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

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 Get Lambda V404P4K Power Supply Repairs

lambda power supply repairsWon’t power up! Erratic vacuum readback! Load issue/no output under load. No output. Intermittently trips instrumentation. Power Supply DEAD! Bad news, right? “DEAD” in this case is not always dead, of course. As it turns out, all of these Lambda v404P4K power supply repairs HAD failed, but were not “dead” forever. In fact, these Lambda power supply examples were all successfully repaired!

Here’s a quick summary of typical problems that cause these types of bad capacitors in lambda power supplyfailures in Lambda V404P4K 450 watt power supplies:
  • Cracked solder joints
  • Bad capacitors
  • Bad power section
  • Bad power board
  • Overheating damage
  • All of the above simultaneously

These Lambda 450 watt V404P4K power supplies are long lasting workhorses. There are a lot of them out there working hard. Eventually they will break down, mostly from aging components.

If your business relies on these Lambda power supplies you are in good company. If your power supply fails, relax. The good news is that most of these power supplies are repairable!

Did you know that you can often extend the life of your power supply? Preventing your power supply from getting fried in the first place is pretty useful information! If you’d like some tips on that from a previous post click this link!

Are you experiencing a power supply failure right now? Think you might need industrial power supply 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, hopefully you have a go-to repair center.

If you need a 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 power supplies 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.

About the Author:

ACS Industrial Services is an independent industrial electronic repair center providing power supply repairs for all types and manufacturers, circuit board 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.

 

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.

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

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.

7 Signs Your Servo Drive Might Need Repairs

kollmorgen servo drive repairsAre you getting error codes? Drive won’t enable? Servo motor won’t move? Not getting the proper voltages to your servo motor? The problem could be inside your servo drive! Servo drives can and DO go rogue! But there are signs to look for to see if your servo drive might need repairs!

So, What’s Wrong With My Drive?!

Industrial electronics, including drives, have a lifetime – and the components do too! Aging components is the single most common reason for failure. Capacitors are often the first component to fail. Other likely failure culprits include resistors, diodes, IGBTs, driver ICs, relays, transistors, transformers, opto-isolators, and rectifiers, as well as others.

What Can Speed Up Servo Drive Component Aging?

Like humans, not getting the right care can speed up the aging of your servo drives. Voltage cycles, voltage spikes, increased switching activity, harsh environmental factors such as excess vibration and heat, and lack of preventive maintenance can all accelerate the aging of your servo drives costing you money!

7 Signs of Servo Drive Failure – What You Should Look For:

Many component failures in a servo drive are visible to the naked eye, even to the non-technical inspector. The circuit boards are often where the problems are. Failing components may still work but cause intermittent problems. Eventually they will fail completely leaving you in the lurch. Here are seven things to look for that tell you servo drive repairs are likely needed soon, if not immediately, for your drive to function optimally:

  1. Burned spots on the circuit boards
  2. Corrosion
  3. Leaking or bulging capacitors
  4. Component color change often due to overheating
  5. Component date codes that have expired or will soon
  6. Tarnish on leads
  7. Cracked resistors

Case Study

Kollmorgen repairsThis Kollmorgen Servo Drive p/n PRD-K0620R0 arrived for repairs from a southern U.S. fabricating facility. The drive would not enable, so no fabricating getting done at all! What was wrong? Plenty! Aging components were replaced including the capacitors, drive IC chips (also a high failure component on these drives) the IGBT, Communication ICs, optocouplers, IPM, TTL ICs. Pretty much everything needed replacing and/or cleaning. This drive was completely repaired and returned to full service for far less than the cost of replacement. These drives are good quality drives that frequently justify getting repairs!

What About the Invisible Problems?

Visual inspection is the first action to take. However, you may see nothing obviously wrong. So, what next? The next step requires the use of test equipment. Oscilloscopes and multi-meters can be used to test components to see if they are failing or out of spec for other reasons. This is where you may find yourself considering an industrial electronic repair company which can ultimately save you time and money.

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. Want a little more about protecting your servo drive investment, go here.

Here’s a sampling of past drive repairs ACS has performed, and past pricing. Your quote may be less or more, depending on the condition of your unit:

Kollmorgen CE03250 Servo Drive $940.00
Kollmorgen CE10250 Servo Drive $1,135.00
Kollmorgen CR03260-000000 Servo Drive $1,317.00
Kollmorgen CR03550 Servo Drive $914.20
Kollmorgen CR06250 Servo Drive $988.00
Kollmorgen LR06565 Drive $1,420.00
Kollmorgen M.3000.0912 Drive $1,200.00
Kollmorgen PRD-K0620R0z-00 Servo Drive $1,850.00
Kollmorgen S67001 Servo Drive $2,915.00
Kollmorgen SC1R06260 Servo Drive $1,929.00
Kollmorgen SE20200-000000 Servo Drive $1,740.00
Kollmorgen SR30201-000000 Servo Drive $312.50

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. 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