Industrial Electronic Repair

Services

● AC & DC Drives ● Chart Recorders ● CNC Controls ● Counters & Timers ● Encoders ● Flowmeters 

● I/O Module ● Industrial Controls ● Industrial Monitors ● PLCs ● Power Supplies ● Printed Circuit Boards 

● Robotics ● Safety Equipment ● Servo Drives ● Temperature Control ● Transducers ● Ultrasonic

Industrial Electronic Repair Service

On the factory floor, industrial electronics are a tremendous tool. They allow you to automate much of the production process and work with greater precision. You can even make use of some electronics to monitor or aid other electronics.

But electronics are also as prone to malfunctions and breakdowns as any other machinery. And when your electronics stop working, it can be difficult to know what to do about them. The same factors that make them so precise and efficient on the job also make them intricate and complex devices to repair.

Global Electronic Services exists for this very reason. We provide testing and repair services for an array of industrial electronic equipment and keep you informed throughout the whole process.

Our Industrial Electronic Repair Process

At Global, we like to be transparent about what we do to your equipment. We offer updates throughout the process on the status of your devices, and we maintain a standard testing and repairing procedure for all equipment. This procedure uses 100% true load testing and custom engineered test stands across the two main stages of the process.

100% True Load Testing

The performance characteristics of any piece of electronics — whether it be a motor, power supply, circuit board or variable frequency drive — will change depending on if it is tested under a load. All electronics are designed to perform at a certain rating, and if you aren’t testing it that way, failures will go undiscovered, leading to downtime in the field.

That characteristic is why we are constantly developing test stands — so that after repairs have been made, we can be sure the device will work at its full capabilities once installed. These test stands include the following:

• Drive dynamometers: Drive dynamometers are designed to test all motor controls we service, including AC, DC, spindle and servo drives.
• Power load banks: Power load banks are for testing the output power characteristics of power supplies, both AC and DC. They encompass both low and high current supplies.
• Motor dynamometers: Motor dynamometers apply full torque at a full rated frequency and voltage to test any type of motor we service. These motors include AC induction, DC, permanent magnet, servo, stepper and spindle motors.
• Dynamic resistive loads: Dynamic resistive loads are for testing power characteristics along a specific response curve.

Stage 1: Drive Testing

After a motor control is repaired and all control function is verified, the final testing is done in two stages. In the first of these stages, a drive is installed on a motor that is not coupled mechanically to any load at the technician’s bench. The technician can then carefully monitor any abnormal change in current or irregular frequency issues and shut down the test before a failure occurs.

This test is performed using a motor undersized for the controller and at a lower speed. The motor is slowly brought up to full speed and closely monitored.

Stage 2: Dynamometers

Once the initial testing is complete, the drive is then installed on a dynamometer appropriate to its size. A dynamometer is a specialized braking device that creates a load by using two motors coupled together, which turn in opposite directions and present resistance to each other.

The drive is then made to perform at low, medium and high speeds while resistance is applied to the shaft that will apply a load on the output lines. The dynamometer is set to bring a drive up to its full amperage rating at each specific frequency.

Custom-Engineered Test Stands

Many electronic devices work in what is called a closed-loop system. A brief definition of this is any device that requires a feedback response from another device to perform its function. Applications such as servo, computing, process control and robotics all use some form of communication to perform tasks within a machine’s operation.

Without this connectivity, very little of a device’s function can be tested. We continually engineer test stands to ensure function on all models and manufacturers we service. These test stands include the following:

• Software platforms: Software platforms connect to devices across many different communication protocols such as DeviceNet, Profibus, SERCOS and Modbus.
• Transmit and receive stands: Transmit and receive stands are used for safety equipment such as light curtains and scanners.
• Multi-axis servo control stands: Multi-axis servo control stands are used for servo applications.
• Programmable logic controller (PLC) racks: PLC racks are for individual supply, processor and I/O testing.
• Flow control test stands: Flow control test stands are used for servo-operated valves, both hydraulic and pneumatic.

