Challenge at Our Customer in Greece.

Approximately two years ago we began working intensively on the Tamagawa encoder series OAER5K-1X-3-8-108. The trigger was a major industrial customer from Greece whose machines were repeatedly shutting down because the manufacturer could no longer supply replacement encoders. Everything he purchased on the used market either failed immediately or stopped working after only a few days. He told us that some sellers “guaranteed functionality” even though the devices clearly came from scrapped machines and were already heavily damaged.

Used Market: 100 Percent Failure Rate

We later confirmed this through our own experience. To gain a realistic understanding of the market situation, we carried out several test purchases. None of the encoders we received were technically usable. Many had worn bearings, cracked sensor holders, corroded electronics or distorted housings. In some devices the TS5850 board had already been tampered with or repaired using cheap substitute components. The signal quality was so unstable that operation on a CNC axis was impossible.

Why Conventional Repairs Were No Longer Possible

This situation led us to develop our own refurbishment concept. We completely disassembled the encoders, documented the mechanical weaknesses and analysed the electronics. It quickly became clear that repairs on component level were hardly feasible because the original ICs had not been manufactured for many years. For that reason we chose a fundamental approach: we developed our own fully compatible TS5850-N60 board that reproduces the original signal parameters and operates more reliably than many ageing original boards.

Our Own Re-Engineering of the TS5850 Electronics

In parallel, we designed mechanical replacement components such as bearing mounts, precision bearings and sensor modules to ensure long-term stability of the encoders. Today our overhaul process consists of approximately 70 percent new components, while the remaining original parts are reworked to match the original manufacturing tolerances.

Precise Alignment and Extensive Test Cycles

After mechanical and electronic reconstruction, the sensor system undergoes precise alignment. Each encoder is then tested for several hours on our Mitsubishi test bench with HA33 motor and MR-S12 drive. During this process we monitor signal quality, thermal behaviour, phase accuracy, jitter and reference track stability. Only when all parameters remain completely stable do we perform the final sealing.

A Like-New Encoder and a Sustainable Solution for Europe

The result is an encoder that performs like a brand-new unit and is especially valuable for companies that depend on functioning OAER encoders but no longer have access to reliable spare parts. For our Greek customer, this solution was the decisive step toward restoring long-term machine availability. Since introducing our overhaul, he has not experienced a single failure. For us, this marked the beginning of a specialized refurbishment process that is now used throughout Europe.

Information about the mentioned Servopack and Servomotor:

• Tamagawa OAER5K-1X-3-8-108 Encoder
• Mitsubishi HA33NC-TS AC Servo Motor
• Mitsubishi MR-S12-33A-E01 Servo Drive Unit

More information about our Mitsubishi repairs can be found here.

📞 Feel free to contact us if you have any questions regarding your Yaskawa drive technology. Our experienced team is always ready to assist you.

Device Data (Technical Specifications)

Operating Environment & Compatible Devices

Used in:
Mitsubishi HA motors, MR-S and MR-C servo drives, CNC machine axes, feeders and positioning units.
Most used encoders on the market show severe wear and are not reliable.

Functional Description

The encoder converts shaft motion into an incremental A B Z signal.
The TS5850 electronics generate accurate waveform signals required by Mitsubishi servo drives.
The internal design consists of a precision bearing, sensor head, signal board and a sealed metal housing.

Alarms & Troubleshooting

Components