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Servo motor repair · India

Servo motor repair in India, tested under load before return

Star Automations repairs and refurbishes AC servo motors for plants and machine builders across India: Fanuc, Yaskawa, Siemens, Mitsubishi, Allen-Bradley, ABB, B&R and many other industrial makes. Your own motor is inspected, the failed parts are repaired or replaced, the encoder or resolver is tested and aligned, and the motor is run with no load and then under load before it is returned with a printed test report. WhatsApp the nameplate and we confirm repairability before you courier. Repair warranty is 3 months to 1 year, stated on each quotation.

Request a quoteWhatsApp
Servo motor repair in India, tested under load before return
  • 25+years of servo repair, since 2000
  • 3,000+customers across India
  • 100+servo brands covered by our universal servo motor test equipment
  • 5sites: Puducherry, Chennai, Bengaluru, Hyderabad, Delhi
  • Same dayemergency repair option*

*Where the fault and parts allow. Every repaired unit returns with a printed test report.

Repair turnaround you can plan around

Send a photo of the nameplate first. We confirm whether the motor is repairable, and the quote, the same working day.

Emergency: same day

For a line-down motor, where the fault and parts allow. WhatsApp us before you send it so the bench is kept free.

Urgent: 3 working days

Repair, encoder alignment and test, counted from the day the motor reaches the bench and the quote is approved.

Standard: 7 working days

Full repair, encoder alignment, run test under load and a printed test report.

  • Free repairability check from a nameplate photo
  • Printed test report with every motor
  • Written warranty, terms stated on every quotation
  • Pickup can be arranged; parts that must be imported are quoted with their own timeline
WhatsApp the nameplateSend by email

Servo motors, encoders and drives: one repair route

Servo motor repair

Bearings, brakes, windings, encoder alignment, no-load and load run, printed report.

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Servo drive repair

Power stage, feedback and control faults, tested with a motor before dispatch.

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Servo testing

Send a motor for a test and report only, before you decide to repair or replace.

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By brand

Fanuc, Yaskawa, Mitsubishi, Siemens, Allen-Bradley, Panasonic, Delta: 100+ brands on our universal servo motor test equipment.

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By city

How to send a motor from 25 cities to our repair benches.

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By industry

Injection moulding, CNC, textile, packaging and wind pitch systems.

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00For your plant

What a tested repair gives your plant

Your own motor back

The same motor, serial and part number go back on the machine, so wiring, parameters and spares stay as they are.

No wait for a new unit

When the OEM quotes a long lead time or the motor is no longer made, a repair puts the axis back in service.

Proof before it ships

The motor is run and load-tested before dispatch, so your line is not where it gets tried out.

The cause, in writing

The test report records what failed and why, so your team can stop the same fault coming back.

Servo motor repair turnaround: same day, 3 days or 7 days

Emergency: same day

For a stopped line. Send the nameplate and alarm code on WhatsApp first so we can plan the bench.

Urgent: 3 days

For a motor you need back this week, once the fault is confirmed on inspection.

Standard: 7 days

The normal route for planned repairs, with the full test and a printed report.

Time depends on the fault and on parts. We are an independent multi-brand repair company, not an OEM service centre. See what affects repair cost.

Servo motor repair near you: Chennai, Puducherry and Bengaluru

Servo motor inspection, repair, encoder alignment and dispatch take place at all three of our facilities. Pick the closest one, or courier the motor from any city in India.

Servo motor fault and alarm guides

01What is included

What a servo motor repair covers

The scope depends on what we find at inspection. You see the findings and the quote before work starts, so nothing is replaced without a reason.

  • Inward inspection with photos and the serial number logged
  • Bearings and oil seals replaced, shaft and keyway checked
  • Brake checked for release voltage and holding; brake parts serviced
  • Encoder or resolver repaired or replaced, then aligned to the rotor
  • Winding insulation, hipot, resistance and balance tested; winding faults repaired
  • Connectors and feedback cables cleaned, repaired or replaced
02Test platform

The servo test and alignment platform behind every repair

A permanent-magnet brushless servo motor depends on its feedback device — a resolver, an incremental encoder or a serial encoder — to tell the drive where the rotor is. A motor can pass a basic electrical check and still fail on the machine because the feedback is faulty, mis-aligned or unprogrammed. That is the part a winding-only repair does not check.

Star Automations runs a complete universal multi-brand servo test platform for exactly this work:

Feedback test and alignment station

We diagnose the feedback device, verify incremental phase and commutation tracks, check the count against the Z pulse or absolute position, and read and program encoder memory on supported serial encoders.

Run test system

We power and run the repaired motor across a wide range of feedback types without needing that motor maker’s own servo drive, then load-test it on our own rig.

  • Feedback aligned and proven the way the OEM would, so the axis holds position when the motor goes back on the machine
  • Obsolete motors, and makes an OEM-tied service often turns away, can usually be tested and returned to service
Test software reading an Allen-Bradley encoder memory report on our universal servo test platform
Reading and programming encoder memory on the feedback test station software.
Feedback test and commutation alignment of a servo motor with our universal servo test platform
Feedback test and commutation alignment of a repaired servo motor.
03Feedback

Feedback devices we test, align and program

Many servo motors that reach us have a feedback fault, not a winding fault. We test the feedback device on the universal feedback test and alignment platform, repair or replace it, align it to the rotor, and on supported serial encoders read and program the encoder memory.

