Indramat Drive Repair: Reducing Cost and Downtime for Manufacturers

Indramat drive repair is less expensive and can take less time than ordering a new Indramat drive. Indramat will sometimes recommend replacing failed drives instead of repairing them but Indramat drive replacement is expensive; And in most cases, the recommendation made by Indramat is the most convenient  and profitable option for Indramat. Indramat obsolete and out-of-stock drives that fail can cost a manufacturer thousands of dollars in production loss while the failed equipment is being replaced or repaired. In some cases, the production loss could turn into an inability to fill customer orders and ultimately, can end with the loss of a customer.

The Indramat Drive Repair Process

Begins with checking the motor and drive terminal connections. This is a crucial and simple step that many people miss or do incorrectly during an Indramat drive repair. Heat cycles and mechanical vibration can lead to sub-standard connections, as can standard preventative maintenance practices. Reusing torque screws is not a good Idea, and further tightening an already tight connection, can ruin the connection. Bad connections eventually lead to arcing. Arcing at the drive input terminal can result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the drive output terminal could result in over-current faults or even damage to the power components. Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable drive starting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections during an Indramat drive repair, and this step is done prior to applying power to the drive unit. If for any reason there is a short on the input side or output side of the drive, further damage can be caused to the unit if power is applied to it. For this reason, Precision Electric uses meters to safely test the input and output power sections of the drive, prior to applying power to the actual unit. If a short is found, the unit can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the Indramat drive repair is too costly, then an Indramat or equivalent product replacement is offered to the customer.

Power Up Unit
If the input and output power sections test healthy during the Indramat drive repair process, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electric slowly increases the power voltage to the Indramat drive until the rated input voltage of the drive is reached. Depending on whether or not the Indramat drive provides a display will determine what further action will be taken. If display is unavailable, disassembly and diagnosis of the internal power supply of the control section of the drive is necessary to further evaluate cause of failure and establish cost and lead time for the Indramat drive repair.

Run A Motor
If the previous three tests have passed during an Indramat drive repair process, Precision Electric will run a basic jog function of the drive with a simple template program. Often when a drive comes into our facility, we make sure to backup all existing programs stored in the drive prior to inputting a template program and running a test procedure. This ensures that we have a backup copy of the program. The best method for backing up depends on the brand of drive, but after it has been backed up, we either reset the Indramat drive to factory defaults through the keypad and recommission a basic start, stop and jog application, or, closed loop if an encoder is present. If the motor will not run, it will be necessary to check the output voltages and current ratings going to the motor to see if the drive is functioning properly to rotate the motor.

Routine Maintenance & Safety
Most Indramat drive failure can be avoided with routine preventative maintenance. Indramat drive repair cost and lead times can also be reduced with preventative maintenance. Indramat drive repair can be expensive and cost manufacturers production throughput loss during the repair process. Most manufacturers keep spare drives in stock to prevent production loss while failed equipment is in process of being repaired.

Indramat drive repair should be taken with extreme caution and only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends to consult an expert in the field when repairing all industrial electrical equipment. Many drive controllers have an internal DC bus that retains a charge after power has been cut to the drive; As a result, cut power does not mean a failed drive is safe to work with. Technicians working with Indramat drives and other electrical equipment must always take extra precautions to ensure proper safety measures are taken to prevent injury or death.

Where Should I Send My Repair?
A lot of companies who offer Indramat drive repair, don’t even have the knowledge, staff, or proper testing equipment to perform the repair themselves. These “repair companies” who offer drive repair just outsource the repair to a third party, such as Precision Electric. Precision Electric receives Indramat drive repairs every day from “repair companies” who offer Indramat drive repair. These “repair companies” mark up the cost to their customer and add extra time to the repair by handling the transaction. Going to these third party “repair companies” for repair services is costly, timely, and unnecessary. The most economical solution for Indramat drive repair is using a repair company who actually performs the repair. Avoid third parties and go straight to Precision Electric or someone else that is trustworthy and performs repair in-house. Precision Electric performs all Indramat drive repair in house.