Industrial Electronic Services We Provide

Our overall repair process remains consistent across different industrial electronic services, and we work with many kinds of equipment. We service a vast array of industrial electronic equipment, from AC drives to circuit boards. Here are the devices we commonly work with.

AC and DC Drives

For any industrial repair company, it’s vital to understand the workings of AC and DC drives. We can quickly diagnose the problem with your drive and have it fixed in no time. We’re familiar with a range of AC and DC drive brands, including the following:

• Mitsubishi
• Allen-Bradley
• Danfoss
• Toshiba
• General Electric
• Reliance

 

When your company sends in an AC or DC drive for industrial repair, we perform standard checks and procedures like these:

• – Component testing with meters and signature analysis devices
• – Evaluating parts prone to failure, including capacitors, output and drive transistors, silicon controlled rectifiers (SCRs), firing circuits and power supplies
• – Checking output waveform
• – Load testing with the appropriate motor and dynamometer

Chart Recorders

When your chart recorder breaks down, you may be inclined to buy a new one, but that isn’t the most cost-effective choice. Global Electronic Services can repair and return your damaged recorders in one to five days. We work with various chart recorder brands such as:

• – Honeywell
• – Chessell
• – Dickson
• – Barber Colman
• – Omega

 

Equipment repair on chart recorders generally includes these steps:

• – Testing batteries, power components and fuses
• – Inspecting for loose connections
• – Troubleshooting to component level
• – Checking inputs, outputs, control circuits and microcontrollers
• – Resetting to factory default input signals
• – Verifying output

CNC Controls

CNC controls are vulnerable to plenty of issues, from dull parts to faulty maintenance. Fortunately, we repair CNC controls from plenty of well-known brands like the following:

• – Haas
• – Mori Seiki
• – Okuma
• – Allen-Bradley

 

CNC control repairs generally consist of these steps:

• – Testing common failure components like diodes, capacitors, switches and potentiometers
• – Checking supply voltages
• – Applying test signals

Counters and Timers

Industrial counters and timers need maintenance occasionally, most often from having a broken connector ring. Thankfully, Global Electronic Services has the equipment to test and repair those devices. We service many different counter and timer brands, including:

• – Red Lion
• – Love
• – Eagle
• – Barber Colman
• – Watlow
• – Eurotherm

 

Repairs on counters and timers include different processes depending on the type. For mechanical timers, repairs may include these steps:

• – Verifying the mechanism
• – Replacing relays
• – Aligning and adjusting mechanics
• – Verifying timekeeping and actuating

 

Electric timers could require these repair methods:

• – Verifying the inputs and outputs and the frequency of the oscillator
• – Evaluating mechanical contacts for tightness

 

Counters often get these repair treatments:

• – Verifying logic functions
• – Testing power supplies
• – Verifying proper count

Encoders

Many different kinds of encoders are used throughout various industries, but we can handle nearly all of them, including the following types:

• – Linear
• – Incremental
• – Serial
• – Moto
• – Absolute
• – Magnetic
• – Parallel
• – Optical
• – Rotary

 

We can repair encoders from brands like SONY and Honeywell, among others. Our standard processes and inspections include these steps:

• – Inspecting the gratical for damage
• – Rotating the shaft at specified RPMs
• – Verifying signals, pulses and counts

Flowmeters

When your flowmeter breaks down, it affects your whole system. You can’t transfer substances without being able to regulate how much gets through, so you’re forced to grind everything to a halt until it’s repaired. That’s why we work to get your flowmeters repaired and returned in less than a week. We service various flowmeter types, including:

• – Positive displacement
• – Mass
• – Liquid
• – Turbine
• – Ultrasonic
• – Gravimetric flow

Our flowmeter repair process generally includes methods like:

• – Checking the sensor wheel for worn or damaged parts
• – Testing circuitry
• – Testing outputs
• – Verifying set points
• – Evaluating transmitters for strength and data content

I/O Modules

I/O modules are common pieces of equipment to need repairs, often from something as simple as being overloaded with dust. We’re familiar with many different I/O manufacturers and can get your I/O boards fixed quickly. Brands of I/O modules we’ve repaired include:

 

• – Fanuc
• – Omron
• – Texas Instruments
• – Allen-Bradley
• – Reliance
• – General Electric

Repairs for I/O modules generally involve these procedures:

• – Checking power supplies
• – Verifying inputs, outputs, ladder logic and sink and source current
• – Assessing common failure components like driver ICs, transistors, optocouplers, transients and capacitors

Industrial Controls

One of the types of equipment we most specialize in is industrial controls. These controls are supposed to tell your other machinery what to do, so if they stop working, so does your other equipment. We’ll take a look at your faulty controls to determine the source of the problem and replace any malfunctioning parts to have it running smoothly again in a matter of days.

Repairing industrial controls typically involves:

• – Checking power and output components
• – Inspecting common failure components like MOVs, capacitors and transistors
• – Load-checking outputs like mechanical outputs, transistors and solid-state relays
• – Verifying functional software
• – Running a test program to evaluate the repair

PLCs

Like industrial controls, PLCs — programmable logic controllers — are vital to the way your different devices and pieces of equipment communicate with each other. Losing a PLC can have major repercussions if not addressed quickly. Global Electronic Services provides fast PLC repair service to get your system up and running again. We specialize in PLC brands like:

• – Allen-Bradley
• – Honeywell
• – Modicon
• – Siemens
• – Texas Instruments
• – Westinghouse

The PLC repair process often includes:

• – Checking inputs and outputs
• – Evaluating common failure components like relays, capacitors and optoisolators
• – Verifying correct functioning of the CPU and logic
• – Testing the circuit, ladder logic and battery backup

Power Supplies

Your power supplies convert energy into the appropriate form for your other equipment to use, so losing one can put everything on hold. Thankfully, we repair many different types of power supplies, including the following:

• – Variable AC power supplies
• – Frequency changers
• – Isolation transformers
• – Unregulated linear power supplies
• – Regulated linear power supplies
• – Switching-regulated power supplies
• – Ripple-regulated power supplies
• – Adjusted regulated power supplies
• – Battery- and solar-powered supplies
• – AC-to-DC converters
• – DC-to-AC converters

When we repair power supplies, we often follow steps like:

• – Checking the input circuit
• – Verifying output voltages, regulation and sense circuit, if present
• – Verifying 2000 Analyzer and OEM specifications

Printed Circuit Boards

Printed circuit boards (PCBs) wouldn’t be cost-effective to replace every time something goes wrong. That’s why it’s a good idea to take advantage of our experience with repairing them. We offer several SMT repair options, like:

• – Gold finger repair
• – BGA pad repair
• – Through-holes
• – Failed component repair
• – Corrosion
• – Impact damage
• – Broken traces
• – Edges
• – Mask
• – Populated boards

Repairs for PCBs can include these processes:

• – Inspecting for missing or damaged parts or blown traces
• – Testing all components and traces
• – Testing for functionality
• – Cleaning and recoating

Robotics

If you use robotics, you do it for a simple reason — to increase the ease and efficiency of your job. But when a piece of robotics is malfunctioning, it usually just has the opposite effect, messing up the production process and forcing you to spend time repairing the equipment instead of doing your actual job.

