Cutler Hammer SVX9000 – An Overview Of Eaton’s General Purpose Drive

Cutler Hammer SVX9000 adjustable frequency drives are the compact, modular solution to variable speed applications. They enable a broad range of new application capabilities. A complete selection of option cards allows you to configure the drive to meet any requirement. With its wide voltage range, high overload ability, and user-friendly alphanumerical keypad, Cutler Hammer SVX9000 drives are the smart decision for every user.

Just three screws link the control module to the power module. What’s more, control units are interchangeable within frame sizes while software, control panels, I/O and communication cards are common throughout the line. Separating the power and control units provides installation advantages and reduced spare parts requirements. For convenience, the Cutler Hammer SVX9000 is field convertible from Type 1 to Type 12 (frames 4–6). Its reduced size equates to less panel space used and easy retrofits.

Even when the drive is unpowered, the Cutler Hammer SVX9000 can be programmed and tested. The control logic module can be powered from an external +24 Vdc source so you’re ready to train, test and go live whenever needed. Whether you choose local or remote operations via the keypad, simple copy/paste functions streamline the process.

The Cutler Hammer SVX9000 may be configured with several different communication protocols, making it easy to communicate with all commonly used control systems. The control unit’s powerful microprocessor can be used for local control tasks, thereby freeing resources of the control system for other control tasks. 9000XEngine, the versatile block-programming tool, eliminates the need for a PLC and significantly simplifies the control system.

The Cutler Hammer SVX9000 adjustable frequency drive offers sensor-less vector control technology coupled with an adaptive motor model and sophisticated ASIC circuit features. This technology allows for steady speed error, fast torque rise time, high immunity to resonance vibrations and high starting torque and current. The SVX9000 is suitable for multiple motor drive systems and high-speed applications.

Cutler Hammer SVX9000 is available in 230V to 125 hp480V to 250 hp600V to 200 hpType 1/IP21 Enclosed or Type 12/IP54 Enclosed. The Cutler Hammer SVX9000 offers the following communication options:

• EtherNet/IP
• Modbus RTU/TCP
• PROFIBUS DP
• DeviceNet
• CANopen
• LonWorks

Cutler Hammer SVX9000 Software Tools

9000XLoad is an easy-to-use tool for uploading system, application and option card software intended for use by engineering, commissioning and service personnel. 9000XLoad is also suitable for loading custom applications to the SVX9000 drive.

9000XDrive is a software tool that allows uploading and downloading drive parameters. Parameters can be changed, saved, and uploaded to any number of SVX9000 drives. The tool has the ability to print parameters or save them to a file for future use and reference. Parameters can be compared to default values to determine drive setup. Operator functions include the ability to set references, start and stop the drive, and to monitor signals and actual values. These values can be displayed via a graphic display.

9000XEngine allows the user to create IEC 1131-3 compliant custom applications with 9000XEngine. This graphical design tool customizes the control logic and parameters in the SVX9000. Functional Block Diagram (FBD), Ladder Diagram (LD) and Structured Text (ST) are all part of the function set. 9000XEngine enables the creation of parameters, fault messages and other application related features.

The Cutler Hammer SVX9000 drive is sometimes mistaken for the Cutler Hammer SPX9000; the SPX9000 is a Cutler Hammer high performance drive and is available through 2000 HP. For Cutler Hammer SVX9000 user manuals and other product downloads, visit the Eaton Website. For Cutler Hammer SVX9000 drive repair and drive replacement quotes, contact Precision Electric. Precision Electric repairs all Cutler Hammer drive products through 2000 HP, in house.

VFD Overvoltage Fault – troubleshooting variable frequency drives

A VFD overvoltage fault is fairly common with VFD regular usage. This fault may arise at different places and times for several reasons. The first step in resolving the problem is identifying when and where the fault occurs. A VFD overvoltage fault can occur on power up, during deceleration, acceleration, during normal run, or while sitting idle.