For Indramat drive specifications and documentation, visit the Indramat Website. For Indramat drive repair and replacement quotes, contact Precision Electric.

Cutler Hammer VFD Fault Codes: Current and Overcurrent Protection

Cutler Hammer VFD Fault Codes, current control and overcurrent protection on the 9000X drive is based on motor current measurement in all three phases. In the FR9/CH61 and above drives, the current sensors are built into the IGBT SKIP modules, and the current signals are combined and fed into a 14-bit A/D converter on the lower ASIC board. The ASIC board sends the current levels to the control board via a fiber optic serial link. In the smaller drives, FR8/CH5 and below, the measured current signal is fed directly to the control board. The SVX has a 10-bit A/D converter and the SPX has a 14-bit A/D converter.

The 9000X air-cooled frequency converter ratings are based on a “High Overload” (IH) capability. This means the drive can provide 150% rated output current for 1 minute if the drive was operating at rated output current (IH) for at least 9 minutes. To get continued 150% overcurrent capability, the average current over the duty cycle cannot exceed the rated output current. The maximum drive output current (IS) for starting produces approximately 200% rated motor torque but because the currents are vector sums, IS is less than 200% IH. The drive can deliver IS for 2 seconds every 20 seconds. The drive current limit can be set to 200% (2 x IH) to deliver IH but to reduce the chance of an overcurrent or IGBT over temperature trip, it is better to set the current limit to 150% (1.5 x IH) or less. The actual drive output current available to the motor is dependent on ambient temperature at the intake to the drive, restrictions in airflow to the drive, and the drive frame size. Drive frames FR4–FR9 can deliver rated current (IH) at 50°C. Drive frames FR10 and above can deliver rated current (IH) at 40°C except for the highest ratings of a drive frame, which may be limited to 35°C. The “Low Overload” (IL ) rating is typically used for variable torque loads where an overload is not necessary even though a 1 (out of 10) minute overload of 110% is allowed. All drive frames are limited to 40°C or less for the IL rating. The rated currents of each frame depend on a reduction of switching frequency when unit temperature reaches the warning level.

LCX thermal current rating: The LCX liquid-cooled drive has a “Thermal” maximum continuous rms current (Ith). Use this value for continuous or any overload requirements of the process. The liquid-cooled drive does not have a 1-minute overload current rating. The thermal current rating is dependent on proper coolant flow to each module and a module coolant inlet temperature of 30°C.

Current limit (software-function): The drive will attempt to limit drive output current to the current limit setting by overriding the Cutler Hammer VFD fault codes and lower the frequency reference until current is within the current limit setting. If unit temperature nears the warning level, the drive will reduce the output frequency in an attempt to bring drive output current down to a continuous current that is approximately the “Low Overload” (IL ) current rating. The control will not allow any further overcurrent conditions until the average current over the duty cycle is less than the drive’s current rating. The liquid-cooled drive control will attempt to limit the output current to the current limit setting up to the drive’s thermal rating, I th. The application should be designed to avoid using the current limiter for control. The safest way to operate the drive is to keep the drive output current within ratings with appropriate ramp times or a controlled reference to the drive.

Current cutter (hardware-function): If the drive software cannot prevent output current from exceeding 200% IH, a current cutter stops firing the IGBTs when the measured instantaneous value of the current exceeds 360% IH to reduce current quickly before overcurrent Cutler Hammer VFD fault codes trip the drive. They are re-fired on the next top of the triangle wave. The current cutter is active on select units FR8/CH5 and smaller.

Saturation fault (hardware-function): If the other current control and protection functions are not fast enough to prevent an extreme overcurrent condition, the IGBT saturates and the resulting voltage drop across the IGBT causes an F7, Saturation trip and all IGBTs are immediately switched off by the gate driver board. The brake chopper IGBT also has saturation protection and gives the same trip indication. Power to the drive must be cycled to reset this trip. This function is not yet available on drives FR10/CH61 and larger.

