REAL LIFE PLANT STORIES: OMRON I/O Has No Sign of Life!

OMRON repairsREAL LIFE PLANT STORIES – “No sign of life”!

That was the “heart stopping” problem description that came along with this OMRON I/O 3G2C7-MC228 unit for repair. There was no input or output! Not really heart stopping exactly, but certainly production stopping! And headache causing for our customer!

What Damaged this I/O Unit?

When our tech team opened up the case of this I/O we found significant damage. The damage was caused by both corrosion and glue. The glue may have come from some previous repair, or even a spill. Corrosion of course comes from either water damage or too much humidity in the work environment.

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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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