Two cartons released 1.1 seconds apart from line A and line B arrive at a 30 degree merge at the same moment, because line A’s release eye is 1.3 m from the junction and line B’s is 1.7 m, and 0.4 m at 0.28 m/s is 1.4 seconds. The rung that let that happen was … Read more
A 42EF retroreflective eye bolted 150 mm back from the discharge roller of a 1.5 m zone stops a 600 mm carton with 750 mm of zone still behind it, and stops a 1219 mm carton with 131 mm. Move the same eye to 50 mm from the discharge and the first carton overshoots into … Read more
On a 1.5 m zone pitch at 0.28 m/s, a 600 mm carton is invisible to both photo-eyes for 3.2 seconds of its journey between them. An upstream zone whose release permissive is nothing more than “the next eye is clear” will use that window to send a second carton, and the two of them … Read more
Time it with a stopwatch before you type anything into the preset: the longest carton you run, crossing the photo-eye, on the slowest zone. A 1219 mm carton at 0.28 m/s sits on that eye for 4.35 seconds, which is why the 2000 ms that came across with the copied project trips every time the … Read more
F059 Safety Open means both PowerFlex 525 safety inputs are unpowered. Read S1, S2 and S+, tell F059 from F111, and know when the jumper must come out.
Assembly instances, sizes, Comm Format and RPI for a device with no catalogue profile and no EDS file, plus the connection error codes that follow.
A 300 mm tote leaving zone 12 at 0.280 m/s onto a metering belt running 0.513 m/s arrives at the scanner 250 mm behind the tote that left in front of it, and a 600 mm carton on the same two belts arrives 499 mm behind its neighbour. Neither number has a timer in it: … Read more
The E-stop is reset, the safety relay is closed, every one of the twelve PowerFlex 525s on the accumulation line has S1 and S2 at 24 V again and F059 cleared from its display, and nothing moves. No fault on any drive, no alarm on the HMI, twelve zones with a carton on every eye … Read more
The takeaway conveyor’s 25B-D010N104, a 480 V PowerFlex 525 on a 4 kW motor, ran all day and tripped F005 OverVoltage on the first stop of every shift, with the PowerFlex 525 decel time at 2.00 s, b005 [DC Bus Voltage] sitting at 812 V in the fault history, and a belt carrying forty cartons … Read more
Two PowerFlex 525s with 42.50 Hz on both keypads were running the takeaway at 0.500 m/s and the palletiser infeed it hands over to at 0.462 m/s, and every carton that crossed the transfer between them arrived 7.6% closer to the one in front than it had left. A 1219 mm carton that left the … Read more
Bit 0 of the PowerFlex 525 logic command word is Normal Stop, and it has to be sitting at 0 before bit 1 will ever start the drive. That footnote under the table in Appendix D of 520COM-UM001 is behind most of the drives that show a green connection in the I/O tree and still … Read more
Several drives faulting F004 in the same second is a supply problem. How to work out the bus volts, log the sag safely, and read the trace it gives you.