Toshiba Drive Damaged Beyond Repair

Repair Zone recently received a Toshiba drive in which the DC Buss dynamic braking circuit was blown beyond economical repair. We contacted numerous repair vendors to have the repairs expedited on the drive, but the drive was too large for anyone to authorize a quick turnaround. The only remaining option for repair at this point, was the original equipment manufacturer (OEM) Toshiba.

The cost to expedite the repair was $150, and lead time was 2 days after receiving the unit, 1.5 days in transit each way putting lead time for the repair to 6 days. The customer opted to purchase a "New" unit.

• Expedited repair cost from Toshiba $15-20K plus $2040.00 each way to ship. Total cost for repair $24,080 with a 6 day lead.
• Cost of "New" drive $23,473.20 plus $2040 shipping one way, total cost $25,513.20.

Considering the nature of the failure, damage to other components was imminent. We needed to perform a field service to verify the motor, cabling, and dynamic brake were in good operating condition before install. John Monville performed the field service and found an open resistor in the dynamic brake. He removed the resistor and tig welded the connection tab back onto it, the motor and cabling megged and surged good.

In the meantime, the customer could not provide a parameter list so we had to dissect the original drive to figure how to power up the logic circuit and retrieve parameters. We were able to write the parameters to the HIM and save them to be loaded into the new drive. The new drive had a revised control board that utilized jumpers instead of dip-switches in some cases. There was some extra time needed to configure these jumpers for the correct inputs as they were not available on a print.

The drive was installed into the cabinet upon Steve and Jeff's arrival @ 6:00 AM. We connected the wiring for the incoming power, output to motor, dynamic brake, and I/O. Jeff had to partially disassemble dynamic brake in order to access the mounting nuts and connection terminals. The drive was completely connected and verified for output @ 8:25 AM. We could not get the drive to enable until 10:00 AM due to a safety relay that was not pulling in. We found the E-Stop was pushed in on the operating panel.

At this point the drive is running but had limited control. As stated previously, this is where the jumper reconfiguration took place. Due to press issues we could not continuously run the drive to check for proper tune. By 1:48 PM the press had completed many cycles and the customer was satisfied with the performance. We were now complete. From the time the job was received to the time the customer was back up making parts was 4 business days.