Plant & Facilities Managers are Super Heros

Industrial Encoder Repair

In any mechanical process, every component has its own job and role – regardless of its size. Whether it’s the main shaft or a simple circuit, everything has to work together for your operation to run efficiently.

Plant & Facilities Managers are Super Heros

When a part begins to show wear or is malfunctioning, the rest of the equipment will not be working to its fullest potential – and other components will begin to feel the effect. It’s a simple chain reaction that can lead to breakdowns and lost time.

Encoders play a key role in translating rotary or linear motion into a digital signal, which helps determine the speed or position of a motor or other moving equipment. Think of an encoder as a measuring system for moving parts.

An encoder falls into basically two categories: linear and rotary. The linear encoder will respond to motion along a dedicated path, while its counterpart will respond to rotational motion. 

Depending on their design, encoders can provide unique position values from the moment they are turned on. Incremental encoders function differently because they generate an output signal each time the shaft rotates.

If a motor or other piece of equipment begins to move too fast or slow – or starts and stops on an irregular basis, the problem could be the encoder. This could be caused by bugs in the controller program, but if a diagnostic test doesn’t turn up anything, the next step is to use a handheld oscilloscope.

This handy tool can help identify problems such as excessive noise or the failure of a cable shield coming loose – or not having been properly attached. One of the advantages of an oscilloscope is that it produces a graphic clearly showing how the electrical signals are behaving.

Encoders for heavy industry are designed to withstand harsh environments and heavy use. In addition, they are built to withstand particulates, moisture and other contaminants, along with a dependable speed performance. 

Other encoders are available to help run servo motors, and are usually encased in the actual motor housing.  Encoders in Servo Systems can be used in a variety of machines, from small to large. They provide speed and distance measurements for all types of applications.

A faulty encoder causes incorrect positioning and/or speed that is critical in Machining. It can mean the difference between a correctly machined part and a waste of material. 

Encoder Repair at ACS

ACS has serviced encoders and resolvers since we opened our doors and we’ve continued that practice for two decades. This depth of expertise translates into professional evaluations delivered with accurate quotes.

ACS repairs all of the popular models and brands and supports most manufacturers. You can check out our website for a partial list, and we also have a Search Repair Catalog that allows users to search by name or part number.

Contact us today or call 800-605-6419, and remember:

ACS

ACS Industrial – We’re Here to Serve You

For more than two decades, ACS Industrial has helped our customers with their repair needs. To date, we’ve completed over 26,000 repairs and we’re not showing any signs of slowing down! 

Our success has been a result of hard work performed by qualified, expert technicians and personnel who value customer service and getting the job done right. 

ACS

Before we opened our doors, our staff had been designing, building, and installing industrial, welding, and electronic automation systems, and we realized getting good industrial electronic repairs shouldn’t be so hard. That’s when ACS Industrial was born.

In addition to a professional attitude, we’re familiar with a wide array of manufacturers and brands. Add a deep inventory to that formula – we repair over 26,000 industrial electronic items –  and you know you can rely on us.

If you’re an owner or operator of a business, you know that it’s important to keep your systems running – and when an electronic part or component breaks down or starts to show signs of failure, you’re facing expensive downtime.

Our main office’s repair services are based in Hickory, North Carolina, easily accessible by all major carriers, which makes receiving and shipping easy and quick, due to its location on the East Coast. This means that you’ll be able to get up and running quickly, and not have to wait on long shipping times.

Because we’ve been in business for more than 20 years, ACS Industrial has become familiar with the demands and needs of customers that represent a wide array of industries

While you may know us from our reputation for working with customers from the manufacturing and construction industries – we also work with businesses from fields such as:

  • Aerospace
  • Automotive
  • Construction
  • Machine Tools
  • Packaging and Conveying Industry
  • Petrochemical
  • Pharmaceutical
  • Printing
  • Warehouse and Distribution
  • Welding

We’ve made working with us as easy as possible, and when you need repair or maintenance on an electronic part or a component, all you need to do is visit our website and fill out a repair form

This gives us the basic information that enables us to provide a quick answer and an accurate quote – usually within 24-26 hours after we receive your item for repair. After this, you can make your decision and ship your part to our facility. 

Of course, if you have questions or need more information, we’re easy to contact – and you’ll be working with one of our knowledgeable and helpful customer service team members. 