Visit the Eaton Website for information on additional Cutler Hammer VFD Fault Codes. Contact Precision Electric for Cutler Hammer VFD repair and replacement quotes.

Eaton Industrial Controls 2017 Nationwide Roadshow Tour

Eaton industrial controls kicked off their 2017 Nationwide Roadshow Tour. The hands-on, 40-foot, interactive showroom will travel to nearly 20 U.S. cities and educate original equipment manufacturers (OEMs), facilities managers, commercial customers, end users, contractors and others about Eaton’s newest energy efficient innovations for heating, ventilation, air conditioning and refrigeration (HVAC/R), pumping, process industry and machinery applications. The Eaton Industrial Controls Roadshow features four interactive demos arranged by commercial and industrial application environments. Live demo areas include: an Eaton VFD system drive, a multi-pump booster system, a material handling conveyor, and a mixing and separating process. An interactive Internet of Things (IoT) component allows visitors to create their own fault situation and receive alerts on their mobile phones.

The Eaton Industrial Controls Roadshow made its first stop in Las Vegas, Nevada at the 2017 AHR Exposition. The roadshow tour recently left St. Louis, MO and is currently in route its next stop. The roadshow is also planned to visit other select cities including Milwaukee, Wisconsin; and Cleveland, Ohio. The tour will conclude in November with a final visit to Fresno, California. Visit Eaton.com/ControlTour to view the full schedule or register here.

Eaton industrial controls have been providing power management needs for more than a century. Over the years, Eaton has expanded their expertise and portfolio of products and services by uniting some of the world’s most respected names with Eaton’s strong heritage of innovation. The roadshow therefore reflects complete packaged solutions that not only include industrial control products, but also our world-class motor control centers and breakers with Bussmann E series fuses, B-Line E series support systems and switches, and Crouse-Hinds E series explosion-proof enclosures. With customers in 175 countries and more than 100,000 employees worldwide, Eaton has experts on the ground to develop more complete and customized solutions to respond to power management needs.

Eaton is a power management company with 2016 sales of $19.7 billion. Eaton provides energy-efficient solutions that help customers effectively manage electrical, hydraulic and mechanical power more efficiently and safely. Eaton has approximately 95,000 employees and sells products to customers in more than 175 countries.

For Eaton VFD repair or replacement quotes, contact Precision Electric. For more information on Eaton products, visit www.eaton.com.

DC Motor Surplus Inventory

The Following DC Electric Motors are currently available in our Surplus Inventory. You can call us anytime to request a quote.

Ph: 877-625-2402

 

