Got Bad Capacitors? Here’s What to Do!

FIVE bad capacitors are what got a Condor power supply grounded! Output voltage reduced to zero! Our customer had fallen victim to one of the most failure-prone components in a power supply: the electrolytic capacitor.

Staying informed on the facts about  bad capacitors is IMPORTANT to protecting your power supply and your other critical electronic assets! The two primary items that are affected by bad capacitors are Drives and Power Supplies. All Drives and Power Supplies use Electrolytic Capacitors in some part of the unit!

Here are some things to know about bad capacitors:

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Real Life From the Plant: C Axis drive not ok Error on Servo Drive

servo drive repairsFrom the outside, this drive looks innocent enough.  But on the inside all HELL was breaking loose! “C Axis drive not ok Error” was the symptom reported.
But this Osai-Prima Electro Servo Drive 97942050N drive was in need of some serious repairs! Burned spots with burned traces were found inside, along with bad capacitors, bus-caps and bad I/O relay.
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osai prima repairsWhat would cause all this in a servo drive?
Excessive heat, over or under voltage surges and sags and/or rises in equivalent series resistance values are all possibilities along with component aging. In the case of the burned traces, other causes could include previous use of inappropriate acid core solder causing a short, or contaminants such as metallic dust, common in manufacturing facilities.

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YES! ACS Industrial Repairs Medical Electronics

GE Healthcare electronics repairsYou’ve been asking!  These days we are frequently asked, “Do you repair medical electronics?” The answer is YES! ACS repairs many electronics for medical and laboratory devices. And, our experienced technicians have more than 20 years of experience with electronic medical and laboratory equipment repairs!

When your electronic equipment is not working, we know that you canphilips monitor repairs’t get the job done and everyone suffers. Our turnaround time is fast with RUSH repairs taking as little as 2-5 days to complete. We are an independent third-party repair house servicing out of warranty equipment that the OEM no longer supports. Our goal is to get your malfunctioning electronic equipment back up and running Fast, Accurately, and Economically.

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Yes, ACS is Open and Repairing Your Electronics! Important Coronavirus Updates

ACS Industrial ServicesEvery day that we wake up, we are thankful to do so! And we are thankful to continue to be of service to our customers! All of us must adjust to practically an entirely new playing field, every day, due to the novel coronavirus COVID-19 and the responses required.

The safety of our employees, our customers, our vendors and supply chain are our top priority as this virus unfolds globally. Additionally, the economic impact of this will likely be immense and felt everywhere. Our customers are still relying on us to get their industrial electronics repaired and back to them quickly, and we take this very seriously.

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Are Industrial Automation and Robotics the Same Thing?

automation repairsWell, yes and no! When we use “automation” and “robotics” in the same sentence, we are usually talking about industrial automation. That is – controlling the physical processes of manufacturing with non-human machinery.

That automated machinery is made up of numerous components including, but not limited to:
  • Teach Pendants
  • Light Curtains
  • Monitors/HMI’s
  • Servo Motors
  • Drives
  • Axis Boards
  • Operator Control Panels
  • Wrist Assemblies
  • Processors
  • Spot Welding
  • Amplifiers
  • Power Supplies
  • Weld Guns
  • End of Arm Tooling
  • Circuit Boards

These components together create both physical machines and control systems that automate previously human tasks in an industrial process. If this sounds futuristic, it’s not! It’s here now and here to stay.

The CNC machines we are all familiar with are common examples of automation in manufacturing. Robots, however, take things quite a bit further.

How are robots impacting us?

Let your imagination run wild and then double that! The automation robotics market is expanding at a fantastic rate as robots replace humans in industry in the U.S. and abroad. For example, construction robotics alone are expected to grow 450% in the next five years, and similarly medical robots. This is mind altering for many of us!

So what exactly IS the difference between automation and robotics?
  • Automation — Automation involves the use of computer software, machines and/or other technology to carry out a task which was previously done by a human. There are many types of automation. These range from the mechanical to the fully virtual. And from the simple to the very complex. A recent tour I took of a major international cosmetics company plant was a great example of both simple and highly complex automation.
  • Robotics — Robotics incorporates multiple disciplines to design, build, program and use robotic machines to complete human tasks, using both physical elements and  usually some type of artificial intelligence.

