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    ECL-Process Magnetic Separator Motor Failure: Motor Speed Control Drive Installation

    Uploaded by

    Prakash Kumar
    The document provides an overview of an electrolytic cleaning line process. It discusses how the process uses electrolysis and mechanical cleaning to remove contaminants from metal coils. It then focuses on one part of the process, the magnetic separators, which remove iron fines from the alkali solutions. The magnetic separator motors were having issues with clutch mechanisms that control speed synchronization. To resolve this, an ABB ACS600 drive was installed on one magnetic separator motor to allow electrical speed control and synchronization instead of relying on the faulty clutch. This improved the cleaning efficiency and reduced equipment wear.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    ECL-Process Magnetic Separator Motor Failure: Motor Speed Control Drive Installation

    Uploaded by

    Prakash Kumar
    112 views7 pages
    The document provides an overview of an electrolytic cleaning line process. It discusses how the process uses electrolysis and mechanical cleaning to remove contaminants from metal coils. It then focuses on one part of the process, the magnetic separators, which remove iron fines from the alkali solutions. The magnetic separator motors were having issues with clutch mechanisms that control speed synchronization. To resolve this, an ABB ACS600 drive was installed on one magnetic separator motor to allow electrical speed control and synchronization instead of relying on the faulty clutch. This improved the cleaning efficiency and reduced equipment wear.

    Original Title

    ECL MS-1 MOTOR

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    © © All Rights Reserved

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    The document provides an overview of an electrolytic cleaning line process. It discusses how the process uses electrolysis and mechanical cleaning to remove contaminants from metal coils. It then focuses on one part of the process, the magnetic separators, which remove iron fines from the alkali solutions. The magnetic separator motors were having issues with clutch mechanisms that control speed synchronization. To resolve this, an ABB ACS600 drive was installed on one magnetic separator motor to allow electrical speed control and synchronization instead of relying on the faulty clutch. This improved the cleaning efficiency and reduced equipment wear.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    112 views7 pages

    ECL-Process Magnetic Separator Motor Failure: Motor Speed Control Drive Installation

    Uploaded by

    Prakash Kumar
    The document provides an overview of an electrolytic cleaning line process. It discusses how the process uses electrolysis and mechanical cleaning to remove contaminants from metal coils. It then focuses on one part of the process, the magnetic separators, which remove iron fines from the alkali solutions. The magnetic separator motors were having issues with clutch mechanisms that control speed synchronization. To resolve this, an ABB ACS600 drive was installed on one magnetic separator motor to allow electrical speed control and synchronization instead of relying on the faulty clutch. This improved the cleaning efficiency and reduced equipment wear.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 7

    Electrolytic Cleaning Line Brief Overview

    ECL-Process Magnetic Separator


    motor failure

    Motor Speed Control Drive


    Installation
    Prepared By –
    Mr. Sailendu Das
    Mr. Prakash Kumar
    M&U EM

    Mills & Utilities Electrical Maintenance


    Electrolytic Cleaning Line Brief Overview

    Electrolytic cleaning is a process where mechanical cleaning done by alkali spraying & Brushing by eight
    Brush Rolls. Electrical cleaning is done by electrolysis process with 4 pairs of Electrodes in high
    conductivity electrolytes to clean both Top & Bottom surface of the coils. The entire process is done to
    remove rolling oil, grease, Iron fines, Mill dirt and other undesired materials so as to enhance quality as
    well to reduce heating cycle in Batch Annealing Furnace.

    Mills & Utilities Electrical Maintenance


    What is ECL Process Magnetic Separator?

     At ECL we are having two no's of Magnetic Separator named as MS#1 & MS#2 connected to
    the brushing section 1 & 2 respectively.
     ECL magnetic separator is used for removing iron fines contamination from returned alkali
    solution to the respective tank.
     LENZE Germany make magnetic separator motor is having a complicated clutch and gear
    box arrangement.
     It controls both radial movement of magnetic strips submerged in returned alkali solution and
    axial movement of Shovel for scrubbing stuck up iron particles from magnetic strips to separate
    out from the process.
    Magnetic separator Motor
    Magnetic separator Front View Magnetic separator Side View With Gear Box

    Shovel axial Magnetic Strips Radial RADIAL AXIAL


    Movement Movement MOVEMENT MOVEMENT

    Mills & Utilities Electrical Maintenance


    ECL Process Magnetic Separator motor problem and it’s remedy

    The problem…

    Clutch unit box after removing clutch


    Clutch adjustment knob
    mechanism
     Normally motor speed is adjusted through clutch knob by mechanical during running so
    that one cycle of Shovel axial movement is synced with one step radial movement of
    magnetic strip.
     Incase of speed not in sync then cleaning efficiency is reduced affecting quality as
    unwanted iron fines again induced in the system. This also leads to breakdown of the
    equipment due to wear & tear in gear box as well in the cleaning mechanism.
     Last year magnetic separator#1 (MS#1) efficiency decreased due to wear & tear in
    clutch mechanism. Mechanical tried to adjust the same but failed to do so.
     As this motor is vital for process and imported one, we tried to repair the clutch mechanism
     indigenously with the help of mechanical and succeed in transferring fixed high speed only.
     As the MS#1 mechanism requires desired sync speed we took it as a challenge and after
     Brain storming we decided to provide a ABB ACS600 drive in existing electrical system.
    Mills & Utilities Electrical Maintenance
    ECL Process Magnetic Separator motor problem and it’s remedy
    Continue….
    Solution for the problem…
     In existing system the power for magnetic separator motor was given
    using DOL. There were no provision for speed control of the motor
    electrically.
     After installing the drive, ID run and parameterization done to run the
    motor at desired sync speed and dependency on the clutch stopped.

    Control voltage 415VAC 415VAC

    O/L

    STOP
    from remote (HMI) I> I>

    START K ACS600
    from remote (HMI) K Drive

    K
    A1 O/L O/L

    K
    A2
    M M

    Before After
    Mills & Utilities Electrical Maintenance 5
    ECL Process Magnetic Separator motor problem and it’s remedy
    Continue….

    The following wiring done in the ACS 600 drive so as to give auto reference of 50% speed.
    SET Parameter 64.7 (SLOWDOWN SPEEDREF)  50%
    Reduced speed reference when slow down function is ACS600 NIOC
    activated (i.e. DI5=0).
    Terminal Block X21 Function
    A
    1 VREF Reference voltage 10
    V
    2 GND Max 10mA
    3 AI1+ Speed reference
    0….10V
    4 AI1-
    Terminal Block X22
    A
    2 DI2 ZERO
    3 DI3 START DIR A
    A
    7 +24DVD +24VDC max 100mA
    C
    Terminal Block X27
    1 RO31 Relay
    + 2 RO32 Output 3
    Fault -N
    3 RO33

    24VDC
    A1 B1

    A (3 sec delay time)


    A2
    -

    Mills & Utilities Electrical Maintenance


    Thank You

    Mills & Utilities Electrical Maintenance 7

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