Eaton VFD Troubleshooting

Eaton VFD Troubleshooting

Eaton VFD TroubleshootingEaton VFD troubleshooting begins with technicians working with the VFD in production. Eaton VFD troubleshooting can be time consuming, so manufacturers tend to keep spare Eaton drives on hand for production lines that cannot afford downtime.When Eaton VFD troubleshooting cannot be resolved in the plant, technicians in the field 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 VFD troubleshooting and VFD repair centers are an asset to manufacturers who use Eaton drive products, and Precision Electric is the best source for Eaton VFD troubleshooting and Eaton VFD repair.Precision Electric has been performing Eaton VFD Troubleshooting and Eaton VFD Repair since 1983.Precision Electric has helped save manufacturers thousands of dollars by repairing their failed Eaton VFD drives in lieu of of replacing Eaton VFD drives.

When Eaton VFD troubleshooting 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 VFD troubleshooting is to diagnose, repair and re-commission the unit as quickly as possible, and these are the steps that Precision Electric follows before anydis-assembly takes place.

1. Take Notes –Eaton VFD Troubleshooting

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 VFD troubleshooting, qualified technicians take note of many important aspects of the equipment including, but not limited to:

    1. Eaton VFD Model Number
    2. VFD Serial Number
    3. Reason for Service
    4. Urgency (Rush Overtime or Standard)
    5. Visual Inspection of External Device

2.Diode and IGBT Tests –Eaton VFD Troubleshooting

Eaton VFD TroubleshootingWhen Eaton VFD Troubleshooting 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.

3. Power Up –Eaton VFD Troubleshooting

If the input and output power sections test healthy during this step of the Eaton VFD troubleshooting 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.

4. Run A Motor – Eaton VFD Troubleshooting

Eaton VFD TroubleshootingIf the previous three tests have passed during the Eaton VFD 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.

5. Contact Customer – Eaton VFD Troubleshooting

At this point we have determined the cause of failure, estimated lead time and cost of the Eaton VFD troubleshooting 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.

6. Send Service Tech – Eaton VFD Troubleshooting

If the customer cannot establish failure on any other aspect of the machine and the Eaton VFD troubleshooting 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 VFD Troubleshooting or for Eaton VFD Repair Quotes, contactPrecision Electric, Inc.

 

 

 

 

 

 

Paper and pulp industry

We’ve Been Servicing the Industrial World Since 1983.

Minimize Your Downtime. Maximize Your Productivity.

Call Toll Free: 1.877.625.2402

Processing pulp and paper is a demanding industry. Crushing loads, high humidity, dirt, dust and grime can all take a toll on the best precision equipment in your manufacturing facility. Keep your equipment in prime operating condition by calling us. Or when a breakdown occurs, you can depend on Precision Electric to provide a wide selection of services, products and/or technical support. Our Automation Controls Group was designed to integrate industrial equipment and industrial electronics for paper and pulp manufacturers around the globe, among other industries. Click here to learn more about the Precision Electric Automation Controls Group.

Nearly all servo motors in the paper and pulp manufacturing world can be repaired for a fraction of what it will cost to buy a new one. We provide expert repairs for all AC servo motorsas well as brushless servo motors, and DC servo motorproducts, and all other related equipment. Click here to learn more about these products and services.

We are a single, reliable source for a wide selection of field and in-shop services. Our objective is toto reduce your operating costs by minimizing downtime, improving efficiency and extending your machinery and equipment life. Precision Electric will work around the clock 24/7 for emergency breakdowns all year round.

All of our repair services are covered by a One-Year comprehensive warranty unless otherwise stated on your quote.Precision Electric has been providing comprehensive AC & DC Servo Motor Repair and CNC & Spindle motor repair services for over 25 years. We routinely repair domestic and foreignmotors. To learn more click here.

If you have paper and pulp electrical manufacturing equipment that you want quoted for repair, or if you want a quote to replace something specific, let me know. I am available via email or telephone. When you call Precision Electric a human being will always answer, because we do not believe voicemail is logical in our industry.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]
Call Toll Free: 1.877.625.2402

How do I use three phase equipment with single phase power

This is popular subject here at Precision Electric. We receive emails and calls all the time for customers who have three phase equipment and need to operate this equipment from single phase power. Since most higher horsepower drives only accept three phase input power, many customers are left with little options or alternatives. However, we have a solution for these applications.

Before you derate your drive it is most important to ensure the drive you are using is properly suited for your application. The following are some basic guidlines to help you in determining whether or not your Variable Frequency Drive is suitable for your application:

  1. Gather motor nameplate data including horsepower (HP), current (Amps), motor voltage, input line voltage and power source phase.
  2. Determine which type of drive your application will require. The type will fall under the category of either Volts per Hertz (V/Hz), closed-loop vector, or open-loop vector (Sensorless Vector).

Heres how to derate a three phase drive for single phase power:

  1. Determine the motor horsepower and motor current
  2. Choose drive with a Horsepower higher than the Horsepower of the motor to compensate for the additional input current from the single phase power source.

The simplest formula used for these types of applications is:
The drive max current needs to be greater than that of the motor current. Take your motor current and multiply by 1.73. Then choose a drive that is rated at or higher than the revised current.