Get in Touch with ACS!

Let the experts at ACS give you a free evaluation and repair quote.

  • Repair can often save as much as 80% of the cost of buying a new piece of equipment.
  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty.

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

Industrial Electronics

Why Industrial Electronics Can Fail

Like all technology, industrial electronics are not immune to issues and repairs. With many hours of wear and tear on a device, repairs are essential to keep your industrial electronics from complete failure. The experts at ACS Industrial Services have rounded up a few common sources for industrial electronic failure and how to help prevent them.

Industrial Electronics

Exterior Issues

The way a device is housed plays a critical role in its longevity. The exterior of a device is susceptible to a great deal of stress throughout the day, including temperature, dust and scratches. Industries that require industrial electronics equipment in a factory are especially susceptible to dust and debris damage. If a device has a crack in it, moisture can seep in and destroy the inside of the electronic device, like the circuit board. It’s crucial to keep the exterior of your industrial electronic device as protected as possible.

Failed Circuit Boards

The circuit board is like the heart of all devices, so therefore, any damage to a circuit board can destroy an item. Circuit boards can fail for any number of reasons, like overheating, exposure to dust, manufacturing defects and more. 

Power Surges

Some industrial electronic devices are more susceptible to power surge damage than others. Letting your circuit board experience excessive heat can cause total device failure. Another reason is a power surge, which can wreak havoc on circuit boards and destroy unprotected devices. 

Relay Failures

When a device’s relay is opened or closed, there is a certain amount of wear and tear on the item. An electrical arc can happen, which puts more stress on your device and can eventually lead to it breaking. 

Age of the Device

Unfortunately, age does play a factor in the longevity of an industrial electronic device. Regardless of the quality of a build, an electronic can age and no longer work. The good news is that even if an industrial electronic device starts to fail, there are components that make up the electronic circuit that can be replaced. This can also be done at the fraction of a price of a new device. 

Contact ACS Industrial 

If your machinery breaks down or is starting to show signs of failing, ACS Industrial can help. We’ve been in business for more than two decades, and our team of experts have years of experience and the proper resources to get yours fixed.

Let the experts at ACS give you a free evaluation and repair quote.

  • Repair can often save as much as 80% of the cost of buying a new piece of equipment.
  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty .

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

Repairing Circuit Boards

Repairing Circuit Boards in Industrial Electronics

Circuit boards are an absolute essential in the technology world. Advances in circuit boards over the last several decades have allowed for new engineering and manufacturing methods for industrial electronic devices across the globe. As circuit board technology has advanced, so have the methods to repair this particular kind of industrial technology. Keep reading to learn what a circuit board is, the different kinds and how they can be repaired, from the experts at ACS Industrial Services. 

Repairing Circuit Boards

What is a Circuit Board in an Industrial Electronic Device? 

To start, let’s review what a printed circuit board, or PCB, actually means. A printed circuit board (PCB) is a sandwich structure of conductive and insulating layers. In other words, a circuit board is a printed board that has electrically conductive pathways that connect electronic components to one another. The invention of the circuit board has been one of the most crucial developments of all time in technology. It’s led to the creation of new industrial electronic devices and manufacturing capabilities. Before circuit boards, electrical wiring used to have to be wired through solder or cable. Now, circuit boards can be very complex, sometimes with as many as dozens of layers. The world market for circuit boards is expected to reach over $79 billion by the year 2024.  

Problems with Circuit Boards in Industrial Electronics

Like all technology, circuit boards can run into their fair share of repairs. Due to their importance in most devices, a failed circuit board can cause a huge headache for your organization. Oftentimes, if a circuit board has problems, it can shut down your entire industrial electronic device. Here are some of the ways that industrial electronic circuit boards fail:

  • Physical Damage: If a device containing a circuit board is physically damaged, like dropped for example, this can cause huge issues for the circuit board.
  • Environmental Elements: Corrosion from moisture exposure is just one environmental element that can damage a circuit board. 
  • Overheating: Overheating the circuit board is especially common in older devices. 
  • Design Issues: If a technological manufacturer does not design a device properly, this can lead to a shorter lifespan for the circuit board. 

Circuit Board Repairs

In most cases, circuit boards can be repaired by an expert company. ACS Industrial has a team that can locate the problem, offer a quote, and then get to work. We’ve worked for more than two decades in the repair field, and we carry a large inventory to speed up the repair process. Let the specialists at ACS give you a free evaluation and repair quote.

