0554639 PPA Industries, Inc. / Protect Plus / Freudenberg Filtration Technologies

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What Arrived: Machine has consistent false overcurrent fault. Troubleshoot over phone, and determined software settings, and extra safety relay in mechanical side, are good. Then Customer said there was burnt smell in the electronics. They found the damage in attached picture. On my call I also discovered they used 20AMP fuses in other machine. Did soften them to the idea, this may not be covered under warranty. Evaluate, and discuss warranty with Jim and Mike. Per David Kelley. (Machine Serial Number:2318-10718 ) Jeremy Hedrick of Freudenberg Filtration Technologies, said the guys just pulled the Motherboard. Sent him an email, warning of potential issues, that this could cause, and requested motor. See attached.
Description of Problem: MFT 350 IP3 XED Serial Number 2318-10718 !!!!!!!!!BE SURE TO TALK ABOUT STATIC TINSIL FIXING FUSE BLOWING ISSUE OF FEEDER WHEN LINE AT MFT!!!!! (3) 30mm SDV SE w/o chambers (3) SW 1099300 (6) 20mm XED Purple Discharge Belts (1) 825 HD Rear Support w/ diamond plate (1) Set Mag Side Guides (cut down) (3) Prod Support Rod ASSY (cut down) (4) Mounting Rods (1) Static Bard w/ mount (1) Product Exit Transfer Plate (2) 7160800 w/o cable, with mounts. (1 Low Prod. 1 Start Sensor (1) E/R (1) A few product samples in the bottom of the crate Repair of MFT 350 IP3 XED Serial Number 2318-10718. Reference RMA Number 0554639. Majority of repairs were covered under warranty, and these items are shown at a 100% discount.
Work Done: Motherboard and rest of circuits where just kind of loosely packed in bottom of crate, see attached picture. But does not appear to be any physical damage. Motherboard is burn in 4 different places, see attached picture. Temperature stickers for motor are all white. Load on Motor seems fine, although they could have had things set too tight, or repeated physical jams. Motor Timing Belt is quite tight. Did see where the lower left cornter of Computer Board got hot from heat generating on the Motherboard. Does not look too bad, and this is an unpopulated area of the Computer Board, so it should be ok. 4/29/24 DTK Showed board to Greg C. Normal possibilities of a big surge due to jam or issue with Motor / Motherboard. Greg did mention that we had an issue with the Tipping Feeders on PPA Blowing Fuses when the line was there. Turns out it was due to massive static electricity generated by conveying of the Filters, After they added Static Tinsel to Driven Discharges to touch filter, and ground out status, Fuse Blowing issue went away. Will need to bring this up to customer. Pulled motherboard from stock to install in machine. 4/30/24 DTK Saw in out back up file we had the Motor Jam Current Limit jacked up from default of 80 to 150, this would disable the Overcurrent Faults, and could have lead to this failure. When installing Motherboard found customer was messing with Motor Encoder and Hall crimps for connection to Motherboard. Crimps had come out of housing, and they jammed in some crimps upside down. Had to cut wires, re-crimp them all and get new housings. Also cover for Power Supply missing, and they damaged the Power Entry Module with all the Fuse Replacements. Installed new motherboard and unlocked motherboard. Rigged up cable to put 24V on Motor Saftery Relay with Low Product Port. Machine has passed all diagnostics. Put into a 24 hour burn in, and observed for proper operation. Will need to send email to Jim and Mike summarizing findings, and see if we will deny warranty. 5/1/24 DTK Sent email to Mike an Jim, with summery of findings to see if we will deny warranty. 5/2/24 DTK Passed burn in and check out. Give to Shawn to pack up. It was decided we will discuss warranty coverage more on Monday. 5/3/24 DTK After discussion with Mike and Jim we decided on covering Motherboard and labor to replace but charge for everything else. Send Mike and Jim draft email to send to customer, and they helped to fine tune it. Attached is that email, and it is pretty close to the Repair Quote notes. Send customer quote and email. 5/8/24 DTK Received PO. Updated assichned serial numbers. Noticed I made some quantity errors when quoting. Brings quote down from $450 to $390. Processed for shipping under SO#045326 DTK 5/30/24
Repair Quotation Notes: Completed By: Motherboard is burnt on the PCB in four different places, making it unrepairable. Failure of the Motherboard is consistent with too much Motor Current. Repeated fuse blowing events can take a toll on Motherboards and result in this type of failure. The fact that we have a report that Fuses of a greater current rating were installed by PPA, we would have grounds to deny warranty coverage. However, there was an early report from PPA, that something smelled burnt in the electrical cabinet from day one. We also want to be a good partner with PPA. For these reasons we will cover the Motherboard and labor to replace it under warranty. However if these types of failures continue at PPA we may not cover those under warranty. There were some items that we found damaged that are not covered under warranty. Power Entry Module was damaged at PPA, when changing Fuses. Also, Low Voltage Motor connectors were rewired by PPA, and crimps were installed backwards, resulting in MFT needing to re-wire this. Also, the Cover for Power Supply was not returned with the machine. Fuse for Power Entry Module, and an Electrical Shock Hazard sticker was needed for Power Supply Cover. Things that need to be done to prevent these failures. - Check Overcurrent Settings are set correctly From the main screen, the motor can Jog from. • Press Menu two times • Press 2 for Technician, and enter Password 89177 • Press 1 for Motor • Press Menu until you get to Motor Jam Time Window – Default of 100ms • Press Menu until you get to Line Voltage, this should be set for the AC Voltage you are providing the machine • Press Menu – Motor Jam Current Limit default of 80 – This is the threshold for what the machine considers an overcurrent event • Press Menu – Motor Jam Accum Limit default of 500,000 – This is how many overcurrent events it will allow in it set time period. - Only use correct-rated AC Fuses 250V 10 AMP Fast Blow - Avoid physical product jams, with proper set up - At MFT, we discovered the cause of Fuses blowing was massive static build up from running the Filters. Fix for this was static tinsel, that the Filters rub against as they are being ran. Make sure tinsel is making contact with Filters, and that this static tinsel has a good connection with Earth Ground. - Product must come to the feeder static free, operators must properly setup and operate the machine per the manual so that the SW’s are not run overly tight as those can generate static.

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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	73604	7051100		MOTHERBOARD ASSY GEN 3	Set Complete		0 hrs	1		$4,667.00	100.00	$0.00	409
Edit	73605	8161000		POWER ENTRY MODULE	Set Complete		0 hrs	1		$118.00	0.00	$118.00	200
Edit	73606	6392000		PWER ENTRY FUSE 10 A 5 X 20 MM	Set Complete		0 hrs	2		$6.00	0.00	$12.00	196
Edit	73607	5003700		6 PIN .100" SPAC STR HOUSING	Set Complete		0 hrs	1		$2.00	0.00	$2.00	52
Edit	73608	5004700		8 PIN .100" SPAC STR HOUSING	Set Complete		0 hrs	1		$2.00	0.00	$2.00	74
Edit	73609	2270300		POWER SUPPLY SHIELD COVER	Set Complete		0 hrs	1		$52.00	0.00	$52.00	66
Edit	73610	3850000		LABEL ELECT SHOCK HAZARD	Set Complete		0 hrs	1		$4.00	0.00	$4.00	153
Edit	73611	LABOR		FOR EVALUATION, REPLACING MOTHERBOARD, AND TESTING	Set Complete		0 hrs	6		$200.00	100.00	$0.00
Edit	73612	LABOR		REPLACING POWER ENTRY MODULE, REWIRING MOTOR, AND ADDING COVER	Set Complete		0 hrs	1		$200.00	0.00	$200.00

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