Repair of HAAS HP Vector Drive and HAAS Servo Amplifiers

Vector Drive
20HP Vector Drive
20/15HP Vector Drive
40HP
Vector Drive
60HP Servo Amplifier
30A Servo Amplifier
45A

HAAS HP Vector Drive and HAAS Servo Amplifier

We test and repair HAAS HP Vector Drive and HAAS Servo Amplifiers
Additionally, we also offer services for Yaskawa motors.

We specialize in the following series:

HAAS HP Vector Drives come in various power levels and configurations:

HAAS Vector Drive example model: 20HP 32-5559
HAAS Vector Drive example model: 20/15 HP 69-1000

HAAS Servo Amplifiers come in different power levels and configurations:

HAAS Servo Amplifier example model: 30A 32-5550J
HAAS Servo Amplifier example model: 45A 32-3551J

Our repair process is preventative and includes a series of steps aimed at ensuring a high quality of repair.

Failure analysis and localization

What can you do?

Failures in Vector Drives and Servo Amplifiers

Possible solutions and tips

Try replacing the motor.
Check cable connections.
Run in jog mode without load.

If these measures do not help, the error is usually in the power stage of the drive module.

More error messages can be found in the alarm list available for download at the end of this page.

Possible solutions and tips

Warm up the device with an external source. If it turns on, it usually indicates a weak power supply that needs to be repaired.
Check fuses.
Check voltage supply of 3 x 200 or 220 volts, depending on the model.

More error messages can be found in the alarm list available for download at the end of this page.

Possible Solutions and Notes

Error Messages:

Alarm #123: Spindle Drive Error
Alarm #160: Undervoltage

Problem:
The machine reports an undervoltage, a common issue with many devices. The customer sees on the machine control display that the target voltage is not being reached – it should be around 320 volts DC.

Symptom Progression:

Initially, the error occurs sporadically. The device often only works again, after warming up or after several power cycles. This is a typical approach used by many operators.
Over time, the problem worsens: it takes longer for the device to work after being turned on, and more power cycles are needed.

Risk:
Repeated power cycling and improper handling can cause the buffer electrolytic capacitors inside the device to explode. In such cases, the device may fail completely and is often beyond repair.

Recommendation:
As soon as the error occurs, the device should be taken in for repair immediately to avoid more severe damage.

Further error messages can be found in the alarm list available for download at the end of this page.

Possible solutions and tips

Try replacing the motor.
Check cable connections.
Run in jog mode without load.

If these measures do not help, the error is usually in the power stage of the drive module.

More error messages can be found in the alarm list available for download at the end of this page.

Possible solutions and tips

Warm up the device with an external source. If it turns on, it usually indicates a weak power supply that needs to be repaired.
Check fuses.
Check voltage supply of 3 x 200 or 220 volts, depending on the model.

More error messages can be found in the alarm list available for download at the end of this page.

Possible Solutions and Notes

Error Messages:

Alarm #123: Spindle Drive Error
Alarm #160: Undervoltage

Symptom Progression:

Initially, the error occurs sporadically. The device often only works again, after warming up or after several power cycles. This is a typical approach used by many operators.
Over time, the problem worsens: it takes longer for the device to work after being turned on, and more power cycles are needed.

Recommendation:
As soon as the error occurs, the device should be taken in for repair immediately to avoid more severe damage.

Further error messages can be found in the alarm list available for download at the end of this page.

The typical process for repairing HAAS HP Vector Drive and HAAS Servo Amplifier

The repair process for Vector Drive or Servo Amplifier includes the following steps

Intensive cleaning.
Preventive overhaul - replacement of all necessary defective and worn-out parts.
Comprehensive final and stress testing on our test benches, as well as on a dedicated HAAS machining center.
Completion of documentation and checklists.

High-quality spare parts for high-quality repairs

In Vector Drives and Servo Amplifiers, we replace

Electrolytic capacitors
Large buffer capacitors
Relays
Current measurement modules
Optocouplers

Additionally, we replace certain parts that have statistically shown to fail frequently after multiple repairs and have therefore been selected for replacement based on statistical data.

