Startup and Commissioning
First Power-Up: A Safe and Methodical Approach
This video emphasizes the crucial importance of a careful and methodical approach when powering up a control panel for the first time. It highlights common mistakes to avoid costly errors.
Prioritize Safety:
Limit personnel present during the initial power-up.
Always wear safety glasses.
Clearly label main power connections with voltage and amperage requirements.
Ensure the main disconnect is OFF.
Open all fuses and circuit breakers.
Engage all emergency stop (E-stop) buttons.
Use Quality Tools: Employ a reliable meter for accurate voltage measurements.
Systematic Voltage Testing:
Check incoming power at the main disconnect.
Test voltage at each fuse, starting with the transformer.
Verify correct transformer output voltage, paying close attention to jumper configurations.
Confirm the 24V power supply is functioning correctly.
Ensure your meter is in the correct AC or DC mode.
Input and Safety Circuit Checks:
Test input devices like buttons.
Confirm the safety circuit is operational before testing outputs.
Troubleshoot any safety circuit issues (e.g., light curtain malfunction).
Output and Signal Testing:
Use temporary code (not forces) to test digital outputs (e.g., indicator lights).
Utilize tools like the PLC Tools SIM ALP2 to simulate and test analog signals.
Integrated System Testing (Example: Robot):
Power up and test integrated systems (e.g., robots), checking emergency stops and safety circuits.
Learn from Mistakes:
The video shares examples of wiring mistakes that could cause significant damage, such as incorrect transformer wiring or improper common wiring for a DC spindle motor.
One Step at a Time: Test each component or circuit individually to simplify troubleshooting.