4 Ways to Protect Your Industrial Electronics from Lightning Damage

repairs for lightning damaged electronicsIs it possible to protect your industrial electronics from lightning damage?  Often!  Is the lightning damage to electronics repairable?  Sometimes.

Some “shocking” facts first:

A lightning strike lasts about 1-2 microseconds…not even time to blink an eye and yet long enough to cause destruction of life and property.  Storms this spring are already ferocious and violent in the U.S. Lightning and electronics do not play well together.  Check out some shocking facts that put your electronic gear (and YOU) in danger:

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Bang! And Ripple? Let’s Talk About VFD Drive Repairs

“Operator heard a BANG when they turned the system on; drive does not function when power is applied.” That’s from our customer and a very unhappy scene played out in small shops and manufacturing plants around the country. A dramatic “call for help” from this ABB variable frequency drive! The result: Drive repairs needed!
So, what happened to this ABB VFD drive?

ABB drive repairsIn this case, it’s a perfect example of aging components combined with accumulated dirt. Inspection showed arc damage on the base in the area of the 3 phase A/C bridge module as well as some discrepancy in the gate circuits.

This ABB VFD ACS550-U1-059A-2+B055, Model: ACS550 first got a much needed thorough cleaning right down to the circuit boards and all components were tested. Repairs included replacing the 3 phase A/C bridge rectifier module and IGBT output module. A little detective work, a lot of cleaning and some new components put this ABB variable frequency drive back to work for our New England customer. ABB drive repairs successful! Pretty good news considering the dramatic call for help!

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Avoid E-Waste: Repair, Replace, Reuse, Donate, or Recycle Your Electronic Equipment?

reuse electronics50 million tons! That’s right – that’s how much e-waste is expected to be generated in 2020, ALONE! What is e-waste, exactly? Discarded electronic equipment– anything discarded that has/had a battery or plug.

Is most of this e-waste industrial? Consumer? It’s both, of course. Both consumers and businesses are regularly faced with the dilemma – is it more cost effective to repair electronics? Or to replace? And if you choose to replace, what then do you do with the damaged item you no longer need? All good questions!

The Bad & The Ugly:

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Can This ABB Control be Repaired? What’s Inside a Control Anyway?

ABB controllerCan legacy controllers be repaired? Is it worth the cost? The answer to these questions are, in most cases, YES!

Here’s a perfect example of a recent successful repair of a “legacy” control – ABB control p/n PM554-RP-AC repairs. This relatively simple control repair means that our marine management customer now has a fully functional controller back in service!

What went wrong inside this ABB control?

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Philips Medical Monitor Repair Success!

philips medical monitor repairsMedical monitors don’t last forever! Very frustrating! But, the good news is that most monitors, like this Philips medical monitor, are repairable! And, best of all, they are usually cost effective to repair! In a recent example, with many Philips  monitors to repair, our clinical asset manager customer needed help fast!

The problem?

“There is no power coming out of this board to the backlight. We switched this boardphilips medical lmonitor repairs out with a working board and the backlight worked.” That was the helpful problem description provided by our customer. The item pictured is a Philips circuit board p/n M8079-66401 out of a Philips medical monitor.

The fix?

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REAL LIFE STORIES: What to do When a Damaged Circuit Board Causes BIG Manufacturing Problems

Nedpar circuit boards OE 1001-1REAL LIFE STORIES: Even a tiny damaged circuit board can cause BIG problems! When you are producing aluminum and steel you need to be able to be able to shear! In the right place at the right time! What happens when you can’t? Downtime and a whole lot of frustration!

This is the frustration we heard from our steel and aluminum manufacturer customer:   “This board input signals are correct but the outputs are random and incorrect. This board controls a shear and the shear will not operate correctly.”

Random and incorrect shearing = big headache! The good news is this Nedpar circuit boards p/nOE 1001-1/  was perfectly repairable! It needed a lot of cleaning and a lot of new components including 11 capacitors, 6 optocouplers and 3 ICs. It was evaluated, quoted, repaired, tested and shipped back in just 5 business days getting our customer back up and running! Or should we say back up and shearing?

Frustration quickly became satisfaction! Here’s what our customer had to say:

Hi Larry, I wanted to thank you and your team for the expedited service fixing our circuit board. The board has been installed and we are back up and running. Thank you all again for the excellent service” – Greg.

