The Challenge
A customer in the injection moulding and packaging industry sent a Baumüller BM5566 drive to Motion Tronic after reporting that the unit was overheating.
Overheating in an industrial drive can raise concerns about reliability and the risk of unexpected production downtime. However, replacing a drive or internal components without first confirming the cause can result in unnecessary costs.
The Motion Tronic team therefore focused on establishing whether the reported overheating fault could be reproduced under workshop test conditions and whether the drive showed evidence of an internal fault.
Our Diagnostic Approach
The drive was stripped and subjected to a detailed visual inspection before undergoing a series of electrical and functional tests.
Our technicians carried out:
- Visual inspection of the internal drive components.
- Cold testing.
- Firing tests.
- Dyno testing.
- Additional wiring and testing of the dumping function using bulbs.
Throughout the workshop testing process, the customer-reported overheating fault could not be reproduced under workshop test conditions indicating that the fault was rather with the customers water cooling lines.
The drive operated on the dyno without overheating. Testing found no evidence that component replacement or major repair work was required.
This distinction is important: the customer had reported an overheating problem in service, but under Motion Tronic’s workshop test conditions, the drive did not exhibit the same fault.
Testing Before Recommending Replacement
This case highlights an important part of Motion Tronic’s approach to industrial electronic repairs: diagnose first, repair only when necessary.
Rather than automatically replacing components based solely on the reported symptom, our technicians tested the drive to establish its condition under workshop test conditions.
Additional testing of the dumping function was also carried out before the unit was completed and prepared for return.
The results provided no evidence during workshop testing to justify component replacement or a major repair.
The Result
From receipt on 11 August 2026 to completion on 12 August 2026, Motion Tronic completed the inspection and testing within one working day.
Most importantly, the customer received a professionally assessed and tested drive without being advised to undertake component replacement or major repair work that was not supported by the workshop test results.
Although the reported overheating fault could not be reproduced under workshop conditions, the diagnostic process provided valuable information about the drive’s tested operating condition and helped avoid recommending an unnecessary replacement based solely on the reported symptom.
For manufacturers relying on critical motion-control equipment, accurate diagnostics can be just as valuable as the repair itself, helping to reduce unnecessary expenditure while giving maintenance teams better information on which to base their next decision.
The Motion Tronic Difference
When you have the right industrial electronics repair partner, the objective is not simply to replace parts. It is to investigate the reported problem, test the equipment and recommend an appropriate course of action based on the evidence available.
At Motion Tronic, we believe in honest, evidence-based diagnostics. When workshop testing does not identify evidence that component replacement or major repair work is required, we communicate those findings clearly.
This approach helps customers make informed maintenance decisions while avoiding unnecessary expenditure on components or replacement equipment.
Experiencing problems with a servo drive, VSD or other industrial electronic drive? Motion Tronic provides professional fault finding, testing and repair support to help keep critical industrial equipment operating reliably.
