During the processing operation, I encountered a problem with the Power Flex 525 VFD suddenly stopping. Despite the PLC and VFD connections being confirmed as functioning properly, the VFD shows no faults. The PLC commands are being received by the VFD, but it is not running and there is no output frequency feedback or current. Can you provide me with any advice or solutions for this issue? Thank you.
Are you able to verify the status of your drive with code b006? This will allow you to ensure the safety of the equipment. Additionally, it is important to review the b012 Control Source to confirm that the start and frequency sources are correctly set. Make sure to also check that the stop jumper is properly installed at Pin 11-1 for optimal performance.
It sounds like you've covered most of the basic troubleshooting steps. One thing you might want to consider is checking the control wire integrity. It's possible that you could be dealing with a broken wire or loose connection that's causing intermittent signal losses. I also suggest looking at the parameters on the PowerFlex drive, mainly the Start/Stop and Reference Source parameters, to make sure they match your command source. I'd recommend running the drive manually from its panel to isolate if the problem is with the drive or the external command. Lastly, a factory reset might be an option to consider if all else fails.
It sounds like you've checked off most of the common troubleshooting steps, but one thing that hasn't been mentioned is the VFD's parameters setting. Even if PLC and VFD connections are correct and there's no fault showing, incorrect parameters in your VFD could prevent it from running. I'd suggest going through the VFD setup again, or performing a factory reset, and then re-entering all the necessary parameters. Don't forget to check the input voltage and motor rating too, just to rule out any outside factors. If the issue persists after all this, it might be a problem with the VFD internal circuitry and you might need to seek professional repair or a replacement unit.
From what you've described, it seems like the issue might be with the control mode on your Power Flex 525. It could be set to Ethernet/IP where it should be set to Unicast for this specific VFD. Another possible cause could be parameter settings. Make sure parameters P036 [Speed Reference] and P041 [Start Source] are set correctly. The control wires should also be checked for any signs of damage. Lastly, also ensure the keypad control is not selected if you are giving commands through the PLC.
It sounds frustrating to deal with that sudden stop, especially if there are no faults showing up. One thing to consider is checking the VFD's parameters to ensure they're set correctly—sometimes, a simple parameter mismatch can cause it to halt without indicating an error. Additionally, verify the wiring and connections for any loose or damaged wires, particularly for the output side and the feedback signals. If everything looks good, it might be worth checking the control signal integrity from the PLC, as signal quality can sometimes affect communication even if it seems fine at first glance. Good luck, and I hope you find the solution soon!
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Answer: Answer: There could be several reasons for this issue, such as parameter settings, communication errors, hardware faults, or software issues.
Answer: Answer: Start by checking the VFD parameters related to control and communication settings, inspect the physical connections for any loose connections, and ensure that the programming in the PLC is correct.
Answer: Answer: You can try resetting the VFD, verifying the communication setup between the PLC and VFD, checking for any alarms in the PLC program, and ensuring that the VFD is receiving the correct signals from the PLC.
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