If the VFD overvoltage fault occurs during power up, the first thing to check is the incoming line voltage with a meter. If the line voltage is within specifications, find the jumper used to ground the common capacitors. This jumper will remove the common mode capacitors from ground. The VFD overvoltage fault may occur from ground noise coming back in through these capacitors causing a rise on the DC bus.

VFD overvoltage fault, at deceleration 

The most common time a VFD overvoltage fault occurs is during deceleration. Sometimes the braking  torque requirement exceeds drive braking circuit capacity. Other times the deceleration is too fast for its load and inertia from the load is going faster than the designated frequency. If you hit stop during a ramp down, the load spins faster than the designated frequency, the motor regenerates power back into the drive. The motor load then turns into a generator. This power is fed back into the drive, and stored on the DC bus. Extending the deceleration time is one way to solve a VFD overvoltage fault during deceleration.

If extending the deceleration time does not solve the VFD overvoltage fault, a dynamic brake may be required to dissipate the excess energy. A dynamic brake is a resistive device that takes energy from the bus and burns it off as heat. The only other solution is to reduce the inertia on the load to the motor. How you do that is dependent on your application. A constant overhauling load may be a good application for a regenerative drive, where instead of a dynamic brake removing energy by converting it to heat, a regenerative unit will put the energy back on the utility line, and may even decrease your energy bill.

A VFD Overvoltage fault during acceleration is uncommon, but it has been known to happen on high inertia loads with extensive acceleration times. A flywheel is a common high inertia application with timely acceleration. During acceleration, these type of loads can actually speed up quicker than the motor due to inertia, and the load becomes regenerative. To solve an overvoltage during acceleration, try to reduce the accel time. It usually takes some experimenting and fine tuning before a technician is satisfied with the results and commits to an accel time setting.

VFD overvoltage fault, operating normally

If the output load has a clutch, that may cause a VFD overvoltage fault. If there is a sudden drop in load, the motor speed may increase quickly, causing a regenerative load. If this is the case, a dynamic brake might help absorb the energy. A dynamic brake removes energy from the bus and burns it off as heat. With a high voltage line, and an application where a conveyor becomes less loaded, may be enough to turn the motor into a regenerative load. The drive is only able to absorb regenerative power to a certain extent, but too much will cause a VFD overvoltage fault. If the load is known to be stable, and not changing torque requirements drastically, then check the incoming line to the drive.

VFD overvoltage fault, when sitting idle

When high incoming AC voltage is present A VFD overvoltage fault can occur while the drive is sitting idle. If this VFD overvoltage fault is sporadic, there’s something nearby that is causing the AC line to fluctuate. If you investigate large induction loads, see if they are causing the distribution line to change voltage. If an improperly tapped transformer is present, that can also cause an overvoltage fault by keeping the incoming line at the high end of the recommended voltage. This won’t allow much room for voltage changes on the DC bus, if they were to occur. Incoming line fluctuations may not be detected by a multi-meter. If the voltage rise is  quick and / or sharp, a multi-meter may not work fast enough to capture the reading. An oscilloscope or voltage monitor may be necessary to capture the voltage rise.
If the main incoming power line has power factor correction caps, switching in and out may also cause a large power spike. In this case, an isolation transformer or line reactor may be required on the front end of the drive to absorb the power spike.

Precision Electric offers drive repair and drive replacement for all manufacturer products. Precision Electric repairs AC and DC variable speed drives up to 3000 horsepower. Call Precision Electric for VFD repair and replacement quotes.

 

 

 

 

 

References: abb lv drives, ab rockwell

Harvey hit the heart of the American Oil Refineries.

Hurricane Harvey Impacts American Oil Refineries

Hurricane Harvey hit the heart of American Oil Refineries last week. So far (as of 8-31), Harvey has shut down 11.2 percent of American Oil Refineries capacity (about one-third of all American Oil Refineries capacity is in Texas’ Gulf Coast) and roughly 25 percent of American Oil Refineries’ production from the Gulf of Mexico (accounting for about 20 percent of American Oil Refineries crude production). Harvey also was the cause of closure to all ports along the Texas coast. Based on American Oil Refineries current operations, it is estimated that anywhere from 1 million to 2.2 million barrels per day of refining capacity are offline, as well as just under half a million BPD of production. The U.S. has been producing around 9.5 million barrels per day, and in general, American Oil Refineries production has beaten 2016 Energy Information Administration estimates for 2017 production. This production has played a major role in keeping global oil prices low, in turn hurting oil-dependent countries like Russia and Saudi Arabia.

