AC Motor Repair

AC Motor Repair

The first step in AC motor repair is identifying that there is a problem. If an electric motor smells like it’s burning, is vibrating and running loudly, or if the motor is not operating at its peak performance, something is probably wrong. When these circumstances present themselves, promptly shut the power off to the motor and machine to prevent further motor and machine damage. Once the power is off, it’s best to contact a trained professional with experience in AC motor repair.

AC motor repair cost always depends upon the extent of motor damage and availability of motor replacement parts. Repaircosts can be decreased by simple awareness that something is wrong. Contacting a motor professional is preferred to prevent injury. Motor professionals can also reduce unnecessary troubleshooting and downtime in the following ways: If the motor repair cost exceeds the replacement cost, an electric motor replacement motor can be shipped out right away. If the application is a DC electric motor, an electric motor professional can determine if replacing the DC equipment with AC equipment is a more economical choice. Often times a DC motor can be replaced with an AC motor, paired with an AC VFD. An AC motor paired with AC VFD has the ability to increase production,
decrease energy costs, reduce future repair costs, and offer other benefits.

AC motor repair can be decreased with preventative maintenance. Preventative maintenance tasks vary depending on the abilities and experience each motor shop offers. AC motor repair should only be performed by trained electrical technicians who have electric motorexperience. A lot of companies offering motor repair and preventative maintenance do not even perform these tasks; these companies outsource their jobs to a third party source, such as Precision Electric. To decrease costand increase turnaround time, ensure that whoever is offering the repair services, is actually performing the repair services.

For more information on AC motor repair or for AC motor repair and replacement quotes, Contact Precision Electric.

Siemens VFD Troubleshooting

Siemens VFD troubleshooting starts with checking the electric motor and VFD terminal connections. Motor and VFD connections can be overlooked, loose, or, wired to the incorrect terminals; so, checking all connections is suggestedbefore pulling the VFD and sending it in for a repair evaluation.

Heat cycles and mechanical vibration can lead to sub-standard connections. 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 that may clear input fuses, or damage protective components. Arcing at the VFD input or output terminals may result in over-current faults or damage to the power components. Loose connections can cause erratic operation. For example, a loose START/STOP signal wire to the drive can cause uncontrollablestarting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, and personnel injury.

Siemens VFD Troubleshooting Diode and IGBT

Prior to applying power during the Siemens VFD troubleshooting process, the input and output power sections need to be tested. If there is a short on the input side or output side of the VFD, further damage can be caused to the unit if power is applied to it. For this reason, special meters should be used to properly test the input and output power sections of the drive, prior to applying power to the Siemens VFD unit. If a short is found, the VFD can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the Siemens VFD repair is too costly, VFD replacement and availability is considered.

Siemens VFD Troubleshooting and Power Up

If the input and output power sections test healthy during the Siemens VFD troubleshooting process, power is applied to the VFD unit to perform amp reading and output frequency testing. Slowly increasing the power voltage during this step of the Siemens VFD troubleshooting process is suggested to gather accurate meter readings and to protect the motor. The power voltage is slowly increased on the Siemens VFD until the rated input voltage of the drive is reached. Depending on whether or not the Siemens VFD 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 Siemens VFD repair.

Siemens VFD Troubleshooting With Motor

If the previous tests have passed during the Siemens VFD troubleshooting process, a basic JOG / RUN function of the drive can be performed with a simple template program. When a Siemens VFD comes into our facility, repair techs will backup all existing programs stored in the drive prior to installing a test template program for this test run procedure. Backing up the Siemens VFD program ensures availability of the program for installation, once the repair is complete. The best method for backing up Siemens VFD programs will depend on the series and model of drive. After the VFD programs have been backed up, the Siemens VFD is reset to factory defaults through the keypad. Once the Siemens VFD is reset to factory default settings, a basic START / STOP is recommissioned of the VFD connected to its motor. Closed loop testing will be necessary when an encoder is involved. If the motor will not run, the output voltages and motor current ratings are tested to verify that the drive is functioning properly for motor rotation.