OUR Stock Number Manufacturer Model Number Type / Description / Nameplate Information Condition
116 PACIFIC SCIENTIFIC SR3624-8291-7-56BC 1/4 HP, 1750 RPM, 56C FRAME, 90VDC, TEFC HAS BASE NS
421 BOSTON GEAR APM925AT 1/4 HP, 1725 RPM, 42CZ FR, 90VDC, PM, TE E OK
173 BALDOR CDP3316 1/3 HP, 1750 RPM, 56C FR, 180VDC, PM TENV E OK
174 BALDOR CDP3330 1/2 HP, 1750 RPM, 56C FR, 90 VDC, PM, TENV E OK
176 PACIFIC SCIENTIFIC SR3640-8293-84-7-56HC 1/2 HP, 1750 RPM, 56 FR, 90 VDC, PM, TENV, D FLANGE E OK
423 GENERAL ELECTRIC 6VFM1050B561A1 1/2 HP, 1725 RPM, 56 FR, 100F, 90A, TENV E OK
425 BALDOR CDP3326 1/2 HP, 1750 RPM, 56C FR, 180 VDC, PM, TENV E OK
108 BALDOR CDP3436 3/4 HP, 1750 RPM, 56C FRAME, 180 VDC, PM, TEFC, NO BASE E OK
118 BALDOR CDP3518 1 HP, 1750 RPM, 56C FRAME, 180 VDC, PM, TEFC, NO BASE NS
428 LEESON C4D28FK6G 1 HP, 2500 RPM, XS56C FR, 180VDC, PM, TEFC E OK
412 GENERAL ELECTRIC 5BPA56RAG9A 1 HP, 1725 RPM, 56 FR, 180 VDC, PM, TEFC E OK
177 BALDOR CDP3455 1 HP, 1750 RPM, 56C FR, 180 VDC, PM, TEFC E OK
131 RELIANCE DC0189ATCZ 2 HP, 1750/1950 RPM, 189ATZ FRAME, 240 A, 150 F, BV E OK
155 GENERAL ELECTRIC 5CD144VC001B008 3 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENV E OK
153 GENERAL ELECTRIC 5CD144VC001B008 3 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENV E OK
133 GENERAL ELECTRIC 5CD144VC001B008 3 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENV E OK
156 BALDOR CD6203 3 HP, 1750 RPM, 184TC FR, 180A / 100/200 F, TEFC E OK
157 GENERAL ELECTRIC 5CD145VC005B001 3 HP, 1750/2050 RPM, CD189ATC FR, 180 A/100/200 F, TENV E OK
162 RELIANCE T18P1118E-7S 3 HP, 1750 RPM, DC0189ATY FR, 200F, 180A, DP E OK
624 RELIANCE T18R1323H-PT 5 HP, 1750/2300 RPM, CT811ATZ FR, 500A, 300F, DP NS
432 CUTLER HAMMER 250-100-0116A 5 HP, 1150/2000 RPM, 256AT FR, 500/300 VDC, DP E OK
150 CUTLER HAMMER 250-100-0116A 5 HP, 1150/2000 RPM, 256AT FR, 500/300 VDC, DP E OK
141 GENERAL ELECTRIC 5CD1531A806A800 7.5 HP, 2500/2875 RPM, 500 A, 150/300 F, CD219T FR, BV E OK
142 MAGNETEK 2190B411L02 7.5 HP, 1750 RPM, 180 A, 200 F, 219AT FRAME, BV E OK
434 BALDOR D5010 10 HP, 1750 RPM, AD219AT FR, 500A, 150/300F, DPFG E OK
130 RELIANCE 11839122T21 15 HP, 1250/3750 RPM, 259AT FRAME, 120 A, 240 F, BV E OK
137 GENERAL ELECTRIC 5CD063KA038A127 15 HP, 1750/2300 RPM, CD258AT FR, 500 A, 150/300 F, BV E OK
433 BALDOR D2018R 15 HP, 1750/2300 RPM, SC2113ATZ FR, 240A, 180F, DP NS
129 RELIANCE 4LA843818TL 20 HP, 1750 RPM, 284T FRAME, 120 A, 240 F, BV E OK
146 RELIANCE 06KA867603-ZU 20 HP, 1750/1950 RPM, LC2512ATZ FR, 500/300 VDC, E OK
147 RELIANCE F28P1701A 25 HP, 2500/3000 RPM, 284AT FR, 240/240 VDC, BV E OK
436 RELIANCE R-66575-T1-HS 30 HP, 500/2000 RPM, 505-AS FR, 240A, 240F, HAS BLOWER E OK
441 CMC 2890B452C01 40 HP, 1750 RPM, 289ATZ FR, 500A, 300F, DP RG
454 RELIANCE T28S1330E-AC 60 HP, 1750/2100 , MC2812ATZ, 300/500 VDC, DPBV RG
152 POWERTEC A28DLF1000900011 75 HP, 2500 RPM, 2810TZ FR, 640 BUS VDC, BRUSHLESS E OK
440 RELIANCE 1U827783T5-LP 100 HP, 1750 RPM, 503A FR, 480A, 240F, FORCE COOLED E OK

Yaskawa Servo Motor Repair

Yaskawa servo motor repair is less expensive than Yaskawa servo motor replacement. Only trained technicians should perform Yaskawa servo motor repair. Trained technicians undergo unique testing procedures on Yaskawa servo motors that are dependent to each servo motors’ model, features, operations, and prints. Trained technicians will have the ability to perform these procedures successfully and safely. The first step of Yaskawa servo motor repair is the inspection of equipment for cosmetic damage or missing parts. Trained technicians take this step to ensure a successful repair is possible before proceeding further. Taking digital photos of the servo motor prior to further processing is also suggested.