Situated higher in the Hill Country, Austin has been spared the worst of what Harvey has wrought in cities like Rockport, Houston and Corpus Christi. But it is near enough to the coast that most of us who call it home know someone afflicted by this particular natural disaster. In a way, it has become personal to us. Communities – and in the United States, states are absolutely communities – are funny like that.

Typhoon Hato, which earned a signal 10 – the highest possible rating in Hong Kong’s classification system – struck the region Aug. 23. The South China Morning Post described it as “the worst typhoon that Macau has seen since 1968.” Typhoon Pakhar, which earned a signal 8 rating, hit the region a few days later on Aug. 27.

Natural disasters like Harvey and Hato are unpredictable. (Advances in meteorological technology clue us in to general arrival times and broad behavior, sure, but even as late as this week no one could confidently say whether Harvey would turn east or west.) They come quickly and, compared to great plains and mountain chains, leave just as quickly. Put simply, there are things that cannot be accounted for ahead of time. Think about Japan’s bad luck at the Battle of Midway. Remember Gen. Robert E. Lee’s miscalculation at Gettysburg. Recall Mount Tambora, whose eruption in 1815 would destroy crop harvests around the world, giving the world in 1816 what would be known as the Year Without a Summer. Hurricane Harvey, and the concurrent storms of southern China, are serious enough to consider whether they qualify.

There are always circumstances we will not be able to anticipate, and the only antidote for that is to be quick to recognize when those circumstances are upon us and to correct our course accordingly.

American Oil Refineries – A Challenge in Relief

Let’s consider, then, the geopolitical importance of the storms that have stricken China and the United States, the largest economies in the world. We’ll start with China. The importance of these typhoons stems not from the tragic deaths and injuries resulting from the storm – although they are indeed tragic. Their importance stems not from the economic fallout – sure, it’ll be a costly reconstruction process, estimated by some to be roughly $1 billion, but China can afford it. Their importance stems not from trade – none of China’s most important trade infrastructure was harmed by Hato and Pakhar. Their importance does not even stem from location – though the most affected areas, Hong Kong and Macau, are vital to China’s economic interests, they serve mostly as a means to access capital markets. It is easier to rebuild a broken stock market than a broken port.

No, the geopolitical significance of these storms results from the political situation they created. In between landfall of the two typhoons, 1,000 People’s Liberation Army troops left their garrison in Macau and took to the streets, at the behest of Macau’s chief executive, to assist with clean-up operations. Though Macau is part of China, it boasts an autonomous government, so the deployment of troops is no small matter.

Of course, disaster relief is not the same as a military invasion, and the deployment can hardly be seen as an act of aggression. But it brings into relief one of China’s most pressing political challenges: managing its special administrative regions. Over the past week in Hong Kong, one such region that is particularly suspicious of Beijing’s intentions, tens of thousands of protesters demonstrated against the arrest of democracy advocates. Though technically a separate issue from the situation in Macau, many protesters believe the troop deployment sets a precedent for losing more of their own autonomy. (Tellingly, Hong Kong reporters have been banned from entering Macau.) It’s unclear whether their suspicions have any merit, but Beijing certainly wants to enhance its control over these territories, and the typhoons have given Beijing pretext to deploy troops.

American Oil Refineries – Severe, but Short-Term

Hurricane Harvey’s impact on American Oil Refineries production will be temporary, even if it is severe. In the short term, though, it could be globally significant. The storm has stalled out over Houston and promises to dump more and more rain over the area. If it damages the Colonial Pipeline – which transports more than 40 percent of the Texas Gulf Coast’s refined product, according to the EIA – U.S. consumers would not only have to pay more at the pump, but U.S. policymakers would have to deal with Russia, which would greatly benefit from even a momentary spike in prices. It won’t be clear what will happen to oil prices until we know what kind of damage coastal facilities have sustained, but the possibility of higher prices can’t be ruled out.