How it works: encoder alignment and programming.

  • Incremental encoders with UVW or Hall commutation tracks
  • Sin/cos encoders (1 Vpp)
  • Resolvers
  • Absolute encoders: EnDat, BiSS and BiSS-C, SSI, parallel absolute
  • SICK Hiperface and Hiperface DSL
  • Serial encoders: Fanuc, Mitsubishi, Yaskawa, Tamagawa and MFE types
  • Hall effect sensors and tachogenerators
04Failure modes

How servo motors fail

Encoder faults

Serial communication errors, position loss and alarms at power-up. Often caused by coolant or oil reaching the encoder through a worn seal.

Bearing wear

Noise, vibration and heat at the drive end. Left too long, a bearing failure can damage the encoder and the shaft.

Brake problems

A brake that does not release overheats the motor; one that does not hold lets a vertical axis drop.

Winding and insulation

Overcurrent or ground-fault trips. Insulation tests show whether the winding can be saved.

05Verification

How the repair is proved

Every repaired motor goes through the same test sequence on our servo motor test system: electrical checks, feedback and commutation, brake, a no-load run on the universal run test system, and then a load run on a custom-built load rig. Measured speed and current are compared with the nameplate, and vibration and noise are checked at rated speed.

The results go on a printed test report that travels with the motor. See the real tester screens and run test and a sample test report.

Repair is not always the right answer. If the frame is damaged, the magnets are weak or the encoder cannot be sourced, we tell you and suggest a stock motor or an upgrade instead.

Rotor and impeller balancing test with a tachometer at the Star Automations bench
Rotor balancing during a servo motor repair, before the motor is reassembled and run. Rotor and impeller balancing is also offered as a separate job.
06Where

Where each step takes place

Each motor follows the same route, at whichever of our three sites receives it.

StepWhere it happens
Nameplate review and repairability checkWhatsApp or email, before anything is shipped
Receiving the motorChennai (Poonamallee), Puducherry (Thattanchavady) and Bengaluru (Mahadevapura), by hand-in, courier or pickup
Inspection, photos and quoteChennai, Puducherry and Bengaluru
Repair: bearings, seals, brake, winding, connectorsChennai, Puducherry and Bengaluru
Encoder or resolver test, alignment and programmingChennai, Puducherry and Bengaluru
Final run test and load testOn the universal servo motor test system before dispatch
Printed test report and dispatchFrom the site that repaired the motor
07Brands

Repair by brand

We also repair Panasonic, Delta, Omron, Bosch Rexroth (Indramat), Kollmorgen, Parker, Schneider Electric (including Elau and Berger Lahr), SEW-Eurodrive, Sanyo Denki, Fagor, Kawasaki, Baumüller, Stöber and Moog servo motors. Send the nameplate to confirm a specific model.

08How to send

How to send the motor

You can send a servo motor from anywhere in India. Talk to us before you courier, so the unit is expected and logged on arrival.

  1. Send the nameplate

    WhatsApp a clear photo of the nameplate, the alarm code and what the machine was doing when it failed.

  2. We confirm repairability

    We tell you whether we can test and repair that model before anything is shipped.

  3. Courier or pickup

    Courier the motor to our Chennai, Puducherry or Bengaluru site, or ask us to arrange pickup where needed.

  4. Inspection and quote

    The motor is opened, inspected and photographed. You get the findings and a quote before work starts.

  5. Repair, test, dispatch

    Repaired, run-tested and load-tested, then dispatched with a printed test report.

09For repair shops

For other repair shops and service providers

Many regional repair shops and automation service companies can handle windings, bearings and brakes but cannot test or align modern feedback, program encoder memory, or run-test a motor without the OEM’s drive. We run that stage for you.

You keep your customer. We receive the motor under your job, test and align the feedback on the feedback test station, program the encoder where supported, run-test it on the run test system, and return it with a report for you to hand over. It keeps motors in service instead of being scrapped for want of a feedback test.

Talk to us about a service-provider arrangement, or WhatsApp a nameplate to +91 97866 22233.

  • Feedback test, alignment and commutation setting
  • Encoder memory read and programming on supported serial encoders
  • No-load and load run test with a printed report
  • Your customer relationship stays yours
  • Written, transparent terms for every job

Free downloads for your maintenance file

Printable one-page sheets from our bench. More on the resources page.

Servo repair send-in form

Fill in and pack with the motor: nameplate details, fault seen, alarm code, drive model and the turnaround you need. Speeds up the quote and the repair.

PDF · 1 page · 4 KB · free, no sign-up

Download PDF

Servo encoder alarm quick sheet

Common encoder and feedback alarms on Fanuc, Yaskawa, Mitsubishi and Siemens drives, what each usually points to, and what to check on the cable and connector first.