Servo Motor nameplate data and preventative maintenance info should be collected by the technician and safely stored for future reference. Once these initial steps are complete, the servo motor should be meter tested before test running on a control panel; Meter testing prevents further damage to parts, motor winding, and insulation. The servo motor should then be connected to a test panel to check EMF (electromagnetic frequency), encoder or resolver feedback, and commutation alignment; These standard tests are to ensure functionality, once the motor is installed for production. Servo motors also need to be tested with an oscilloscope to create an operation print. Once an operation printout is generated, a technician will check for connection issues, magnet failure, and winding failure. Once this is complete, the trained technician will perform a 100% component test to the servo motor. Once these tests are finished, the cost to repair and replace parts is estimated and labor is also determined. If the cost to repair the servo motor exceeds 50-60% of the cost to replace, the customer is offered a replacement quote. Otherwise, the technician can create a repair quote with lead time and communicate all pertinent information to the customer. Once the customer approves the repair quote, the technician will proceed with the repair.

Now, the technician will have an in-house machinist perform shaft and bearing housing repairs that are damaged. Old bearings are removed and saved for future reference. The technician will clean up and make repairs to all other damaged parts; replacement parts that cannot be repaired are ordered at this time. Finally, the technician will install new bearings and reassemble the servo motor for final testing. During the final test procedure, technicians should connect the motor to an inverter, with and without a load. Running the servo motor on an inverter ensures complete functionality; Running the servo motor with a load will ensure full functionality once it is running in production. Testing with an inverter also allows verification that the servo can operate at full voltage and withstand full load amps of motor specifications. Yaskawa servo motor repair shops should work closely with all servo motor manufacturers. Working closely with servo motor manufacturers allows repair shops accessibility to servo motor data sheets, parts, and other valuable information. Repair technicians use data sheets to ensure that the servo motor performs equal to or better than, the original manufacturer standards.

Most Yaskawa servo motor repair shops offering servo motor repair don’t perform the repair themselves. These repair shops actually outsource the repair to a third party and then mark up the repair price to their customer. Outsourcing the servo motor repair is not a good idea. Outsourcing the repair is done when the repair shop does not have the ability or training to perform the servo motor repair. Repair shops use third party repair shops such as Precision Electric, because Precision Electric has been in the manufacturing industry since 1984 and their competent staff have the skills and training needed to perform these services. Most customers don’t find out that their repair shop is outsourcing the repair to Precision Electric until they contact the repair center asking technical questions. When this happens, the repair center is unable to communicate or provide technical information to the customer; and the repair center has their customer call Precision Electric for the answers they need.

This process ends up costing the manufacturer more money, time, and additional problems with their equipment. Manufacturers and other servo motor users should send their Yaskawa servo motor to the company that is actually performing the repair. This will save money, time and this will ensure a professional and high quality repair. Yaskawa servo motor repair from Precision Electric is performed in house and includes a 12 month in-service warranty. For Yaskawa servo motor repair and replacement quotes, contact Precision Electric at 574-256-1000. Or, initiate your servo motor repair here and send it to Precision Electric today.