Siemens VFD Troubleshooting and Routine Maintenance

Siemens VFD troubleshooting should be performed by trained electrical technicians during regular routine maintenance. Routine maintenance prevents Siemens VFD failure and production loss due to machinery downtime. Siemens VFD repair cost and lead times can also be reduced with routine maintenance. Siemens VFD repair can be expensive depending on board and component damage which ultimately will cost manufacturers production downtime during the repair process. Most manufacturers keep spare Siemens VFD units in stock to prevent production downtime during the Siemens VFD repair.

Siemens VFD Troubleshooting and Safety

Siemens VFD troubleshooting and Siemens VFD repair should be taken with extreme caution and only be performed by technicians who have training and experience in working with electrical equipment. Precision Electric strongly recommends consulting an expert in the field when repairing all industrial electrical equipment. Many drives have an internal DC bus that retains a charge after power has been cut to the drive, and as a result, it does not mean that it’s safe to work with. Technicians working with Siemens VFD units and other related equipment must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

Siemens VFD Troubleshooting and Repairs

Most companies who offer Siemens VFD troubleshooting and Siemens VFD repair do not even perform these services themselves. These companies outsource the repair to a third party certified VFD Repair Center, such as Precision Electric. Precision Electric receives Siemens VFD repair jobs everyday from companies who offer VFD repair. Those third party repair companies then mark up the repair cost to their customers. Manufacturers are encouraged to ensure that their Siemens VFD Repair is being performed at the actual site of whoever is offering the service.

To learn more aboutSiemens VFD Troubleshooting, visit the Siemens Website. For Siemens VFD repair or replacement, contact Precision Electric.

ABB Field Service

ABB field service should only be performed by ABB-certified engineers. ABB-certified engineers must complete ABB startup training courses to qualify for ABB extended warranties. ABB field service offered by Precision Electric provides professional troubleshooting, diagnosis and repair skills, installation and commissioning services all at the jobs site for manufacturers to optimize drive safety, availability and performance.

ABB field service helps to minimize installation and commissioning time and cost.Manufacturer service needs depend on their operation, life cycleof equipment and business priorities. ABB hasidentified their customers four most common needs anddefined service options to satisfy them. It’s imperative tokeep ABB drives at peak performance. Operation depends upon the most optimalconfiguration, set up and maintenance programs. Whenit comes to important operations,everything needs to be done correctlyfrom the start.From commissioning to spare parts and preventivemaintenance, Precision Electric is with the customer through the entire process. Manufacturers need tohave all the support to correctly install and rundrives efficiently. ABB field service performed by ABB-certified engineerscan undertake the entire drive installation and commissioningfor the customer. Correctly installed drives are more reliable, andwell-commissioned drives lead to energy savings and loweroperational costs.

ABB Field Service And Preventive Maintenance

ABB field service and preventative drive maintenance schedule manages the partsreplacement at the right time. This regular maintenancekeeps costs down, prevents drive repair, and keeps lifetime performance optimal. Thereare preventive maintenance kits designed to match specificdrive types. Highly skilled and trained engineers carry out allannual inspections and component replacementsaccordingly.Life cyclemanagement is one of the most important aspects in defining ABB field service. ABB field service performed by Precision Electric combines experienceand top solutions to extend, analyze and optimizethe life cycle of ABB drives.When customers need information on the condition of theirequipment and the life cycle of components, Precision Electricprovideshelp in diagnosis and assessment of ABBdrives in a modernand easy service.

ABB Field Service And Life Cycle Assessment

ABB field service and life cycle assessment gives manufacturers powerful knowledge to determine exactly where processstands, now and in the future.Reconditioning an ABB drive improves the ABB drive reliability and extends itslifetime. ABB recommends these services at least once in every drive’s lifetime.Reconditioning ABB drives at Precision Electric providesrestoration of ABB drives to their original condition and includes a fullinspection, thorough cleaning, individual componentanalysis and replacement, and final testing with and without a load. Every drive reconditionedby Precision Electric isthoroughly tested and comes with a one-year warranty.Control Upgrade servicesensures full life cycle services for ABB legacydrives by removing all concerned components and replacing them with upgraded components. Investmentcosts and process downtime are minimized with anengineered solution in the life cycle assessment process.

