10.09.2025 by Viktor Siebert
Yaskawa XtraDrive XD-02-MSD0 AC Servopack: Technical Analysis and Repair Practice
A customer sent in several Yaskawa XtraDrive XD-02-MSD0 units that repeatedly failed with Alarm A.10 (Overcurrent/Overheating) and occasionally with Alarm A.D0 (Faulty pulse control).
Step 1: Inspection and Cleaning
Upon opening the units, heavy dust and contamination were found in the cooling channels. The fan was blocked, which caused uncontrolled heat buildup. Boards were carefully cleaned, and heat sinks were thermally inspected.
Step 2: Preventive Replacement
Critical components such as electrolytic capacitors, fans, relays, and power modules were replaced as a preventive measure. These are known wear-out parts in older XtraDrive models.
Step 3: Electrical Testing
Isolation resistance was measured first. Function tests followed, simulating real motor load profiles. Special focus was placed on pulse command processing and encoder feedback, as these were linked to the A.D0 alarm.
Step 4: Load Testing
Each unit underwent long-term testing under thermal load on a CNC test machine that simulated real working conditions. The heat sink temperature and fan performance were closely monitored.
Step 5: Documentation and Protocols
All work was logged in detailed checklists and service protocols, documenting replaced components and measured values.
Result: All units were successfully restored and returned to the customer. The feedback confirmed significantly improved reliability in continuous operation.
Preventive Measures for the Customer
- Regular cleaning of fans, cooling fins, and housings
- Fan replacement every 3–5 years depending on duty cycle
- Periodic insulation testing during scheduled maintenance
- Inspecting encoder cables and connectors for wear
- Seal checks to prevent dust and oil ingress
Conclusion
The Yaskawa XtraDrive XD-02-MSD0 is a compact and reliable servo amplifier that can provide long service life if properly maintained. Common issues such as overcurrent (A.10) or pulse overflow errors (A.D0) can be effectively prevented through regular maintenance and preventive replacement of critical parts.
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Technical Profile:
| Feature | Value |
|---|
| Model | XD-02-MSD0 |
| Input Voltage | 200–230 V AC, single-phase (+10 %, –15 %) |
| Input Current | approx. 3,4 A |
| Output | 3-phase, 0–230 V AC |
| Output Current | approx. 2.1 A |
| Rated Power | 0.2 kW |
| Frequency | 50/60 Hz |
| Weight | approx. 1.1 kg |
| Cooling | Convection/Fan |
| Protection Class | IP20 (for cabinet mounting) |
| Ambient Temperature | 0–55 °C (optimal ≤ 45 °C) |
Application Environment & Compatible Devices
The XD-02-MSD0 model is designed for compact drive applications in machine tools, handling systems, and light automation solutions. It is typically used in combination with Yaskawa servomotors of the SGMAH or SGMPH series.
Applications include CNC machines, pick-and-place systems, and material handling equipment, where precise motion control in a compact format is required.
Functional Description
The XtraDrive XD-02-MSD0 is a servo amplifier that supplies the motor with regulated voltage and frequency. It enables position, speed, and torque control, supports Yaskawa serial encoders as well as A/B encoders, and features internal protection mechanisms such as overcurrent and overheating shutdown.
Control can be executed via pulse/sign inputs or analog references. An integrated auto-tuning function simplifies adaptation to different load conditions.
Alarm Messages and Troubleshooting
| Alarm Code | Description | Cause | Solution |
|---|
| A.10 | Overcurrent / Heat sink overheated | Blocked fan, contaminated heat sink, defective power transistors | Cleaning, fan and capacitor replacement, check power modules |
| A.D0 | Position error pulse overflow | Faulty pulse command, encoder malfunction, incorrect parameter settings | Check control signals, encoder, and wiring |
| A.02 | Parameter memory fault | Corruption in internal memory | Reset parameters, replace ICs if needed |
| A.03 | Encoder error | Cable break, defective encoder | Inspect wiring, replace encoder |
| A.04 | Parameter setting error | Incorrect configuration, incompatible values | Reconfigure parameters, factory reset |
| A.40 | Overvoltage | Supply voltage exceeded | Check power supply, install surge protection |
| A.41 | Undervoltage | Supply voltage too low | Verify network supply, ensure stability |
| A.51 | Overspeed | Motor exceeds rated speed | Inspect reference signals, check encoder feedback |
| A.71 | Overload (high load) | Mechanical friction, overload | Inspect mechanics, reduce motor load |
| A.72 | Overload (low load) | Incorrect parameterization, insufficient cooling | Adjust load profile, ensure cooling |
| A.73 | Dynamic brake overload | Excessive braking cycles, overheated resistor | Install external braking resistor |
| A.C1 | Servo overrun detected | Signal instability or loop error | Optimize tuning, adjust parameters |
Components
| Component | Function |
|---|
| Control PCB | Signal processing and parameter setup |
| Power stage | Supplies power to the servomotor |
| Encoder interface | Feedback for motor position |
| Power supply section | Rectification and DC bus |
| Heat sink with fan | Thermal management |
| Terminal blocks | Power and signal connections |