The two are typically interrelated, though not always. Robots are used to automate some physical tasks, such as in manufacturing.

Some good news!

These systems can be expensive but they can also save a lot of money in the long run. If you’ve invested a lot of money into your automation systems you will want them to last for a good, long time! The really good news is that this often-expensive equipment can be repaired when damaged.

Do you have questions or concerns about your robotics and automation equipment, or do you think it may need service? If it’s still under warranty, contact your OEM. If it is out of warranty, contact an independent industrial electronic repair center. They should offer free evaluations for your automation components and, if needed, a free quote for repairs. They should also provide repair reports and a good warranty that covers both parts and labor.

About the Author: ACS Industrial is an independent industrial electronic repair center providing repair services for automation equipment of most types and most all manufacturers including Fanuc repairs, Nachi repairs, Kawasaki automation repairs, ABB repairs, Yaskawa repairs, Sick repairs, Kuka repairs, Comau repairs, and Motoman repairs , as well as servo drive repairs, VFD drive repairs, teach pendant repairs, HMI and Operator Control repairs, servo motors, encoders, printed circuit board repairs, monitors and touchscreens, PLCs, test equipment, light curtains, and much more. Our customer service team is available to answer your questions and help solve your industrial electronic repair concerns. Legacy equipment can be repaired! RUSH Service is available. You can reach them by calling 800-605-6419

Can Your Legacy Pacific Scientific Servo Equipment be Repaired?

servo amp repairsIn a word: Yes! Legacy Pacific Scientific servo equipment CAN typically be repaired! There’s a ton of really good Pacific Scientific servo equipment still out there in manufacturing plants being used every single day. You might also be wondering what ever happened to this excellent brand. Don’t worry! The story of the Pac Sci brand isn’t mysterious or unusual.

The Pac Sci equipment brand was purchased by Kollmorgen several years ago and until 2011 kept the Pacific Scientific branding and developed a few new products under the Pac Sci name. But, when the Danaher Corporation divested itself from the Pacific Scientific Aerospace business (a separate business from the Kollmorgen business) it included the sale of the Pacific Scientific brand name and logo. This forced Kollmorgen to remove all the Pacific Scientific branding and replace it with Kollmorgen branding. Simple, just business as usual.Pacific scientific servo drive

The good news is that your legacy Pacific Scientific equipment is usually repairable. And, also usually well worth repairing. Here’s a handy chart with a few part numbers of Pacific Scientific equipment that we frequently see in our shop for repairs with reference pricing based on previous repairs. Your repair may be slightly different depending on the amount of damage or cause of failure.

 

Pacific Scientific SC323A001 Servo Drive $2,174
Pacific Scientific SC753A001-01 Servo Drive $2,710
Pacific Scientific SC902 Servo Drive $1,789
Pacific Scientific SC902-001-01 Servo Drive $2,174
Pacific Scientific SC903-001-01 Servo Amplifier $1,672
Pacific Scientific SC903-001-01 Servo Amplifier $1,488
Pacific Scientific SC905-001-01 Servo Drive $2,304
Pacific Scientific SC905-001-01 Servo Drive $2,048

servo drive circuit board repairsDo you have questions about your Pacific Scientific servo amplifier or drive? Do you think it may need service? If it is out of warranty, contact an independent industrial electronic repair center. They should offer free evaluations for your servo controller and, if needed, a free quote for repairs. They should also provide repair reports and a good warranty that covers both parts and labor.

If you want to find out more about identifying the problem with your Pacific Scientific, or any other servo drive, here’s a previous post with some helpful information.

About the Author: ACS Industrial is an independent industrial electronic repair center providing repair services for servo amplifiers and servo controllers of all types and most all manufacturers including Pacific Scientific and Kollmorgen repairs, as well as servo drive repairs, AC/DC drives, VFD drives, servo motors, encoders, printed circuit board repairs, monitors and touchscreens, PLCs, test equipment, light curtains, and much more. Our customer service team is available to answer your questions and help solve your industrial electronic repair concerns. Legacy equipment can usually be repaired! RUSH Service is available. You can reach them by calling 800-605-6419

 

 

How to Extend the Life of Your Circuit Boards and Avoid Circuit Board Repairs

burnt circuit board needs repairsAs you probably know by now, printed circuit boards don’t last forever.  Not even the expensive ones inside your industrial equipment.   But did you know that you can extend the life of your circuit boards? And, potentially put off the need for circuit board repairs a little longer?

