Fanuc servo motor repair
Common failures, what the test checks, repair or replace.
FanucServo motor repair · India
Servo motor repair in India, tested under load before return
Star Automations repairs and refurbishes AC servo motors for plants and machine builders across India: Fanuc, Yaskawa, Siemens, Mitsubishi, Allen-Bradley, ABB, B&R and many other industrial makes. Your own motor is inspected, the failed parts are repaired or replaced, the encoder or resolver is tested and aligned, and the motor is run with no load and then under full load before it is returned with a printed test report. WhatsApp the nameplate and we confirm repairability before you courier.
00For your plant
What a tested repair gives your plant
Your own motor back
The same motor, serial and part number go back on the machine, so wiring, parameters and spares stay as they are.
No wait for a new unit
When the OEM quotes a long lead time or the motor is no longer made, a repair puts the axis back in service.
Proof before it ships
The motor is run and load-tested before dispatch, so your line is not where it gets tried out.
The cause, in writing
The test report records what failed and why, so your team can stop the same fault coming back.
01What is included
What a servo motor repair covers
The scope depends on what we find at inspection. You see the findings and the quote before work starts, so nothing is replaced without a reason.
- Inward inspection with photos and the serial number logged
- Bearings and oil seals replaced, shaft and keyway checked
- Brake checked for release voltage and holding; brake parts serviced
- Encoder or resolver repaired or replaced, then aligned to the rotor
- Winding insulation, hipot, resistance and balance tested; winding faults repaired
- Connectors and feedback cables cleaned, repaired or replaced
02Test platform
The servo test and alignment platform behind every repair
A permanent-magnet brushless servo motor depends on its feedback device — a resolver, an incremental encoder or a serial encoder — to tell the drive where the rotor is. A motor can pass a basic electrical check and still fail on the machine because the feedback is faulty, mis-aligned or unprogrammed. That is the part an ordinary rewind shop cannot see.
Star Automations runs the complete Mitchell Electronics (USA) servo test platform for exactly this work:
TI-5000JX — Feedback Test & Alignment
We diagnose the feedback device, verify incremental phase and commutation tracks, check the count against the Z pulse or absolute position, and read and program encoder memory on supported serial encoders.
TI-3000JX — Run Test System
We power and run the repaired motor across a wide range of feedback types without needing that motor maker’s own servo drive, then load-test it on our own rig.
- Feedback aligned and proven the way the OEM would, so the axis holds position when the motor goes back on the machine
- Obsolete motors, and makes an OEM-tied service often turns away, can usually be tested and returned to service
03Feedback
Feedback devices we test, align and program
Many servo motors that reach us have a feedback fault, not a winding fault. We test the feedback device on the Mitchell Electronics TI-5000JX feedback test and alignment platform, repair or replace it, align it to the rotor, and on supported serial encoders read and program the encoder memory.
How it works: encoder alignment and programming.
- Incremental encoders with UVW or Hall commutation tracks
- Sin/cos encoders (1 Vpp)
- Resolvers
- Absolute encoders: EnDat, BiSS and BiSS-C, SSI, parallel absolute
- SICK Hiperface and Hiperface DSL
- Serial encoders: Fanuc, Mitsubishi, Yaskawa, Tamagawa and MFE types
- Hall effect sensors and tachogenerators
04Failure modes
How servo motors fail
Encoder faults
Serial communication errors, position loss and alarms at power-up. Often caused by coolant or oil reaching the encoder through a worn seal.
Bearing wear
Noise, vibration and heat at the drive end. Left too long, a bearing failure can damage the encoder and the shaft.
Brake problems
A brake that does not release overheats the motor; one that does not hold lets a vertical axis drop.
Winding and insulation
Overcurrent or ground-fault trips. Insulation tests show whether the winding can be saved.
05Verification
How the repair is proved
Every repaired motor goes through the same test sequence on our servo motor test system: electrical checks, feedback and commutation, brake, a no-load run on the Mitchell Electronics TI-3000JX run test system, and then a full-load run on a custom-built load rig. Measured speed and current are compared with the nameplate, and vibration and noise are checked at rated speed.
The results go on a printed test report that travels with the motor. See the real tester screens and run test and a sample test report.
Repair is not always the right answer. If the frame is damaged, the magnets are weak or the encoder cannot be sourced, we tell you and suggest a stock motor or an upgrade instead.
06Where
Where each step takes place
Each motor follows the same route, at whichever of our three sites receives it.
| Step | Where it happens |
|---|---|
| Nameplate review and repairability check | WhatsApp or email, before anything is shipped |
| Receiving the motor | Chennai (Poonamallee), Puducherry (Thattanchavady) and Bengaluru (Mahadevapura), by hand-in, courier or pickup |
| Inspection, photos and quote | Chennai, Puducherry and Bengaluru |
| Repair: bearings, seals, brake, winding, connectors | Chennai, Puducherry and Bengaluru |
| Encoder or resolver test, alignment and programming | Chennai, Puducherry and Bengaluru |
| Final run test and full-load test | On the universal servo motor test system before dispatch |
| Printed test report and dispatch | From the site that repaired the motor |
07Brands
Repair by brand
We also repair Panasonic, Delta, Omron, Bosch Rexroth (Indramat), Kollmorgen, Parker, Schneider Electric (including Elau and Berger Lahr), SEW-Eurodrive, Sanyo Denki, Fagor, Kawasaki, Baumüller, Stöber and Moog servo motors. Send the nameplate to confirm a specific model.