This makes our day! Solving our customer’s electronic repair problems is what we live for! Do you need circuit board repairs too? Nedpar circuit board repairs? We can help!

If you want to know how you can get more out of your circuit boards and extend their life use this link to a previous post you will want to check out. 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 your industrial circuit boards or electronics are out of warranty and need repairs, 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 upon completion 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.

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

 

 

Real Life Stories: Sanyo Denki Drive Unit Down! Please Rush!

sanyo denki drive unit repairs“Please rush this as fast as possible! We are down!”

We get it! We don’t like downtime either! It’s costly! Time to jump into action! Let’s get this Sanyo Denki Drive CFZ0A100DR4601 with error codes back to working order.

So what was wrong with this old and very dirty sanyo denki repairsdrive unit?

Mostly just that – age and dirt, lots of build up! There’s no getting around that! Testing showed numerous components had failed.  To repair this drive would mean virtually rebuilding it. And that’s what our customer needed us to do!

We replaced many components including:
  • 10 capacitors on all control boards, bus-cap, and IGBT
  • installed a new fan
  • reworked the gate circuits
  • tested and repaired the breaking /regenerative circuits
  • tested and repaired the relay’s contacts
  • tested the entire unit
  • Did we mention it was really dirty? Lots of cleaning to get rid of all the build up!

sanyo denki CFZ0A100DR4601In just a few days this unit was back to work – practically brand new again! With a two year warranty! And best of all, our mid-west US customer reported success after installing their rebuilt Sanyo Denki drive! Their CNC shop was back to work machining both gray and ductile iron! Good stuff! We love our CNC machining customers!

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 drive and, if needed, a free quote for repairs. They should also provide repair reports and a good warranty that covers both parts and labor. Need a little more information about identifying a problem with your servo drive? Go here for a previous post on the 7 Signs!

Is your Sanyo Denki drive giving you error codes? Not working? We can help! 

 

About the Author: ACS Industrial is an independent industrial electronic repair center providing repair services for servo drives and motors of all types and most all manufacturers as well as for AC/DC drives, VFD drives,  encoders, printed circuit board repairs, monitors and touchscreens, PLCs, test equipment, light curtains, and much more. Their helpful and knowledgeable 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

How To Tell The Difference Between a Servo Controller and a Servo Drive or Amplifier?

servo amplifier repairsHave you ever noticed that the terms servo controller, servo drive, and servo amplifier are often used interchangeably?  This can be confusing!

Here is the explanation in very basic terms:

  • Technically, the Servo Drive (also called a Servo Amplifier) provides power to the Servo Motor. The Servo Controller provides the specific command to action. For example: Move 10 feet at a rate of 20 feet per minute. The Servo Amplifier takes that signal and provides the necessary power for the necessary time to accomplish that task. It does this while constantly monitoring the feedback from the Encoder. It has enough onboard control circuitry to interpret control and feedback signals.
  • Here’s where it gets a bit trickier – the Servo Amplifier and Servo Controller are sometimes incorporated into ONE device. This is likely the reason why these two terms get interchanged. Generally, they are independent units – one for control, and one for power and feedback.

REAL LIFE EXAMPLE:

For example, this recently repaired Anilam servo amplifier SA 301A  (Drive) provides power to multiple servo motors (multiple axis).anilam servo amplifier repairs

 

 

 

The above Anilam servo amplifer (Drive) is connected to this repaired Anilam controller CC 516F  that provides the commands for each axis used.anilam servo controller repairs

 

 

Now that we’ve cleared that up, you might have more questions!

What if they get damaged? Are they Repairable?

In this example, both of these units were repairable. Typically, the servo amplifier has a slightly higher repair success rate than the servo controller, but both are often repairable. The controller is more complicated and often contains several levels of OEM proprietary programming. The amplifier, if not catastrophically damaged, has a higher rate of repair success. It is always best to get a qualified industrial electronic repair service to evaluate your damaged servo amplifiers (drives) and servo controllers when considering whether to repair or replace.

Do you have questions or concerns about your servo controller or servo amplifier, 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 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.

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 Anilam 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 be repaired! RUSH Service is available. 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