Storms such as Harvey introduce unknown variables into our model. We can’t predict them, but we can design our model to account for them when they happen. And why wouldn’t we? Nation states tend to act differently when they stare down the ultimate geopolitical power: nature itself.

Precision Electric is now repairing and replacing all damaged equipment for American Oil Refineries in Texas. This is in hopes of getting American Oil Refineries back on their feet in a timely manner. Many of the American Oil Refineries use Eaton VFD products on their rigs and Precision Electric is familiar and experienced in repairing Eaton equipment; Precision Electric has been working with American Oil Refineries in Texas for nearly ten years. Contact Precision Electric for repair and replacement quotes.

References: https://geopoliticalfutures.com/ as well as portions of article are from an article by Jacob L. Shapiro of GPF

Eaton power board failure: the main reason Eaton drives quit working

Eaton power board failure is a common problem among Eaton drive users. Power board damage is the cause of failure in most non-functional Eaton drives. Power board failure is usually caused from either Eaton drives reaching the end of their life cycle, the incorrect drive enclosure was being used, or, neglecting preventative maintenance of Eaton equipment. If the power board damage is excessive, an entire board will need to be replaced. Eaton takes a long time to diagnose and repair equipment. Most of the time Eaton will hold onto a manufacturer’s drive for months and then tell them that the drive must be replaced because “it isn’t worth repair”. Precision Electric has repaired many Eaton power boards and Eaton drives that Eaton deemed “not worth repair”.

Although they offer drive repair, most Eaton distributors don’t even repair drives themselves. These Eaton distributors outsource Eaton drive repair to third parties because they don’t have the equipment, documentation, knowledge, or technical staff to perform Eaton drive repair. Going through an Eaton distributor who is outsourcing the repair to a third party is cost prohibited and time-consuming. It’s best to go directly to an Eaton repair center, such as Precision Electric. Precision Electric is an Eaton repair center and Precision Electric performs all Eaton power board and Eaton drive repair in house. Precision Electric also offers immediate 24/7 emergency repair for breakdowns.

The Eaton power board failure repair process should always be taken with extreme caution. Eaton power board repair should only be performed by technicians who have required training and experience to work with electrical equipment. Troubleshooting and repairing an Eaton power board is time consuming and tedious because every Eaton power board can be unique depending upon the Eaton drive functions and capabilities; But, the overall structure of troubleshooting and repairing always remains the same. The ultimate goal when repairing an Eaton power board is to diagnose the cause of failure, repair of the power board, reassembly of drive module; Then, the appropriate steps to avoid repeat problems is communicated to the customer. Lastly, re-commission the drive with its corresponding equipment.

Precision Electric performs all Eaton power board failure repairs in house. In house repair ensures efficient turnaround time, better repair cost, and less handling of Eaton equipment. Precision Electric also offers Eaton emergency repair services for customers who are broke down and require immediate repair services.

To learn more about Eaton drives, visit the Eaton Website. Contact Precision Electric for Eaton drive repair and replacement. Precision Electric can be reached by phone at 574-256-1000 or by email at sales@precision-elec.com

 

 

 

 

Differences Between ABB ACS550 and ACH550 VFD

The are many differences between ABB ACS550 and ACH550 VFD products. If an exact replacement is unavailable, it’s important to know the differences between the ABB ACS550 and ACH550 VFD before deciding on which product to order. An ABB ACH550 can only be replaced with an ABB ACS550 (or vice versa) in unique circumstances. The goal of replacing any drive is to get your machine running again, as efficiently & quickly as possible, without negatively impacting the application. This can be achieved by consulting an ABB certified low voltage drives integrator. In unique circumstances where an ACH550 can be replaced with an ACS550, maintenance technicians can potentially improve throughput and delivery while decreasing installation time and hardware cost.

