ACS Industrial Services Blog

REAL LIFE REPAIR SOLUTIONS: Gettys DC Drive Controller

REAL LIFE REPAIR SOLUTIONS FROM THE PLANT FLOOR:  Gettys DC Drive Controller Quits Working

Gettys drive controlThe SAD part of the story: “the axis was real jerky and continued to get worse until it QUIT”. Ouch! Quitting on the job is never good, human or machine. So, what’s up with this nice looking Gettys DC Drive controller?

It quit on the job! This happened in a mid-west U.S. custom fabrication shop after our customer replaced a drive motor. Suddenly there were problems. DC drives like this are awesome for providing variable speed controls for DC motors. This is especially true with applications that require low speed control, torque, and power. They are relatively simple machines so what could go wrong?

Real Life Repair Solutions from the Plant Floor – PLC Needs Repairs NOW

Real Life Repair Solutions from the Plant Floor – Festo PLC Needs Repairs NOW!

festo plc In real life things break, especially when you are in a hurry, right? For our U.S.-based supplement manufacturer customer having a PLC go down was not good for filling orders on time.

In their words, “This (Festo PLC P/N FEC-FC34-FST) isn’t getting the signal properly to the vertical dies and telling them to move up or down; PLC will cycle one or two times, then the run light changes from green to red and the machine stops. Also, when this happens the dies will close and not reopen.” Bummer!

Repair Solutions: Heidelberg Repairs Restart the Presses

Heidelberg repairs“Stop the Presses!” is only a GOOD thing when there is exciting breaking news. It’s all bad news when the press comes to a stop because it is BROKEN. This Heidelberg Press Electronic Drive went bad leaving our East Coast fine printing press customer in the lurch and needing Heidelberg repairs

“Voltage going in but nothing coming out” was the problem description. Yes, that WOULD happen when 14 bus capacitors were blown, the IGBT was bad and the gate board needed repairs.

Following a regular preventive maintenance program can help minimize dreaded downtime. A printing press preventive maintenance program would include, at a minimum:

CASE STUDY – REPAIR SOLUTIONS FROM THE PLANT: TINY Charmilles parts cause BIG problems

burned ISO circuit board repairCASE STUDY – REPAIR SOLUTIONS FROM THE PLANT:  TINY parts can cause BIG problems. Perfect example – this 6 inch square ISO board was blowing a 1 amp fuse bringing the Charmilles Form 20 to a stop in our customer’s Mid-Atlantic tooling shop

The results of this “mini-explosion” are a burned ribbon cable and connector and a burned pcb. Not to mention the dreaded down-time. This sounds ominous and it did look pretty bad. But yes! This ISO board WAS repairable! The capacitor was bad and five transistors shorted, all of which were replaced. Damaged traces were also repaired.

Dirty Repair Jobs – Relax, It's Part of the Repair Service

dynamag repairsIt’s a good thing we have always liked playing in the dirt! Because this guy (and a few more just like it) were so dirty when they arrived on our dock we had to degrease and clean them just to identify the components.

But we get it. We know our customers work in some pretty grimy situations. Degreasing and cleaning each repair is part ocontroller repairsf our standard service. Every. Single. Day. Every. Repair. As simple as that.

A CASE STUDY: MG Industries Plasma Table Control Fails

control repairsREPAIR SOLUTIONS FROM THE PLANT FLOOR – A CASE STUDY: MG INDUSTRIES PLASMA TABLE CONTROL FAILS

Is double-sided tape the only thing holding YOUR control together? Or maybe a bit of duct tape? If so, you are very much not alone.  We see this all the time!

Take this MG Industries Plasma Table Control DNC 2.8 for example. Our customer is a very busy Texas fabrication shop. So busy that they really didn’t want to take ANY down-time to get this guy repaired and had resorted to double-sided tape to hold the display together. This worked…for awhile. Controller repairs

Case Study: Allen Bradley VFD Blown! Can it be Repaired?

REPAIR SOLUTIONS FROM THE PLANT FLOOR – Allen Bradley VFD Blown! Can it be Repaired?  Should it be repaired?

Allen Bradley VFD repairsUnlike in a box of Cracker Jacks, there was an UGLY surprise waiting inside of this drive! When this Allen Bradley VFD failed, the screen gave only a wimpy “bad fuse” alarm. But it was much uglier than that for our Western U.S. power generation customer.

Case Study: Is it “Economically Feasible” to Repair Your Circuit Board?

Repair Solutions From the Plant Floor

What would YOU do if your OEM told you they wouldn’t repair your circuit board because it mitsubishi circuit board repairswasn’t “economically feasible to repair”? The OEM should know, right? Well, not always. And, there ARE often other factors that go into that business decision about whether to repair or replace.

Our golf club manufacturer customer was not willing to throw in the towel on their Mitsubishi MC116 control board from their Mazak CNC lathe. And, theydidn’t want to spend more than necessary.

Repair Solutions From the Plant Floor: A Cure for “MSKS” – Machine Shop Keyboard Syndrome

charmilles operator keyboard repairs Is your CNC operator keyboard having problems? Has your F2 key gone bad and refusing to do anything? If so, you could have a nasty case of “MSKS”! That’s short for Machine Shop Keyboard Syndrome! This is a common “infection” in machine shops everywhere.

The pictured dirty Charmilles keyboard p/n 200970625/ISS C is the perfect example of MSKS! These excellent but pricey keyboards are usually repairable and for FAR less than the cost of buying a new one – in this case THOUSANDS of dollars less.

Knowledge is Power: How to Identify Overheating Damage to Your Circuit Boards

printed circuit board repairsHeat, moisture and dirt are the mortal enemies of circuit boards! That means nearly ALL circuit boards eventually need repairs. Useful knowledge about preventive care and maintenance can extend the life of your circuit boards. It can also put off the need for repairs a little longer. This is especially important for those very expensive industrial circuit boards that can cost $30,0damaged circuit board00 each and sometimes more!

Signs of Overheating on Your Circuit Boards

  • Burnt, brown or blackened components
  • Burn marks on the board substrate
  • Delamination of the board
  • That well-known “burnt electrical smell”burned circuit board