The number one reason printed circuit boards need repair is aging components.  There’s not much you can do about that.  But, what about the second biggest reason they end up needing repair? That is damage caused by dirt, heat, moisture, and neglect/accidents.  Now THAT is something you  CAN control.

Here’s 5 key tips to save money with good circuit board maintenance:

  1.  Clean house. – Clean the dust that accumulates on the PCB boards every 3-6 months. You can also use special cleaning fluid designed for electronics. After all the dust and dirt is cleaned, use a blower to dry the boards before reinstalling them or using the equipment.  Keep your work environment as clean and moisture-free as is possible to delay the need for circuit board repairs.
  2. Be Proactive – Why wait until your line goes down to troubleshoot…that’s just expensive down time with a side dish of aggravation. Regularly check your PCB components to look for obvious trace damage (usually caused by overheating). Look for burn marks, solder blobs, broken traces, and check the electrolytic capacitors for bulging or leakage.  Anyone can do this as these are all obvious problems, visible to the naked eye, and require no test equipment.
  3. Check connectors for signs of corrosion which is common, especially with edge connectors. They can be gently cleaned with an eraser and soft, lint-free/static-free cloth.  Corrosion is a sign of excess moisture so to avoid future damage, find out where the moisture is coming from and eliminate it if possible.
  4. Treat equipment as the manufacturer requires – For example, if you are using a device coated with thermal grease, you should check to see if the thermal grease is dried.   If it has become overly dry, gently wipe it out and then coat with new thermal grease to aid with heat dissipation – especially important since we know that too much heat will result in damage
  5. Protect your PCBs with Good Storage and Handling Techniques
  • Store your electronic equipment in Moisture Vapor Barrier Bags (MVBs). Thicker is better so buy the best you can afford. Vacuum and heat seal the bags to remove as much air as possible.
  • Use desiccant bags to absorb moisture and include a moisture/humidity card which can detect any moisture.   This will let you know if the storage bag has been compromised.
  • Keep your spare circuit boards at a consistent and cool temperature – between 60-70 degrees Fahrenheit
  • If you have many circuit boards or other electronics stored, invest in the best moisture-free environment you can afford. Best choice is a Dry Atmosphere Cabinet to maintain a very low humidity (>5% Relative Humidity). By using this type of cabinet you can forego the MVBs.
  • Locate your electronics storeroom away from dirt, temperature extremes, and moisture, as well as excess vibration. It is best if you have a dedicated and secure Storeroom with strict access records on what parts come and go.

If your industrial circuit board has lasted a solid 10 years before failure – congratulations! You’re doing something right! But if the time has come for circuit board repairs and you find yourself searching for a repair center for your damaged electronics, check first to see if your equipment is still under warranty.  If it is still under warranty contact the OEM about repairs.

If it is out of warranty, contact an independent industrial electronic repair center to find out if they are a good fit for your company and your particular repair needs. They should offer free evaluations for your damaged equipment and, if needed, a free quote for repairs (no bench fees!).  They should also provide repair reports if requested and a good warranty of at least one year that covers both parts and labor.

 

About the Author: ACS Industrial Services is an independent industrial electronic repair center providing repairs for all types of industrial electronic equipment and most all manufacturers including circuit board repairs, logic board repairs, industrial power supply repairs, drives, servo motors, CNC equipment, encoders, monitor and touchscreen repairs, test equipment, light curtains, and much more. Rush Service is available and a comprehensive 2-Year Warranty covers most repairs.  The knowledgeable and helpful customer service team is available to answer your questions and help solve your toughest industrial electronic repair problems. You can reach them by calling 800-605-6419.

Are Your Servo Controllers Repairable?

servo controller repairsSmall yes, but oh so important! That’s your servo controller! What are your options if your servo controller stops functioning during machine operation? Are your servo controllers repairable?  Is replacement the answer?  It all depends!

