07.07.2025 by Viktor Siebert
Major Breakdown on Sanyo Denki BL Super PE0A030MXXXC00 Caused by Defective 65ZBM040HCSS6 Motor
In this article, we report on a severe damage case involving a Sanyo Denki BL Super PE0A030MXXXC00 Servo Amplifier, caused by a defective motor of type Sanyo Denki 65ZBM040HCSS6. This case is representative of many Brother machines using this drive technology and highlights how important timely inspections are.
Typical Weak Point in Brother Machines
The motors from the BL Super series by Sanyo Denki are frequently used in Brother machines operating under harsh conditions. Emulsion mist and oil-laden air gradually attack the seals over the years. The motors are literally “run to failure” although compact and powerful, they are not designed to withstand such aggressive environments permanently.
The frequent result: the motor becomes internally flooded. Oil and emulsion infiltrate the housing, damaging bearings, windings, and especially the encoder. The repair success rate is around 80 percent, but not every motor can be saved.
Drive Failures as a Common Consequence
An oil-damaged encoder often causes short circuits that affect the connected drive. Typically, the encoder amplifier circuit is destroyed. Damage ranges from thermal stress to actual burn marks on the control board. If the board is burnt, it must be replaced significantly increasing the repair cost.
From our experience: almost every failed motor leads to a failed drive. With proper inspections, we can identify and prevent such scenarios early on.
Current Case: Company from Switzerland
A mid-sized company from Switzerland brought us a damaged drive in person. The customer operates many machines with this technology, some of which are more than 15 years old. Since replacing them is neither economically nor spatially feasible, he pursues a thoroughly sustainable strategy.
New spare parts from the OEM are barely available or come with extremely long lead times. In addition, prices have tripled over the past few years. For this customer, repair was the only viable solution.
Our Repair Expertise
We have over ten years of experience with Sanyo Denki modules and operate a self-developed testing platform that allows us to test seven different Sanyo Denki series including the BL Super line. A video of this testing platform will be attached to this article soon.
In this specific case, the control board was fortunately not burned but only thermally stressed. We replaced almost all components of the encoder output stage and carried out a full preventive overhaul of the drive. The power stage and power supply unit were also brought up to the latest standard.
Quick Turnaround and Follow-Up Order
The repair was completed in just five working days. Since then, the machine has been running without issues. The customer was convinced by our work and has decided to send in all remaining motors and drives this summer for inspection and overhaul.
Conclusion: Prevention Saves Costs and Downtime
Anyone using Brother machines with BL Super drives should have their motors regularly inspected. Preventive maintenance and overhaul can avoid secondary damage, damage that not only destroys the drive but may also cause critical production downtimes. Our experience clearly shows: early intervention pays off and ensures continued operation even with older systems.
Additional Information: Sanyo Denki BL Super PE0A030MXXXC00 Servo Amplifier
For further details on our Sanyo denki repair services, please visit here.
📞 Please feel free to contact us if you have any questions regarding your Sanyo denk drive technology. Our experienced team is always available to assist you.
Technical Specifications (Table)
Parameter | Value |
---|
Model Number | PE0A030MXXXC00 |
Control Power Input | AC 200V / 0.2A |
Main Power Input | AC 200V / 5.5A |
Operating Temperature | 0 to 55 °C |
Humidity | Max. 90% non-condensing |
Vibration Resistance | Max. 0.5G (10 to 55 Hz) |
Shock Resistance | Max. 2G |
Air Quality Requirements | Dust-free, oil-free, non-corrosive, non-combustible, non-explosive |
Power Dissipation (with P30B08075D motor) | 46 W |
Minimum Clearance for Cooling | ≥ 50 mm top/bottom/sides |
Function Overview
- Converts three-phase AC power (200–230 V) into regulated voltage pulses for servo motors.
- Supports:
- Position control
- Speed control
- Torque control
- Controlled via CN1 and CN2 connectors:
- CN1: Control I/O (Servo ON, Alarm, Monitoring, Velocity)
- CN2: Motor encoder interface
- Optional:
- External regenerative resistors for higher braking energy dissipation.
Alarm Codes and Troubleshooting (Table)
Code | Abbr. | Description | Suggested Action |
---|
1 | OC | Overcurrent | Check wiring or motor compatibility |
2 | OL | Overload | Inspect mechanical load |
3 | AOH | Amplifier Overheating | Check ambient temperature |
5 | OV | Overvoltage | Reduce line voltage |
6 | OS | Overspeed | Verify encoder, adjust input values |
7 | PE | Control Power Error | Check control voltage |
8 | DE | Encoder Error | Inspect encoder wiring |
9 | MPE | Bus Power Error | Check main power supply |
A | FP | Missing Bus Phase | Verify power phase connections |
C | SE | Speed Control Error | Re-tune servo parameters |
d | OVF | Position Deviation Overflow | Reduce load or pulse input |
E | EXOH | External Reg. Resistor Overheat | Check fan or resistor placement |
F | DSPE | DSP Error | Replace amplifier |
H | RGOH | Internal Reg. Resistor Overheat | Improve cooling or reduce load |
J | RGOL | Regeneration Overload | Increase brake resistor capacity |
P | MEME | Memory Error | Replace amplifier |
U | AEE | Absolute Encoder Error (inactive) | Not relevant for this version |
— | CPUE | CPU Error | Device non-operational |
Internal Components (Table)
Component Type | Model Reference | Quantity |
---|
Control Board | PRS-3260C / PRS-3260D | 1 |
Logic/Communication PCB | PRS-3204B | 1 |
Power Supply Board | PRS-3203B | 1 |
Power Amplifier Board | PRS-3205B | 1 |
Power Module | – | 1 |