Example:

  • Drive rated current > Motor Current Rating * 1.73
  • Drive rated current > 27 Amps * 1.73
  • Drive rated current > 46.71

Now it has been determined this example application will need a 230 VAC 3 phase Volts per Hertz (V/Hz) Variable Frequency Drive with an input current rated at or above 47.0 amps. This particular application would need a 15hp 240V three phase drive to operate on single phase power.

 

Variable frequency drive torque control inverter vfd

Weve Been Servicing the Industrial World Since 1983.
Minimize Your Downtime. Maximize Your Productivity

Call Toll Free: 1.877.625.2402

Customers of Precision Electric have been using variable frequency drives to better control torque on electric motor applications for a number of years. This posting is to help you decide what type of variable frequency drive will work best for your application.

For a new VFD application:

  • Research the motor andVFD specifications.
  • Research yourapplication requirements.
  • Learn more abouttheVFD products that are available to you.
  • Understand thefeatures of thoseVFD products to determinewhatis an appropriate solutionfor yourapplication.

There are a several different types of Variable Frequency Drives. The following is a short summary ofthe three different types of drives that are available, and when these types of drives should be considered in an application:

V/Hz (Volts per Hertz) Variable Frequency Drives (VFDs)

The most commonly used and most basic VFDavailable; this product is for a basic applicationinpumps, fans, conveyors, blowers and others. These applicationsdo not require high starting torque, full motor torque at low rpm, and/or speed feedback. Most V/Hz VFDshave adequate programming features for many applications. Be certain adequate I/O and programming features are available to meet your application requirements. This product is an inexpensive alternative to a phase converter since they will acceptsingle phase input while providingthree phase output.

Sensorless (Open Loop)Vector Variable Frequency Drives (VFDs)

The next VFDtype that is commonly used in a lathe, mill or any applicationwhere full torque is require throughout the motor speed range.Sensorless Vector VFDsareare also referred toas open loop vector drives; these drives are morecomplex than V/Hz drives and should always be applied to applicationswhere high starting torque and/or full torque operating at lowRPM is required. If speed feedback and/or extremely complex programming must be considered in your applicationyouCANNOT use a sensorless vector VFD. Sensorlessvector/open-loop vector VFDsdo offer complex programming to a certain degree, but when your applicationexceeds sensorless vectorprogramming features, there is a third solution.

Closed Loop Vector Variable Frequency Drives (VFDs)

This next level of VFDsare more advanced. Applicationsthat require accurate speed regulation and feedback from the motor and/or require complex programming will require a closed-loop vector drive. Thistype of VFDis often offered as a “three in one” and able to operate in all operating modes.

  • V / Hz (Volts per Hertz)
  • Sensorless (Open Loop)Vector and
  • Closed Loop Vector

These products are complex and extremely efficient when properly applied. Used in the most complex, advancedmanufacturing facilitiesacrossthe world, closed-loop vector technology has few limitsin drive technology. The product features are phenomenal. Applicationswhere these products are utilized provide superior speed regulation and torque performance.

Before choosing a drivefor your applicationconsult with a qualified integrator, distributor, or manufacturer who will ask all the right questions and make an appropriate recommendation. Here at Precision Electric Inc we offer proper service and telephone support from when you, or your qualified electrician, are setting up the drive for your application. Call us today.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]
Call Toll Free: 1.877.625.2402

Infrared thermography testing services

Infrared inspections provide a means to view systems (electrical, mechanical, building envelopes) under normal operating conditions to identify abnormally hot (or cool) areas or components. This is a powerful maintenance tool. In many instances, equipment failure is preceded by a period of increasing heat. This is especially true of electrical equipment.

With infrared thermography you can identify overheating electrical connections and other machine components, scheduling repairs to be made during planned downtime. This increases reliability and productivity for the entire operation.

This thermogram shows a loose connection of the lug on incoming power supply. Operating equipment with loose connections can
cause many problems, some damages could be un-repairable

Financial Savings

  • Fewer interruptions while in operation mean more uptime and greater productivity.
  • Equipment problems are fixed before they fail and damage or destroy the rest of the machine.
  • Identifying developing problems and planning the repairs results in fewer panic situations, those costly predicaments that force excessive overtime and monetary premiums for emergency rush equipment orders.

This thermogram shows a loose fuse clip that needs tightened or replaced. Loose fuse clips could lead to serious equipment damages.

Safety

  • An industrial process that runs reliably and without surprises produces a safer work environment. Many industrial processes are complex and run at high speed. A sudden failure on one machine can have a cascading effect of failures that may include flying debris.
  • Fire avoidance. Overheated electrical connections can start fires. You may have heard of a fire in your area that it was caused by faulty wiring. This means many things including bad design and overloaded circuits. It also commonly means a bad electrical connection that was overheating and was not found in time.

Other advantages of thermography:

  • Shows a visual picture so temperatures over a large area can be compared
  • Able to find deteriorating: (higher temperature components prior to their failure)
  • Measure or observe in areas inaccessible or hazardous for other methods
  • Non-destructive test method
  • Locate defects in shafts, pipes, and other metal or plastic parts

Call Precision Electric, and schedule infrared thermography services to prevent unnecessary damages to your industrial equipment.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]
Call Toll Free: 1.877.625.2402