To counter shortages and discontinuations, we have processor-driven software solutions that monitor our inventory. We pre-order some parts in advance, and for serial repairs, we ensure sufficient spare parts for a year, allowing us to maintain a large stock at all times.

Quality and level of repair

A professional repair requires the use of a test system. The Vector Drives or Servo Amplifiers are tested at a specially equipped test bench and subjected to stress and long-term tests in the HAAS machining center.

The following aspects are thoroughly tested:

Control (Computer to drive module)
Alarm states
Speed (Min. & Max.)
Current and voltage consumption
Temperature

We continuously expand our repair portfolio with new series

Since drive and power electronics are often discontinued prematurely, you may feel pressured to deliver replacements to your customers on time. We support you in analyzing shortages and work together to find optimal solutions.

The typical process includes:

Development of test benches and procedures
Organization of spare parts
Preventive repair at the component level
If necessary, redevelopment or re-engineering of modules or complete devices

Frequently Asked Questions

Motor repair

In which quality/level are load tests performed at your company?

Complex and specially adapted test equipment is developed for each new series. Devices are tested with long-term load test thoroughly checked for functionality. Get an idea of our test facilities.

Do you have special spare parts, which are necessary for qualitative repair?

In times of shortages and discontinuations, we have process-oriented software solutions that monitor our inventories. We order some parts in advance, for series repairs even for 1 year, so that we can fall back on a large stock of spare parts. Certain modules are re-engineered by us.

Can you parameterize the devices?

If possible, a copy of the parameters is always read out and stored upon receipt. After successful repair, the data is compared and in case of exchange or sale, original parameters are transferred or restored to the new device. We have all the necessary hardware as well as software applications to parameterize Yaskawa devices according to the specifications.

What processes are involved in the repair of motors?

The repair process for motors includes, but is not limited to, the following:

New and fine adjustment of encoder/encoder systems
As needed winding repair and balancing
As needed connector repair or replacement
For irreparable equipment, an alternative solution will be offered (e.g. replacement or sale)

You can find more information on the process flow for motor repair here.

Further information

Will I get a detailed repair report after a successful repair?

We document the repair process for every order. You can download a detailed description of the process here.

Do you commission new or unknown equipment?

We are continuously looking for new areas of activity. After consultation with the customer, we determine the necessary steps for a safe and qualitative repair

Can it happen that after repair my device continues to show errors?

It may happen that error messages continue to be displayed with the connected device. Already during the analysis of the errors, we give the customers suggestions for solutions for different malfunctions and errors. error cases, if we suspect further error causes. Errors and faults are documented, among other things, in the log file of the respective device, which may indicate, for example, encoder communication problems, cable defects or overloads.

What does serial repair or overhaul mean

Many of our customers have defective devices of the same model in larger quantities. We have optimized our processes for series repair and have the capacity to repair many devices in parallel quickly and to a high repair many devices in parallel.

Cost & Warranty

How much does a repair or overhaul of a device cost? What does "flat repair rate/standard repair price" mean?

The repair process itself represents a high degree of technical complexity, which we always want to master with a qualitative and long-term solution for you. solution for you. However, the maintenance of these quality characteristics requires, to agree on a repair flat rate or standard repair price. We communicate honestly and transparently all the information you need. For example, prices, previous and completed work steps, delivery times, etc.

Is there a warranty for the respective repair?

Basically we give 12 months warranty.

Vector_Drive_Troubleshooting_Guide _CHC.pdf (3.85 MB)

HAAS_Electrical_Service_Manual_96-0284F_Rev_F_English_January_2009.pdf (7.92 MB)

Servo_amplifier_troubleshooting_guide.pdf (5.82 MB)

You can contact us in the following way:

Chat with our customer support, write us a message: [email protected] or call us: +49 6251 9888430

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