Greetings everyone, I am new to this community and eager to expand my knowledge in controls. I recently joined a new manufacturing plant and encountered issues with AB ultra3000i servo drives failing on one of the assembly lines I oversee. These drives are failing frequently throughout the year, leading to costly replacements. The assembly line in question is equipped with light curtains that are being unintentionally disrupted during servo movements, resulting in premature drive failures. Additionally, I observed several concerning factors: 1. The drive enclosure is generating significant heat, with non-functioning vents and fans. 2. The panel houses 9 bowl feeder controllers, possibly contributing to electrical noise. 3. Absence of AC noise filters raises concerns about electrical interference. 4. There is a suggestion that the light curtains are drawing power directly from the 460V instead of using a 24V signal for stop commands. Seeking advice on resolving these issues and improving the efficiency of the assembly line. Any guidance or recommendations would be greatly appreciated.
If the light curtains are cutting off the 480V power supply to the servo system, it could lead to premature damage. We had a customer who experienced frequent losses of powerflex 40s due to this issue. The Ultra model has two sets of power inputs: L1, L2, and L3 should be the only ones affected by safety measures, while L1Aux and L2/NAux should remain operational to prevent power loss.
Robertmee mentioned that if the light curtains are cutting power to the 480V line side of the servo, it can lead to a decrease in its lifespan. A similar issue was experienced by a customer using PowerFlex 40s, resulting in frequent failures. The Ultra model has two sets of power inputs, with only L1, L2, and L3 supposed to lose power during safety operations. L1Aux and L2/NAux should remain powered. It seems likely that this is the issue. What other options are available besides cutting power to the line side? I will verify tomorrow that the other inputs are still receiving power.
Robofrog mentioned a possible solution to the issue at hand: considering an alternative to shutting down the line side. Tomorrow, I will verify that the other inputs are still receiving power. The Ultra3000 drives are quite aged and lack the safety features found in more modern drives. The aging drives are likely facing stress on the charge capacitors due to frequent power cycles, potentially leading to their failure. It is important to inspect the actual contactor connected to the line side to determine the power it is losing. It may be beneficial to explore the possibility of bringing the drive to a safe stop before releasing the contactor, although this may not fully resolve the problem given the circumstances. While it has been some time since I worked with Ultras, it is hoped that someone with more recent experience will offer their insight.
In a discussion, robertmee expressed uncertainty regarding the older Ultra3000 drives lacking modern electronic safe off features. He noted that the drive's age may have caused stress on the charge capacitors from frequent power cycles, potentially leading to failure. Investigation into the contactor on the line side is recommended to determine power drops. While bringing the drive to a safe stop before releasing the contactor could be beneficial, it may not be enough to resolve the issue completely. It has been some time since dealing with Ultras, so input from someone with more recent experience is welcome. It has been confirmed that the 480V is dropped to L1/2/3 but the auxiliary power remains active. Changes in the setup, including enclosing a line and adding light curtains, may have contributed to the issue. Feedback from AB suggests that the drives are being powered on and off too frequently.
Do temperature readings indicate that they are moderately warm? Maintaining optimal temperatures is crucial for the functionality of electronic devices. Our storage drives are equipped with air conditioning units to prevent overheating. In case of malfunctions, do error codes appear?
Welcome to the community! It sounds like you are dealing with a complex issue. From what you've described, the heat buildup in the drive enclosure could be a significant player in the frequent breakdowns - the consistently high temperatures might be pushing the servo drives beyond their designed operating conditions. Attending to the ineffective vents and fans should be your first step. Reducing electrical noise is also key, so look into installing AC noise filters, and considering the re-routing of your light curtains' power source might prove beneficial. This could involve using a relay to switch them on and off using a 24V signal rather than using a directly wired line. From my experience, cleanliness of the area is often overlooked as well, dust and debris can cause overheating and electrical interference issues. Hope you find this useful, and don't hesitate to ask more - we're all here to help each other!
Welcome to the community! It sounds like you're dealing with a complex situation. For the overheating drives, I’d recommend checking the overall ventilation design in the enclosure. If the fans aren’t functioning, that alone could be causing significant heat build-up. Regarding the light curtains, likely drawing power from the wrong source could definitely lead to malfunctions; switching to a proper 24V supply for the stop commands should help stabilize that aspect. Additionally, implementing AC noise filters could reduce the interference from your bowl feeder controllers, potentially giving the drives a more stable operating environment. Have you also considered the positioning of the light curtains during servo movements? It's important they are aligned correctly to avoid unnecessary disruption. Hope this helps, and good luck with troubleshooting!
Welcome to the community! It sounds like you're facing quite a challenge with the servo drives. First off, addressing the heat problem is crucial; make sure to check if you can fix the vents and fans to allow proper airflow — perhaps even consider relocating the drives if overheating is a consistent issue. As for electrical noise, using properly shielded cables and AC noise filters can really help minimize interference, especially with the number of controllers you're managing in that panel. It might also be worth reviewing your light curtain setup; powering them from the 24V might prevent more stress on the system and help with drive failures. Good luck, and it’d be great to hear how things progress!
Hey there! It sounds like you're dealing with quite a few challenging issues. First off, it would be wise to look into addressing the heat problem by ensuring the enclosure is well-ventilated—maybe even consider adding external cooling solutions if the fans aren’t cutting it. For the electrical noise, incorporating AC noise filters could definitely help reduce interference impacting your servo drives, and drawing power for the light curtains via a more suitable method could prevent potential overloads or spikes. It might also be worth examining the setup and configuration of your bowl feeders to see if they can be adjusted to minimize noise. Have you thought about conducting a thorough audit of the entire electrical system to identify other hidden issues? That could provide some useful insights! Good luck, and keep us updated on your progress!
Welcome to the community! It sounds like you're dealing with quite a few challenges with those servo drives. Given the heat issue, I'd suggest checking the enclosure’s airflow and possibly redesigning it to enhance cooling, since that alone could mitigate some drive failures. For the electrical noise, using ferrite beads or shielded cables might help reduce interference from the bowl feeders. Regarding the light curtains, it's definitely worth investigating their power supply—running them directly off 460V sounds risky. Switching to a more appropriate 24V setup not only could improve reliability but also might solve some of those disruption issues. Consider involving a controls engineer to conduct a thorough assessment as well. Best of luck with your troubleshooting!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: Answer: The drives are failing due to disruptions to the light curtains during servo movements, generating premature failures.
Answer: Answer: Factors include the drive enclosure generating excessive heat, non-functioning vents/fans, electrical noise from multiple bowl feeder controllers, absence of AC noise filters, and potential direct power draw for light curtains.
Answer: Answer: To improve efficiency and prevent failures, consider addressing ventilation issues in the drive enclosure, reducing electrical noise from multiple controllers, installing AC noise filters, and ensuring light curtains use a 24V signal for stop commands instead of drawing power directly from 460V.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.