For more information or for ABB field service quotes or ABB drive repair and replacement quotes, Contact Precision Electric.

Magnetek VFD Repair

Most Magnetek VFDrepair can be prevented with routine maintenance. Magnetek VFDrepair costs and lead times can also be reduced with routine maintenance. Magnetek VFD repair can be expensive and also cost manufacturers production downtime while the Magnetek VFD repair is in process.Most manufacturers stock spare Magnetek VFD modulesto prevent production downtime in the event of a Magnetek VFD failure.Components used for Magnetek VFDmodules are often cheaply made and prone to failure. Knowledgeable repair shops should replace cheaply made components with high quality components during the repair process. Using high quality components during a MagnetekVFDrepair ensures a longer lifespan of the VFD during production.

Connections
Checkingconnections is a step many people miss or do incorrectly during the Magnetek VFDrepair process. Heat cycles and mechanical vibration can lead to sub-standard connections, as canpoorroutine maintenancepractices. Reusing torque screws is not a good Idea on connections, and further tightening an already tight connection can ruin the connection.Bad connections eventually lead to arcing. Arcing at the VFDinput can result in nuisance over voltage faults, clearing of input fuses, or damaging protective components. Arcing at the VFDoutput could result in over-current faults or damage to the power components.

Loose connections can also cause erratic operation. Loose START/STOP signal wires can cause uncontrollable inverterstarting and stopping. A loose speed reference wire can cause the VFDspeed to fluctuate, resulting in scrap, machine damage, injury or death.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections during Magnetek VFD repair processes, and this step is essential prior to applying power to the VFDunit. If there’s a short on the input or output side of the VFD, further damage to the VFD may result if power is applied to it.

For this reason, Precision Electric uses meters to properly test the input and output power sections of the VFDprior to applying power to the 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 repair is too costly, then a replacement is offeredto the customer.

Power Up Unit
If the input and output power sections test healthy during this step of the Magnetek VFDrepair process, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the unit until the rated input voltage of the VFDis achieved.

Depending on whether or not the VFD provides a display will determine what further action(s) will be taken. If the VFD display is unavailable, dis assembly and diagnosis of the internal power supply of the control section of the VFD is likely necessary to further evaluate cause of failure and establish costand lead time of the VFDrepair.

Run A Motor
If the previous tests have passed during the Magnetek VFDrepair process, Precision Electric willrun a basic jog function of the VFDwith a simple template program. Often when Magnetek VFD repair jobscome into our facility, technicians will backup operation programs that are stored in the VFD prior to inputting a template program and running test procedures. Backing up the operation program will ensure that Precision Electric canreinstall the program once the Magnetek VFD repair is complete.

The best method for backing up an operation program depends on the manufacturerof drive, but after it has been backed up, Precision Electric will either reset the VFDto factory defaults through the keypad and recommission a basic start, stop function. If the VFD is closed loop requiring an encoder, the encoder is tested for faults prior to running the start, stop test function. If the motor will not run in factory default mode, the motor output voltages and motor current ratings are checked to see if the VFD is functioning properly for motor rotation.

Magnetek VFDrepair should be taken with extreme caution. VFDrepair should only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends consulting an expert in the field when repairing or installing industrial electrical equipment.Many VFD units have an internal DC bus that retains an electrical charge after power to the drive is turned off, which means it’s unsafe to work with. Technicians performingMagnetek VFD repair should always take extra precautions to ensure proper safety measures are taken to prevent injury or death.

For Magnetek VFDrepair and Magnetek VFDreplacement quotes, contact Precision Electric.

Eaton SV Repair

Eaton SV Repair

Eaton SV repairshould be taken with extreme caution andonly be performed by technicians who have required training and experience with electrical equipment. Alwaysconsult an expert in the field when repairing or troubleshooting industrial electrical equipment. Most drive controllers have an internal DC bus that retains a charge after power has been cut to the drive, as a result, the power being cut doesn’t mean that the drive issafe to work with. Technicians working with variable frequency drives and other electrical equipmentmust always take extra precautions to ensure proper safety measures are taken to prevent injury or even death.