Robotic Automation: ABB Robots For The Packaging Industry

ABB robotic automation ensures shorter product life cycles, new packaging designs, product variants and batch manufacturing. Compared to dedicated hard automation, robot lines are shorter and allow far better utilization of floor space. In addition to increased up-time and total throughput of production, fewer accidents and increasingly demanding workplace laws are compelling reasons to make the transition to ABB robotic automation. Robots are usually associated with handling repetitive tasks in a process – either in high volume production roles or where flexible handling systems are needed for frequent changes. In the packaging industry, robots generally fall into three main areas:

 

  • Pick and Place Applications (where products are packed into trays or secondary packages)
  • Feed Placement (where products are prearranged on a conveyor to ease future packaging procedures)
  • Palletizing (pallet loading and unloading)

 

Picking

This is an area in which ABB services a multitude of products, applications and packaging line set-ups. Frozen food, bakery and confectionery, ice cream, meat and fish, cheese, pet food, medical products, shampoo and perfume bottles are a few examples. The ABB IRB 360 is the first 2nd generation delta robot; The FlexPickerTM . The new robot family will initially see three models available. Stainless steel versions are available for wash down duties such as in meat and dairy handling applications. Apart from even greater performance, the new delta robot has a significantly increased payload of up to 3 kg – opening up further application possibilities, especially at the end of line. For full 6-axis flexibility, less demanding cycle times and payloads of up to 5 kg, ABB recommends the IRB 140.

Palletizing

Placing boxes, trays, bags, bottles or other items on a pallet seems easy enough. But, when you’re dealing with the rigorous demands of multiple feeder lines, quick box-pattern changes and high up-time, nothing compares to ABB robotic automation. The ABB IRB 660 has the versatility, reach and handling capacity needed for most palletizing applications. For even greater payload requirements, ABB standard 6-axis robots are the largest and are built to handle as much as 1,433 lbs.

The IRB 660 is a refinement of the well established, proven, ABB IRB 640 palletizer, with more than 1,800 installations worldwide. The new version of this robot blends speed, reach and payload like no other. Exceptionally fast, this 4-axis performer combines a 3.15 meter reach with a 250 kg payload, making it ideal for palletizing bags, boxes, crates, bottles and more. The new palletizer comes in two versions; a high throughput version designed for 250 kg and a high-speed version built to handle 180 kg payloads at full speed. The IRB 660 has the versatility, reach and handling capacity to meet the demands of just about any palletizing application. And it’s robust enough to perform steadily in the toughest environments.

Tailor Made Robots For Demanding Packaging Industries

ABB robotic automation includes specialized robots for picking, packing and palletizing. In addition, ABB provides a wide range of standard 6-axis robots which allows customers to meet the demands of nearly all applications in the packaging industry. What’s more, ABB’s unique packaging software, including vision technology and conveyor tracking, facilitates continuous production flows and packing on-the-fly. This allows for efficient handling of food and beverages, pharmaceuticals, cosmetics, electronics or personal care products.

High Speed Packing

The ABB FlexPicker IRB 360 is a unique parallel-arm robot designed for the most exacting high-speed picking and packing applications. The new robot succeeds ABB’s widely used FlexPickerTM IRB 340 system and is the result of 10 years’ experience and research and development combined with proven packaging technology. ABB has over 2000 delta robots installed globally and is the leader in this state of the art picking and packing technology. The newest version of the IRB 340 is called the FlexPickerTM IRB 360.

Cost Efficient Packing

The 4-axis IRB 260 houses all the necessary features for placing items in boxes, tray handling and more. Optimized for packing applications this robot can work closely to its own base, allowing very compact packing cells and integration into tight packing machines. IRB 260

features a 30 kg payload capacity and short cycle times to meet the packing industry requirements. Like all ABB robots, the IRB 260 is compatible with PickMaster, our dedicated software for packaging applications, including vision guidance and easy programming.

Food Safety & Pharmaceutical

ABB builds robots to meet the most demanding work conditions – as well as the highest hygiene standards. In addition, all ABB robots are IP67 certified, ensuring tightly sealed joints and connectors. The IRB 360, which is most likely to handle open food, is available in wash-down and stainless steel and is IP69K certified.

The demands on quality validation and traceability are extremely high in pharmaceutical production. The absolute accuracy, repeatability and high up-time of ABB robots result in massive improvements over manual operation or dedicated production equipment. All ABB smaller robots are suited to primary packing and are verified for clean-room operation.