  • Repair can often save as much as 80% of the cost of buying a new piece of equipment.
  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty .

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

not Recycling Your Electronics

The Consequences of Not Recycling Your Electronics

A recent study found that the average American household owns around 11 electronic devices. In our consumer-driven society, many of these devices are swapped out each year for newer models. It’s important to remember to properly recycle the electronic devices you no longer use or want to help protect your community. Here are a few ways that improper electronic recycling can affect you and your community.

not Recycling Your Electronics

Local Pollution

Throwing away your electronic devices rather than recycling them can lead to the devices ending up at a landfill. Many devices can take thousands of years to decompose. So as those electronics sit there in the landfill, harmful toxins like mercury and lead can seep into the ground. This can affect the soil composition around the landfill, which can eventually trickle into community rivers, ponds and other groundwater areas. This can pose multiple and serious health risks to future generations, including cancer and reproductive issues.

Ocean Pollution

If your organization’s disposed electronic devices are not ending up at the landfill, then chances are they are being dumped into the ocean. A remarkable several tons of garbage ends up in the ocean each year, some of which can include electronics that are not biodegradable. This can lead to disrupting the ocean ecosystem as a whole. 

Why Recycle Your Electronics

Now that you’ve read about some of the environmental reasons to recycle your industrial electronics, here are several others:

  • It’s the law. Many states have made improper electronic disposal illegal. Check your local laws to see if improperly disposing electronics could affect you legally. 
  • Cybersecurity. When you recycle your electronics properly, then the data on those devices can be safely destroyed. You don’t want your company or personal data to get in the hands of the wrong individuals. 
  • Discounts. Some companies will allow you to trade in an old device (to be properly recycled) in exchange for a discount on an upgraded device.

If you are not ready to properly recycle your industrial electronic devices, then consider repairing them instead! Trying to repair your devices on your own can be time consuming, and you may not have the resources or expertise to get the job done right. Professional repair services handled by experts ensure the problem will be solved, and extend the life of your equipment. ACS Industrial has a team that can locate the problem, offer a quote, and then get to work. We’ve worked for more than two decades in the repair field, and we carry a large inventory to speed up the repair process.

Let the specialists at ACS give you a free evaluation and repair quote.

  • Repair usually saves up to 80% the cost of buying a new piece of equipment.
  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty .

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

Servo Drive

What Does a Servo Drive Do?

In manufacturing and automation processes, there are multiple pieces of machinery that ensure the operation is being performed correctly and precisely, without deviation. These automated control systems are used in everything from the manufacture of cars on an assembly line to warehouse automation.

Servo Drive

The motors that drive these systems use servos to take in and regulate the power that goes to the entire operation. A servo system requires four basic parts, although in some cases depending on size and need, there may be more parts, but rarely less.

Controller

The first component in a servo system is the controller, which performs two duties. The first is to track command input and the second is to improve the system’s disturbance rejection.

Servo Drive

The role of the servo drive is to take the command signals from the controller and then transform them from low power commands to higher power voltage and current to the motor.

Motor

The parts of a machine are rotated by the motor, which can be moved and adjusted according to what the process is built to achieve. The motor is a closed-loop mechanism which controls the rotational speed and position.

Load

This term is used to describe the combination of the inertia, mass, viscous damping, and torsional stiffness. This system consists of a DC-motor reduction gear, an output sensor, and a microcomputer that makes constant calculations for adjustment.

The Role of the Servo Drive

The servo drive’s role in an automated controls system is regulating the powering of the servo motor. Once the drive has sent the power to the motor, it continues to regulate and properly coordinate the motor’s position, speed, torque, and other actions.

An automatic control system – also known as a closed loop system – is regulated by feedback. In this case the feedback is generated by the motor’s performance and then closely monitored by the servo drive. 

The accuracy and dependability of the servo drive makes it a vital piece of machinery in several different areas of operation. For instance, a servo drive can help position a globe valve so that it’s in the right position to function properly.

Mechanical Problems

Like any other component or piece of machinery, a servo drive’s output and performance can decline over a period of time. Besides the regular wear and tear, the drive can be damaged by the buildup of dirt and grime, intense swings in temperature, and improper installation.

