Most Magnetek VFD repair can be prevented with routine maintenance. Magnetek VFD repair 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 modules to prevent production downtime in the event of a Magnetek VFD failure. Components used for Magnetek VFD modules 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 Magnetek VFD repair ensures a longer lifespan of the VFD during production.

Connections
Checking connections is a step many people miss or do incorrectly during the Magnetek VFD repair process. Heat cycles and mechanical vibration can lead to sub-standard connections, as can poor routine maintenance practices. 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 VFD input can result in nuisance over voltage faults, clearing of input fuses, or damaging protective components. Arcing at the VFD output 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 inverter starting and stopping. A loose speed reference wire can cause the VFD speed 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 VFD unit. 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 VFD prior 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 offered to the customer.

Power Up Unit
If the input and output power sections test healthy during this step of the Magnetek VFD repair 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 VFD is 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 cost and lead time of the VFD repair.

Run A Motor
If the previous tests have passed during the Magnetek VFD repair process, Precision Electric will run a basic jog function of the VFD with a simple template program. Often when Magnetek VFD repair jobs come 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 can reinstall the program once the Magnetek VFD repair is complete.

The best method for backing up an operation program depends on the manufacturer of drive, but after it has been backed up, Precision Electric will either reset the VFD to 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 VFD repair should be taken with extreme caution. VFD repair 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 performing Magnetek VFD repair should always take extra precautions to ensure proper safety measures are taken to prevent injury or death.

For Magnetek VFD repair and Magnetek VFD replacement quotes, contact Precision Electric.