Yaskawa Engineered Systems Group

New Plain City, Ohio New Plain City, Ohio OfficeOffice

Yaskawa Engineered Systems Yaskawa Engineered Systems GroupGroup

... supporting customers throughout North and South America Located in Plain City, Ohio

Serving high volume Japanese American Customers which have been or will be equipped with Yaskawa products from overseas

Organization consists of: Distributed R&D facilities Sales and service offices Training centers Manufacturing and repair operations

Technical Support & Engineering Technical Support & Engineering ServicesServices

Application engineering Systems engineering Custom manufacturing“Turn-Key” systems integration Repair services Component sales 24-hour technical support Training

YESG provides a wide range of technical support and engineering services such as:

Systems EngineeringSystems Engineering

YESG supports your goals: Updating equipment Improving processes

Increasing efficiency

Engineering Capacity Retrofit to complete “turn-key” system

Technology expertise in: Variable Frequency Drives (Inverters) Motion Controllers Servo Drives Programmable Logic Controllers (PLC) Robotic Systems HMI Programming Vision Systems

Applications EngineeringApplications Engineering

Broad range of application engineering expertise: Automotive applications

Stamping lines Weld lines Assembly lines Paint lines

Other applications Pumping Air handling Material handling Web processing lines Conveyor systems

YESG has the experience to find the best solution for your applications.

Custom ManufacturingCustom Manufacturing

Quality custom products Our engineers and production associates work with you throughout the design and manufacturing process Products delivered on time

Quality control Ultimate reliability and performance

Manufactured products include: Custom cables Terminal boxes Operator panels System control enclosures

New 6,000 sq. ft. Mfg. Facility New 6,000 sq. ft. Mfg. Facility ……

… … with Paint Boothwith Paint Booth

Product TrainingProduct Training

Training Offerings: In-house and on-site Hands-on experiences

Using Yaskawa software and hardware products Small class size Machine Controllers (PLC and Motion Controllers) Variable Frequency Drives (Inverters) Servo Systems

Component SalesComponent Sales

Components and parts For all Yaskawa global products, including:

Programmable logic controllers (PLC) Variable frequency drives (Inverters) Motion controllers Servo drives (AC and DC)

Expedited counter-to-counter delivery

Repair ServiceRepair Service

Certified product repair center For current and legacy products Uses approved parts, procedures, and testing Normal return/repair: 6 days 48-hour emergency turn-around Some of the installed Yaskawa products in North America are

over 30 years old and are still repairable

Our commitment to customers and our products enhances the investment made in Yaskawa products!

Service and Support Service and Support EngineeringEngineering

Available for all Yaskawa products On-site startup of new control systems Phone support:

Phone: (614) 733-3200 Hours: 8am – 5pm (EST)

24-Hour emergency hotline support and dispatching: Phone: (614) 733-3277

On-site inverter and servo system analysis: Chart recording baseline data Parameter backup Documentation

Preventive maintenance programs

Reduction of downtime.

Accurate, complete machine documentation

Reduction of on-site service and maintenance time.

Reduction of maintenance costs.

VFD Preventative MaintenanceVFD Preventative Maintenance

1. Cleaning of the unit - This includes cleaning the outside of the inverter as well as carefully removing dust from the circuit boards inside the unit.

2. Inspection of control board - Yaskawa will visually inspect the control board for any possible problems such as leaking capacitors or overheated resistors.

3. Documentation of Parameter settings - This allows for easier troubleshooting and replacement. The parameters will be saved to disk and also printed out in list format for easy reference.

4. Chart Recording and Tuning of Speed and Torque characteristics - Chart recording should be done on a monthly basis to help find small problems, such as bearing wear and abnormally high torque or current. Proper tuning of a motor and inverter will reduce unnecessary wear on the motor, which in turn will prolong the life of both the motor and inverter. The goal of the tuning process is to reduce the torque as much as possible while still maintaining the desired speed curve. This is accomplished by adjusting the gain settings in the inverter. A printout of each chart recording will be given to the customer and also saved in our files for future comparison.

