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?

(more…)

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

Tips: Why Did Your Ingersoll Rand Controller 22173579 Stop Controlling and What to Do

Did your Ingersoll Rand Controller 22173579 stop controlling? Quit on the job? This is frustrating! We get it – it’s a time consuming, costly annoyance to deal with a damaged or malfunctioning controller.

Good news! These Ingersoll Rand controllers are pretty well made and usually repairable! This is often true even for LEGACY units that are well past their warranty expiration date.

What might be wrong with YOUR Ingersoll Rand Controller?:

There are some commonly seen failures for these units. These are usually related to aging components. Problem description reports include getting ERROR Codes 51 and 71. The CAN communication IC (CAN is a specific communication standard) is a high failure rate in these units.  This is due to their susceptibility to noise and spikes. The voltage to frequency IC is also a common failure.

The electrolytic capacitors, as always, have a ‘lifetime’ and will need to be replaced eventually. There is a backup battery (a repair tech is needed for this as it is not customer replaceable) that may eventually fail as well. Output transistors also are occasionally bad in these controllers and can be replaced.

Here are a few recent examples of Ingersoll Rand Controller repairs.  Key failures and major component replacements are shown (all repairs also included cleaning and testing and/or repair of all other components):

  • Ingersoll Rand Controller OEM – 22173579

Problem reported: stopped “working”. Repairs included: Replacing bad capacitors, interface IC, opamp IC . This unit was repaired for about 75% less than the cost of replacement!

 

  • Ingersoll Rand Wedge Controller Comm. No. 22173579

Problem reported: Machine runs 20 seconds and shuts off prematurely and will not speed up. Sometimes won’t crank. Repairs included: Replacing bad capacitors and ICs

  • Ingersoll Rand Controller 22173579

Problem reported: Has a fault code 71 “CAN bus”. Repairs Included: leaky capacitors replaced and damage from leak cleaned/repaired, CAN IC replaced.

  • Ingersoll Rand Wedge Controller 22173579

Problem reported: Error code: 51. Cannot communicate with engine to start. Repairs included: COMM IC AND Serial Logic IC replaced.

We believe knowledge is power. If you are searching for a repair center for your damaged Ingersoll Rand Controller or other industrial 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 (more would be better!) 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 Ingersoll Rand repairs, repairs for touchscreens, controller repairs,  circuit board repairs, power supplies, VFD AC & DC drive repairs, servo motors, CNC equipment, encoders, monitors, test equipment, light curtains, and much more.  RUSH SERVICE is available and a comprehensive 2-Year Warranty covers most repairs.  The super-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. Or check out ACS’s incredible new easy-to-search Repair Catalog!

What Have We Done Lately – Mitsubishi Repairs!

Mitsubishi fork lift controller repairsIn our experience, Mitsubishi industrial electronic products are pretty great products. Even older, legacy Mitsubishi products are usually WELL worth getting Mitsubishi repairs.

Many of our ACS customers have legacy Mitsubishi products in their plants and shops. Lately, we’ve had lots of damaged or malfunctioning Mitsubishi industrial electronics in our shop for repairs– servo amps, inverters, operator panels, circuit board assemblies, servo drives, PLCs, controllers, and power supplies – just to name a few!

Why so many? No, not because they are all failing at once! More likely just because there are SO many good industrial electronic Mitsubishi products out there in use.  And our customers know the value of maintaining their equipment. These units may no longer be under the OEM warranty, but they are also nowhere near needing to be replaced. They are still perfectly good!

Electronic repairs and refurbishing are a great way to keep good, strong Mitsubishi and other equipment in place. This can potentially save you a ton of money over buying NEW equipment that could be better spent elsewhere in your plant!

So what have we done lately?

Here’s a few examples of successful electronic Mitsubishi repairs that have arrived on our docks for lately!

operator control panel repairs

Mitsubishi Operator Control Panel E-1061 – arrived with a broken screen, bad battery, bad IC and a lot of dirt/wear and tear all of which was replaceable/repairable!