REAL LIFE SITUATION ON THE PLANT FLOOR:

Our customer, an aircraft manufacturing contractor, found themselves in this very predicament. Their waterjet system was down due to a failed servo controller. Would they need to replace their equipment? Or were repairs possible? The good news, as is often the case, repairs WERE possible. Their Copley Controls 800-1689 servo controller was making loud noises before it failed after about 600 hours of operation. Aging components were the main cause of the failure. With the replacement of all seven capacitors, thorough cleaning and testing, the controller was back in action! This was a great relief and cost saver for our customer!

What other failures are typical in these types of servo controllers?
  • Over voltage alarms/machine will not move the axis the drive controls
  • All LED’s out
  • No power
What kind of repairs are typically required to get these units back in action? This can vary a great deal depending on the age and environment but here are a few common causes:
  • Bad or weak capacitors
  • Bad MOSFETs
  • Bad PWM

Do you have questions or concerns about your servo controller, or you think it may need service? If it’s still under warranty, contact your OEM. If it is out of warranty, contact an independent industrial electronic repair center. They should offer free evaluations for your servo controller and, if needed, a free quote for repairs. They should also provide repair reports and a good warranty that covers both parts and labor.

Are you wondering about repair costs? Here are some of our recent prices for Copley Control repairs:

Copley Controls 800-1689 Servo Amplifier $1053-1316
Copley Controls 800-200 Amplifier $623
Copley Controls 800-232 Servo Amplifier $1095

About the Author: ACS Industrial is an independent industrial electronic repair center providing repair services for servo amps and controls of all types and most all manufacturers as well as servo  drive control repairs, AC/DC drives, VFD drives, servo motors, encoders, printed circuit board repairs, monitors and touchscreens, PLCs, test equipment, light curtains, and much more. Our customer service team is available to answer your questions and help solve your industrial electronic repair concerns. Legacy equipment can be repaired! RUSH Service is available. You can reach them by calling 800-605-6419

What To Do When Your Display Unit Won’t Power Up

Heidenhain won't power upWON’T POWER UP 🙁

Ugh! Have you had this happen to your formerly reliable display equipment? It’s a frustrating, but not uncommon problem. From metalworkers to fabricators to scientists – work can come to a sudden stop when your display unit won’t power up.

Why Won’t Your Display Unit Power Up?

There are more reasons than you can shake a stick at for failure to power up. But some reasons are more common than others. DRO display units often get hard use in harsh environments. And because they are sturdy yet familiar, operators tend to hang on to them for a very long time. Eventually problems will develop and most of the causes boil down to one thing: aged components.

The most common problem areas are:

  • Bad power supply overall (this means most likely several bad components)
  • Bad or very weak capacitors
  • Bad PWM IC chips
  • Bad connections and solder joints

Case Study: Heidenhain Operator Display Unit p/n PGM246271-07 Repairs

Heidenhain display unit repairsThese Heidenhain DRO display units are perfect examples of excellent quality display units that last a long time but may develop intermittent problems. Eventually, they may fail to power up at all. In most cases the display unit’s power supply has gone bad. Bad capacitors and bad PWM IC chips are the main cause, although there can be others. Often the units are also covered in dirt and grease. They typically need a good cleaning, in addition to repairs, for optimum performance.

Virtually all of the many Heidenhain display units p/n PGM246271-07 that our technicians have received for repairs have been successfully repaired. These units can be repaired for less than the cost of purchasing a new one. They are sturdy units that will go back to work after repairs for many more years of good service.

What Can You Do?

If you have some experience with electronics AND you are absolutely certain that the electrical power is OFF to your display unit, you can do a visual inspection.  Check to see if the capacitors are bulging or leaking (please don’t touch them!).  Look for burn marks or cracked solder on the circuit board.  These are obvious problems and can usually be repaired. However, problems with these components are not always visible to the naked eye and good quality test equipment will be needed. For your safety and to minimize any self-inflicted additional repair costs, testing is best completed by trained technicians.

If you think you need your display unit and/or its related power supply needs repairs check first to see if your equipment is still under warranty. If so, contact the OEM about repairs. If it is out of warranty, send it to your go-to industrial electronic repair center.

