Industrial Equipment Diagnostics & Automation Support
Independent, instrument-based troubleshooting for light production machinery, conveyors, drives, field sensors and machine controls across San Jose, Los Gatos and the Bay Area.
Diagnostics first, then a written estimate
What this service is — and what it is not
Production and facility equipment usually stops for a reason that can be measured: a failed field device, a loose or damaged conductor, a drive protecting itself, a worn mechanical component, or a control interlock doing exactly what it was wired to do. KONGRA starts with the fault behaviour and the machine’s own documentation, verifies power and control conditions with instruments, and writes down what was measured before recommending any part.
Every visit begins with a paid diagnostic. You receive a written estimate after the inspection, and repair proceeds only after your approval. Findings, measured values and parts used are documented so your maintenance team can keep the record with the asset.
Equipment categories KONGRA supports
Selected light production, material handling and electromechanical systems
Light production equipment
Packaging, filling, sealing, labelling and small-batch production machines. Typical work: intermittent stops, jam and misfeed faults, worn drive components, heater and thermocouple faults, and machines that run but drift out of adjustment.
- Intermittent stops and unexplained cycle faults
- Heater, thermocouple and temperature-control faults
- Worn belts, bearings, couplings and cam followers
- Pneumatic leaks, valve and cylinder faults
Conveyors & material handling
Belt, roller and chain conveyors, transfer units and accumulation sections. KONGRA checks tracking, tension, drive alignment, gearmotor condition and the sensors and interlocks that stop a line unexpectedly.
- Belt tracking, tension and splice condition
- Gearmotor noise, heat and current draw
- Photoeye, proximity and encoder faults
- Start/stop and interlock circuit troubleshooting, without bypassing protections
Motors, drives & pneumatics
Electric motors, variable-frequency drives, gear reducers, pumps, blowers and compressed-air components. Diagnostics use electrical measurement rather than parts swapping.
- Motor winding, insulation and current-balance checks
- VFD fault-code reading and parameter review
- Overload, contactor and capacitor failures
- Air preparation, regulator and leak-down issues
Sensors, field devices & wiring
Field devices and wiring are a frequent starting point when a line stops, because a machine that appears to have failed is often responding correctly to a signal it is no longer receiving. KONGRA traces the signal path with instruments and documents what actually failed.
- Photoelectric, inductive and capacitive sensor faults
- Limit switches, safety switches and door interlocks
- Thermocouples, RTDs, pressure and flow transmitters
- Damaged cabling, connectors and terminal faults
Controls & automation support
Control-cabinet inspection, relay and contactor logic, HMI fault interpretation and PLC I/O verification on existing machines. KONGRA works with the machine as it is built and documented — this is troubleshooting support, not new control-system design.
- Control cabinet inspection and thermal condition
- Relay, contactor and control-power troubleshooting
- HMI alarm interpretation against machine documentation
- PLC input/output verification at the terminal
Selected CNC & machine-tool troubleshooting
Support on selected machine tools for electromechanical and auxiliary-system faults — coolant, lubrication, pneumatics, drives, limit and home switches, and enclosure hardware. Spindle rebuilds, control retrofits and machine-tool geometry realignment are outside KONGRA's scope.
- Coolant and lubrication system faults
- Axis limit, home and safety switch problems
- Drive and motor overheating or fault codes
- Auxiliary pneumatic and enclosure hardware
Service scope and limits
Stated plainly, before you book
- Electromechanical diagnostics and component-level repair
- Field-device, wiring and control-circuit troubleshooting
- Motor, drive, gearbox and pneumatic condition assessment
- Documentation for internal maintenance records
- Coordination with your own vendors and parts suppliers
- Heavy process plant and high-voltage distribution
- Safety-rated system design, validation or certification
- Turnkey automation integration and control retrofits
- Machine-tool geometry realignment and spindle rebuilds
- Any work requiring a license KONGRA does not hold
Regulated electrical, gas, refrigerant and contractor-licensed work is performed only within KONGRA’s legal license, insurance and practical service scope. Where a licensed specialist is required, KONGRA says so and can coordinate with a properly licensed independent contractor.
What to send before a drive or motor visit
Please identify the exact drive, motor and driven load, and say whether the machine stops under load or fails at startup — they point in different directions. Capture the active code as displayed, along with the operating conditions and the event immediately preceding it, before anyone resets the drive: the display and machine state can change on reset, and whether any history is retained afterwards depends on the controller.
For AC drives the reference is a different document family. One example is the Allen-Bradley PowerFlex 523 and 525 user manual 520-UM001O-EN-E (September 2025, 274 pages; fault material in chapter 4, pages 159–166). It applies to those AC variable-frequency drive models only, and the 523 does not carry every fault the 525 does. That is a separate document family from the DC drive manual above, and the two are not interchangeable. More on how these are read: VFD faults & motor drive diagnostics.
Independent service
Frequently asked questions
What kind of industrial equipment does KONGRA look at?+
KONGRA supports selected light production and facility equipment: conveyors and material-handling drives, packaging and sealing machines, pumps and blowers, electric motors and variable-frequency drives, sensors and field devices, and control panels on that equipment. Heavy process plant, high-voltage distribution and safety-rated systems are outside KONGRA's scope.
Is this a full automation integration service?+
No. KONGRA provides diagnostics, electromechanical troubleshooting and component-level repair support. KONGRA does not sell turnkey automation integration, and does not claim manufacturer authorization for any control platform.
How does an industrial diagnostic visit work?+
The visit starts with a paid diagnostic. KONGRA reviews the fault behaviour, checks power, control and mechanical condition with instruments, and documents what was measured. A written estimate follows the inspection, and work proceeds only after your approval.
Can KONGRA work on equipment that needs a licensed specialist?+
Regulated electrical, gas, refrigerant or contractor-licensed work is performed only within KONGRA's legal license, insurance and practical service scope. Where a licensed specialist is required, KONGRA says so and can coordinate with a properly licensed independent contractor.
Do you provide documentation for a maintenance department?+
Yes. Findings, measured values, parts used and recommendations are written up so an internal maintenance or facilities team can keep the record with the asset.