To learn more about ABB Robotic Automation, visit the ABB Website. For ABB robot integration or replacement quotes, contact Precision Electric. Precision Electric can retrofit obsolete packaging machines / inefficient packaging systems with ABB Robotic Technology. We also offer servo drive repair and servo motor repair for All industrial robots.

 

Yaskawa Servo Drive Repair: Increasing Production for the Customer

Fanuc Servo Motor Repair, Short Summary Of Our Procedure

Fanuc servo motor repair is less expensive than Fanuc servo motor replacement. Only trained technicians should perform Fanuc servo motor repair. Trained technicians undergo unique testing procedures on Fanuc servo motors that are dependent to each servo motors’ model, features, operations, and prints. Trained technicians will have the ability to perform these procedures successfully. The first step of Fanuc servo motor repair is the inspection of equipment for cosmetic damage or missing parts. Trained technicians take this step to ensure a successful repair is possible before proceeding further. Taking digital photos of the servo motor prior to further processing is also suggested.

Servo Motor nameplate data and preventative maintenance info should be collected by the technician and safely stored for future reference. Once these initial steps are complete, the servo motor should be meter tested before test running on a control panel; Meter testing prevents further damage to parts, motor winding, and insulation. The servo motor should then be connected to a test stand to check EMF (electromagnetic frequency), encoder or resolver feedback, and commutation alignment; These standard tests are to ensure functionality once the motor is installed for production. Servo motors also need to be tested with an oscilloscope to create an operation print. Once an operation printout is generated, a technician will check for connection issues, magnet failure, and winding failure. Once this is complete, the trained technician will perform a 100% component test to the servo motor.

Once these steps are complete, the technician will make repairs to applicable parts and order replacement parts that cannot be repaired. Finally, the technician will reassemble the servo motor for final testing. During the final test procedure, technicians should connect the motor to an inverter, with and without a load. Running the servo motor on an inverter ensures complete functionality. Testing with an inverter also allows verification that the servo can operate at full voltage and withstand full load amps of motor specifications. Repair shops should work closely with all servo motor manufacturers. Working closely with servo motor manufacturers allows repair shops accessibility to servo motor data sheets, parts, and other valuable information. Repair technicians use data sheets to ensure that the servo motor performs equal to, or better than, the original manufacturer standards.

Most repair shops offering Fanuc servo motor repair do not even perform the repair in their facility. Instead, these repair shops outsource the repair to a third party such as Precision Electric. Most manufacturers don’t know that their repair center isn’t even performing the repair. This process ends up costing the manufacturer more money, time, and additional problems with their equipment. The best option for manufacturers is to send their Fanuc servo motor to the company that’s actually performing the repair. This will save the manufacturer money, time and ensure the best possible repair. Fanuc servo motor repair from Precision Electric is performed in house and includes a 12 month in-service warranty. For Fanuc servo motor repair and replacement quotes, contact Precision Electric at 574-256-1000

MotiFlex E180 ABB Servo Drive – Product Overview

The MotiFlex e180 ABB servo drive delivers versatile motion control performance, capability and dependability to power machine innovations. Flexible connectivity with Ethernet and motor feedback technologies is highly integrated and optimized for demanding motion applications. With the MINT WorkBench PC tool you can quickly and easily customize the drive to the exact control requirements of your machine.

The MotiFlex e180 ABB servo drive delivers capability and performance you can depend on. It combines Ethernet technology, advanced multitasking programming and safety as standard. The MotiFlex e180 can operate from 200 to 480 V AC three-phase with motor RMS current range from 3 to 50 A servo duty. Ethernet and motor feedback interfaces are fully integrated and optimized for demanding motion applications.

Metal Forming and Converting Machinery

The metal industry sets high requirements for motion control. In applications such as pressing, bending, laser cutting, drilling or polishing the motion control system must perform well in tight tolerance levels and changing inertia loads. MotiFlex e180 ABB servo drive adapts to various roles in different metal forming and converting machinery.