The type of product is one of the main differences between ABB ACS550 and ACH550 VFD products. The ACH550 is an industry-specific drive, used mainly for HVAC (heating, venting, and air conditioning) applications. The ABB ACS550 is a general purpose drive (used by manufacturers, refineries, OEM’s, farmers, etc.) The keypad differences between ABB ACS550 and ACH550 VFD products makes them incompatible with each other.

Macros – differences between ABB ACS550 and ACH550 VFD

Macros are also key differences between ABB ACS550 and ACH550 VFD products. On pages 49-66 of the ACH550 user manual, technicians are able to view the following macros that are unique to the ABB ACH550:

  • HVAC Default
  • Supply Fan
  • Return Fan
  • Cooling Tower Fan
  • Condensor
  • Booster Pump
  • Internal Timer
  • Dual Setpoint with PID
  • Eclipse Bypass Macro
  • Bypass – Many more Bypass Options which are more commonly used in HVAC.

Fieldbus unique to ACH:

  • BACnet Router  BACnet /IP to MS/TP
  • Lonworks
  • Metasys   (JCI)
  • Profibus DP/FMS

Start Enable 1 & 2 on the ACH550 has permissive start interlock inputs that are typically used for connection of safety interlock contacts (Firestart, Freezestat). This makes the ACH550 drive inoperable and closes dampers during fires.

ACS550 Communications – differences between ABB ACS550 and ACH550 VFD

The following ABB ACS550 communications options are included in the ACS550 drives shipping package when purchased new but they are Not installed:

  • Speed Pot, Start / Stop and Fwd / Rev Switches
  • DeviceNet Adapter
  • Profibus DP Adapter
  • CANopen Adapter Module
  • ModBus RTU Adapter
  • ControlNet Adapter
  • Ethernet Adapter
  • Dual Port Ethernet Adapter

Experience – differences between ABB ACS550 and ACH550 VFD

Precision Electric has been working closely with manufacturers, OEMs, refineries, utilities and other customers in the industrial electrical field since 1983. Precision Electric offers the following onsite and in-house services: industrial electrical equipment repair and replacement, PLC programming, installation and repair; board repair, control cabinet design & manufacturing; customized engineered retrofit packages, AC & DC electric motor repair & rewinding services, and many other services to customers across the USA. Many repair centers in the USA send their customers’ equipment to Precision and then they markup the repair cost to their customers.

Precision Electric is an authorized & trained integrator, certified start up center and distributor for ABB low voltage drives. Precision Electric strongly suggests that technicians contact an ABB low voltage drives integrator before replacing an ACH550 with an ACS550 (or vice versa). Replacing an ACH550 with an ACS550 may seem like a good idea to buyers if it’s saving their employer money on the hardware end. But, if the ACH550 drive-specific functions are needed in the application, the “money saved” will actually end up costing the buyer more money, time, throughput and possibly even their job.

For ABB ACS550 and ABB ACH550 documentation, visit the ABB Website. For ABB replacement or repair inquiries, contact Precision Electric.

ACS380 ABB VFD: ABB announces their Newest Machinery Drive

The ACS380 ABB VFD was recently released and is available in most power ratings through 10 hp. Exact ratings that are now available and future release dates of the ACS380 are listed at the bottom of this page. The ACS380 ABB VFD is a machinery drive and is the newest product addition to the machinery drive family of ABB low voltage drives. The ACS380 machinery drive is ideal for machine builders looking to integrate a VFD without incurring significant cost. The ACS380 ABB VFD is also ideal for end users wanting to increase productivity without sacrificing performance. The ACS380 is part of ABB’s all-compatible drives portfolio designed to offer a technically compatible drive, an all-compatible solution for people, process, business and environmental goals. With pre-configured drive variants, adaptive programming and an icon-based user interface, the ACS380 ABB VFD is simple to integrate into any system.

The compact ACS380 drive is ideal for machine building that requires motor technologies with powers from 0.25 to 7.5 kW and voltages from 200 to 480 V. With enclosure class IP20 as standard, these modular drives easily integrate into machines and automation systems within industries such as food and beverage, material handling, and plastics. The ACS380 ABB VFD offers universal dimensions that simplify the process of wiring into cabinet installations; For typical constant torque applications like mixers, extruders, conveyors, and palletizers.