Yaskawa servo motor repair
Common failures, what the test checks, repair or replace.
YaskawaSiemens servo motor repair
Common failures, what the test checks, repair or replace.
SiemensMitsubishi servo motor repair
Common failures, what the test checks, repair or replace.
MitsubishiAllen-Bradley servo motor repair
Common failures, what the test checks, repair or replace.
Allen-BradleyABB servo motor repair
Common failures, what the test checks, repair or replace.
ABBB&R servo motor repair
Common failures, what the test checks, repair or replace.
B&RDelta servo motor repair
Series we repair, common failures, what the test checks.
DeltaPanasonic servo motor repair
Series we repair, common failures, what the test checks.
PanasonicOmron servo motor repair
Series we repair, common failures, what the test checks.
OmronBosch Rexroth servo motor repair
Series we repair, common failures, what the test checks.
Bosch RexrothKollmorgen servo motor repair
Series we repair, common failures, what the test checks.
KollmorgenParker servo motor repair
Series we repair, common failures, what the test checks.
ParkerSchneider Electric servo motor repair
Series we repair, common failures, what the test checks.
Schneider ElectricBeckhoff servo motor repair
Series we repair, common failures, what the test checks.
BeckhoffSEW-Eurodrive servo motor repair
Series we repair, common failures, what the test checks.
SEW-EurodriveLenze servo motor repair
Series we repair, common failures, what the test checks.
LenzeSanyo Denki servo motor repair
Series we repair, common failures, what the test checks.
Sanyo DenkiFuji Electric servo motor repair
Series we repair, common failures, what the test checks.
Fuji Electric08How to send
How to send the motor
You can send a servo motor from anywhere in India. Talk to us before you courier, so the unit is expected and logged on arrival.
Send the nameplate
WhatsApp a clear photo of the nameplate, the alarm code and what the machine was doing when it failed.
We confirm repairability
We tell you whether we can test and repair that model before anything is shipped.
Courier or pickup
Courier the motor to our Chennai, Puducherry or Bengaluru site, or ask us to arrange pickup where needed.
Inspection and quote
The motor is opened, inspected and photographed. You get the findings and a quote before work starts.
Repair, test, dispatch
Repaired, run-tested and load-tested, then dispatched with a printed test report.
09For repair shops
For other repair shops and service providers
Many regional repair shops and automation service companies can handle windings, bearings and brakes but cannot test or align modern feedback, program encoder memory, or run-test a motor without the OEM’s drive. We run that stage for you.
You keep your customer. We receive the motor under your job, test and align the feedback on the TI-5000JX, program the encoder where supported, run-test it on the TI-3000JX, and return it with a report for you to hand over. It keeps motors in service instead of being scrapped for want of a feedback test.
Talk to us about a service-provider arrangement, or WhatsApp a nameplate to +91 97866 22233.
- Feedback test, alignment and commutation setting
- Encoder memory read and programming on supported serial encoders
- No-load and full-load run test with a printed report
- Your customer relationship stays yours
- Written, transparent terms for every job
Which servo motor brands do you repair?
Fanuc, Yaskawa, Siemens, Mitsubishi, Allen-Bradley, ABB, B&R, Panasonic, Delta, Omron, Bosch Rexroth, Kollmorgen, Parker, Schneider Electric, SEW-Eurodrive, Sanyo Denki and other industrial makes. Your own motor is repaired and returned, with its serial number traced from inward to dispatch.
Can you repair a motor that loses position after winding or encoder work elsewhere?
Usually, yes. Position loss after winding or encoder work is often a commutation offset problem. We realign the encoder or resolver and prove it on the test system.
What decides repair or replace?
Frame and shaft condition, magnet strength, whether the encoder can be sourced, and how the repair cost compares with a new or stock motor and its lead time.
Is there a warranty?
A written warranty is given after a successful repair. Warranty terms are stated on each quotation.
What do I need to send for a quote?
A photo of the nameplate, the alarm code, and a short note on the symptom: noise, heat, position loss or brake trouble.
Can you test and align a servo encoder without the original drive or OEM software?
Yes. On the Mitchell TI-5000JX we test and align the feedback device directly, and on the TI-3000JX we run-test the motor without that maker’s servo drive. This covers incremental and sin/cos encoders, resolvers, EnDat, BiSS, SSI, SICK Hiperface and Hiperface DSL, and serial encoders from Fanuc, Mitsubishi, Yaskawa and Tamagawa.
Do you read and program encoder memory?
On supported serial and absolute encoders, yes. We read the encoder memory, align the feedback, and program the memory so the motor keeps its correct position reference after repair.
Do you test the motor under load before it is returned?
Yes. After a no-load run on the TI-3000JX we load-test on our own rig and compare measured speed and current against the nameplate. The results travel with the motor on a printed test report.
Can you help a repair shop that does not have this equipment?
Yes. We run feedback testing, alignment, encoder memory programming and run-testing as a back-end service for other repair shops and service providers. You keep your own customer, and the motor returns with a report.
Do you ship across India?
Yes. We take motors from anywhere in India by courier or pickup, through our Chennai, Puducherry and Bengaluru facilities. Send the nameplate on WhatsApp first so we can confirm repairability before you courier.
Send the nameplate. We confirm repairability before you courier.
WhatsApp a nameplate photo and the alarm code to +91 97866 22233, or email info@starautomations.com.