  • Dynamic control for rotary and linear servo motors with up to 300% overload modes
  • Highly integrated connectivity to various feedback devices as standard and dual feedback to eliminate mechanical errors
  • Real-time communication over Ethernet ensures optimal machine performance

Textile Machinery:

The textile industry requires high dependability, throughput and performance in harsh environments exposed to dust, humidity and high temperatures. Typically textile machines operate 24/7 with high production speeds and big volumes. An unwanted interruption of a machine turns quickly to big losses in production. MotiFlex e180 ABB servo drive provides dependable performance, accurate speed and tension control to textile machinery such as winding, reeling, spinning, dyeing, stretching, weaving, knitting, finishing and printing.

  • The drive can be used for stand-alone single axis control, in centralized systems for multi-axis control or as the master drive controlling other drives
  • Highly integrated and flexible feedback device connectivity as standard, including rugged resolvers and precise encoders

Plastics Machinery:

  • Plastics machinery requires versatility from motion control. From high starting torque in extrusion to high speed and tension control in winding, and high accuracy and dose control in injection and blow molding.
  • Versatility and flexibility are key attributes for the MotiFlex e180 ABB servo drive
  • A broad operation range with continuous currents up to 90 A, and overloads up to 300%
  • Real-time Ethernet connectivity enables high precision and quality of end-products
  • Highly integrated connectivity to various feedback devices comes as standard, including robust resolvers

Packaging:

Packaging applications, over wrappers and vertical form fill seals, demand high throughput and repeatable quality of product with minimum downtime. MotiFlex e180 ABB servo drive features high performance servo control for dynamic motion, with tightly integrated Ethernet control and feedback devices to match the machine needs of precision and resilience.

  • Safe torque off (STO) as standard eliminates costly power cycles, with immediate restart in the event operators open machine guards
  • High speed registration inputs provide precise registration of product and label for high speed labeling

ABB designs motion control solutions to power machine innovations. From servo motors and drives to complete systems with programmable logic controllers (PLC), motion controllers and safety technology, ABB’s offering is designed to scale and integrate seamlessly to different machines, providing dependable performance, high process quality and productivity. ABB engineers work together with machine builders in a broad range of industries to know what it takes to succeed in this dynamic world of motion control.

For Motiflex e180 ABB servo drive repair and replacement quotes, contact Precision Electric.

Machining a NEW Fan Hub

Machining a New Fan Hub

 

Repairing Electric Motor Bearing Housing

Layne preparing a bearing housing for a sleeve insert.

Differences Between ABB ACS Drives ACS-xxx-01E/03E/01 And ACS-xxx-01U/03U/U1

What are the drive differences between an ABB ACS Drives, model: ACSxxx-01E/03E/01 and ACSxxx-01U/03U/U1

Answer: The ABB ACSxxx-01E/03E/01 drive’s motor information parameters default to the following MOTOR NOM FREQ to “50Hz”, MOTOR NOM POWER is in “Kw”, REF1 MAX to “50Hz”, MAXIMUM SPEED to “1500RPM” and MAXIMUM FREQ to “50Hz”. The EMC metal screw is installed activating the EMC filter. 50 Hertz default output and power ratings in Kilowatt are standard for drives and other industrial electrical equipment in Western Europe, the United Kingdom and most countries located outside the United States of America. This is because electric motors are sized in Kilowatt ratings outside the USA; and, electric motors manufactured outside the USA run at full load speed when operating at 50 hertz.

The ACSxxx-01U/03U/U1 drive’s motor information parameters default to the following MOTOR NOM FREQ to “60Hz”, MOTOR NOM POWER is in “Hp”, REF1 MAX to “60Hz”, MAXIMUM SPEED to “1800RPM” and MAXIMUM FREQ to “60Hz”. The EMC plastic screw is installed deactivating the EMC filter, but the drive ships with the metal screw to activate the EMC filter. 60 Hertz default output and power ratings in Horsepower are standard for drives and other industrial electrical equipment in the United States of America. This is because electric motors are sized in horsepower ratings in the USA; and, electric motors manufactured in the USA run at full load speed when operating at 60 hertz.

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