23.06.2025 by Viktor Siebert
Weekend Rescue in Düsseldorf: Mitsubishi Servo Drive Unit MDS-D-V2-160160 (MDSDV2-160160) Failure
Unexpected machine failures can bring entire production lines to a halt – and that’s exactly what happened to one of our customers in Düsseldorf. The affected unit: a Mitsubishi Servo Drive Unit MDS-D-V2-160160, which suddenly stopped working and showed no signs of functionality.
Urgent Inquiry – Alternative: Import from the USA
We had never repaired this exact model before. Still, the customer contacted us with a clear question:
“Can you repair it over the weekend?”
An alternative would have been importing a new unit from the USA – with a price tag of over $7,000 and shipping costs exceeding €300. Not to mention the longer delivery time.
Internal Coordination – Fast Go/No-Go Decision
Our sales engineer immediately checked with our repair department to see if the repair was feasible.
While we hadn’t serviced this specific unit before, our engineers were familiar with other models from the same series – both stronger and weaker variants.
After reviewing the schematics, our technician concluded: “Yes, it’s doable.”
We had the necessary spare parts in stock, and the likelihood of hitting an unexpected roadblock was minimal.
Same-Day Arrival and Diagnosis
The customer arranged a courier to deliver the drive unit directly to us. We received it on Friday morning and immediately began diagnostics.
Thanks to our extensive experience with similar models, the failure patterns were familiar, and the repair process could start without delay.
No Shortcuts: Full Overhaul Instead of a Quick Fix
Technically, we could have returned the repaired unit on Friday evening. But that would have been just a basic fix.
We don’t believe in halfway solutions.
Instead, we performed a preventive express overhaul, including:
- Replacement of all critical components based on failure data from similar models
- Full cleaning, washing, and drying of the unit
- Several hours of load testing in our in-house original test environment
Result: Perfect Functionality, Zero Downtime
By Monday morning, the unit was ready for pickup and reinstallation.
The machine was back in operation without any downtime, as the USA delivery would have taken even longer.
In total, the customer saved over €5,500 and made an environmentally responsible choice by opting for a repair instead of a new purchase.
Conclusion: A New Model in Our Portfolio, Another Satisfied Customer
With this successful express repair, we’ve added the MDS-D-V2-160160 to our repair portfolio.
Another example of how we never compromise on quality – even under pressure – and continue to help customers reduce costs and avoid unnecessary waste.
To mentioned Mitsubishi Drive: Mitsubishi Servo Drive Unit MDS-D-V2-160160 (MDSDV2-160160)
More details about our Mitsubishi repair services can be found here:
Mitsubishi drive Repair by Industrypart
📞 Feel free to contact us with any questions about your Mitsubishi drive technology.
Our expert team is happy to help!
Device Description and Technical Data
Device Data (based on nameplate and manual)
| Parameter | Value |
|---|
| Model | MDS-D-V2-160160 |
| Power Output | 4.5 kW / 4.5 kW (L/M axis) |
| Input Voltage | 60A DC270–311V |
| Control Voltage | 1-phase 200–230V, 50/60Hz |
| Output | 29.6/29.6A, 3-phase 155V, 0–240Hz |
| Weight (approx.) | approx. 9–10 kg per module |
| Manual No. | IB-1500875 |
| Serial Number | J3AAFSFX209J |
| Manufacturer | Mitsubishi Electric, Japan |
Operating Environment
The MDS-D-V2-160160 is a dual-axis servo amplifier used in Mitsubishi CNC-controlled machines, typically in:
- Machining centers with high-precision axis control
- CNC machines using two synchronized servo axes (e.g. X/Y or U/V)
- Combined with HF or HP series Mitsubishi servo motors
- Environmental specs:
- Operating temp: 0–55 °C
- Humidity: max. 90% RH (non-condensing)
- Must be installed in a clean, dust- and oil-free cabinet
Functional Overview
The MDS-D-V2-160160 is a digital 2-axis servo drive unit with the following features:
- Optical communication with the CNC control
- Absolute encoder compatibility
- Dynamic braking support (via external unit)
- Precise control of torque, speed, and position
- Supports closed-loop feedback via encoders on both motor and machine side
- Integrated protection functions: overvoltage, overcurrent, thermal fault, etc.
Alarm Messages & Troubleshooting (Excerpt)
| Alarm No. | Description | Reset Method | Recommended Action |
|---|
| 10 | Bus voltage too low | PR | Check power supply |
| 13 | Software processing error | PR | Restart or replace unit |
| 16 | Initial magnetic pole detection error | PR | Re-execute magnetic pole setup |
| 25 | Absolute position data lost | AR | Perform reference origin return |
| 30 | Over-regeneration detected | PR | Check regenerative resistor |
| 31 | Overspeed | PR | Check load, verify parameter set |
| 45 | Cooling fan stop detected | PR | Replace fan |
| 50 | Motor or unit overload | NR | Inspect ambient temp and motor load |
| 87 | Axis-to-axis communication error | PR | Check optical communication cabling |
Internal Components (Based on Part List)
| Component | Board Marking | Qty |
|---|
| Control Board | RM115A-22 or BC886A028G51 Ϟ | 1 |
| Power Board | RM162C-V2 or BC886A010G52 B | 1 |
| Power Module | A2-D-V2-160160 | 1 |