Variable Frequency Drives (VFD’s) have over the past decade allowed to become a cost efficient way to reduce power costs and increase system efficiency. Manufacturers around the globe within a wide range of industries are finding more ways to apply VFD’s to their rotating equipment.From past experience, smaller horsepower VFD’s typically fail in eight years and are more often replaced rather than repaired.Larger horsepower VFD’s last longer by virtue of repairs that often require replacement of circuit boards and other electrical components.

Eaton SV Repair Versus Eaton SV Replacement

Eaton SV repair is common for Sullair Service Centers and manufacturers who use Eaton equipment. Eaton SVrepair is preferred by Sullair service centersand manufacturers because Eaton SV replacement is more expensive than Eaton SV repair.Most companies who offer Eaton SV repair don’t have the capabilities or experience to repair Eaton equipment themselves; so they outsource the VFD repair to third party repair centers, or they send it to Eaton and charge their customer more than the actual repair cost. Eaton offers SV VFD repair services for their products but it’s inefficient because Eaton always has extensive lead times for repairs, and Eaton drive users cannot wait forextensive lead times due toproduction downtime.Precision Electric offerscomplete Eaton SVrepair, and all Eaton SVrepair jobs are performed in house at Precision Electric.

Eaton SV repairis an asset to manufacturers who use Eaton VFD equipment because Eaton usually recommends replacing their equipment when it fails. Eaton SV VFD replacement is more expensive than Eaton SV repair. Eaton SVreplacement also has extensive lead times that aren’t economical when production is down. Eaton SVrepair can be performed by Certified Eaton SV Repair Centers morequickly than waiting for Eaton to produce a replacement SV VFD.

ContactPrecision Electric today forEaton SV repairand Eaton SV replacement quotes.

Eaton Cutler Hammer Drive Repair

Eaton Cutler Hammer drive repair is an asset to manufacturers because Eaton usually recommends replacing failed drives instead of repairing them.Eaton Cutler Hammer drive repair is quicker and less expensive than Eaton drive replacement.

Checking connections is a step many people miss or do incorrectly during an Eaton Cutler Hammer 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 Eaton Cutler Hammer drive repair, and this step is essential 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 properly 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 repair is too costly, then a replacement is offered to the customer.

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

Run A Motor
If the previous three tests have passed during an Eaton Cutler Hammerdrive repair process, then it is time to 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 ensure 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 adjustbale speed drive to factory defaults through the keypad and recommission a basic start, stop and job application or closed loop if an encoder is involved. 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.

Contact Customer
At this point we have determined the cause of failure, estimated lead time and cost of the parts that need replaced for the Eaton Cutler Hammer drive repair, and are ready to offer the customer our repair quote. If the drive has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electric will gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system including, but not limited to, PLC communications, faulty I/O, bad wiring or even bad cabling. There is no single way to do this step since it depends on a wide variety of variables.

Routine Maintenance
Most Eaton Cutler Hammer drive repaircan be prevented with routine maintenance. Drive repair cost and lead times can also be reduced with routine maintenance. Eaton Cutler Hammerdrive repair can be expensive and also cost manufacturers production downtime during the repair process. Most manufacturers keep spare drives in stock to prevent production downtime when their equipment repairs are in process.

Eaton Cutler Hammerdrive repair should be taken with extreme caution. Drive repair should 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, it does not mean it’s safe to work with. Technicians working variable frequency drives and other electrical equipmentmust always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

Call Precision Electric today forEaton Cutler Hammer drive repair quotes.

Eaton Drives Troubleshooting

Eaton drivestroubleshooting can be time consuming, so manufacturers tend to keep spare Eaton drives on hand for production lines that can’t afford downtime.When Eaton drivestroubleshooting cannot be resolved in the plant, technicians are known to send their Eaton VFD to the original equipment manufacturer or Eaton VFD repair centers for repair and replacement options. The original equipment manufacturer of Eaton drives and Eaton VFD repair centers usually only offer a replacement for failed drives, but this isn’t usually the most economical solution for manufacturers. Eaton also repairs failed drives but the lead-time for Eaton to repair their own drives is extensive and expensive.

