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Paint Booth Control System, Troubleshooting & Repair, Allen Bradley PLC
Troubleshot an Allen Bradley Micrologix 1000 plc system that is the heart of the control system for a very large paint booth. They can get large trucks and transports into this one. The system also uses 2 Mitsubishi AC inverter drives (E500 & A500). A 10HP Exhaust unit and a 25HP Air Make-Up unit.
Samatic 12500R Automatic Digital Motor Tester Repair
Troubleshot a video problem with this unit and the display of erroneous characters. This type of test equipment and similiar is used by electrical motor repair shops to verify the integrity of their finished product, the motor.
110 Engel, Allen Bradley, Mini PLC 2-15 System Intermittent
I was called-in by a local customer to find an intermittent nuisance trouble. It’s hard to see in this picture but this little glass fast acting fuse was causing some interesting machine trouble. The fuse failed with a thin fracture in the filament which would open and close intermittently through a heating/cooling effect and vibration. While troubleshooting this 110 ton Engel injection molding machine I noticed that all PLC outputs would loose power, dropping out all hydraulic valve solenoid power. I managed to be measuring the 24vdc power supply when the problem occured and knew it was fine. Examining the schematic I noticed the fuse was in the dc supply line feeding the PLC2 output common.
Sotcher Electrical Product Tester Model 352 ‘The Short Stop’
This week I had a rush job to troubleshoot and repair 3 of these testers for a local customer. Two of the units required calibration as well.
Model 352 Short Stop
• All 120V power tools in common use can be tested.
• Manually Operated
• The quality and continuity of the ground circuit is measured, Hi-pot test, Short test Line & Case, Line powered then leakage current measured & product AC current.
• No data acquisition
• Adjustable Hi-Pot 0-3000 Volts AC test voltage
• This is an economical solution for lower volume production lines
Baker Motor Winding Analyzer, D12R
My electronic shop has been busy recently with several Motor Winding Analyzers, made by Electrom & Baker Instruments. This unit needed repair and calibration.
Electrom Instruments, Motor Winding Analyzer, TigC
Trouble-shot several serious problems on an Electrom TigC Motor Winding Analzer. I have some obsolete special parts on order to fix the last issue with this unit.
Electrom Website Link
Baker Instrument Motor Winding Analyzer, AWA12000
Trouble-shot this tester which can perform various tests such as ‘Surge / Hipot / Resistance’
Baker Tester Specs.
Matsuura MC-1000VF Vertical Machining Center, Memory Upgrade, YASNAS i80M CNC Control System
Performed a memory upgrade to a Matsuura vertical machine center that uses a YASNAC i80M CNC sytem. The original system had 64k of program memory which is equivalent to 167 meters of paper tape backup. I added a memory card to give an additional 2 megs of program storage space which is equal to 5.12km of paper tape! This allows the machine operator to keep certain common program jobs in memory for fast access instead of ‘drip feeding’ larger programs through the RS-232 serial connection. This was an interesting job since the machine is from 1995 and a special installation procedure must be completed to ‘regenerate’ the new larger memory format.
Safety E-STOP Upgrades , Telemecanique
Switch, 22mm, 40 MM E-STOP OPERATOR, UNLIT, PUSH-PULL, RED. Installed 2 additional Stop buttons on 2 different packaging machines to upgrade the machine safeties for a local customer. It makes sense to review on a regular basis how equipment/machines are being operated since the work environment configuration may change making what used to be logical safety device positions then unsafe.