 

 

Mitsubishi Servo Drive MDS-B-V2-4520 – arrived making noise in the z axis which kept servo drive repairsgetting worse and alarming out with an overcurrent Z alarm. This very dirty unit was full of weak and bad components including all of the capacitors, IGBT, and heat sinks – all replaced.

 

 

plc repairsMitsubishi PLC FX0S-14MT-D12SS – this damaged PLC required new capacitors, driver ic, resistors, and a dc to dc converter

 

 

 

Mitsubishi Power Supply MDS-B-CV-185 – damaged power supply arrived with a voltage problem, 41 alarm, and flashing LEDs; intermittent current – altogether this successfully repaired power supply needed replaced resistors in internal contactor circuit, replacedpower supply repairs capacitors on the control board plus replacement of 7 other capacitors and replacement of broken leads that were not making contact.

 

Mitsubishi Controller F9421500 – this sturdy but damaged controller arrived coveredcontroller repairs inside and out with grease and dirt with power problems and the ready light not flashing. Repairs needed included replacements for all of the capacitors, diodes, repair of cracked solder joints, plus a thorough cleaning/degreasing – which every unit gets!

 

Knowledge is Power

At ACS we believe knowledge is power. If you are searching for a repair center for your damaged industrial 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 (more would be better!) 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  operator control repairs,  circuit board repairs, touch screen repairs, power supplies, VFD AC & DC drive repairs, servo motors, CNC equipment, encoders, monitors, test equipment, light curtains, and much more.  RUSH SERVICE is available and a comprehensive 2-Year Warranty covers most repairs.  The super-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. Or check out ACS’s incredible new easy-to-search Repair Catalog!

Tips for Buying Used Industrial Electronics

Vickers S40 CNC controllerBuyer beware! Caveat emptor….you’ve heard it many times.  And when buying used industrial electronics (or anything for that matter) be hyper alert for problems.  This 1986 Vickers controller S40 was purchased second hand for use in a sheet metal fabricating shop.

As it turned out, the controller did have more than a few problems.  Soon after purchase the Y Axis controller was losing Y values during a run which the customer kept to a minimum by cooling with an external fan.  Months later the unit was failing on start up. When this unit is working properly the L5 L6 L7 all light up ready to work but the customer ended up with just the L4 lighting.

On top of all that, it appeared that previous repairs had been attempted which had not solved the problems.  In fact, the “repairs” themselves were the biggest problem.  Because it was purchased used, our customer had no idea what the history was with this unit.   It was just a hot mess, literally.

Bad times at this Australian sheet metal fabrication shop.  Luckily, this unit was repairable, and just as importantly, worth repairing.  After disassembling the unit and identifying the problems repairs were performed including repairing the switcher supply circuitry and replacing all the supply caps and buss caps.   All of the components were checked including the IGBTs and any that were aging were replaced. The unit was thoroughly cleaned, reassembled and tested before shipping back to the customer in working order.

After receiving the repaired unit back in Australia, our customer gave our team a 5 STAR review and had this to say:  “repaired unit works as it should, many thanks”  – John .  We are glad this story turned out so well!

Not all stories do turn out so well.  Buying used electronics can save a lot of money, or sometimes not.  It’s not necessarily that the seller is trying to get one over on you (although they may), it’s just that sometimes the problems may be unknown.   Before purchasing used industrial electronics do your due diligence to the extent possible including:

  • Inspect the condition
  • Test the unit if possible
  • Confirm its authenticity
  • Make sure there is a warranty, or at least know the return policy before purchasing
  • If it seems too good to be true, it probably IS, so walk away and keep looking

If the good deal you bought turns out to be a possible dud and you end up needing an industrial electronic repairs center for your damaged controller or other industrial electronics, check first to see if your equipment is still under warranty and if so, 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 power supply repairs, circuit boards, drives, servo motors, CNC equipment, encoders, monitors and touchscreens, test equipment, light curtains, and much more.  Rush Service is available and Two Year Warranties cover 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.