5. Check and document the revision level of the inverter - This will allow for easier replacement in the case of breakdown.

6. Verify all line voltages - All incoming voltages, both AC and DC, will be measured to verify they are within the tolerance of the inverter.

7. Perform megger test on motor - Each phase of the motor will be megged to verify the integrity of the motor windings.

Servo Preventative Servo Preventative MaintenanceMaintenance

1. Cleaning of the unit - This includes cleaning the outside of the servo as well as carefully removing dust from the circuit boards inside the unit.

2. Inspection of control board - Yaskawa will visually inspect the control board for any possible problems such as leaking capacitors or overheated resistors.

3. Documentation of Parameter settings - This allows for faster troubleshooting and replacement in the case of failures. The parameters will be saved to both hard and soft copies utilizing Sigma Win software.

4. Verify the integrity of all soldered connectors - Over time, connections can weaken from vibration and movement. Checking these connections can avoid problems before they occur. These include the I/O cable, encoder cable, and the motor power cable connectors. Each connection will be checked and documented.

5. Chart Recording and Tuning of Speed and Torque characteristics - Chart recording and tuning on a monthly basis can help find small problems, such as bearing and armature wear, before they become large problems. A printout of each chart recording will be given to the customer and also stored in our archives for future comparison. The goal of the tuning process is to reduce the torque as much as possible while still maintaining the desired speed curve. This is done by adjusting the gain settings and integral time constants in the servo. Any changes made will be documented as per item 3.

6. Vibration measurements on the motor encoder - Large vibration on a motor's encoder can greatly reduce the life of the motor. If high vibration is found it can be reduced through tuning, and in cases of very high vibration, by adding vibration reducing couplings. Vibration measurements will be taken along all three axes to ensure that all vibration is within the tolerance of the encoder of the motor being tested.

7. Battery Check – Verification of the battery will ensure that when power is turned off, the servo will maintain the settings needed to restart when power is applied.

8. Document revision level on the servo amplifier - This will allow for easier replacement in the case of breakdown.

9. Verification of all line voltages - All incoming voltages will be tested to verify that they are within the tolerance of the servo amplifier and motor.

Machine Controller Machine Controller Preventative MaintenancePreventative Maintenance

1. Cleaning of all components - This includes cleaning the outside of the modules as well as carefully removing dust from the circuit boards on the inside of each module. Excess dust built up on the circuit boards inside the modules could cause a malfunction leading to downtime.

2. Tightening of all screws - All power and I/O modules screws will be tightened to specification. All screws found to be stripped or broken will be replaced.

3. Program Backup and documentation - The current CPU program will be backed up. Yaskawa will then add or change any comments necessary based upon customer documentation or hand written notes. The customer will receive a copy of the program on disk as well as a printout including the updated comments and cross references.

4. Check and document all DIP and rotary switch settings on all modules - Yaskawa will verify and document all switch settings. These settings will be documented in both the machine drawing package and spreadsheet.

5. Verification of all I/O allocations - Yaskawa will check to make sure all I/O is properly allocated and that there is no unnecessary allocations.

6. Check and document the CPU revision level - This will facilitate the replacement of components in emergency downtime situations and will allow for quick product changes.if there is ever a problem discovered with your current revision level.

7. Check the power level of the CPU backup battery - Battery failure could cause the loss of valuable machine and program data. This can occur during a power outage or during maintenance. Yaskawa will check the power level of the current battery and determine if its replacement is necessary.

8. Verification of all line voltages - All incoming voltages will be tested to verify that they are within the tolerance of the servo amplifier and motor.

U.S. Locations R&D Sales & Services Training Manufacturing & Repair

Yaskawa Engineered Systems Yaskawa Engineered Systems GroupGroup

Plain City, OH

Yaskawa Engineered Systems Group

Yaskawa Engineered Systems Group8628 Industrial PkwyPlain City, OH 43064

Phone: (614) 733-3200Fax: (614) 733-3222

Email: yesg-oh@yaskawa.comwww.yaskawa.com

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