ACS Industrial Services Blog

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:


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


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

Knowledge is Power: Cold Soldering Connections are a Hot Mess!

loose solder connectionWhat are cold soldering connections and why should you care? You should care because a cold solder connection is bad soldering! And bad soldering often results in a bad connection. Bad or loose connections will often cause your industrial electronic equipment to fail – a hot mess! Who needs that?!

So, what exactly is a cold solder joint? Just what you might think – making a soldered connection without adequate heat. This means that the solder will not flow to fill in all the spaces which may make a mechanical bond but does not make a proper connection to the necessary wire.

Repair Solutions From the Plant Floor: Allen Bradley Servo Drive Blows Up!

servo drive repairs





KABOOM! Rarely a good sound on the plant floor! What happened to this Allen Bradley Powerflex servo drive p/n 20AD065A0AYNANC0 to give our food industry plant customer a headache – literally!?

Excessive current is the typical cause for damage like this to fuses in a drive. In this particular case, the bridge rectifier module was shorted resulting in extreme current and damage to the fuses and capacitor.

Yow! Simultaneous violently exploding fuses and a capacitor! All kinds of bad news here at first glance – this drive needed replacement of the diode module, IGBT, capacitors and optocoupler.