Problem In Abb Servo Motor Drive

[AB2005]

Dear Friends,

 

I am extremely worried about frequent malfunctioning of ABB Servo Motor Drives installed in the Splicer units of our recently installed second hand Corrugator machine. There are five splicers in machine and each has two same drives. Drive # 1 (Reel Launch) works only when operator splices the next paper reel at the end of paper on running reel. This drive just only stops a running roll and then re-moves during the splice sequence. Drive #2 (Dancer Roll) always works which controls the tension of web whatever the machine speed. PLC gives two different reference signal (0-10v), Speed reference and Torque reference.

There are three PCBs inside a drive;

1) Mother PCB having power circuit and power supply

2) Control & Memory PCB (having back up battery)

3) Connection PCB having terminal blocks for control wiring and a 7 segment displayer.

 

During last one year, both drives in different splicers malfunctioned for 7 times. Most of the time, the problem appeared in second (Memory) PCB that the 7 segment displayer displayed an error but all the related things were ok. If we installed another god drive in the place of that malfunctioned drive, it worked correctly. Only two times the problem appeared in first (power) PCB. The repairing of drive is almost impossible as it has very small electronic components. I had four spare drives which I replaced with four malfunctioned drives and then used the good PCB of that malfunctioned drives for repairing other three malfunctioned drives. This time I don’t have any spare good drive

 

I talked with machine supplier but they did not give me proper answer. ABB has also been stopped the manufacturing of that drive for a long time. Now I am wondering what to do.

Please help me out. I want to know why I have been facing such problem with this drive and what to do now so that no more drive would be malfunctioned.

 

The type of drive and motor is as following;

 

Drive ABB

AC Servo Motor Drive, 12.4KVA, 19A, 400V, 3phase

Type Bivector 535 "18" Ser# 00128-04

 

Servo Motor ABB with Resolver

Type 8C543000V002SN3MB Ser# BS024019

 

Any help would be highly appriciated.

 

[marke]

Hello AB2005

 

Looks as though no one has experience with these drives. I certainly do not.

I would suggest that perhaps it is time to replace them with new drives as they fail.

There is a limited finite life on any of this equipment and it sounds like they have reached their limit.

I would determine a suitable replacement that is currently available and NOT about to be dropped from the cataloaue and carry one or two in stock so that as they ABB drives fail, you can replace them.

 

Best regards,

Mark.

[AB2005]

Hello AB2005

 

Looks as though no one has experience with these drives. I certainly do not.

I would suggest that perhaps it is time to replace them with new drives as they fail.

There is a limited finite life on any of this equipment and it sounds like they have reached their limit.

I would determine a suitable replacement that is currently available and NOT about to be dropped from the cataloaue and carry one or two in stock so that as they ABB drives fail, you can replace them.

 

Best regards,

Mark.

 

Dear Mark

 

I am too thinking so that we need to replace the drive but at this stage of our new project where the machine has started production now, it is very hard to convince the top management to expend a huge amount of money as we have ten drives and ten motors. Every time the maintenance department is burdened that “we have to work with this equipment because we don’t have the budget”

[AB2005]

 

Dear Friends,

 

I am now about to work on an idea but first I want to share my thinking with seniors and experts.

As I mentioned in my first mail, we have two servo motors with drives in each splicers and we have five splicers in our corrugator machine. During normal operation, only one motor for dancer roll work and controls the tension of web. The second motor (2U2) installed at Reel Launch Roller works only when the paper on running reel over and operator splices the paper of next reel with running paper without any stoppage. 2U2 is coupled with that reel launch roller through a timing belt and pullies. During normal operation, paper traveling over this roller, drives it with its speed. PLC calculates the speed of web through an encoder coupled with this roller.

When operator presses the SPLICE button, PLC immediately stops the Reel Launch roller through braking with 2U2 and after completion of splice sequence (1.5sec), PLC sends the 0-10V signal to the drive of 2U2 and it rapidly speeds up exactly at the speed where it stopped. With the stopping and rapidly speeds up of this reel launch roller, system calculates the 0-10V signal for E/P regulator which sends 0-5bars to the brake cylinders of paper reel for a positive splice without tearing off the paper or paper joint.

 

Now I want to replace this servo motor (2U2) and its drive with simple AC motor and inverter. Some detail of drive and motor is as following;

 

DRIVE

Input = 400V, 3phase

Out put = 400V 3phase

12KVA, 18A

 

MOTOR

3Phase AC PM Synchronous Servo motor

V = 347

Const Stall Torque = 30Nm 17.8Arms

Peak Stall Torque = 105Nm 69.3Arms

Speed = 300RPM.

 

My questions are that

 

1) Is it possible to replace this motor and drive with AC motor and inverter?

2) What should be the KW of motor?

3) Can AC motor would stall the running roller immediately if it is running over 2020M/m.

4) Can AC motor would rapidly speed up the roller

 

Under above mentioned conditions, kindly help me so that I would be able to start my working with a positive direction.