The new HMI, above, with the Siemens PLC, right and the old control panel, above. By Adam Daffern, Technical Services Manager A manufacturer of boiler cylinders needed a quick fix when an old Siemens S7-200 PLC broke down on a critical machine. Our engineers were quickly on site in Wakefield to repair the unit and have the company back in production the next day. To safeguard the machine's long term operation, we planned a retrofit of the PLC, to parts that aren’t obsolete. A Siemens S7-1200 PLC was selected, as this was the closest modern replacement to the original along with a Unified four-inch HMI. Our technical services engineers studied the operation of the machine and prepared the new PLC program off-site to allow for a quick swap over. The retrofit was undertaken in a morning’s downtime, and the machine was back up and running for the afternoon shift to continue production. The customer was happy with the service, commenting that our new program managed to save a bit of time per cycle of the machine which allows more production throughput.
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By Steve Ormondroyd, Workshop Manager Although we are renowned for rewinding electric motors, our work often extends beyond that. For example, we recently rewound an alternator stator which had failed. It came from a small boat and was driven by the boat’s engine. Unfortunately, because of a seal leak on a coolant pump, the alternator suffered water ingress which caused the windings to blow to earth. As our pictures, above, show, it's now back to as-new condition. The pictures below show its condition on arrival at our Service Centre. We have also just completed the urgent rewind of a three-phase brake which is mounted to a large overhead crane. Westin Drives has introduced two ranges of WEG industrial alternators to complement the industrial motors and controls we already stock and distribute. WEG, one of the world's leading manufacturers of industrial electrical products, recently launched the range to the European market. The alternators are ideal for the supply of continuous prime and standby power. Popular applications include generator sets, UPS systems, data centres, mining and petrochemical. Our two WEG ranges are the G Plus Line – extremely cost effective and easy to maintain – and the AG10 Line, which delivers increased power density due to innovation in the electromagnetic design. We can help to ensure that the correct alternator for the application is supplied. Availability is usually ex stock and we are confident that our customers will be delighted with the quality, pricing and support. Our modern custom built workshop can also provide a repair and rewind service. We would welcome any enquiries for your alternator requirements. Two of our experienced apprentices, Oliver and Charlie, put the finishing touches to five Radicon motor gearboxes, ordered by a returning customer in the incineration sector. To ensure swift progress between order and delivery, the lads built the gearboxes from our stock, under the supervision of Richard Bruffell. By Oliver Lowe Technical Sales A regular customer needed urgent help. A failed gearbox had caused a line to go down in the works. Our engineers specified as a replacement a new unit from our Radicon stock. Within four hours the unit was assembled along with a WEG 2.2kW motor and prepared for delivery to the customer. Because of our large stock, we are able to specify alternatives to most brands of gearboxes. Instead of a wait of four to six weeks from the manufacturer, we can build and deliver them with speed to minimise downtime. All our gearboxes come with a data plate with all the relevant information and a specific reference number, so they can be returned to us at any time for additional support. Having issues installing a drive on site to control your geared motor? We can help. Members of our Technical Service department will be pleased to visit your site to specify and set up the inverter drives to your specification. Steve Ormondroyd, Workshop Manager Here's part of a 4kW Friedrich vibrator motor that we received for repair. After dismantling and inspecting it, significant electrical and mechanical damage was found. The windings had failed, both the male and female spigots were significantly worn and the bearing housings showed evidence of wear. We could have repaired this vibrator to the best of our ability, and that may have been more cost-effective than replacing it. But there is always an element of risk in doing such significant mechanical repair work on a vibrator motor – and on this occasion we decided the risk was too great. Due the massive mechanical stresses these vibrators are subject to, any mechanical weakness will quickly lead to failure. For us, clear and honest communication with the customer – perhaps, on occasion even talking ourselves out of a job – is the best policy, It helps to establish a good working relationships and build trust which is critical. So we have offered to replace the vibrator motor with a new model and we await the customer's response. By Steve Ormondroyd, Workshop Manager We recently repaired a 200kW WEG compressor motor which was removed due to increasing vibration. During routine bearing failure analysis, evidence of electrical discharge was found – despite an insulated bearing at the non-drive end. This had causing fluting on the raceways, the cause of the increasing vibration readings We can only speculate that some damage to the insulating coating was allowing the current to pass through the bearing and causing the raceways damage. The motor was subjected to our usual high standard of repair and extra care was taken when fitting the new SKF Insocoat bearing at the N.D.E to ensure the insulating coating wasn’t damaged. We also fitted an additional grounding brush there. This motor can be returned to the customer safe in the knowledge that it will run correctly for years to come. Lenze has announced the phasing out of its 8400 frequency controller series. The last chance to place an order is December 31, 2025, with the final delivery two years later. Spares can can be ordered until December 2030 if materials are available. The phase-out covers the following products:
Lenze gives the following reasons:
For the future, Lenze is recommending the standard Lenze i-series controllers: i5xx frequency controllers, suitable for in the control cabinet and in the field, the multi-axis i750 and i950 servo controllers. Westin Drives is a Lenze Distribution Partner. If you have any questions about present or future Lenze products, please contact Adam Daffern, our Technical Services manager, on 01484 453399. Apprentice Oliver Lowe introduces work experience student Dylan Smith to a WEG motor in our new products assembly area. It's being flanged up, then coupled to a Radicon gearbox, replacing a faulty bespoke DC geared motor on an accumulator infeed in the textile industry. Dylan, 15, has thoughts of becoming an engineer after leaving Netherhall High School – and Britain urgently needs more engineers. A recent report by EngineeringUK found that demand is predicted to grow faster than for other occupations. Dr Hilary Leevers, EngineeringUK's chief executive, said: “Given the soaring demand for engineers across all sectors, it’s essential that the UK has a robust plan and funding in place to train the future workforce, bringing more young people from all backgrounds into engineering and technology.' At Westin Drives, we are helping to find the engineers of the future by encouraging school pupils and college students to apply for work experience. Several of our team joined us that way and have progressed through the company. We also go into schools to explain what sort of work we do and to answer general questions about a career in engineering. Dylan's father, Wayne, has been a skilled engineer with Westin Drives for 20 years and is happy to see his son follow in his footsteps. A Serfilco air-operated double diaphragm pump (AODD) came in for urgent repair. However, the parts required were on a two to three week lead time. Being an authorised distributor of SAMOA’s flow division, we were able to specify and source a replacement unit within two days from SAMOA HQ in Spain. The SAMOA unit is a plug and play solution for the customer, critically including its performance, flanges and footprint. This unit pumps diluted sulphuric and hydrofluoric acid, for a West Yorkshire company in the renewables industry, so the specification of the materials was crucial. In this case it has ATEX approved, polypropylene manifolds with PTFE internals, capable of up to 200L/min at five metres head. |
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