When Eaton drivestroubleshooting leads to Eaton VFD repair, the repair process should be taken with extreme caution. Eaton VFD repair should 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 and troubleshooting Eaton VFD equipment.The troubleshooting techniques for each brand of VFD can be unique, but the overall structure of troubleshooting always remains the same.The ultimate goal when performing Eaton drivestroubleshooting is to diagnose, repair and re-commission the unit as quickly as possible, and these are the steps that Precision Electric follows for Eaton drive repairs.

Take Notes

This is often a subject that is passed by many individuals who are attempting to troubleshoot industrial electrical equipment. Before Precision Electric begins to perform Eaton drivestroubleshooting, qualified technicians take note of many important aspects of the equipment including, but not limited to:

  • Eaton VFD Model Number
  • VFD Serial Number
  • Reason for Service
  • Urgency (Rush Overtime or Standard)
  • Visual Inspection of External Device

Diode and IGBT Tests

When Eaton drivesTroubleshooting exceeds parameter changes, Precision Electric tests the input and output power sections of the Eaton VFD. This step is essential prior to applying power to the VFD unit. If for any reason there is a short on the input side or output side of the VFD, further damage can be caused to the unit if power is applied to it.

For this reason, Precision Electric uses meters to properly test the input and output power sections of the Eaton VFD 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 repair is too costly, then a replacement is offered to the customer.

Power Up

If the input and output power sections test healthy during this step of the Eaton drivestroubleshooting and repair process, Precision Electric will power up the unit and perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the unit until the rated input voltage of the VFD is achieved.

Depending on whether or not the VFD provides a display will determine what further action(s) will be taken. If display is unavailable, dis-assembly and diagnosis of the internal power supply of the control section of the VFD is likely necessary to further evaluate cause of failure and establish cost and lead time for the Eaton VFD repair.

Run A Motor

If the previous three tests have passed during the Eaton drives troubleshooting and repair process, then it is time to run a basic jog function of the VFD with a simple template program. Often when a VFD comes into our facility, we make sure to backup whatever program is currently stored in the VFD prior to inputting a template program and running a test procedure. This is to ensure 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 Eaton VFD to factory defaults through the keypad and recommission a basic start, stop and job application or closed loop if an encoder is involved. 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 VFD is functioning properly to rotate the motor.

Contact Customer

At this point we have determined the cause of failure, estimated lead time and cost of the Eaton drivestroubleshooting and VFD repair. If the VFD has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electricwill gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system including, but not limited to, PLC communications, faulty IO, bad wiring or even bad cabling. There is no single way to do this step, as it depends on a wide variety of variables.

Send Service Tech

If the customer cannot establish failure on any other aspect of the machine and the Eaton drivestroubleshooting tests appear to be good, then it may be necessary to send a Precision Electric field service technician on site to establish cause of failure. Precision Electricfield service technicians are trained to troubleshoot any issue ranging from standard VFD repair to advanced robotics, servo systems, electric motor issues and more. Precision Electric field technicians are trained to establish cause of failure and come up with solutions as quick as possible.

To learn more about Eaton Drives Troubleshooting or for Eaton VFD Repair Quotes, contactPrecision Electric, Inc.

 

 

 

 

 

 

Eaton SVX9000 Over Temp

The trip level for Eaton SVX9000 over temp default is 90Conthe IGBTs and B5C for the power board. Depending on the drive size there may be up to B different temps that can be read from the HMI. FRB and below drive only have one sensor for the IGBTs and one for the power board. The power board is not read out on the HMI. Onlarger Eaton SVX9000 drives you there’sa sensor for every IGBT, although only the highest from each phase is displayed on the HMI. It will also display the power board’s temperature. The temperature displayed in the monitor menu is the highest reading of the IGBTs. To see the individual reading, go to the multi monitor which is normally located in the system menu.

When there is an Eaton SVX9000 over temp trip, the first thingto determine is whether it’s an Eaton SVX9000 over temp power module trip or a power board trip. In the fault history the fault will list a module and sub-module. The sub module is the one that will say either module or board and this tells you where the fault is coming from. If it says module this is from the IGBTs and if it says board it is from the power board.

