17.09.2025 by Viktor Siebert
Yaskawa SGDK-3030AEA Servopack + Repair and Analysis of an Overcurrent Fault
Recently, a customer sent us an SGDK-3030AEA Servopack for analysis. The customer had previously submitted motors for repair, and this time the drive unit itself showed an unusual issue: At low feed rates, the machine’s X-axis operated normally. However, when increasing the feed or switching to rapid traverse, scratching noises could be heard, followed by an “Axis not ready” alarm on the CNC screen.
When tested in our in-house CNC test machine, the fault was confirmed. Axis DR5 ran smoothly, but axis DR6 failed above a certain speed threshold. Up to 120 on the speed scale, the axis worked, but at 140 the unit consistently triggered alarm A.10 (Overcurrent).
The investigation began with a visual inspection. Dust and coolant residue were cleaned, and fans and heatsinks were serviced. Further analysis focused on the power stage: testing revealed that one of the IGBT modules was thermally stressed and became unstable under higher loads.
The repair procedure included:
- Replacement of defective IGBTs and gate drivers
- Preventive replacement of electrolytic capacitors and optocouplers
- Thorough cleaning of the boards in an ultrasonic bath
- Rework of solder joints under microscope inspection
- Reparameterization and adjustment of servo data
After the repair, extensive testing followed:
- Long-term load test at 80% nominal current for several hours
- Simulation of fast axis movements under varying load profiles
- Continuous monitoring of temperature, current, and fault logs
The drive passed all test phases without further issues.
For the customer, the benefits were clear: Instead of purchasing an expensive replacement unit, the repaired Servopack was restored to full functionality, minimizing downtime and cost.
Preventive Measures for the Customer
To extend the service life of the Servopack, we recommend:
- Regular cleaning of fans and heatsinks
- Replacement of worn-out fans every 3–5 years
- Insulation checks during machine downtime
- Ensuring sealing against coolant and dust contamination
- Documentation and backup of parameter settings
Conclusion
The Yaskawa SGDK-3030AEA Servopack is a robust and reliable servo amplifier. Typical failures such as overcurrent can be effectively resolved by targeted fault analysis and preventive replacement of critical components. Customers benefit from a sustainable repair approach that reduces costs and maximizes machine availability.
Additional Information: Yaskawa SGDK-3030AEA Servopack
For further details on our Yaskawa repair services, please visit here.
📞 Please feel free to contact us if you have any questions regarding your Yaskawa drive technology. Our experienced team is always available to assist you.
Technical Specifications
| Parameter | Value |
|---|
| Model | SGDK-3030AEA |
| Manufacturer | Yaskawa Electric, Made in Japan |
| DC Input | 270–325 V, 17.3 A |
| AC Output | 0–230 V, 3 Phase |
| Output Current | 24.8 A |
| Output Power | 3.0 kW (4.0 HP) |
| Weight | approx. 12–15 kg (depending on version) |
| Type | Servopack, Digital AC Servo Drive |
Application Environment & Compatible Devices
The SGDK-3030AEA is widely used in CNC machinery, machine tools, and automation systems. It is typically applied in axis drives for X, Y, or Z axes, often in Siemens/Yaskawa joint venture systems.
Compatible motors include Yaskawa SGMGH, SGMGV and similar series.
Functional Description
The Servopack controls servo motors with high precision, ensuring accurate torque and speed regulation. It monitors motor and axis movements while providing built-in protections such as overcurrent, overvoltage, and overheating detection. This guarantees reliability in demanding industrial continuous operation.
Alarm Messages and Troubleshooting
| Alarm Code | Description | Cause | Solution |
|---|
| A.02 (0x02) | EEPROM data error | Memory failure | Reinitialize, replace board if necessary |
| A.03 (0x03) | Main circuit error | Faulty power stage | Inspect/replace power module |
| A.10 (0x10) | Overcurrent | Short circuit, defective IGBTs | Test and replace IGBT modules |
| A.21 (0x21) | Control error | Signal loss | Inspect control board |
| A.32 (0x32) | Regeneration overload | Faulty brake resistor | Inspect/replace resistor |
| A.40 (0x40) | Overvoltage | Power surge | Inspect power supply |
| A.51 (0x51) | Overspeed (motor) | Encoder malfunction | Test/replace encoder |
| A.60 (0x60) | Incomplete tuning | Parameter mismatch | Retune servo system |
| A.71 (0x71) | Overload | Mechanical blockage | Inspect axis mechanics |
| A.79 (0x79) | Motor overheat | Overload, fan failure | Inspect cooling system |
Components
| Type | Board designation | Quantity |
|---|
| Control board | DF0300104-B0 or SGDK-CA01A Rev.B0 | 2 |
| Communication board | DF0300108-A0 or SGDK-IFW01MA Rev.A01 | 1 |
| Power board | BF0200088-A0 or SGDK-CB3030AAA REV-A | 1 |
| Power module | Power module | 1 |