The main extruder of a CCV (Continuous Catenary Vulcanization) line is driven by a 125 kW AC motor controlled by a Parker AC890 132 kW AC drive. The drive communicates with a Siemens S7-400 PLC via PROFIBUS for integration with the existing machine control system.
In this project, Parker Vietnam replaced the existing Parker AC890 with a Parker AC30 132 kW AC drive. The upgrade focused on replacing the main extruder drive and configuring PROFIBUS communication to maintain integration with the existing Siemens S7-400 PLC.
1. Project Overview
- Application: Main extruder drive for a CCV line.
- Motor: 125 kW AC motor.
- Original drive: Parker AC890, 132 kW.
- Replacement drive: Parker AC30, 132 kW.
- PLC: Siemens S7-400.
- Communication protocol: PROFIBUS.
- Project scope: AC drive replacement, parameter configuration, and integration with the existing PLC control system.
2. Replacing Parker AC890 with Parker AC30
The Parker AC890 was previously used to control the main extruder motor. The replacement with a Parker AC30 132 kW required consideration of the motor characteristics, load conditions, speed control requirements, and existing control architecture.
The project involved the following tasks:
- Replacing the Parker AC890 with a Parker AC30 132 kW AC drive.
- Configuring motor parameters and drive control settings according to the application requirements.
- Checking control signals, operating status, and fault signals.
- Configuring PROFIBUS communication between the AC30 and the Siemens S7-400 PLC.
- Reviewing process data mapping, communication addresses, and PLC input/output assignments.
- Testing the interaction between the drive, motor, and existing machine control system.
Selecting a replacement drive requires more than matching the rated power. The drive’s rated current, motor specifications, operating conditions, and required control functions must also be verified.
3. PROFIBUS Integration with Siemens S7-400 PLC
One of the key tasks in this project was integrating the Parker AC30 into the existing PROFIBUS network connected to the Siemens S7-400 PLC.
When replacing an AC890 with an AC30, the communication data structure and parameter mapping cannot be assumed to be identical. The new drive must be configured according to its own communication profile and the requirements of the existing PLC program.
The integration work includes:
- Configuring the Parker AC30 as a PROFIBUS device.
- Verifying the PROFIBUS address and cyclic process data configuration.
- Mapping control commands such as Run/Stop, Enable, direction, and speed reference according to the machine control design.
- Mapping feedback data such as actual speed, drive status, and fault information.
- Reviewing and modifying the PLC program or process data mapping where necessary to ensure compatibility with the AC30.
Correct PROFIBUS configuration allows the replacement drive to communicate with the existing PLC system while minimizing unnecessary changes to the overall machine control architecture.
4. Project Results
The project replaced the existing Parker AC890 132 kW with a Parker AC30 132 kW for the main extruder of a CCV line.
The main objectives of the upgrade were to:
- Replace the existing AC890 drive with the Parker AC30.
- Establish PROFIBUS communication with the Siemens S7-400 PLC.
- Configure control commands and feedback data for the replacement drive.
- Verify integration with the existing motor and machine control system.
Final acceptance should be based on commissioning tests under the actual operating conditions and the production requirements of the CCV line.
5. Parker Vietnam – Industrial Drive Replacement and Integration Solutions
Parker Vietnam, operated by Cong Ty TNHH Ky Thuat Viet, provides industrial drive replacement, control system integration, and electrical upgrade solutions using Parker AC890, AC30, AC20, and DC drive products.
Our services include existing system assessment, drive selection, parameter configuration, PLC communication integration, electrical cabinet modification, and commissioning support.
Contact Information
Southern Vietnam Office
74/9/9–74/9/11 Duong So 9, An Hoi Dong Ward, Ho Chi Minh City, Vietnam.
Northern Vietnam Office
CX2-107, Co Xanh 2 Street, Vinhomes Ocean Park 2, Hung Yen Province, Vietnam.
Hotline: +84 908 353 714
Email: info@kythuatviet.vn
Website: https://parkervietnam.com/
Parker Vietnam provides drive replacement and automation integration solutions for industrial machinery, including applications requiring Parker AC drive upgrades and Siemens PLC communication.
