27.06.2025 by Viktor Siebert
A Look Inside Our Workshop: How We Test Your Repaired Servopacks Yaskawa SGDV-5R5A01A
Recently, we received a Yaskawa Servopack SGDV-5R5A01A for repair, showing the error A.100 (Overcurrent / Heatsink Overtemperature). While this may seem like a routine case, we treat every device with the same care and diligence as the original manufacturer.
What appears to be a standard repair on the surface requires expertise, experience, and a well-structured testing process behind the scenes.
What exactly do we do?
For this device, we carried out the following work:
- Replacement of the power stage (IGBT section)
- Replacement of the gate driver module
- Renewal of all DC link capacitors
- Cleaning, visual inspection, and renewal of the thermal compound
- Replacement of the cooling fan
- Re-soldering of thermally stressed joints (hotspots)
Our Test Bench: Developed In-House – Tested Like the Manufacturer
To ensure the quality of our repairs, we developed our own test racks for Sigma-5 Servopacks over seven years ago. These simulate real-world conditions with various load profiles and control scenarios.
What happens during testing?
- Initial power-up check: Voltage, current draw, encoder feedback
- Partial load testing: Analog input response, ramping, braking function
- Full load testing with simulated motor operation: Continuous run >30 minutes
- Fault simulation and safety checks: Triggering and verifying protective shutdowns
- Final test with log documentation: All parameters recorded and compared to factory specs
We test using the same standards applied by the manufacturer – in some cases even enhanced with our own tools to better detect latent faults.
Transparency Builds Trust
We created a short video for this repair that showcases our test setup. We don’t just want to say we do quality work – we want to show it. Transparency is a core value of our company and one of the key reasons many customers choose to work with us long-term.
Conclusion: Even though error A.100 is a relatively common fault in Yaskawa SGDV devices, we approach every repair with technical precision, perform in-depth testing, and document everything clearly.
If your device is showing an error – feel free to get in touch with us.
Information about the mentioned Servopack: Yaskawa Servopack SGDV-5R5A01A
For more details about our Yaskawa repair services, visit: Yaskawa Sigma V Repairs
📞 Feel free to contact us if you have any questions about your Yaskawa drive technology!
Technical Device Data
| Parameter | Value |
|---|
| Model | SGDV-5R5A01A |
| Input (MAIN) | 3PH 200–230 V, 50/60 Hz, 3.7 A |
| Control Power (CONT) | 1PH 200–230 V, 50/60 Hz, 0.2 A |
| Output | 3PH 0–230 V, 0–400 Hz, 5.5 A, 750 W |
| Ambient Temperature | 0–55 °C |
| Protection Class | IP10 |
| Manufacturer | Yaskawa Electric Corporation, Japan |
Internal Components
| Component | PCB Label | Qty |
|---|
| Control Board | SGDV-IFA01B | 1 |
| Power Board | SGDV-CB7R6AAB | 1 |
Operating Environment & Compatibility
The SGDV-5R5A01A belongs to the Sigma-5 series and features an analog/pulse interface. It is compatible with:
- SGMJV, SGMAV, SGMGV, SGMPS, SGMSV, SGMCS servo motors.
Typical applications:
- High-speed, high-precision positioning tasks
- Systems with variable mechanical loads
- Machines requiring real-time encoder feedback
Environmental specs:
- Operating temp: 0–55 °C
- Storage temp: -20–85 °C
- Humidity: ≤ 90%, non-condensing
- Max altitude: 1000 m above sea level
Functional Description
The SGDV-5R5A01A Servopack supports:
- Speed control (V-mode)
- Position control (P-mode)
- Torque control (T-mode)
Features include:
- Speed control ratio of 1:5000
- Analog inputs ±12 V for V- and T-mode
- Pulse input (up to 4 Mpps with line driver)
- Encoder output: A/B/C phase (line driver)
- Adjustable smoothing & zero offset
- Parameter-based brake resistor configuration (Pn600)
Alarm List (Excerpt)
| Code | Description | Countermeasure |
|---|
| A.100 | Overcurrent / Heatsink Overtemperature | Check wiring, rule out short circuits, replace SERVOPACK if needed |
| A.300 | Regeneration error | Check wiring and value of brake resistor, verify Pn600 |
| A.320 | Regeneration overload | Increase brake resistor rating, correctly configure Pn600 |
| A.400 | Overvoltage | Check supply voltage, install surge suppressors if needed |
| A.410 | Undervoltage | Check grid voltage and stability, adjust Pn509 if required |
| A.830 | Absolute Encoder Battery Fault | Check or replace battery |
| A.C90 | Encoder communication failure | Inspect encoder wiring, grounding, and connectors |
| A.CC0 | Multiturn limit mismatch | Check Pn205, correct with Fn013 if necessary |
