Electrical System Overview

Control architecture overview for service and troubleshooting.

1. Scope

Use this section to understand the i5 control architecture at a block level.

Use the electrical schematic pack for exact part numbers, terminals, and wire IDs.

⚡ ELECTRICAL HAZARD Isolate and lock off power before opening panels or disconnecting devices.

2. Control architecture (high level)

The machine is built around these layers:

• Power distribution: mains isolator, fusing/breakers, 24 VDC control power.

• Control: PLC CPU plus local/remote I/O.

• Motion: servo drives + servo motors + feedback devices.

• Safety: safety controller/relay, safety I/O, safe drive torque-off.

• Operator interface: HMI panel.

• Networks: Industrial Ethernet / fieldbus linking PLC, drives, I/O, and options.

3. PLC and I/O

PLC

The PLC executes:

• Sequence logic (cycle control, interlocks, alarms).

• Recipe handling and setpoints.

• Diagnostic handling and event logging.

I/O (local and remote)

I/O is typically split between:

• Panel I/O: safety devices, power/aux circuits, critical sensors.

• Remote I/O: zone wiring close to sensors/actuators to reduce cable runs.

For troubleshooting, always confirm:

• Input status changes at the PLC when the device is actuated.

• Output commands change when the function is requested.

• Field voltage is present at the terminal when the output is ON.

4. Motion and servo drives

Servo drives handle axis control for functions such as:

• Tooling movement.

• Conveying/indexing (where servo driven).

• Film feed and tension control (where servo driven).

The PLC coordinates motion via the motion network.

Common drive-related signals:

• Enable / STO status (safety dependent).

• Ready / fault.

• Position feedback and limit/reference conditions.

ℹ NOTE If a safety channel is open, many drives will report “STO active / inhibited” and will not enable.

5. Safety system

The safety system is independent of standard control logic.

Typical safety functions include:

• Emergency stop circuit.

• Guard door and interlock monitoring.

• Safety-rated output control for hazardous motion.

• STO (Safe Torque Off) to servo drives.

Safety device status is usually visible on the HMI.

If safety faults repeat, capture the HMI safety message and the safety device involved.

6. Network communication

Most i5 machines use an Industrial Ethernet backbone.

Typical nodes:

• PLC CPU.

• HMI.

• Servo drives.

• Remote I/O blocks.

• Optional equipment (printer, labeler, vision, modem/router).

Service checks:

• Link LEDs and switch power.

• Device online/offline status in PLC diagnostics.

• IP/device name consistency with the project.

7. Service access (what to capture)

When escalating electrical faults, capture:

• Machine serial number.

• Software version (PLC + HMI).

• Alarm text and timestamp.

• Drive fault codes (if applicable).

• Photos of the relevant terminals and device labels.