AES - Austin Electrical Services Ltd

13/05/2025

Eyes on this beauty of a mill, showing this weekend - Here’s a recent stone milling plant we completed last year for the team at Minchins Milling

12/12/2024

Here we are fault finding a Plockmatic 200E booklet maker which has a staple head fault. This is the finishing part of print works.

The booklet maker checks for the presence of staples in the cartridge head by continuity through the staple, clincher and socket head back to the CPU PCB.

- Fault find and point to point test from socket back to PCB
- Found high resistance connection on DB24 plug end.
- Replaced wire and resoldered to staple head wire socket.

Liven and test run the booklet maker in production, as you will see the final product ready to be sent out.

11/12/2024

Here’s our main game we specialise in - the print industry.
This is a Heidelberg SM52 5 colour offset sheet fed print press.
They have had the blanket wash cloth motor icons intermittently come and go on the console for print unit 3 and has gradually got worse over a year or two, it was time for us to work some magic.
We completed the following:
- Fault find blanket wash motor and sensors, via Heidelberg electrical drawings.
- Recreate fault on PU4 to prove motor at fault, simple motor disconnection which writes to the EPROM If the motor is present or not.
- Continuity test from motor plug right through press via 6 multi pin plugs, back to drive card.
- Ribbon IDC plug ends replaced
- Locate on drive card OVDC pin with bad connection, contact clean and reset pin.
- Reconnect blanket wash cloth motor, liven test and commission.

A simple fix, but extensive methodical point to point testing to find the root cause after years of intermittent issues, a bit of time spent can pay off in the long run.

Another call shortly after we had a Heidelberg SM52 2 colour with the right angle MCCB isolator shear it’s gears, We managed to source one in Germany and had it on a plane in no time for immediate replacement. There’s always a solution to minimise downtime.

10/12/2024

Here’s a 3 phase duty standby wastewater system which has no power on the HMI screen.
We completed the following:
- Fault find transformer fault on main microprocessor PCB
- IRT both duty standby pumps and 3 level floats:
Located water ingress tracking in the cable from pump 2, underground joins and or failing seals (to be replaced). A failing float with water ingress identified and results recorded for future works.
- Replaced PCB with current upgraded V3 variant.
- Liven test and commission system

Another wastewater system back up and running, this time for the team at Christchurch Adventure Park.

09/10/2024

Today was take a kid to work day - Here we have our son Had’s partially on the tools doing a wastewater pump replacement on a Biocylce treatment plant - He used his quality MFT tester to diagnose a short in the windings between Phase+Neutral to Earth.
New pump connected, with all alarms cleared and tested this tank is back into full operation. Onto the next one 👏🏻

27/09/2024

27/09/2024

Another septic tank controller upgrade we completed recently from an old analogue system that was water damaged and outdated.
We supplied one of our controllers and relocated to the external of the turret and raised it all on steel unistrut.
Testing all equipment with IRT while we are at it which gives us a strong condition indication of all the equipment along with date stamps, we keep records for future works saving breakdowns and call outs.

17/09/2024

We get a wide range of machinery breakdowns and call outs to attend over the years, here’s another interesting one with a bottle scrubber used to strip old paint work from gas cylinders.

Customer reported smoke from the rotation VFD and we completed the following:

-Assess machine and fault find; Omron 3G3MX2 (European) VFD blown with no DC bus voltage, removed drive and identified blown capacitor.

-Source equivalent current and local 3G3MX2-V2.
Extracted old parameters from VFD by applying 24VDC to the logic card and using CX-one software. Transferred to new VFD.

-Using data sheets between the two models we created a terminal corresponding table and wired the new drive accordingly.

-The HMI uses the PLC logic in the 2 drives and communicates via RS232. With some local support from the team we ironed out some comms compatibility issues via extracting the existing HMI programme and adjusted the parameters on the VFD’s accordingly.

With breakdowns like these and replacements not being exactly like for like there is usually always adjustments that are required. We like to take extensive notes and record keeping which helps make the process run as smooth as possible with minimal down time.

We service all aspects of electrical machinery always finding a solution and keeping our customers operating and in good spirits, until the next one 🍻

15/09/2024

Here we have completed a large installation of a wetlands wastewater treatment and discharge pump station.
This included the following electrical works:

-Run 300mm2 1C x2 AL cantols underground via 100mm HD orange duct 330m, tailed down via shear links to 25mm 1C BFX flex tails.
-Install single phase MEN MSB for power distribution with RCD protection.
-Design and Build PLC controlled solenoid valve discharge controls using our preferred M221 PLC ‘s.
-Install 2 duty standby single phase pump controller’s for flow balance and discharge pump chambers.
-Install several float switches for level control along with 4 single phase submersible pumps.
-Install flow meter for totalising intake volumes.

The wetlands are located 600m away from the original toilet block installation we completed. This system is used to control and treat raw sewage, move it through natural processes (wood chip bio reactor bed) and eventually release it back out through a discharge field back into the ground.

14/08/2024

13/08/2024

Recent works on the Goss M600 web fed print press. We replaced the original degraded and perished sensors for these Laser photoelectric sensors with custom fabricated adjustable brackets made from stainless steel.
These sensors are detecting when a break in the web is detected which shuts off the print unit and catches the web from causing substantial damage to the remaining print units.
The digital input feeds back into a Siemens PLC and reads the signal only when the press is running at a pre-set speed.
They are lifted out of the way on a pivoting bar for maintenance works.
We deal with all sensors and detectors in the automation and industrial sectors commonly used in the printing industries.

25/07/2024

A customer had an issue with their Perfecta 76UC Guillotine where it was giving error 9 indicating the blade catch not locking in place at top of dead center.
We removed the service panel off the back to expose the unit, while the operator controlled the machine through its process we noticed the catch rotating on the large lobe with the 8mm hex head bolt was extremely slow to retract back to the down position and timing out via.
We removed the catch with the solenoid plunger re-greased and oiled the catch and solenoid shaft, reassembled the unit and test run.
We installed a washer to minimise the angle the chain was pulling on the solenoid shaft which was causing sticking - New parts are on the way, and more importantly the customer is back into production!