Because the system was new, the Quad Plus team began the troubleshooting with a systematic evaluation of the entire system, installation, and programming. We verified that the installation was clean, the motor leads were properly terminated and using the correct motor cables, the cabinet was well-designed, and the Fieldbus (Profibus network) was installed correctly and working well.
When the encoder feedback was evaluated with instrumentation, the presence of switching noise in the encoder signal was observed. We also discovered that the encoder was wired for unipolar operation, which is not wired in the best method for heavy industrial installations. We rewired the encoders and reconfigured the entire system.
The customer was then able to operate the line at 1000 feet per minute without any further issues.