If the Eaton SVX9000 over temp trip is from the module the first thing that you need to check is to see whether the cooling fans work. If the fans work the next thing to check is whether you have air flow through the drive. If air flow isn’t present, you may need to send your Eaton drive to Precision Electric for repair services. If you have air flow check the temp of the air flow to see if there is really hot air coming out of the drive or if it’s cool air. If you have cool air flowing through the drive and it is still tripping out more than likely the temperature monitoring circuit is bad. This type of failure normally requires repair service. Another thing to look for is the ambient temp of the environment that the drive is located in. The drive is meant to be in a location that does not exceed 40C and is no more than 1000 M above sea level. If either of these 2 conditions are exceeded, the drive may needto be de-rated.

If the trip is from the power board it can be caused by a couple of things. If the ambient temp around the boards is too high you can get this trip. More likely this trip will occur on FR10 and above drives. This trip is coming from the ASICs board and normally tells you the fan that cools the ASIC board is not working. Something to note with this trip is that the drive will try to prevent this trip by changing its switching frequency. The drive will start to do this 1C before the warning level and will reduce its switching freq faster the closer it gets to the trip level. The drive will lower its switching frequency down to 2kHz.

Power board failure is a common problemfrom Eaton SVX9000 over temp tripping. For Eaton SVX9000 over temp repair and replacement inquiries, contactPrecision Electric. To learn more about Eaton SVX9000 adjustable speed drives, visit the Eaton Website.

Variable Frequency Drive Repair

Variable frequency drive repair is an asset to industrial manufacturing because drive replacement isexpensive and prolongedlead times for OEM drive repair is a common problem.

Technology has evolvedvariable frequency drive manufacturers to consistently release new and better drive products for industrial manufacturing. This constant new technology puts the drive manufacturer at an advantage, and the variable frequency drive user at the mercy of purchasing new equipment in place of obsolete and discontinued drive products. Variable frequency drive repair service centers are the backbone of minimizing downtime while maximizing productivity for manufacturers.

Variable frequency drive repair service centers are often the quickest and least expensive means of getting a manufacturer back into production due to variable frequency drive failure. Since minimal downtime is critical for manufacturers, variable frequency drive repair centers offer expeditedvariable frequency drive repair solutions. Drive repair service centers can often repair failed equipment and get the repaired drive equipment installed and back into production in less time than the drivemanufacturer will offer a replacement or repair quote.

Manufacturers should keep spare variable frequency drives for production lines that must continuously operate to meet customer demands. When crucial equipment fails, manufacturers emphasize the importance of installing spare equipment to get production back up; which is then followed by promptly sending out the failed drive for repair. This process will ensure that whenever a piece of equipment fails during production, there is always a rebuilt spare piece of equipment that can be quickly installed to replace failed equipment, to meet production demands.

The objective of Precision Electric variable frequency drive repair is to provide manufacturing facilities with prompt repair services so that manufacturers can meet their customer’s demands. Precision Electric variable frequency drive repair consists of removing all variable frequency drive parts, cleaning parts and all other components, replacement of damaged components, final testing of all electrical components, assembly, final test of drive with electric motor, and safely package and ship drive back to the customer. All variable frequency drive repair work is performed in house by Precision Electric and comes with a 12 month in service warranty.

Eaton LED Solutions For Oil Refinery Applications

Eaton has over 100 years of oil and gas market leadership and servesthe world’s oil companies,original equipment manufacturers and EPCs with electrical, hydraulics and filtration solutions supported by a global network of over 2,500 services professionals. Over the years, Eaton’s innovative portfolio has grown, including solutions from names like Aeroquip-Vickers, B-Line, CEAG, Crouse-Hinds, Cutler-Hammer, Holec, and Synflex among others.

Refineries are commonly faced with the growing challenge of keeping up with uptime, budget and regulatory requirements despite aging equipment. Operating around the clock in harsh environments also demands the utmost in visibility and illumination to support worker safety. Eaton LED solutions for oil refinery applications with todays modern light emitting diode, (LED) technology delivers increased energy efficiency, lowers maintenance costs and improves light quality, lighting upgrades present a great opportunity for refineries to cut costs while bettering work environments.

