When an imported production machine stops because its servo drive is obsolete, damaged or no longer supported, replacing the device is only the visible part of the job. The real challenge is restoring motion safely: motor compatibility, encoder feedback, braking, electronic gearing, homing, communication and the machine sequence must all work together. Farad Otomasyon provides local servo drive replacement and commissioning support in Turkey for overseas OEMs, factories and system integrators.

Prepared by Farad Technical Team · Last updated: 9 September 2026 · Estimated reading time: 8 minutes

What does a professional servo drive replacement include?

A replacement begins with a compatibility study. Rated torque, peak torque, motor current, encoder type and resolution, holding brake voltage, regenerative energy, mechanical ratio and control mode are documented. The existing PLC commands and fieldbus structure are checked before any parameter is transferred. If the original drive cannot be powered, nameplate data, wiring, machine documentation and the PLC program are used to reconstruct the operating profile.

Farad Otomasyon can support inspection, product sourcing, panel modification, cabling, parameterization, PLC/HMI changes, motion tuning, safety checks and production trials. We do not claim manufacturer-authorized service status unless separately documented; our role is an independent engineering and field-service partner.

Field scenario: the axis runs, but positioning drifts

Consider a packaging line transferred to a factory near Istanbul. A new servo drive is installed after the original unit fails. The axis jogs correctly, yet every production cycle ends a few millimetres away from the target. Repeated tuning does not solve the problem. A structured diagnosis reveals that the electronic gear ratio was copied without accounting for the replacement encoder resolution. After recalculating pulses per revolution, verifying the mechanical reduction and teaching the home offset, positioning becomes repeatable again.

This scenario shows why “the motor turns” is not an acceptance criterion. Repeatability, stop accuracy, torque margin, homing behaviour, alarm recovery and communication loss response must also be tested.

Servo commissioning checklist

1. Record motor and drive nameplate information.
2. Verify supply voltage, grounding, shielding and brake wiring.
3. Confirm encoder type, pinout and feedback direction.
4. Back up the existing PLC, HMI and drive parameters.
5. Check control mode: position, speed or torque.
6. Set current, speed, acceleration and travel limits conservatively.
7. Verify STO and machine safety circuits before motion.
8. Perform low-speed jog tests without production load.
9. Tune the axis while monitoring following error and torque.
10. Test home, limits, emergency stop and power recovery.
11. Run repeated production cycles and document final values.

Common mistakes that cause repeat failures

Blindly copying parameters between different drive generations, mixing encoder cables, ignoring regenerative load, disabling alarms instead of finding their cause and tuning under unsafe mechanical conditions can create new failures. Another frequent mistake is leaving the final parameter set only inside the drive. A dated offline backup and a short commissioning record should be handed over to maintenance.

Servo platforms and technical context

Project-based support may include Siemens, Mitsubishi, Delta, Yaskawa, Panasonic, Schneider Lexium and Omron servo systems. The correct replacement is selected according to motor/encoder compatibility, application dynamics, spare-part availability and the existing PLC network—not simply by matching power ratings.

We serve Istanbul, Tuzla, Orhanlı, Pendik, Çayırova, Gebze, Darıca and Dilovası, including industrial facilities around İstanbul Tuzla OSB, GOSB, GEPOSB, Gebze Güzeller OSB, TOSB and Dilovası OSB. Farad Otomasyon can also work as a local technical subcontractor for overseas OEM teams visiting Turkey.

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Frequently asked questions

Can you replace a discontinued servo drive?

Often yes, after confirming the motor, encoder, brake, communication and motion requirements. Some projects require replacing both motor and drive.

Can you work with an overseas OEM remotely?

Yes. Scope, documentation, remote engineering support and on-site responsibilities can be coordinated before the visit.

Do you provide parameter backups?

We can include final drive parameters and relevant PLC/HMI backups in the agreed project handover.

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Safe maintenance in a hazardous area requires more than checking for an Ex logo. International OEMs, machine builders, integrators and factories working in Turkey must match the complete equipment marking, certificate, manufacturer instructions and site zone classification before any intervention. Farad Otomasyon supports industrial sites in Istanbul, Tuzla, Gebze, Cayirova and Dilovasi as a local field-service and technical coordination partner.

Prepared by the Farad Technical Team · Updated 2 September 2026 · Estimated reading time: 8 minutes

Define the Ex maintenance scope before opening equipment

Create an asset register for motors, enclosures, sensors, cable glands, junction boxes and control panels. Record the hazardous-area zone, gas or dust group, temperature class or maximum surface temperature, EPL/category, permitted ambient range and certificate reference. Directive 2014/34/EU requires clear marking for equipment intended for potentially explosive atmospheres. The IECEx system uses international standards such as the IEC 60079 series and independent conformity assessment. Neither reference makes a device universally suitable: the evaluated configuration must match the real installation.

Inspection frequency should reflect risk, operating hours, contamination, vibration, corrosion and the technical file. A single generic interval for every device is rarely appropriate.

Inspect without compromising the protection concept

Visual inspection

Confirm that markings remain legible. Check housings, specified fasteners, earth connections, stopping plugs, cable glands, seals and signs of overheating. On Ex d enclosures, flamepath surfaces and manufacturer-specified bolts are critical; they must not be painted, ground or replaced with arbitrary hardware.

Detailed inspection

After safe isolation under the plant permit system, inspect terminals, manufacturer-specified torque, protective-conductor continuity, insulation condition and operating temperature. For Ex i intrinsically safe circuits, verify the field device, barrier, cable parameters and segregation as one system. Replacing one component with a similar-looking model can invalidate the entity calculation.

Field scenario: repeated overheating of an Ex motor

Consider a ventilation motor that heats up after several hours while current stays close to the nameplate value. The correct response is not an immediate motor replacement. First compare ambient temperature with the marked Tamb range, clean cooling surfaces without damaging the coating, inspect airflow, mechanical load and alignment, and verify drive parameters. Compare the measured surface temperature with the permitted class and document the result. If the marking, certificate or conditions of use do not match, keep the equipment out of service until an engineering assessment is completed.

Practical Ex maintenance checklist

• Confirm the latest zone classification and hazardous substance.
• Record the complete nameplate and certificate details.
• Match group, temperature class, EPL/category and ambient range.
• Inspect cable glands, stopping plugs, seals and protective earthing.
• Look for corrosion, loosening, vibration, dust and overheating.
• Use only parts permitted by the manufacturer documentation.
• Record defects, measurements, corrective work and the next inspection date.

Common mistakes that create hidden risk

Typical failures include fitting an ordinary cable gland to an Ex enclosure, mixing metric and NPT threads, losing a certified stopping plug, modifying a flamepath, damaging the earth connection and changing a component without checking the certificate. Farad Otomasyon personnel have completed Ex 000 awareness and Ex 004 maintenance training referenced to ATEX 2014/34/EU and 1999/92/EC. This does not represent product certification, notified-body status, Ex 003 installation authority or Ex 005 overhaul authority.

Frequently asked questions

Can Ex equipment be repaired on site?

Only within the permitted scope, competence and documentation. Work that changes the construction or protection concept requires separate assessment and appropriate authority.

Is an Ex logo sufficient?

No. Check the full marking, certificate, special conditions of use and suitability for the classified area.

Does IECEx certification make equipment suitable for every plant?

No. Certification covers an assessed configuration; suitability depends on the actual zone, substance and installation conditions.

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