Challenges with Rockwell Products: A Frustrating Experience

Question:

For 30 years, I have been a dedicated supporter and integrator of Rockwell products. While I have encountered some quirks along the way, my recent experience with commissioning 30 Kinetix 5700 axes for a startup has been challenging. Two 2198-P141 bus converters failed to boot, with a manufacturer defect involving cured urethane on the 24DC controller supply pins. Additionally, 5 out of 18 2198-H2DCK Hiperface to DSL converters were faulty out of the box due to voltage differentials, which were resolved by switching to universal bus connectors. Other issues included a malfunctioning 2198-D012-ERS3 and a problematic MPL-B230p motor that would trigger a thermal fault upon activation. Despite enjoying startup challenges, these obstacles with Rockwell products have been frustrating. I expect better quality from new equipment.

Top Replies

The transition to automated equipment is a challenging process that many are facing. With each upgrade and migration, there is a noticeable improvement in usability but a potential decline in quality. Personally, I have found myself replacing numerous 525 power modules within a short period of time. Despite facing booting issues with the 40p, I have never had to deal with PWM failure. While individual experiences may vary, it is important to address potential equipment failures proactively.

I am frustrated by the lack of consideration in the product design regarding ease of migration. It is inconvenient to have to drill new holes for a PowerFlex 753 when the mounting plate could have been designed with the same spacing as a 70 model. The similarities are so close, yet make a significant difference in installation. This issue is also present with panel views, requiring the purchase of adapter plates or enclosure modifications.

Patrickmoneyy expressed dissatisfaction with the product design's lack of consideration for easy migration. Why should one have to drill new holes for a powerflex 753 when the mounting plate could have been designed with the standard spacing at 70? The same frustration is felt with panel views, requiring adapter plates or enclosure modifications. While Rockwell's lack of backward compatibility is a concern, this issue is not unique to them. It is a common frustration in various industries, seen even in DIY projects at home where fittings and fixtures never seem to align perfectly. This drives users to seek alternative VFD suppliers for a hassle-free experience and cost-effective solutions.

While Rockwell is a well-established company with strong capabilities in various aspects of user experience, the issue of powerflex mounting holes stands out as a significant concern. This particular issue appears to be easily preventable, which can be frustrating for users.

Patrickmoneyy mentioned that while Rockwell is a large company excelling in various areas of user experience, the lack of powerflex mounting holes is a significant issue. This oversight could potentially lead to a loss for Rockwell as customers may opt for a cheaper VFD due to the inconvenience of having to create new holes. This shortsightedness is a common problem across industries, attributed to a lack of experience and exposure. Designers often overlook maintenance issues, resulting in beautifully crafted machines that are difficult to maintain.

I feel your pain, mate. I've been working with Rockwell products for the better part of two decades now and I've seen my fair share of these hiccup-style issues. It seems like quality control should've caught these problems on the factory floor before they got to us! However, in my experience, despite these frustrating setbacks, Rockwell's customer service and troubleshooting resources have been invaluable in resolving such issues. And let's be honest, no product line is perfect - it's all about how the company supports you when issues pop up. But I agree - for new equipment, we should never be facing these many issues. Perhaps it's an indication of the need for better in-house testing?

I empathize with your frustration. As an integrator, those unexpected defects can certainly throw a wrench in the smooth operation of startup commissioning. Rockwell typically delivers reliable products, so your experience is surprising and disappointing. The throughput and quality control in manufacturing should definitely be better. Have you reached out to their technical support or requested replacements? Hopefully, they can provide effectively solutions, as well as take this feedback to prevent such quality issues in future.

I completely understand your frustrations. As a fellow user of Rockwell products, I've had my fair share of product glitches too. It's fairly disappointing, especially when you expect top-notch quality after investing a hefty amount into seamless, new equipment. Have you tried corresponding directly with Rockwell about these defects? It's essential to provide them with such feedback for improvements. Could there have been issues during transportation causing these problems, or perhaps an oversights during manufacturing? It'd seem Rockwell needs to tighten up its quality control. Also, consider reaching out to other integrators about their experiences. This might help identify whether it's an isolated issue or if it's more widespread. Hang in there, startup challenges can be tough but they also provide avenues for growth and learning.

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Frequently Asked Questions (FAQ)

FAQ: 1. What specific challenges were encountered with Rockwell products in the recent experience mentioned in the thread?

Answer: The challenges included failed bus converters, faulty Hiperface to DSL converters, malfunctioning controllers, and problematic motors triggering thermal faults.

FAQ: 2. Were there any common issues observed with the Rockwell products during the commissioning process?

Answer: Yes, issues such as manufacturer defects involving cured urethane on supply pins, voltage differentials leading to faulty converters, and thermal faults in motors were common.

FAQ: 3. How were the issues with the Rockwell products resolved during the startup commissioning process?

Answer: The issues were resolved by addressing manufacturer defects, switching to universal bus connectors for converters, and troubleshooting specific components like the ERS3 controller and problematic motor.

FAQ: 4. How did the recent challenges with Rockwell products impact the overall experience of the integrator who shared the thread?

Answer: The integrator mentioned feeling frustrated by the challenges faced with Rockwell products, especially considering their long history of supporting and integrating these products.

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