Application Cases– Eaton LED Solutions For Oil Refinery Applications In USA

When a major U.S. refinery was looking to modernize its lighting systems to provide a better environment for personnel, it sought a solution that could also reduce ongoing maintenance, replacement and energy costs. The increasing costs incurred from the aging high-pressure sodium (HPS) and incandescent lighting technology began to compound, and the refinery knew it needed to collaborate with an industrial lighting expert to develop a solution that would continue to deliver benefits well into the future.

Solution

Following an extensive inspection by lighting experts in Eatons Crouse-Hinds business, the refinery replaced legacy HPS and incandescent fixtures with Champ VMV Series and Vaporgard Series explosion proof LED luminaires. Exceeding the refinerys expectations as a HPS replacement for overall light quality and durability, the Champ VMV Series LED fixtures provided full-spectrum lighting and custom distribution at a fraction of the energy consumption.

Consuming less than 50W, the Champ VMV3L delivers equivalent lighting levels of a traditional 100W lamp, offering a lifetime energy savings upwards of 77 percent compared to traditional HPS luminaires. The robust design provides protection from flammable vapors, gases, corrosive chemicals and liquids to withstand the harshest of environments and has a lifespan more than six times that of typical luminaires. The Vaporgard LED explosion proof luminaires were implemented to provide the refinery with uniform, crisp light in low-mounted applications. An ideal replacement for traditional 100-200W incandescent applications, the luminaires comply with T5 temperature codes in Class 1, Div. 2 locations to provide the safety and performance required in downstream applications. The 22W LED system can also help save up to 85 percent in energy costs, and provides a rated life of up to 50,000 hours for nearly 10 years of maintenance-free lighting.

Results

By implementing the Eaton LED lighting technology, the refinery was able to reduce its annual energy usage by $34,668 while decreasing annual maintenance costs by $766,647. The complete lighting solution is also designed in compliance with applicable industry standards, providing the highest quality, safety and optical performance for hazardous areas.

To learn more about Eaton LED solutions for oil refinery applications, visit the Eaton Website. For Eaton Drive Repair and Replacement quotes, contact Precision Electric.

 

Drives Save Labor And Reduce Energy Costs

Variable frequency drives save labor and reduce energy costs while extending the lifespan of equipment for industrial applications. In the following ABB case study, afarm owner began looking toralternatives to an old irrigation system, which worked by running the water pumps at constantspeed, with control than being done bymanual opening and closing of valves In the pipelines. The system still worked, but it wascertainly not energy efficient.In addition, the need tor manual opening and closing of valves during startup combined withfrequent power outages and voltage dips from the electrical utility, made the whole process varylabor-intensive. To start one of the six pumping stations could take one person up to an hour andwith sometimes as many as three power outages a day, start ups became almost a full-time job.

The young owner of this farm was not previously a customer of ABB, but upon meetingwith ABB energy efficiency engineers, he decided to test variable frequency drives (VFD)on the water pumps at one of Its six pumping stations. ABB recommended a VFDand working witha system integrator, assisted in thedesign, installation and commissioning of five variable frequency drives running irrigation pumps with 45 to 75 kWmotors, and the sixth variable frequency drive used on the water transfer pump.The results were quite dramatic. With the new VFD installed, Riecor saw a significant drop inelectric energy. Demand from the irrigation system went from 291 kW, 308 kVA down to only 175kW, 186 k:VA. This amounted to 116 kW; an impressive 40 percent reduction in electric consumptionfor just one pumping station.

In financial terms, based on the local crop factor tor this region that Indicates the irrigationpumps would operate at 2,970 hours per year means an annual savings of $19,700 U.S.D. in electricitycosts. The payback time amounted to a short 7 months. The farm quickly made a repeat order and hasinstalled similar drives on a second pumping station

MajorBenefits
In addition to the financial savings on the electricity bill, the farm also had further operationalsavings in both labor hours and troubleshooting the initial start up process. Operators now only need to flicka switch to start, and in the eventof power interruptions the system wouldstart back up automatically at pre-set times.The variable frequency drivesgive a long ramp-up timethat allows for a very smooth pipe filling process, so the previous mechanical stresses on the pumpcouplings during start up were completely eliminated, together with fewer friction losses in thepipes. Additionally water hammering following switching off disappeared and fewer losses on theimpeller were seen due to these extended ramp-up and ramp-down times.

