Engineering Projects
Case studies from the engineering bench
Each case study documents the equipment, the fault, how it was analysed, the repair method and how the result was verified.
Project list
Industrial Controller Repair
Toshiba VF-AS1 30 kW inverter: heavy internal dust cleaned and fully tested
Toshiba VF-AS1 inverter (30 kW, three-phase)
A Toshiba VF-AS1 30 kW inverter came in packed with dust. We cleaned it out, checked the power and I/O sections, and ran it at 400 V and on a motor. No parts were damaged and it tested normal.
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ESA VT300 operator panel (HMI): blurry display replaced
ESA VT300 operator panel (HMI)
An ESA VT300 operator panel powered on but its display was blurry. The keypad tested fine, so we took the panel apart, replaced the display module on its driver board with a brand-new one and reassembled it. The panel works properly again.
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Industrial Controller Repair
Elmo HAR-1/200 servo drive: programmed board moved to keep the customer's program
Elmo HAR-1/200 servo drive
The customer needed to keep the program stored in one Elmo HAR-1/200 drive. Each drive is a stack of three boards soldered together, so we desoldered both units in stages, moved the programmed middle board into the second drive and soldered it back exactly as it came apart. It started with its program and parameters intact.
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Industrial Controller Repair
EEC510 electron beam controller: blown tantalum capacitor, failed switching regulator and unstable internal USB link
EEC510 electron beam controller
A tantalum capacitor on an EEC510 electron beam controller's I/O board had burst, and the switching regulator beside it had failed. We replaced both and the unit powered up normally. Communication errors with the I/O board then showed up at start-up: the I/O board's USB-to-serial bridge was not always recognised. Without rewriting the original software, we changed the BIOS USB mode and connected the I/O board to the PC board's second USB-A port with a new cable; three cold starts in a row passed.
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