07.07.2025 by Viktor Siebert

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