01.10.2025 by Viktor Siebert
Repair Story: Yaskawa CACR-SR15BE12F-E Servopack on Kondia B-1000 CNC Milling Machine
Initial Situation:
A customer reported disturbances on a Kondia B-1000 CNC milling machine. The symptom was unusual: The machine table vibrated slightly in the Y-axis, accompanied by a humming noise. At first glance, this seemed harmless, but it was a clear indication of an emerging fault inside the Servopack.
Risk Potential:
If the machine had continued operating like this, the vibrations would have worsened. The risk: axis crash, defective workpieces, or even complete drive train failure. In production, this would have meant downtime and high costs.
Analysis:
We opened the Servopack and carried out an initial visual inspection. Dust deposits and slight thermal discoloration on the power board were noticeable. However, since this fault only appears under dynamic conditions, a dedicated test bench was required.
Our Test Bench:
For exactly these Yaskawa CACR-BE models, we developed a dedicated test environment. Here, we can run load tests, monitor temperature and signals, and simulate real-world conditions. In this case, clear signal distortions appeared under load, pointing to a developing defect in the current regulation.
Repair Process:
- Complete cleaning: Removal of dust, oil, and production residues.
- Preventive replacement: Electrolytic capacitors, fans, and thermally stressed components were replaced.
- Signal verification: Encoder and motor feedback tested, faulty connectors replaced.
- Final testing on the bench: Load run, thermal monitoring, long-term test.
Documentation:
Every step was logged using a checklist and test protocol, ensuring full transparency and traceability.
Customer Benefit:
After repair, the Kondia B-1000 ran again without vibration or noise. The customer could immediately return the machine to production. Thanks to preventive part replacement, the service life was significantly extended, avoiding costly failures.
Preventive Measures for the Customer
- Regular cleaning of the Servopack in the control cabinet.
- Fan replacement every 3–5 years.
- Periodic insulation measurement of motor cables.
- Inspection of connectors for corrosion and tight fit.
- Documented maintenance and visual checks during each machine inspection.
Conclusion
The Yaskawa CACR-SR15BE12F-E Servopack is a proven drive unit that ensures precise control and high reliability.
The repair story demonstrates: Early diagnosis and preventive replacement save costs, protect production quality, and prevent unplanned downtime.
To mentioned Yaskawa Drive: Yaskawa CACR-SR15BE12F-E Servopack
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Device Description
| Feature | Value |
|---|
| Manufacturer | Yaskawa Electric Corporation, Japan |
| Model | CACR-SR15BE12F-E |
| Device Type | AC Servopack (Servo Drive Unit) |
| AC Input | 200–230 V, 50/60 Hz, 3-phase, 10.0 A |
| AC Output | 0–230 V, 3-phase, 9.7 A |
| Rated Power | 1.5 kW (2.01 HP) |
| Control | PWM-controlled inverter with feedback |
| Cooling | Forced ventilation, internal fan |
| Weight | approx. 8–10 kg |
| Dimensions | approx. 320 × 180 × 150 mm (estimated) |
| Protection Class | IP20, for cabinet installation |
| Standards/Approval | CE, UL |
Operating Environment & Compatible Devices
The Yaskawa CACR-SR15BE12F-E Servopack belongs to the proven CACR-BE series and is typically used in CNC machine tools, milling machines, production lines, and handling systems.
- Typical machines: Milling machines, lathes, drilling centers, handling units.
- Compatible controllers: Yaskawa CNC and motion controllers, also in combination with Siemens and Fanuc CNCs (e.g., in Kondia, Mazak, Mori Seiki machines).
- Compatible motors: Yaskawa AC servomotors of the US series and comparable models with 1.5 kW rating.
Functional Description
The Servopack is responsible for the precise control and regulation of AC servomotors.
Key functions:
- Current and torque control: Real-time motor regulation for precise machining.
- Speed and position control: Feedback via encoder signals.
- Protective functions: Overcurrent, overvoltage, undervoltage, overheating, phase failure.
- Communication: Connection to CNC control, processing of command values, and return of feedback signals.
Alarm Messages & Troubleshooting
| Code | Error Description | Cause | Solution |
|---|
| A.10 | Overcurrent/Overheat | Defective transistor module or current circuit | Replace Servopack, check cooling |
| A.20 | Circuit protector tripped | Faulty thyristor, MCCB OFF | Switch on MCCB or replace Servopack |
| A.30 | Regeneration error | Defective transistor or regenerative resistor | Replace Servopack or regenerative resistor |
| A.40 | Overvoltage | Excessive load inertia or defective regenerative circuit | Check machine inertia, replace Servopack |
| A.51 | Overspeed | Encoder or motor connection error | Adjust encoder, check motor wiring |
| A.60 | Undervoltage | Low supply voltage, defective thyristor | Check supply, replace Servopack |
| A.71 | Instantaneous overload | Overload due to excessive torque | Reduce load, adjust system |
| A.72 | Continuous overload | Motor wiring error or defective PWB board | Check wiring, replace Servopack |
| A.b1 | External current limit error | Faulty external current reader | Replace component, reset system |
| A.c1 | Overcurrent at motor start | Motor wiring error, encoder connection issue | Check motor wiring, correct encoder wiring |
Components
| Module | Function |
|---|
| Power board | Switches and regulates motor current via IGBT/transistors |
| Control board (PWB) | Signal processing, protection, interfaces |
| Power supply module | Supplies control and power sections |
| Heat sink & fan | Heat dissipation, overheating protection |
| Regeneration module | Energy feedback to the power grid |
| Connectors & terminals | Connection to motor, encoder, and CNC control |