Emergency: same day
For a line-down motor, where the fault and parts allow. WhatsApp us before you send it so the bench is kept free.
Servo motor repair · Allen-Bradley · Encoder
Allen-Bradley servo motor encoder error, reprogramming and alignment
An encoder or feedback error on an Allen-Bradley servo motor does not always mean a bad encoder. The cause can be the feedback device, the cable, the connector or the drive input. Star Automations tests the motor feedback on its universal servo test bench, repairs or replaces the feedback device, then reprograms and aligns it to the motor before return. Star Automations is an independent repairer and is not a Rockwell Automation authorised service provider.
- 25+years of servo repair, since 2000
- 3,000+customers across India
- 100+servo brands covered by our universal servo motor test equipment
- 5sites: Puducherry, Chennai, Bengaluru, Hyderabad, Delhi
- Same dayemergency repair option*
*Where the fault and parts allow. Every repaired unit returns with a printed test report.
Repair turnaround you can plan around
Send a photo of the nameplate first. We confirm whether the motor is repairable, and the quote, the same working day.
Urgent: 3 working days
Repair, encoder alignment and test, counted from the day the motor reaches the bench and the quote is approved.
Standard: 7 working days
Full repair, encoder alignment, run test under load and a printed test report.
- Free repairability check from a nameplate photo
- Printed test report with every motor
- Written warranty, terms stated on every quotation
- Pickup can be arranged; parts that must be imported are quoted with their own timeline
01Failures
Common encoder and feedback problems
Feedback loss or encoder fault on the drive
The drive cannot read position. The fault can sit in the encoder, the cable, the connector or the drive.
Fault after an encoder was replaced
A new feedback device must be set up for the motor and aligned to the rotor. Without it the motor can run rough, trip or lose position.
Intermittent fault with vibration or temperature
A cracked connector, a damaged cable in a drag chain or a failing encoder shows up only when the axis moves or warms up.
Position jumps or noisy running
Contaminated or damaged feedback, bearing play or misalignment can cause position error.
02Process
What we do on the bench
- Read the nameplate and the drive fault text.
- Test the feedback signals on the universal servo test bench to place the fault on the encoder, cable or motor.
- Repair or replace the feedback device where needed.
- Reprogram and align the feedback device to the motor.
- Run the motor and check it before it goes back to you.
→How it works
From nameplate photo to a tested motor in 7 steps
One route for servo motors, encoders and drives. You see the price before any work starts, and the report before the unit leaves our bench.
- 1 · Nameplate photoSend it on WhatsApp or the form
- 2 · Repairable? QuoteUsually the same working day
- 3 · Courier or pickupThe unit reaches our bench
- 4 · Bench diagnosisInsulation, windings, brake, encoder
- 5 · RepairFailed parts, bearings, seals, brake
- 6 · Align and run-testEncoder aligned; no-load and load run
- 7 · Report and dispatchPrinted test report with the unit
- Line down?Servo Swap ships a tested unit first. How Servo Swap works
EmergencySame day*
Urgent3 working days
Standard7 working days
*Where the fault and parts allow. Turnaround counts from when the unit reaches our bench and the quote is approved.
04Questions
Questions
My Allen-Bradley drive shows an encoder error. Is the encoder bad?
Not always. The cable, connector or drive input can cause the same fault. We test the motor feedback on the bench to place the fault.
Can you reprogram an Allen-Bradley servo motor encoder?
Yes. We reprogram and align the feedback device to the motor on our universal servo test bench.
Why does the motor run rough after the encoder was replaced?
A replaced feedback device has to be aligned to the rotor. If it was fitted without alignment, the motor can run rough or the drive can trip. Send it for alignment.
What should I send for an encoder error?
The motor with its nameplate, a photo of the drive fault text, and the cable if you suspect it.
Do you also repair the drive?
Yes, see Allen-Bradley Kinetix and Ultra servo drive repair. We can test the motor on its own first.
Send the nameplate. We confirm repairability before you courier.
WhatsApp a nameplate photo and the fault to +91 97866 22233, or email info@starautomations.com.