Case Report: Malfunctioning of a Yaskawa Servopack CACR-IR44SEB

15.04.2025 by Viktor Siebert

Case Report: Malfunctioning of a Yaskawa Servopack CACR-IR44SEB

Initial Situation: Unclear Customer Issue

Recently, we received a Servopack CACR-IR44SEB from a robot for inspection. According to the customer’s statement, the device operated sporadically. The customer’s attempt to exchange the Servopack with identical units within the robot cabinet unfortunately failed. Although three identical Servopacks were installed, the exchange led to a complete malfunction.

Error Analysis: Small Mistake – Big Consequences

Upon further inquiry, we discovered that the customer did not adjust the switch settings (addressing) when swapping units. The Yaskawa Servopack CACR-IR44SEB features specific addressing, which must be adjusted when changing positions. This simple yet crucial detail, unfortunately not always obvious, led the customer to incur significant costs of nearly €5,000 for a new motor—without solving the issue.

Technical Inspection and Repair

During our initial inspection and subsequent testing in our robot setup, the issue was confirmed. The Servopack would fail after approximately 20-30 minutes of operation, displaying an error message, but became operational again after cooling down briefly. Further examination revealed that the issue lay within the power output stage directly connected to the motor—an unfortunately common problem for this device type.

We performed a preventive overhaul according to established standards. Since then, the system has been running reliably.

Conclusion and Recommendation

This case clearly illustrates that customers are often inadequately informed by manufacturers or service providers. Especially with older devices whose support has ended, there’s often a reluctance to deeply analyze faults. We see our responsibility in addressing these cases, providing customers with transparent, honest, and comprehensive solutions.

Technical Specifications and Operation of the Yaskawa Servopack CACR-IR44SEB

Manufacturer: Yaskawa
Model: CACR-IR44SEB
Power Supply: AC 200–230 V
Control: Analog regulation for position, speed, and torque control
Operation:
- Receives analog signals to control position, speed, or torque of the connected servomotor.
- Features internal addressing (DIP switch) for clear identification within a system.
- Integrated protection mechanisms for thermal overload, overcurrent, or voltage faults.
- Common failure points include defects in the power output stage, thermal issues due to dirty or defective fans, and connection issues with connectors.