If you do not have a reliable repair center, contact an independent industrial electronic repair center to find out if they are a good fit for your company and your particular repair needs. They should offer free evaluations for your damaged display units or other equipment, and a free quote for repairs (no bench fees!). They should also provide repair reports if requested and a good warranty of at least one year that covers both parts and labor.  If you want to know more about whether your industrial power supply can be repaired here’s more on that!

 

About the Author: ACS Industrial Services is an independent industrial electronic repair center providing power supply repairs for all types and manufacturers, DRO display unit repairs, circuit board repairs, power supply repairs, repairs for drives, servo motors, CNC equipment, encoders, monitors and touchscreens, PLCs, HMIs, test equipment, light curtains, and much more. RUSH SERVICE is available on request and Two Year Warranties cover most repairs. The very helpful customer service team is available live to answer your questions and help you solve your toughest industrial electronic repair problems. You can reach them by calling 800-605-6419 or going to www.acsindustrial.com.

Troubleshooting and Repairs For Your Teknic SST-1500-561 Servo Drive

Teknic repairsSmall but mighty, servo drives are critical players on the industrial playing field. These drives are common in CNC machining, factory automation, and robotics . The Teknic SST-1500-561 servo drive is a frequent flyer – meaning there are a lot of them out there working hard (see photo). If your drive faults out you will know it! Production pretty much comes to a stop!

These Teknic servo drives are good, solid equipment. But, like anything getting hard use in a harsh environment, these drives eventually break down. What should you look for? What should you expect? Here’s some answers:

What Happened?

Here’s are some common failures for these drives. Do any of these sound familiar?

  • DC voltage overload, have a blinking green fault indicator
  • Count 5 ERROR
  • LED Blinks 5 times
  • Currently running with the z axis drive but having intermittent problems, giving an xb axis drive fault
  • Blink Count 3 ERROR. “Over Current/Voltage” message displayed on m/c control
  • 5 Blink count, as soon as the motor is signaled to move
  • 3 blink count, will not power off during a reboot
  • Z-axis controller ERROR message – servo stop z-axis

That all sounds like major frustration on the plant floor, but there’s a fix for that! These Teknic drives are usually repairable for a reasonable cost. The repair cost is usually less than it would cost to buy a new one or refurbished one.

Typically you will find aged and blown components inside, along with trace and solder damage. Occasionally this type of damage may be visible to the naked eye. More often it requires testing to find which components are blown and which are about to go next which is an important part of a good repair!

Common repairs for these drives:

  • Mosfets and capacitors replaced
  • Regulator and the capacitors replaced
  • Regulator, capacitors, driver ic replaced, repaired cold solder joints
  • Recapped, reflowed cracked solder joints, replaced driver ICs and Mosfets
  • Replaced shorted IGBTs, shorted Mosfet and 5 others that work in sequence on an output
  • Recapped and rebuilt output circuit replacing all optos, FETs, and driver ICs
  • Replaced Mosfets capacitors and driver ICs

These servo drive problem descriptions give you the picture – recurring component failure. Typically, the culprits are the capacitors, mosfets, regulators, ICs, and IGBTs. A thorough testing, cleaning and replacement of blown and aging components can bring these Teknic SST-1500-561 servo drives back to life quickly.

Have Questions?

Do you have questions or concerns about your servo drive, or you think it may need service? If it’s still under warranty, contact your OEM. If it is out of warranty, contact an independent industrial electronic repair center. They should offer free evaluations for your servo amp and, if needed, a free quote for repairs. They should also provide repair reports and a good warranty that covers both parts and labor.

Repair of quality industrial equipment like this Teknic servo drive can be a great way to save money and time, as well as be environmentally responsible. If your Teknic SST-1500-561 servo drive needs repairs, we can help! 

About the Author: ACS Industrial Services is an independent  industrial electronic repair center providing repair services for drives of all types and most all manufacturers including servo drive repairs, AC/DC drives, VFD drives, servo motors, encoders, printed circuit board repairs, monitors and touchscreens, PLCs, test equipment, light curtains, and much more.  Our customer service team is available to answer your questions and help solve your industrial electronic repair concerns. Legacy equipment can be repaired! RUSH Service is available. You can reach them by calling 800-605-6419.