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What Arrived: Returning MB Control Box for repair. Customer says metal object got in box and shorted things out, and expect a board to need to be replaced. Returning for evaluation, quote, and billable repair. (Machine Serial Number:1920-03151 )
Description of Problem: (1) Unwind / Rewind ASSY Part Number 9430100 Serial Number 1920-03151 (WO# 2019073 CBN 2) - Back Plate and Support Plate removed from Hub - Hub Veins and Springs Missing - CAP 2490100 missing Need to ask about these items, if they have them there.
Work Done: Had some shipping damage. See attached picture. Doesn't look too major. Asked customer if threaded end looked like this when they sent it or if this happened in shipping. Customer confirmed the threaded end looks like this. 2/2/23 DTK Knob Labelr Hub separated from thread, added 1394100 to quote, note on hub stated fix hole in hub, need to replace 1394100, added to quote. Saw were pulley was rubbing on frame, see attached photos. Metal shavings were cleaned out well. 3/8/23 DTK Found DC Power Supply Board failed. Checked one out, and replaced it. Then found consistent False Major Product Jam Fault, when Motor was told to Jog. Motor not holding position, but giving Motor Encoder Feed Back. Found no DC Bus Voltage. Pulled Motherboard ASSY. give all boards close visual inspection. Not burn spots any where. Did find metal shavings that got between MOtherboard and Heat Sink, and also landed on Power X, see attached photos. Made Back Up on device on file 7. Changed name of back up file on network to end original, and backed up settings to network. 15V CC is not present, so Power X will not charge. Found short through regulator, and Power X. Replaced both Power X and 15V VCC regulator. Put on test fixture, still not charging of DC Bus Voltage then 15V VCC Regulator U52 Smoked. This time it looks like Power X did not short. Going to discuss with Greg C. Sent Customer email asking about missing Hub Parts. 3/10/23 DTK Found that 5V VCC was shorted, and that is what probably caused U52 to smoke. Had Penny pull U53, found the short was after U53 5V VCC regulator. Had Penny pull U55, U57, U59, U60, U61, U62, and U58. Penny got a little carried away and pulled U65, and U67 only charging for 6 of 6211600. 5V VCC was still short, then discovered there was a U69 Analog Optocoupler physically on the board, as I was looking at a newer rev. Penny pulled U69 and whal ah this is the source of the short. Greg C. is ok not repopulating, and not updating to full newer rev. Installed a new U52, and got a good 15V Vcc out. Put load resistor 2.2K, in for sub of U53 missing, to see Zener function and drop the 5.1V, and that looked good. Installed new U53 and got a good 5V Vcc Out. Penny to add new U55, U57, U59, U60, U61, U62, and U58 and U65 & U67. 3/13/23 DTK Now motherboard will run a Motor. Put into burn in on test fixture and observed for proper operation. Ed was not much help on replacement standard Set Screws. Mizumi who makes the part shows M6 Set Screws, ,and the Pulleys we have in stock have M6 Set Screws. Looks like I can tap out to M5, and did so, with success. Tina said to go a head and add Spring, Veins, Cap, and Plastic Washer. Passed burn in on test fixture. 3/15/23 DTK Had to take some time off for my Wife's tumble. Added these items to the quote, and emailed Tina a status update. 3/17/23 DTK Installed Motherboard into Box. Replaced Bearings while I was in there. Per Peters Suggestion Added 3 20mm plastic washers PN 3504301, between Driven Pulley and bearing. Added bearing grease to washers, and was able to have Driven Pulley far enough out so it was not pushing on the washers. put bearing PN Used M5 X 10 BLK Oxide W/O Tip set screws on large driven pulley, cranked down hard with Loctite 242 on them. Also added Loctite 242 to set screws of Motor Pulley. Passed all diagnostics. To be able to burn in scuesfully Labeler needs to be turned off. Before I turned off Labeler I made a Back Up File on the machine on #7. Put in to burn in, 200 MPM, Off 500ms, On 10,000 ms. After a few hours of successful burn in, completed repair quote and emailed to the customer. 3/22/23 DTK Presented Tina with situation of what work we already did. And give her option of minimum repair First 6 items removed, and less 1 hour. Total $2,587.00 4/14/23 DTK Requoted for minimum, and sent to Tina. She did day she would get us a PO for this minimum repair. 4/21/23 DTK Finished putting it back together. Restored Back Up File #7, and checked settings in machine, completed to the latest back up we had. All looked good. Passed Diagnostics. Updated assigned serial numbers. Shipping under SO# 043157 DTK 4/26/23
Repair Quotation Notes: Completed By: First 6 parts on the Repair Quote are to replace the Hub Reel where the finish product ends up. We have previously discussed all these parts. Power Supply Board 5501700 has failed short, causing the DC power to just blink on and off, when trying to power up. Then found with a good Power Supply Board, the Motor would not run, but everything else functioned electrically. The remaining parts on the quote are electrical ICs that shorted on the Motherboard, that caused it to be unable to drive the Motor. I increased the diameter and length of the Set Screws in the Driven Pulley that moved, and added blue Loctite 242 to the Set Screw for both the Driven Timing Pulley, and the Motor Timing Pulley. Cranked down hard on the set screws. I think it is unlikely it will move again. Per Peter's suggestion, I was able to fit 3 Plastic Washers between the Driven Timing Pulley, and were it was rubbing. I added some Bearing Grease to the Plastic washers, so in the unlikely event the Driven Pulley moves again, the washers will wear slower. Box will be fully tested, and motor ran in simulated production for at least 24 hours before return shipping.


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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	65521	5501700		POW SUPPLY 90-265VAC 5-24 VDC	Set Complete		0 hrs	1		$75.00	0.00	$75.00	55
Edit	65522	5506800		POWEREX PS21A79 50A 600V	Set Complete		0 hrs	1		$227.00	0.00	$227.00	87
Edit	65523	5504400		DC CONV 2W 5-15V SING CE SIP-7	Set Complete		0 hrs	1		$46.00	0.00	$46.00	8
Edit	65524	6211600		OPTO 20MBD 3750VRMS OC 5-SOP	Set Complete		0 hrs	6		$6.00	0.00	$36.00	14
Edit	65525	6050900		74HC04 HEX INV SOIC-14	Set Complete		0 hrs	1		$3.00	0.00	$3.00	21
Edit	65526	RMA		LABOR	Set Complete		0 hrs	11		$200.00	0.00	$2,200.00


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