The standard variant of the ACS380 comes with extensive I/O and built-in Modbus RTU protocol. The drive offers a built-in icon based interface that makes commissioning and adjusting the drive fast and easy. Optional control panels include the basic control panel and the assistant control panel with and without Bluetooth. Adaptive programming provides additional flexibility for different machine requirements, meeting the demands of exact machine design. The ACS380 ABB VFD is designed for optimal cooling with thermal management up to 50 °C ambient temperatures, without having to de-rate. Additional features include: integrated safety (STO) is built-in as standard for safety sensitive applications. An EMC C2 filter and built-in brake chopper are standard to save space and installation time. The ACS380 ABB VFD uses a common architecture for a smooth transition to other ABB drives, including the ABB ACS880.

A fieldbus enables communication between drives and PLC systems, I/O devices and the process. Fieldbus communication reduces wiring costs when compared with traditional hard wired input/ output connections. Fieldbus systems also offer the ability to gather large amounts of data which can then be utilized for improving the performance or safety of the machine. The ACS380 ABB VFD is a configured variant and is compatible with a wide range of fieldbus protocols. Fieldbus modules preconfigure drive parameter settings at power-up to allow programming directly from the PLC. The optional fieldbus adapter can be easily be mounted on the drive. The ACS380 standard variant comes with built-in Modbus RTU protocol.

Almost anyone can set up and commission the ACS380 ABB VFD using the integrated control panel or one of the available assistant control panels – AP-I, AP-S, AP-W, or BP-S. The ACS380 includes the integrated icon based control panel as standard. You do not need to know any drive parameters as the control panel helps you to set up the essential settings quickly and get the drive into action.

Now available:

Late 2017:

  • 1~230 V, expand to 5 HP
  • 3~230 V, 1/2 to 15 HP
  • 3~380 to 480 V, expand to 30 HP

Future Releases – in early development (planned 2018)

  • 1~115 V, 1/4 to 1.5 HP
  • 3~600 V, 1 to 30 HP

For additional product info or product documentation on the ACS380 ABB VFD, visit the ABB Website. For ACS380 ABB VFD quote requests or availability requests, contact Precision Electric.

Allen Bradley Servo Motor Repair: an Asset for Manufacturers

Allen Bradley servo motor repair is less expensive than Allen Bradley servo motor replacement. Only Trained technicians should perform Allen Bradley servo motor repair. Technicians undergo unique testing procedures on Allen Bradley servo motors that are dependent upon their model, features, operations, software, and prints. Allen Bradley servo motor repair should initially be inspected for cosmetic damage. Taking photos of the servo motor prior to further processing is suggested. Allen Bradley servo motor repair requires unique software that allows a technician the ability to communicate with the Allen Bradley hardware.

Servo Motor nameplate data and preventative maintenance info should be collected by the repair 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, 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, winding failure, and perform a 100% component test.

Once the trained technician finishes making all repairs, he or she will reassemble the servo motor for final testing. During the final test, the servo motor is connected to a compatible servo drive that is powered from a test panel. This should be done for approximately thirty minutes with and thirty minutes without, a full load. The technician will measure start up current draw and full load current draw, with and without a load, throughout the final test run.  The technician will also perform speed and vibration tests to ensure the servo motor is operating at the manufacturer specifications.  Running the servo motor on a compatible servo drive also ensures complete functionality. Testing the servo motor with a compatible servo drive also allows verification that the servo motor can operate at full voltage and withstand full load amps of motor specifications. If the servo motor tests good and still does not run at peak performance when installed in production, other underlying problems are communicated to the customer and further investigation is necessary.

Repair shops should work closely with all servo motor manufacturers. Working closely with servo motor manufacturers allows for access to servo motor data sheets. 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 Allen Bradley 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. Using a third party repair shop is risky, more expensive, and has a longer lead time than going directly to the repair source. Allen Bradley servo motor repair from Precision Electric includes a 12 month in-service warranty; The in-service warranty encourages customers to repair all failed equipment so the equipment is ready for install whenever spare equipment fails while in service.

