI / 6 DQ, 24 V DC

  Inputs I0.0-I0.7 are PNP: 24 V on the terminal turns the input on, with 1M at 0 V. Outputs Q0.0-Q0.5 source 24 V from 3L+.

• Terminal strip X2: 24 V DC distribution

  Positions 1-6 are bridged +24 V, 7-12 are bridged 0 V. Top and bottom of each position are the same point.

• Terminal strip X1: motor

  The motor cable from the plant lands here.

• Terminal strip X3: E-STOP second channel junction, 3 terminals bridged

  Takes the E-STOP's second contact (21-22) and splits it to the drive's STO2 and to the PLC input I0.3.

• PE bar

  Protective earth, bonded to the incoming supply's earth.

• Push button FWD, green, 1 NO

• Push button REV, green, 1 NO

• Push button STOP, red, 1 NC

• Emergency stop, 2 NC, twist to release

  Contact 11-12 feeds STO1 and 21-22 feeds STO2: two independent channels. Contact 21-22 also tells the PLC.

• Speed potentiometer 10 kOhm, 0 to 100 %

  Between the drive's 10V and AGND, with the wiper on AI1: 0 to 10 V is 0 to 100 % speed.

• Pilot lamp green 24 V: RUNNING

• Pilot lamp amber 24 V: DRIVE FAULT

• Motor 3-phase 1.5 kW, 415 V, 3.6 A, driving infeed conveyor IC-701

Questions

Is it free?

Yes. The lab is free to use with a free account. There is nothing to buy to open this scenario.

Do I need to install anything?

No. It runs in your browser with a 3D panel, a circuit drawing, a meter and a PLC.

What will I do in Panel Lab 7?

You wire a control panel, then check your work against an acceptance test.

How long does it take?

Plan for one sitting. You can stop and come back.

Do I need experience?

No. Each work order says what to do step by step, and hints are there if you get stuck.