In my facility we are running a couple AB 2098-DSD-HV220 and 2098-DSD-HV030 (discontinued) servo drives on some of our equipment. There are 2 pieces of equipment that communicate with each other through DB9 cables back to the TRIO controller (then back to the HMI), I'll call them equip EQ A and EQ B. EQ A enclosure contains a 2098-DSD-HV220 (call it D1), 2098-DSD-HV030 (call it D2) and a TRIO controller, EQ B contains a 2098-DSD-HV030 (call is D3).
Approximately 2.5 (2-21) weeks ago we had a failure at about 5 months after I installed a replacement D1. This drive has had numerous failures in the past before I was employed here, I believe due to very poor cooling in a very packed enclosure. When this drive failed 2.5 weeks ago it took the TRIO controller with it (or vice versa). Since then here is the sequence of events:
2-25 - EQ A- New Drive (D1) and controller installed and programmed. Drive failure within 2-3 hours of initial powerup. Loud POP, cleared fuses.
2-27 - EQ A- New Drive (D1) installed and programmed, new large servo motor installed - Drive failure within 15 minutes with only line side connected. Loud POP, cleared fuses
(both these drives were purchased from Radwell, I suspect they were surplus drives sitting on a shelf without the capacitors being maintained)
3-3 - OEM of EQ A and B onsite - New (D1) installed in EQ A. This drive was ordered from a local AB rep that assured us the drive has been remanufactured to near new and capacitors maintained. OEM rep. goes through all wiring (which I had already done including pinning out all connectors) and finds nothing suspect. Drive has been powered on and off numerous times at this point. Mid-afternoon, equipment seems to be working so we power on EQB to test functionality. 2098-DSD-HV030 is stuck on "8" on the readout. I replace the small servo motor in EQ B, power on equipment and D1 fails again with a loud POP, fuses cleared. No replacement onsite.
3-6 - Local AB supply reps/engineers on site to reform capacitors and help with new drive. Install new D1 in EQ A and D3 in EQ B after capacitor reforming and install power fluke power monitoring. All leads and comm cables from D1 and D2 disconnected. D3 in EQ B will not home itself. I suspect programming issue.
3-8 - OEM believes 44 pin connector is suspect, overnighting new cable.
3-9 - Cable installed, no change. I spliced in alternate conductor on pin for input 2, drive recognizes the input, will not spin motor.
3-10 - Install new D3 and programmed. OEM remotes into equipment controller and finds programming issue. Reconnect all leads and can get the motors in EQ A and EQ B to run off of HMI and through laptop but EQ B will not home correctly after moving off home position without a power cycle. Suspect programming error again.
3-11 - Working through HMI and PBs, move EQ B to home then move it off of home position, now it will not home. Power cycle, and it homes itself correctly through PB, move it off of home position to test again. Use the PB to home EQ B, hear faint pop and D1 has failed again without clearing fuses.
This is where I'm at and have no idea which way to go. If anyone has any advice or has run into something similar let me know.
Approximately 2.5 (2-21) weeks ago we had a failure at about 5 months after I installed a replacement D1. This drive has had numerous failures in the past before I was employed here, I believe due to very poor cooling in a very packed enclosure. When this drive failed 2.5 weeks ago it took the TRIO controller with it (or vice versa). Since then here is the sequence of events:
2-25 - EQ A- New Drive (D1) and controller installed and programmed. Drive failure within 2-3 hours of initial powerup. Loud POP, cleared fuses.
2-27 - EQ A- New Drive (D1) installed and programmed, new large servo motor installed - Drive failure within 15 minutes with only line side connected. Loud POP, cleared fuses
(both these drives were purchased from Radwell, I suspect they were surplus drives sitting on a shelf without the capacitors being maintained)
3-3 - OEM of EQ A and B onsite - New (D1) installed in EQ A. This drive was ordered from a local AB rep that assured us the drive has been remanufactured to near new and capacitors maintained. OEM rep. goes through all wiring (which I had already done including pinning out all connectors) and finds nothing suspect. Drive has been powered on and off numerous times at this point. Mid-afternoon, equipment seems to be working so we power on EQB to test functionality. 2098-DSD-HV030 is stuck on "8" on the readout. I replace the small servo motor in EQ B, power on equipment and D1 fails again with a loud POP, fuses cleared. No replacement onsite.
3-6 - Local AB supply reps/engineers on site to reform capacitors and help with new drive. Install new D1 in EQ A and D3 in EQ B after capacitor reforming and install power fluke power monitoring. All leads and comm cables from D1 and D2 disconnected. D3 in EQ B will not home itself. I suspect programming issue.
3-8 - OEM believes 44 pin connector is suspect, overnighting new cable.
3-9 - Cable installed, no change. I spliced in alternate conductor on pin for input 2, drive recognizes the input, will not spin motor.
3-10 - Install new D3 and programmed. OEM remotes into equipment controller and finds programming issue. Reconnect all leads and can get the motors in EQ A and EQ B to run off of HMI and through laptop but EQ B will not home correctly after moving off home position without a power cycle. Suspect programming error again.
3-11 - Working through HMI and PBs, move EQ B to home then move it off of home position, now it will not home. Power cycle, and it homes itself correctly through PB, move it off of home position to test again. Use the PB to home EQ B, hear faint pop and D1 has failed again without clearing fuses.
This is where I'm at and have no idea which way to go. If anyone has any advice or has run into something similar let me know.