To learn more about Allen Bradley servo motors, visit the Allen Bradley Website. For Allen Bradley servo motor repair and replacement quotes, contact Precision Electric.

Is the American workforce ready for the Fourth Industrial Revolution?

By Greg Scheu, President – Americas Region, ABB

Innovation can be disruptive. History shows us that, in the face of major disruption, the winners embrace change and adapt. Just look at the impact that personal computers have had on the workplace. Today, it would be difficult to find a good job that does not require at least basic computer skills. The innovations unleashed by computer science in the 1980s and 1990s triggered unprecedented productivity gains and changed our lives.

We now stand at a new crossroads. The Fourth Industrial Revolution has brought artificial intelligence, cloud computing and predictive analytics to the workplace. In the emerging industrial era, machines are increasingly capable of telling us how they feel, which means they can be repaired before they break down. Renewable energy will be unlimited by geography as transmission systems expand under seas and across continents. Cities of the future will be free of traffic emissions, and many buildings will produce more energy than they consume. Collaborative robots will work side-by-side with humans.

Countries that embrace innovation are leading in competitiveness and job creation. Robotics, one of the fastest-growing technologies in the world, is a case in point. While some people are concerned that robots could take jobs away from humans, the reverse turns out to be the case. The three countries with the highest density of robots per factory worker—South Korea, Germany and Japan—also enjoy exceptionally low unemployment rates. Without investing in automation, these strong economies would not be globally competitive, and their workforces would certainly feel the repercussions.

Rising productivity has always contributed to greater prosperity. Every previous industrial revolution has increased productivity, created jobs and raised incomes. The World Bank estimates that, since 1990, more than a billion people have emerged from extreme poverty and, globally, the proportion of those in extreme poverty has fallen from 35 percent to less than 10 percent. Thanks to higher productivity, the United Nations estimates that poverty was reduced more in the past 50 years than in the previous 500.

The potential gains from the Fourth Industrial Revolution are equally large. The United States has already taken many of the steps necessary to maintain its leading role in the technologies associated with these changes. As a country that has always been a driver of innovation, America is well-positioned to benefit from the latest methods of production.

Yet we must ensure that the American worker is not left behind. As manufacturing rebounds in the United States, it will not look the same as it did before. Modern industry needs trained and skilled employees in automation and advanced manufacturing. We must retrain the workforce of today and adapt education and training for the workforce of tomorrow.

To achieve the skills transition for the Fourth Industrial Revolution and ensure that all of society benefits from rising prosperity, partnerships are needed between government, industry and academia. Education, particularly the community college system, will play an important role in retraining our manufacturing workforce to operate the factories of the future. Industry and government need to show leadership by supporting STEM education with more resources, close collaboration and specialized expertise.

Industrial and technology companies are driving the progress the world requires. Technology from ABB, for example, enables utilities, industry, and transport and infrastructure customers to make their operations stronger, smarter and greener around the globe. Companies like ABB are developing solutions that are on the verge of triggering a great new surge in productivity and wealth creation. We all need to work together to make sure that the American worker wins with us.