ACS Can Repair Your Servo Drive

Despite making sure the inverter drive is installed properly and maintained, breakage can occur and the power source’s output might not be regulated. This can cause multiple problems throughout the system. 

If you’re considering whether to repair your servo drive, choose ACS and let us give you a free evaluation and repair quote.

  • Repair usually saves up to 80% the cost of buying a new piece of equipment.
  • Most repairs are back in your hands in 7-15 days after approval.
  • Our Rush Repair Service ships in just 2-5 days after approval.
  • We Guarantee Our Repairs With A Full Two-Year Warranty .

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

touch screen

How to Care For Your Industrial Touch Screen Monitor

Industrial touch screen monitors are not only easy to use,  they’re built to withstand harsh environments and heavy use, which is perfect for industrial settings, including machine shops and production facilities.

touch screen

Touch screens can serve a variety of purposes, including controlling sensitive machinery, and making quick adjustments on production lines. Industrial touch screen monitors can also function as early warning systems by displaying messages and lights to alert users that something is going wrong. 

While they are built to be sturdier than desktop style touch screen monitors, industrial monitors still need to be cared for. Wiping down the screen with specially designed cleaning cloths can remove dirt and debris, which can build up and decrease the sensitivity of the screen. Using rags, paper towels, or napkins isn’t a wise choice, as they tend to smear grease and dirt and in some cases press debris and dirt into the screen’s surface.

When your industrial touch screen monitor isn’t performing well, you may need to recalibrate it. Poor accuracy can result in machine malfunctions, which results in downtime. Most touch screens provide calibration functions directly on the screen, while others may need operators to calibrate via buttons on the monitor frame. 

Touch screens which are connected to larger computers or mainframes can malfunction due to improperly installed operating systems – or they may require updates. If the screen isn’t working correctly, your IT department may need to check the software to see if it’s out of date or requires a patch – software updates that help correct security holes or other recently discovered problems.

You can also access the screen’s setting to determine if the sensitivity level is too high or too low, either setting can affect performance – and if users aren’t careful they can damage the electronics that lay directly under the screen’s surface. Over time the sensitivity of the screen can be affected by heavy use.

Some screens come with a stylus, which comes in handy when users are wearing gloves or other protective gear. Keep the stylus nearby to discourage people from using pens, pencils or other objects with sharp points – when holes are poked into the screen, the surrounding area can malfunction or stop working altogether.

Regardless of how careful you and your coworkers are, industrial touch screen monitors may need to be repaired, which can save on having to completely replace the equipment. 

ACS Industrial has been repairing these types of monitors for more than two decades, and our connections with parts suppliers helps ensure quick turnaround with quality components.

In addition we offer free evaluation and a repair quote so you experience minimal downtime. When your bring your industrial touch screen monitor in for service you can expect:

  • To save up to 80% of the cost to buy a new one
  • Your monitor will be back in your hands in 5-15 days. 
  • With our Rush Repair option you can have your equipment back in just 2-5 days.
  • A guarantee on our repairs with a full two-year warranty .

For a Free Evaluation, use our RMA Form link or visit our website and click on the “Contact Us” button on the upper right hand. You can also reach out to us at 800-605-6419 and speak to someone on our customer support team.

Varian Circuit Board Repair

Varian03-930210-01  RepairsEvery week…no, no, make that every DAY we get interesting items in for repair.  They are causing trouble for the various industrial plants, offices, or wherever they came out of.  This week’s Troublemaker:  a Varian circuit board 03-930210-01.  The defective board (pictured) comes out of a Varian Saturn 2000 MS power suppy  located in a plant in Liechtenstein- problem was, it wasn’t supplying any power causing a hold-up in production.   In case you didn’t know, Liechtenstein is located in central Europe between Austria and Switzerland.

The European plant needed electronics repair fast and they couldn’t find it in Liechtenstein or anywhere nearby.   They contacted ACS Industrial and we were able to turn this around and ship it back repaired to Liechtenstein in just 8 days.  Doesn’t matter where you are, we will jump through hoops to help you out!  Do you need electronics repair?  Call our helpful customer service team at 800-605-6419 or go straight to our website to fill out a Free Repair Evaluation form at www.acsindustrial.com.

How to Change Your Processes to Meet the EPAs NESHAP Rule 6X

Industrial Electronic Repair ServicesThe EPAs NESHAP Rule 6X went into effect in July 2011.  Did you miss the announcement of this rule?  If so, according to The Fabricator.com reports you are not alone.

