Part 21 Report - 2002-100

Rockwell Automation
P.O. Box 250, 4349 Avery Drive
FIowery Branch, GA 30542 USA
Te: 770.967.3381

NUCLEAR NONCONFORMANCE REPORT

1. CUSTOMER:

Howden BuffaIo Inc
338 South Broadway
New Philadelphia, Ohio 44663

2. PURCHASE ORDER:

1) NL774400 - QTY 1
2) NL979400 - QTY 1
3) NM187700 - QTY 1
4) NM219300 - QTY 1
5) 2827 - QTY 2

3. PART/COMPONENT NAME:

AC MOTORS

4. PART/COMPONENT NUMBER:

1) 1KXV60028 - HOWDEN P/N 600287-85R
2) 1KXV60084 - HOWDEN P/N 600287-52R
3) 1KXV60125 - HOWDEN P/N 600276-3R
4) 1KXV60133 - HOWDEN P/N 600276-17R
5) 1KXV60247 - HOWDEN P/N 600276-3R

5. QUANTITY ON HAND -0 SHIPPED - 6

6. LOCATION OF ALL UNITS:

1) ?
2) DUKE ENERGY
3) DUKE ENERGY (CURRENTLY AT WESTINGHOUSE SERVICE CTR - MADISON, PA)
4) TOLEDO EDISON
5) 1 AT DUKE ENERGY, 1 AT WESTINGHOUSE

7. DATE NONCONFORMANCE ASCERTAINED:

May 9,2002

8. DESCRIPTION OF DEFECT/NONCONFORMANCE:

INSUFFICIENT SLOT FILL OF MOTOR WINDNGS (1 UNIT, 1KXV60125 AT WESTINGHOUSE SERVICE CTR, SHORTED IN SLOT WHILE IN SERVICE).

9. CORRECTIVE ACTION TAKEN:

HAVE NOTIFIED HOWDEN QUALITY ASSURANCE. THROUGH THEM WE WILL INITIATE REWIND AND OR REPLACEMENT OF UNITS AS NECESSARY. DETAILS YET TO BE DETERMINED. ALSO THE 1KXV60247 UNIT CURRENTLY AT WESTINGHOUSE WILL BE INSPECTED TO VERIFY FOR ADEQUATE SLOT FILER MATERIAL AS A CHANGE WAS ISSUED TO ADD FILLER STICKS AND WE BELIEVE THE MOTORS ON THAT ORDER DO HAVE ADEQUATE SLOT FILL.

10. ANY ADVICE RELATED TO DEFECT/NONCONFORMANCE:

SUDDEN CURRENT SURGES CAN CAUSE THE COIL TO MOVE INSIDE SLOT. CURRENT SURGES CAN BE CAUSED ON START-UP, DURING SPEED CHANGES, OR DURING SEVERE LOAD CHANGES. THE MOTOR MAY NEVER EXPERIENCE PROBLEMS BUT THE POSSIBLITY DOES EXIST. MOTORS RUNNING AT CONSTANT SPEED WITH NO LOAD CHANGES SHOULD ACHIEVE 40 YEAR LIFE.

11. INDIVIDUAL COMPLETING THiS REPORT:

James Thigpen QA Manager, Rockwell Automation Gainesville, GA May 9, 2002