Inverter Drive System

Inverter Drive System Repair

The regulation of energy in any operation is critical to performance and output – in cases where power isn’t controlled the result can be damaged equipment or high maintenance costs – and lost production time.

The role of an inverter drive system is to handle energy coming from the main power source. When the power arrives at the inverter, the first step is to convert it from AC to DC power, which occurs in the rectifier. 

Inverter Drive System

Once the power has been converted, it then goes into a set of capacitors. Here, the energy is “smoothed out” – basically the waveform is adjusted for safe consumption by the machinery. Once this occurs, the power is fed to the motor.

It’s an important step since the frequency and voltage is modified based on the amount of energy that is needed – this step not only saves energy and reduces power costs, it also helps ensure that the machinery is running properly.

Factors that Cause Damage

Like any piece of machinery, an inverter drive system can fall prey to a variety of problems that can be caused by internal failure, the operating environment, and overuse. Without proper maintenance the machinery can function below capacity or ultimately wear out.

Capacitor Wear

Capacitors are an integral part of an inverter, and they can wear down due to their sensitivity to temperatures. High current causes increased heat, which is why it’s crucial to regulate the operating speed of any system.

Overuse

Relying on one inverter or a bank of inverters that aren’t right for the job speeds up the wear and tear on an inverter. Over time, despite regular maintenance, the parts simply wear down and then break.

Over Voltage

When voltage increases beyond the capacity of the inverter, components can be severely damaged and cease to work, mostly due to excessive heat. Fuses and circuit breakers usually regulate this problem. Sometimes, though there are power surges that overcome these fail safes and can be attributed to lightning strikes and even solar flares.

Vibrations

Regardless of the age or quality of machinery, vibrations are unavoidable. Excessive vibration can loosen electronics or cause them to corrode. Heat caused by vibration is another culprit. Simple maintenance procedures, which can easily be forgotten include cleaning terminals in the battery box, fuses, and the inverter connection.

ACS Can Repair Your Inverter 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 inverter drive system then 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.

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.

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.

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.

6 Top Tips to Extend the Life of Your Power Supply

ACS Repairs Lambda Power Supplies

Power supplies – they are ever present for most of us, both at work and at home.  They come in all sizes and levels of quality and for myriad purposes.   Even so, they have some things in common – their universal dislike of moisture, heat, and dirt – which I like to refer to as the electronic axis of evil.

Here are 6 top tips to extend the life of your power supply and avoid having to replace or repair your power supply:

1.  Number one tip, by far, is to buy the best power supply you can afford that is adequate for the load.  A power supply is absolutely one of those things where you get what you pay for.  If you opt for a cheap unit, it may not supply adequate current even when used within nominal power ratings.  Power supplies don’t like to die alone either – they usually take down other components with them when they go.  Buying a cheapie power supply will cost you in the end!

2.  Know the MTBF…that is your “Mean Time Between Failures” rating of your power supply.  To do this you can check the electrolytic capacitors used in your PSU.  Capacitors have a limited life that affects the life span of the power supply.  Either ask your sales rep for this data or check on these:

  • Size of Capacitor – bigger is usually better
  • Operating Temperature – the hotter your work environment, the shorter the power supply’s life
  • Component Rating – how much voltage the unit can safely handle

3.  Make sure the area around the power supply is well ventilated.  (Remember…power supplies hate excess heat.)

4.  Keep the vent and fan clean and free of lint, grease, dust or whatever it is that accumulates in your plant or office.  This may mean cleaning it often, at least once a week.

5.  Minimize vibrations.

6.  Don’t get your power supply wet – ever.  Unless it is made to operate in a wet environment.

If your power supply does quit on you, know that most power supplies are repairable.  Even those that are choked in grease and dirt (as they often are) can usually be revived.  If your unit is still under warranty call the power supply manufacturers to get assistance. If your power supply is out of warranty, you can still get power supply repairs from a reputable industrial electronic repairs shop.  However, none of this applies if you bought one of those no-name, super-cheap power supplies from some mystery website.  If this is the case, your best and cheapest (really!) course of action is probably to replace it with a better quality power supply.

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, repairs for industrial power supplies, drives, servo motors, CNC equipment, encoders, monitors and touchscreens, test equipment, light curtains, and much more.  Rush Service is available and a comprehensive 2-Year Warranty covers most repairs.  The customer service team is available to answer your questions and help solve your industrial electronic repair problems. You can reach them by calling 800-605-6419 or going to www.acsindustrial.com.

Power Supply Repairs for TV Stations

Get Expert Power Supply RepairsHey, so what’s going on in all those television stations around the country?  For some reason we have been seeing a huge increase in damaged power supplies sent in for repairs from television stations.  Maybe things are getting a little rough out there in TV land?

As it turns out, these power supplies are pretty repairable and we’re pretty darn good at repairing them.  So never fear, you will be watching your favorite TV shows and sports games this weekend (The real NFL refs are back!! Yes!!) without interruption.

Need to get power supply repairs fast?  Click here or short cut to these popular TV station power supplies below:

Sony Power Supply Repairs

Cherokee Power Supply Repairs

Pioneer Magnetics Power Supply Repairs

ACS Industrial Services has got your back!  Let us get you back up and running!

Winning Solution For “Jerry-Rigged” Circuit Boards

Unique Solutions for Unrepairable Circuit Boards

Three New Circuit Boards Made From One Original

Sometimes we receive some pretty mysterious repair jobs on the old loading dock.  Recently we received three printed circuit boards that were so, so, well, so “jerry-rigged” that we were wondering how they ever worked in the first place what with the point to point hand wiring, jumpers, and patches all over them.  (Truth is, sometimes I miss the old days working on that loading dock…every day it is full of surprises!)

These “jerry-rigged” circuit board repairs were going to take a lot of man-hours and the cost was going to be pretty high.  The solution we offered this customer was to build them some brand new boards in-house at ACS rather than repair the scary boards – and for lower cost than it would have been to repair them!  Sometimes, the solution to the problem is staring you in the face and you just have to go with it.

There were actually four PCB’s needing repair in this shipment, three as described and one more than had been professionally manufactured.   Ultimately, copying the professional board to make the three new ones provided this customer with a more reliable solution, as well as having the added benefit of being able to reproduce them on-demand in the future from the files that were created.  This was a winning solution in every way.

ACS Industrial Services is here for you.  We want to make sure you always get the best solution that meets your needs in the time you need it.

Simplified On-line Repair Form Makes Getting Electronic Repairs Easy

Have you tried our new, simplified on-line repair form yet?  It’s been live for a few weeks and WOW is all we can say!  Wish we’d done it sooner.

The process is working great and our customer surveys are producing comments like this:

  • “Easy as pie. Nothing more needed.”
  • “I really do not see how you could have made it any more easier.”
  • “CANNOT IMPROVE ON PERFECTION .”
  • “This form was super-easy to understand and complete. My suggestion is “Don’t do anything to improve; it works perfectly as is.””

We boiled everything down to the basics to make it a whole lot faster and easier on you.  We’ve all gotten stuck in annoying on-line forms and it’s just really irritating.

If your equipment is down and needs repair we know you are ALREADY irritated. We wanted to reduce the irritation factor and keep the process simple and straightforward– that is, getting your electronics repaired and back to you as fast as possible for the best price possible.

Need repairs?  Give our new on-line repair form a try by clicking here.  Need more information about our industrial electronic repair services?  Click this link:  ACS Industrial Services.