PDF · 1 page · 4 KB · free, no sign-up

Download PDF

Servo motor encoder quick reference

Encoder families, interfaces, counts per revolution and the motors they sit on: Fanuc pulsecoders (alpha A64, A1000), Mitsubishi OBA/OSA, Yaskawa UTOPH, Tamagawa, Heidenhain ECN/EQN/ERN and SICK SKS/SRS/SRM.

PDF · 2 pages · 8 KB · free, no sign-up

Download PDF
→How it works

From nameplate photo to a tested motor in 7 steps

One route for servo motors, encoders and drives. You see the price before any work starts, and the report before the unit leaves our bench.

  1. 1 · Nameplate photoSend it on WhatsApp or the form
  2. 2 · Repairable? QuoteUsually the same working day
  3. 3 · Courier or pickupThe unit reaches our bench
  4. 4 · Bench diagnosisInsulation, windings, brake, encoder
  5. 5 · RepairFailed parts, bearings, seals, brake
  6. 6 · Align and run-testEncoder aligned; no-load and load run
  7. 7 · Report and dispatchPrinted test report with the unit
  8. Line down?Servo Swap ships a tested unit first. How Servo Swap works

EmergencySame day*

Urgent3 working days

Standard7 working days

*Where the fault and parts allow. Turnaround counts from when the unit reaches our bench and the quote is approved.

Start with step 1WhatsApp the nameplate
11Questions

Repair questions

More on the FAQ page.

Which servo motor brands do you repair?

Fanuc, Yaskawa, Siemens, Mitsubishi, Allen-Bradley, ABB, B&R, Panasonic, Delta, Omron, Bosch Rexroth, Kollmorgen, Parker, Schneider Electric, SEW-Eurodrive, Sanyo Denki and other industrial makes. Your own motor is repaired and returned, with its serial number traced from inward to dispatch.

Can you repair a motor that loses position after winding or encoder work elsewhere?

Usually, yes. Position loss after winding or encoder work is often a commutation offset problem. We realign the encoder or resolver and prove it on the test system.

What decides repair or replace?

Frame and shaft condition, magnet strength, whether the encoder can be sourced, and how the repair cost compares with a new or stock motor and its lead time.

Is there a warranty?

A written warranty is given after a successful repair. Warranty terms are stated on each quotation.

What do I need to send for a quote?

A photo of the nameplate, the alarm code, and a short note on the symptom: noise, heat, position loss or brake trouble.

Can you test and align a servo encoder without the original drive or OEM software?

Yes. On our universal feedback test platform we test and align the feedback device directly, and on the run test system we run-test the motor without that maker’s servo drive. This covers incremental and sin/cos encoders, resolvers, EnDat, BiSS, SSI, SICK Hiperface and Hiperface DSL, and serial encoders from Fanuc, Mitsubishi, Yaskawa and Tamagawa.

Do you read and program encoder memory?

On supported serial and absolute encoders, yes. We read the encoder memory, align the feedback, and program the memory so the motor keeps its correct position reference after repair.

Do you test the motor under load before it is returned?

Yes. After a no-load run on the run test system we load-test on our own rig and compare measured speed and current against the nameplate. The results travel with the motor on a printed test report.

Can you help a repair shop that does not have this equipment?

Yes. We run feedback testing, alignment, encoder memory programming and run-testing as a back-end service for other repair shops and service providers. You keep your own customer, and the motor returns with a report.

Do you ship across India?

Yes. We take motors from anywhere in India by courier or pickup, through our Chennai, Puducherry and Bengaluru facilities. Send the nameplate on WhatsApp first so we can confirm repairability before you courier.

How much does servo motor repair cost?

The cost depends on the motor, the fault and the parts needed. We inspect the motor first and then send a quote, so you decide before any repair work starts. The page on repair cost factors explains what changes the price.

How fast can a servo motor be repaired?

Emergency repairs can be done the same day, urgent repairs in 3 days and standard repairs in 7 days, depending on the fault and parts. Send the nameplate and alarm code on WhatsApp so we can plan the bench.

Also repaired at Star Automations: power electronics, e-mobility and solar

Permanent-magnet servo and BLDC motors are also used in EV traction and e-mobility. We repair PMSM and BLDC traction motors with resolver and encoder faults, alongside the servo motors above. Send the model and fault and we confirm repairability before you ship.

UPS repair

Online, line-interactive and industrial UPS boards.

Pickup from all cities and Servo Swap exchange apply to injection moulding servo motors too.

Common worries, answered in plain language

Send the nameplate. We confirm repairability before you courier.

WhatsApp a nameplate photo and the alarm code to +91 97866 22233, or email info@starautomations.com.

Send the nameplateWhatsApp

More servo repair

Motor checker on our bench

Motor checker EMC-30 for testing motor windings and insulation

Before and after repair, we check every motor on our bench with a motor checker, alongside our universal servo motor test system, so winding and insulation faults are found before the motor goes back to your machine.

Need a tested spare while yours is repaired?

Ready stock of servo motors and drives is listed in our shop, with condition and price on each listing.

See also: Industrial robot repair: servo motors, drives, encoders and teach pendants.

See also: AC servo motor repair and DC servo motor repair.