This op-ed was also published on ABB.comAutomation.com and Newsandobserver.com

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 NumberManufacturerModel NumberType / Description / Nameplate InformationCondition
116PACIFIC SCIENTIFICSR3624-8291-7-56BC1/4 HP, 1750 RPM, 56C FRAME, 90VDC, TEFC HAS BASENS
421BOSTON GEARAPM925AT1/4 HP, 1725 RPM, 42CZ FR, 90VDC, PM, TEE OK
173BALDORCDP33161/3 HP, 1750 RPM, 56C FR, 180VDC, PM TENVE OK
174BALDORCDP33301/2 HP, 1750 RPM, 56C FR, 90 VDC, PM, TENVE OK
176PACIFIC SCIENTIFICSR3640-8293-84-7-56HC1/2 HP, 1750 RPM, 56 FR, 90 VDC, PM, TENV, D FLANGEE OK
423GENERAL ELECTRIC6VFM1050B561A11/2 HP, 1725 RPM, 56 FR, 100F, 90A, TENVE OK
425BALDORCDP33261/2 HP, 1750 RPM, 56C FR, 180 VDC, PM, TENVE OK
108BALDORCDP34363/4 HP, 1750 RPM, 56C FRAME, 180 VDC, PM, TEFC, NO BASEE OK
118BALDORCDP35181 HP, 1750 RPM, 56C FRAME, 180 VDC, PM, TEFC, NO BASENS
428LEESONC4D28FK6G1 HP, 2500 RPM, XS56C FR, 180VDC, PM, TEFCE OK
412GENERAL ELECTRIC5BPA56RAG9A1 HP, 1725 RPM, 56 FR, 180 VDC, PM, TEFCE OK
177BALDORCDP34551 HP, 1750 RPM, 56C FR, 180 VDC, PM, TEFCE OK
131RELIANCEDC0189ATCZ2 HP, 1750/1950 RPM, 189ATZ FRAME, 240 A, 150 F, BVE OK
155GENERAL ELECTRIC5CD144VC001B0083 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENVE OK
153GENERAL ELECTRIC5CD144VC001B0083 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENVE OK
133GENERAL ELECTRIC5CD144VC001B0083 HP, 2500/2750 RPM, 180 A, 200/100 F, 186ATC, TENVE OK
156BALDORCD62033 HP, 1750 RPM, 184TC FR, 180A / 100/200 F, TEFCE OK
157GENERAL ELECTRIC5CD145VC005B0013 HP, 1750/2050 RPM, CD189ATC FR, 180 A/100/200 F, TENVE OK
162RELIANCET18P1118E-7S3 HP, 1750 RPM, DC0189ATY FR, 200F, 180A, DPE OK
624RELIANCET18R1323H-PT5 HP, 1750/2300 RPM, CT811ATZ FR, 500A, 300F, DPNS
432CUTLER HAMMER250-100-0116A5 HP, 1150/2000 RPM, 256AT FR, 500/300 VDC, DPE OK
150CUTLER HAMMER250-100-0116A5 HP, 1150/2000 RPM, 256AT FR, 500/300 VDC, DPE OK
141GENERAL ELECTRIC5CD1531A806A8007.5 HP, 2500/2875 RPM, 500 A, 150/300 F, CD219T FR, BVE OK
142MAGNETEK2190B411L027.5 HP, 1750 RPM, 180 A, 200 F, 219AT FRAME, BVE OK
434BALDORD501010 HP, 1750 RPM, AD219AT FR, 500A, 150/300F, DPFGE OK
130RELIANCE11839122T2115 HP, 1250/3750 RPM, 259AT FRAME, 120 A, 240 F, BVE OK
137GENERAL ELECTRIC5CD063KA038A12715 HP, 1750/2300 RPM, CD258AT FR, 500 A, 150/300 F, BVE OK
433BALDORD2018R15 HP, 1750/2300 RPM, SC2113ATZ FR, 240A, 180F, DPNS
129RELIANCE4LA843818TL20 HP, 1750 RPM, 284T FRAME, 120 A, 240 F, BVE OK
146RELIANCE06KA867603-ZU20 HP, 1750/1950 RPM, LC2512ATZ FR, 500/300 VDC,E OK
147RELIANCEF28P1701A25 HP, 2500/3000 RPM, 284AT FR, 240/240 VDC, BVE OK
436RELIANCER-66575-T1-HS30 HP, 500/2000 RPM, 505-AS FR, 240A, 240F, HAS BLOWERE OK
441CMC2890B452C0140 HP, 1750 RPM, 289ATZ FR, 500A, 300F, DPRG
454RELIANCET28S1330E-AC60 HP, 1750/2100 , MC2812ATZ, 300/500 VDC, DPBVRG
152POWERTECA28DLF100090001175 HP, 2500 RPM, 2810TZ FR, 640 BUS VDC, BRUSHLESSE OK
440RELIANCE1U827783T5-LP100 HP, 1750 RPM, 503A FR, 480A, 240F, FORCE COOLEDE OK