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Tara is a Long Island, NY native that recently moved to Virginia with her family. Tara will be wearing a few different hats here, being our receptionist, bookkeeper, and sales assistant. She enjoys spending time with her family which includes two slightly spoiled Beagles.
Lauren is a Richmond native, recently graduating from Randolph Macon College in Ashland, VA with a degree in accounting. She was also a forward on the college basketball team.
Prolonged Failure Of A VFD Gets Political Attention In South Central VA Town – Situation Abated by Delta Automation Engineers And Sales Team.
Delta Automation received an emergency call from water authority officials to repair a variable frequency drive (VFD) that controlled a very important monumental fountain that was erected in memory of a prominent local citizen. The operation and maintenance of the fountain is funded from a private grant. The problem of the fountain being down for so long became a sensitive political issue that was escalated all the way to the office of the Mayor.
The primary reason a VFD was utilized in this application is because the spray from the fountain could get misdirected due to moderate wind. The VFD and hence its pump motor, is piloted by wind speed (via an anemometer). The lower the wind speed, the greater the force of the fountain spray and water volume output. As the wind speed increased, the VFD would act to slow the pump speed down thus reducing the fountain’s force and volume of water spray.
Once Delta was contacted about the problem, our field service engineers, Lee Gleason and Kevin Randolph went to the site to investigate the problem, determined that the VFD was damaged beyond repair and that a new VFD was needed. Delta engineers specified and selected a replacement WEG CFW 11 VFD that was available with a low cost, quick shipment option. Once the price quotation furnished by the Delta sales specialist, Win Bradley, was approved by the municipality, the drive was ordered and installed the following business day and the fountain was returned to service. Both the Mayor’s office and maintenance officials were extremely pleased with the rapid response by Delta Automation on this project. The political ‘fire’ was extinguished once the fountain had been restored to service.
Several Variable Frequency Drives (VFDs) were sent into Deltas’ shop for repair. The clients’ complaint for them was that they were failing with an “Overtemp” fault. This is a very common fault/failure on all brands of VFDs. With only a very few exceptions, all VFDs have cooling fans, usually multiple cooling fans. All cooling fans have a finite life span. This lifespan is measured in run-time hours. It is typically several thousand hours, which usually translates into 3-5 years of 24/7 operation. Of course this rating is in a clean environment. The VFD depends upon air flow created by the cooling fans moving air across its’ heat sink fins to dissipate the heat generated by the high power components. The fans and the heat sinks on these VFDs sent if for repair, were completely blocked. Zero air flow was passing through these units. Consequently, they failed on “Over temperature”. Fortunately, the circuitry that detected the over temperature condition, protected the VFD from further damage.
These units, as the photos illustrate, show just how badly the units were blocked. These units required above what Delta typically refers to as a “Level 2” bench cleaning/P.M. service. These may have been a “Level 4” if such a level existed! They had to be completely disassembled, vacuumed, brushed, washed and scrubbed to get all of the foreign matter removed. Then they had to be reassembled and tested. This was to say the least, a very labor intensive process. That translates into a higher than normal cost for the client as well. Since these were large, high horsepower units, it was cost effective to perform the service. In this case, a more frequent preventive maintenance service would have prevented the complete shutdown of these units and would have not incurred the added cost of a bench level cleaning. Delta provides preventive maintenance (P.M.) plans tailored to the specific needs of our clients. Contact Delta at 804-236-2800.
A Delta client had an aging production machine, that was in need of a total gearbox replacement or rebuild. This machine had a small 1 horsepower D.C. “pony” motor and speed controller to Jog the process during set-up and feeding, and a large 75 horsepower A.C. main motor that was running full speed “across the line”.
Lee Gleason, a Delta senior field service engineer, suggested that the client remove the gearbox completely, remove the small pony motor and install a WEG CFW-011 variable frequency drive and a WEG motor to replace the current main drive motor. This would eliminate the worn out mechanical gearbox completely, the D.C. pony motor, its’ D.C controls, the old inefficient main drive motor, plus allow the operator to have complete control over the machine speed. All of the way from a slow Jog to the full production speeds, plus the operator would have a reverse in case of machine jams.
The client accepted the proposal and the project moved forward over a planned shutdown time. After the start-up and commissioning the operators enjoyed the “one button” control and the ability to adjust the production speed as dictated by varying materials and conditions. Additionally, the inherent soft start functionality of a VFD, allows for a tremendous reduction in mechanical wear and tear on the mechanics of the machine and eliminates the peak in-rush of A.C. current which could result in additional peak demand charges from the local power provider.
The client was so pleased with the completed project, that they decided to repaint the entire machine WEG blue!
This project was a huge success, in machine maintenance, power consumption, production up-time and operator satisfaction and ease of use.
Contact Delta for all of your VFD and motor needs.
From the day after Christmas on through fours days past the New Years holiday, two teams of Delta Engineers were busily working long 12+ hour days testing, repairing and certifying Modicon remote I/O and Modbus Plus networks during a plant holiday shutdown. This project included over a dozen production lines, each with both, remote I/O systems and ModBus Plus systems. Almost all of the Modbus Plus systems had multiple (up to 4) segments. This made for a total of 59 separate and individual certifications performed.
All of these systems had been experiencing issues and required repair. Many previously unknown issues and problems were found and repaired. Additionally, dozens of undocumented changes, modifications, replaced/updated equipment, spare connections and hidden splices were located, documented, and repaired where necessary.
Upon bringing the plants production lines back up, after being down for 10 days, all of the newly certified systems came up with no issues or errors.
Shown here is the collection of certification reports, one for each line and system, that were provided to the client. The documents show and detail the repairs, all of the test results and any recommendations for the network. These reports prove to be invaluable in times of additions, modifications or troubleshooting.
Call or email Delta Automation for more information or a quote on certifying your networks!
Delta Automation is Honoring, Supporting, Celebrating and Saluting our Veterans of all services by displaying green! Thank you! From everyone in the Free World!
“All Gave Some……….Some Gave All!”