drforsythe
Lifetime Supporting Member
I am having an issue with a PowerFlex 755 system that is controlled by a ControlLogix L61 using digital I/O for monitoring and control. The problem is that twice now, without a known reason, the drive will fail to stop when the RUN signal is removed*. (* I was not in the plant at the times this has happened, so I have not personally measured the input to the drive to see if the signal is actually removed from an electrical standpoint. I was told it was off at the drive. The program definitely removes the command to the output and there is a relay between the plc output and the drive input.) Here are the details of the system:
• Original machine built in 1998
• PLC replacement to L61 in 2007, with minor upgrade in functions in 2012. PLC is at v20.15.
• Original ABB drive replaced with PowerFlex 755 drive in 2018. The above problem has only occurred twice since the drive replacement and both have been in the last 30 days. The machine has been in operation almost every weekday for at least one shift since the drive was installed in 2018. Details of the drive are as follows:
o 302A drive, revision 14.002, uses input line reactor and grounded, shielded drive cable to motor. Motor cable is terminated per manual recommendations and the run is approximately 70 feet.
o 20-HIM-A6 installed in Port 1, revision 2.007, installed on enclosure door.
o LCD module installed in Port 2, revision 3.010, installed on drive.
o 2262C-2R installed in Port 5, revision 1.008
DI 0 is wired to safety circuit and set up as Enable
DI 1 is wired to N.O. relay contact and set up as Run, Edge Detect
RO0 is wired N.O. contact to a PLC DC input and is set up as a Running output
RO1 is wired N.O. contact to a PLC DC input and is set up as a Faulted output
Ai0 is wired to a PLC analog output and is configured for commanded speed
AO0 is wired to a PLC analog input and is configured for speed feedback
AO1 is wired to a PLC analog input and is configured for power feedback
No other I/O on that board is wired or configured
o Safe Torque Off installed in Port 7, revision 1.001 (wired to safety circuit).
o Embedded E/IP in Port 13, revision 1.001 (used for parameter monitoring and setup, not used for control).
o Embedded DeviceLogix in Port 14, revision 2.005 (not used)
Some questions:
Have any of you seen this type of behavior before?
Is it ok to have both a HIM on the drive and an externally-mounted HIM installed?
Would changing the RUN input to LEVEL detect instead of EDGE detect make a difference?
Is it possible for an issue with one of the HIMs to “hold” or initiate a command to run?
I hope to be able to diagnose this myself, but I have not been able to repeat the issue while I am at the plant. I appreciate any responses any of you may have. Thanks in advance.
• Original machine built in 1998
• PLC replacement to L61 in 2007, with minor upgrade in functions in 2012. PLC is at v20.15.
• Original ABB drive replaced with PowerFlex 755 drive in 2018. The above problem has only occurred twice since the drive replacement and both have been in the last 30 days. The machine has been in operation almost every weekday for at least one shift since the drive was installed in 2018. Details of the drive are as follows:
o 302A drive, revision 14.002, uses input line reactor and grounded, shielded drive cable to motor. Motor cable is terminated per manual recommendations and the run is approximately 70 feet.
o 20-HIM-A6 installed in Port 1, revision 2.007, installed on enclosure door.
o LCD module installed in Port 2, revision 3.010, installed on drive.
o 2262C-2R installed in Port 5, revision 1.008
DI 0 is wired to safety circuit and set up as Enable
DI 1 is wired to N.O. relay contact and set up as Run, Edge Detect
RO0 is wired N.O. contact to a PLC DC input and is set up as a Running output
RO1 is wired N.O. contact to a PLC DC input and is set up as a Faulted output
Ai0 is wired to a PLC analog output and is configured for commanded speed
AO0 is wired to a PLC analog input and is configured for speed feedback
AO1 is wired to a PLC analog input and is configured for power feedback
No other I/O on that board is wired or configured
o Safe Torque Off installed in Port 7, revision 1.001 (wired to safety circuit).
o Embedded E/IP in Port 13, revision 1.001 (used for parameter monitoring and setup, not used for control).
o Embedded DeviceLogix in Port 14, revision 2.005 (not used)
Some questions:
Have any of you seen this type of behavior before?
Is it ok to have both a HIM on the drive and an externally-mounted HIM installed?
Would changing the RUN input to LEVEL detect instead of EDGE detect make a difference?
Is it possible for an issue with one of the HIMs to “hold” or initiate a command to run?
I hope to be able to diagnose this myself, but I have not been able to repeat the issue while I am at the plant. I appreciate any responses any of you may have. Thanks in advance.