The ABB Energy Efficiency engineers who worked most closelyon the project, says that the Riecor Farming installation is a good example of how energyefficiency projects can also give additional benefits on the operational side.

Cost efficient retrofit

  • 40 percent reduction in energy consumption gave rapid seven- month payback of investment
  • Reduced labor costs, manpower needed for startup process is dramatically reduced
  • Smoother operation and pipe filling, power drops handled easier, water hammer and system shockseliminated

To learn more about applications where drives save labor and reduce energy costs, or for additional information about ABB Drives, visit the ABB Website. For ABB variable frequency drive repair or replacement, contact Precision Electric, Inc.

Industrial Packaging Systems Using Variable Frequency Drives

D&D Engineering (Hull) Ltd is a manufacturer ofconveyors and product handling equipment. Eighty percent ofits customers are in the food industry, mainly in the preparedproduce sector, with some involved in the production ofchilled products and bakery goods.One of D&D Engineerings recent customers is John BaardaLtd, a company specializing in the growing of tomatoes.John Baarda Ltd needed to replace its current tomatohandling conveyor system, which used inefficient chainsand sprockets, with a solution that would allow it to packtomatoes more quickly and accurately while allowing qualityinspection of the tomatoes.The company was experiencing difficulties with themechanically interfaced conveyors, as their coordinatingseries of chains and sprockets are subject to wear andstretch. This causes maintenance problems, with any timingadjustments having to be made mechanically, leading toproduction interruptions and reduced output.Gavin Walker, Engineering Sales Manager of D&D Engineering(Hull) Ltd explains: The speed of the conveyor must becoordinated with the speed and timing of the wrapper toensure that the tomatoes are delivered to the flow-wrapperat exactly the right time.

Quick And Accurate Industrial Packaging Systems Using Variable Frequency Drives

Integrating their industrial packaging systems using variable frequency drives was the goal for this application. The conveyor systemthat uses ABB servo motors and ABB high performancemachinery drives to control the speed of the tomato handlingconveyors, matching the speed of the packing machineand ensuring that the tomatoes are packed quickly andaccurately. An ABB component drive runs rollers on theconveyors, allowing the tomatoes to be turned automaticallyand inspected for quality.The two feeder conveyors are each driven by an ABB highperformance machinery drive in master-slave configuration,with the master receiving an encoder signal from the wrapper.This ensures that the drive knows where the wrapper is in itscycle and can control the speed of the conveyor precisely toensure the tomatoes arrive at the wrapper at the correcttime. If the speed of the wrapper changes, the drive canalter the speed of the conveyor accordingly to maintain thecorrect timing.

Challenges:

  • Accurate co-ordination of tomato handling conveyor withwrapping machine to allow quicker packing of tomatoeswhile providing quality inspections

Solution:

  • ABB servo motors controlled by ABB high performancemachinery drives match the speed of the tomato handlingconveyors to the speed of the packing machine
  • ABB component drive controls rollers on the conveyors,allowing the tomatoes to be turned for inspection

Benefits:

  • Tomatoes are packed quickly and accurately
  • Packing rate has doubled from 40 packs per minuteto up to 80 packs per minute
  • The drives programmed product menus allow different
  • products to be run on the conveyor with quick changeovers
  • Easier to build thanthe previous mechanical interfaced systems
  • Operation and maintenance costs reduced

Doubling The Packing Rate

Tim Howarth, Business Development Manager with JohnBaarda says: With mechanical systems, we can achievea maximum rate of around 60 packs per minute. Withstoppages, this averages around 40 packs per minute.The ABB machinery drive based electronic control systemgives us an average of 70 to 80 packs per minute.The ABB high performance machinery drives can be used withboth synchronous and induction motors and their modulardesign and flexible software make them suitable for use in arange of machinery applications, including those of the foodand beverage industry, material handling and packaging.

To learn more about ABB Low Voltage Drives or for ABB Repair and Replacement Quotes, contact Precision Electric, Inc.

Information References:

www.abb.com/drives
www.abb.com/drivespartners