The good news is we can handle those repairs for you. We’re familiar with robotics brands such as:

• – ABB
• – Fanuc
• – Motoman
• – ASI Robotics

Depending on the system, robotics repairs may include steps like these:

• – Inspecting for surface defects and mechanical damage
• – Testing electromechanical assemblies
• – Testing common failure components like relays, capacitors, switches and diodes
• – Refurbishing front panels
• – Servicing cooling fans, cables and interface boards
• – Loading and restoring power supplies to OEM specifications
• – Performing a final full power-up, output verifications, burn-in cycling and load testing

Safety Equipment

In any industrial job, “safety first” is an excellent motto to have. Production speed and quality are fantastic, but you can’t prioritize them over your workers’ safety. So when your safety equipment is down for the count, you need to get it back up quickly. At Global Electronic Services, we repair many different types of safety equipment, including:

• – Safety light curtains
• – Photo-eyes
• – Scanner sensors

Repairs for safety equipment generally involve procedures like these:

• – Inspecting lenses for deep scratches or chips
• – Checking connections for bent or broken pins
• – Polishing lenses
• – Verifying signals or communications

For scanners, additional maintenance steps might include these:

• – Cleaning the scanning mirror
• – Verifying optical alignment
• – Checking alarm outputs

Servo Drives

With their compact size, high torque and extreme precision, it’s no wonder servo drives are critical to your workplace. A lot of your machinery is dependent on them, so when they’re not working properly, you need to get them fixed quickly. Thankfully, we have years of experience working with servos. We’ll repair your equipment with minimal downtime to get you back in gear.

When repairing servo drives, we might follow some of these methods:

• – Checking for missing components, damaged components, standoffs and bent hardware
• – Evaluating IGBTs, relays, MOSFETs, inputs, outputs, power supplies and feedback circuits
• – Verifying correct phase, feedback, rotation and direction underload

Temperature Control

A common cause of equipment malfunctions is overheating, which is why it’s crucial to have a temperature control unit to keep everything in check. But what do you do when your temperature control unit is what’s malfunctioning? Bring it to Global Electronic Services. We service temperature control brands like the following:

• – Watlow
• – Honeywell
• – Red Lion
• – Barber Colman

Repairing a temperature control unit often involves:

• – Checking for worn or missing parts
• – Identifying and replacing defective components
• – Testing the unit to confirm an accurate repair

Transducers

While other machine failures can cause your equipment to shut down, transducer malfunctions have a different effect. When your sensors aren’t working correctly, the other equipment might continue to run but do its job incorrectly without accurate feedback from the sensor.

That’s why it’s vital to get service on any faulty transducers as soon as you can. At Global Electronic Services, we work with transducers from OEMs such as:

• – Balluff
• – Norgren
• – Revere
• – Transducer
• – HBM
• – MTS
• – Dynisco
• – ITT
• – Micron

When we repair transducers, we often use these methods:

• – Resolving sensor errors
• – Identifying and replacing defective components
• – Testing sensors in real-world scenarios

Ultrasonic

Measure controls, ultrasonic welders and other ultrasonic equipment are as vulnerable to malfunction as any other machinery, so it’s essential to troubleshoot them when it appears something might be going wrong. We service many different ultrasonic brands, including the following:

• – Crest Ultrasonics
• – Panametrics
• – Genesis

Ultrasonic equipment repairs generally include these steps:

• – Checking for missing or broken parts
• – Identifying and replacing defective components
• – Evaluating performance in real-world scenarios

We’ll keep you informed on the status of your equipment and get it back to you in good condition within only a few days.

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Why Choose Global Electronic Services Repair?

At Global Electronic Services, we have an array of experienced technicians who are intimately familiar with the workings of the equipment they service. We also practice ongoing education and certifications to keep current in the fast-paced, ever-changing electronic world. These practices include:

• Factory-authorized training: We provide factory-authorized training through a wide variety of manufacturers.
• EASA certification: We have certification and training from EASA, the electromechanical authority, for all rotating apparatus, including AC and DC motors, generators, servos and spindles.
• Mitchell Electronics certification: We possess the Mitchell Electronics certification for testing all feedback types, includingabsolute encoders, incremental encoders, resolvers and tachometers.
• Certified technicians: Our technicians hold ISCET, IPC and MIL-SPEC certifications.

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