The rule applies to companies that are primarily engaged (that is 50 percent or more of their total labor) in one or more of the following categories: electrical and electronic equipment finishing, fabricated metal products, fabricated plate work (boiler shops), fabricated structural metal manufacturing, heating equipment (except electric), industrial machinery and equipment finishing, iron and steel forging, primary metal products manufacturing, and valve and pipe fittings.  That describes quite a lot of our customers!

Operations that are impacted by this new rule include:  dry abrasive blasting (3 types), dry grinding, dry polishing with machines, dry machining, spray painting (2 types), and welding.

Excluded from this new rule are:  military installations; NASA facilities; national nuclear security facilities; military munitions facilities; some research or laboratories (defined by the Clean Air Act); tool, quality control, and equipment repair facilities; and welding facilities that use less than 2,000 lbs of rod or wire that does not contain any identified HAPs.

Why did the EPA establish this new rule?  To prevent cancer, birth defects, and other health effects caused by exposure to Hazardous Air Pollutants as defined by the EPA in 2008.  Just some of these materials are those that contain 0.1 percent by weight of cadmium, chromium, lead or nickel; or 1.0 percent by weight of manganese.

What should you do if you fall into the categories above?

  1. Notify the EPA
  2. Change your processes to eliminate the HAP (dust and fume collectors with high-efficiency cartridge filtration is considered acceptable)
  3. Conduct a Method 22 emissions test (See EPA.gov website for how to do this)
  4. Retest to confirm

If you want more information on this important subject, here’s a FAQ that can answer a lot of your questions:  http://www.epa.gov/ttn/atw/6x/metal_fabrication_q_a_nov-2011-rev3.pdf

ACS Industrial Services provides industrial electronic repair services for virtually all types of commercial and industrial electronics. Need servo motor repair?  Drive repair? Circuit board repair?   CNC repairs? Call our customer service team at 800-605-6419 for assistance or head straight to our website at www.acsindustrial.com to request a free evaluation and quote for repairs.

 

American Manufacturing Plant Managers Bullish About 2012 – Read What They Have to Say

Plant Engineering has just released the results of their 2012 Salary Survey Analysis which very nicely covers much more than just salary data.  The overall impression from this survey is that American manufacturers are really raring to go and are ready to be done with all things recessionary.

In 2010 Plant Engineers/Managers were growing increasingly concerned with maintenance issues – in fact it was their number one plant concern.  That concern grew even louder in 2011 with survey responders frequently pointing out that their plant was lacking skilled workers, capital, direction from upper management, and funding for maintenance including for maintenance personnel.

Here are some of the highlights of the 2011 survey:

Plant Engineers’ 2011/2012 Top Plant Facility Concerns:

  • 37.3% Maintenance
  • 25% HR/Personnel Training Issues
  • 25% Automation

What Should Get the Most Attention?

  • 44.4% Maintenance
  • 28.8% HR/Personnel Training
  • 20.8% Automation Systems

Although energy concerns were fairly low on both of the above lists, 82% of respondents said that sustainability does play a role in decision-making at their organization.

Plant Engineers’ 2011/2012 Top Issues:

  • 30% Skills gap
  • 23%  Ineffective management
  • 20.5% Government interference
  • 13.7% Company downsizing

Respondents reported that the Skills Gap had two components – an age issue (many of America’s skilled workers are now in their 50s and will age out) and a training issue.

Looking to the Future:

  • 28% see no end to their recession in sight
  • 52.2% say the recession has ended
  • 18.4% see the recession ending soon for them
  • 44% expect to add lines or shifts in 2012 (the
    same as in 2011)

The Plant Manager/Engineer in a Nutshell:

  • Average Age: 58 (17% are over 60, 2.3% are under 30)
  • 71.1% have a college degree
  • 94% Use social media (up from 43% in 2010) primarily LinkedIn (59%) which they use mostly for business networking purposes but not so much for problem solving (15%) or product reviews (10%).

For more details, graphs and charts, click on this link PlantEngineering.

Plant managers are, of course, some of ACS Industrial Services’ very favorite people.  We work hard to make your life a little bit easier by providing timely and reliable industrial electronic equipment repairs from circuit boards, to CNC equipment to servo motors and everything in-between.