ABB DCS800 Case Notes
Case notes
New ABB DCS800 drive debuts in paper
mill’s slitter-rewinder
ABB drives increase production and improve roll quality and uptime; eliminate mill shutdowns
A vital part of any paper mill is the slitter-rewinder
– responsible for unwinding huge, newly made
rolls from the main papermaking machine, cutting
them into smaller sections, and rewinding them as
more manageable rolls for distribution. To increase
productivity and efciency, one leading paper mill
facility in the Southeastern United States turned
to SDS, Inc, a U.S.-based systems integrator, to
rebuild its slitter-rewinder and incorporate the latest
technology.
SDS provided a cost-effective solution that utilizes
existing motor and components, integrating ABB’s
state-of-the-art ACS800 AC Drives with its new
DCS800 Drives – the most advanced DC drive
of its kind. The drive hardware was rounded out
with SDS’s Intelli-Wind, a popular two-drum
winder HMI that provides TNT control, recipes,
numeric and graphical set points, permissives and
diagnostics.
Outdated Equipment – Inefcient and
Costly to Maintain
This paper mill was among a large number of
manufacturers that are still operating with drive
systems that are 25-to-30 years old. The drive
system on the slitter-rewinder was becoming
expensive to maintain. Craig Tierno, senior
application engineer with SDS, explains that a
retrot, which would replace analog regulators with
digital counterparts, was not practical. The SCRs
inside the power modules would not be dependable.
“Often, if a company’s DC power modules are
still within their life cycle, we will recommend
retrotting them with new digital, high-
performance front ends (DFE) to enhance the
regulation performance while ring the existing
SCRs,” says Tierno, “In this case, we could not do
that.”
Case notes
© Copyright 2005 ABB. All rights reserved. Specications subject to change without notice.
New DCS800 Technology, in Concert
with ACS800 Drives, Provide Valuable
Synergy
SDS found a solution when it learned ABB was
developing the DCS800, designed with some of the
same software tools and communication modules
as its AC products. Four ABB DCS800 drives were
installed. The rst drive controls the 500HP unwind
motor that provides tension regulation for the
unwind roll. The second DCS800 drive was installed
on the 50HP lead-in paper roll, which is used to
transport the paper to the slitter section. The third
and fourth drives were installed on the 250HP front
and rear drums – components that are responsible
for providing machine speed reference and proling
torque to the re-wound roll. Two ACS800 AC drives
and motors rated at 15HP were connected to the
two ends of the rider roll to provide vertical force
for acceleration and deceleration torque.
The load cells, which measure web tension on the
unwind section of the machine, were replaced with
ABB PillowBlock style Pressductor® transducers.
Pre-calibrated for the application, the ABB
load cells enhance tension control and reduced
installation time and cost.
In coordination with the drives, the system
integrator installed their own winder-operating
software, called iWind, which is designed to
optimize roll prole and quality while offering
automatic stopping, product recipes, numeric
and graphical set-points, permissives and full
diagnostics.
Compatible Platforms; Retrot and Use
Existing DC Motors
Integrator personnel felt the DCS800 was a perfect
t for the paper mill’s Engineering and IT staff,
who were already familiar with the operating and
commissioning functions of DC drives. ABB’s
complementary ACS800, with a look and feel similar
to the DC product, made it easy for the mill to
transition to AC.
“Making sure that the DC drives were fully
complementary – hand-in-hand, step-in-step – with
what we were going to do with the AC product, that
was really important; having those two on the same
platform,” says Tierno. The new DC drives enable
retrotters to provide up-to-date technology and
outstanding regulation at a fraction of the cost of
replacing the entire power system.
Winning Combination Enables
Optimum Uptime
Since the installation of the DCS800 and ACS800
drives, in complement with iWind software, the
mill has been able to realize their goals of increased
production, top-speed efciency, better roll quality,
reduced maintenance and minimal shutdowns.
In fact, they have been able to virtually eliminate
shutdowns that happened previously because of
component malfunction.
Ofcials at SDS say they have been so pleased
with ABB products and support that they plan to
recommend ABB drives for eight upcoming paper
manufacturing projects.
ABB and SDS have another reason to celebrate:
the paper mill installation marks the rst time that
a DCS800 has been integrated into a total systems
package in the United States. With the almost
unlimited scalability of the DCS800, the entire team
is looking forward to supplying customers with drives
and software for many years to come.
Galco Industrial Electronics
26010 Pinehusrt Dr.
Madison Heights, MI 48071
Ph. 248-542-9090
Fax 248-542-8031
www.galco.com
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