Wake Indramat Repair Services – DKC Drives, DDS Drives, MKD and MSK Motors

Wake Industrial offers expert repair services to restore your equipment to like-new performance. By opting for professional repair, you can save 50–70% of the cost of buying new replacements while maintaining original performance. Wake Industrial offer fast quotes, one-year warranties on reconditioned motors and drives, and expedited shipping to minimize your downtime. Minimize your downtime and get your line back up and ready ASAP by contacting Wake Industrial for a quote via the form on the page or by calling  1-919-443-0207.

Bosch Rexroth Indramat systems are renowned for their reliability and precision in industrial automation. However, even these robust Indramat servo drives and motors can fail after years of service or under harsh conditions. This comprehensive guide focuses on repair and refurbishment solutions for four key Indramat product lines: DKC drives, DDS drives, MKD servo motors, and MSK servo motors. If you’re experiencing faults or downtime with any of these Indramat components, click here to navigate to the easy to read fault chart.

Indramat DKC Servo Drive Repair (EcoDrive Series)

Indramat DKC drives (part of the EcoDrive series) are advanced servo drive controllers used to precisely control servo motors in numerous industries. They come in several series covering a wide power range from 1.5 kW up to 200 kW, making them suitable for everything from small pick-and-place machines to large robotics and machining centers. These drives are valued for their high power density and accuracy in motion control, and have found extensive use in robotics, precision machining, printing, packaging, and general industrial automation.

Despite their quality, DKC servo drives can encounter issues over time. Common causes of DKC drive malfunctions include overloading, environmental factors, and power supply problems. For example, running a motor beyond its rated load can cause thermal stress inside the drive, while excessive dust, humidity, or heat in the cabinet can lead to overheating or component failure. Power fluctuations or surges can likewise damage the drive’s internal circuits if protections are insufficient. Indramat drives are smart enough to alert users to many issues via fault codes. A typical fault on a DKC EcoDrive is “F219 – Motor Overtemperature Shutdown,” which triggers if the attached motor exceeds a safe temperature. When F219 appears, the drive halts motion to prevent damage, usually caused by either an overloaded motor or failed cooling. Another maintenance-related alarm on DKC drives is “F248 – Low Battery Voltage.” The controller’s backup battery has about a 10-year lifespan; once its voltage falls below ~2.8 V, the drive will post an F248 warning.

Indramat DDS Drive Repair (Digital AC Servo Drives)

The Indramat DDS series comprises modular digital AC servo drives widely used in the 1990s and 2000s for multi-axis motion systems. DDS drives are often found in machine tools, printing presses, packaging lines, and other equipment of that era, frequently paired with Indramat servo motors like the MDD or MKD series. These drives are designed to be modular – multiple DDS drive modules can be “stacked” and run off a common DC power supply, which made them very flexible for multi-axis control. Indramat DDS controllers support various interfaces (Analog, SERCOS fiber optic, or different control cards like DLC single-axis cards) for integration into diverse control systems. In terms of capacity, the DDS product line spans 14 different power variants from about 15 A up to 200 A peak current rating, covering a broad range of motor sizes and loads.

Many DDS drives remain in service today, but since they are older, they can be prone to age-related failures or wear-and-tear issues. Capacitors in the power section can degrade over decades, and connector contacts or solder joints may fail due to thermal cycling. Additionally, these drives produce diagnostic fault codes that can be cryptic without the manuals. Some common Indramat DDS faults mirror those of DKC/EcoDrive since the systems share design philosophies – for instance, an F229 “Motor Encoder Quadrant Error” can occur on DDS drives if the feedback from the motor’s encoder is lost or erratic. Other faults like F860 (Overcurrent/Short) or various F2xx and F3xx codes might appear, indicating internal issues or communication problems. Because the DDS drives are part of Indramat’s DIAX drive family, they rely on proper firmware (DDS2.1 uses Diax02 firmware, DDS2.2 uses Diax03) – sometimes firmware corruption or incompatibility can cause fault codes as well.

Indramat MKD Servo Motor Repair and Refurbishment

The Indramat MKD series synchronous servo motors are a family of brushless AC servo motors widely used alongside Indramat drives (like DDS and DKC) in industrial machinery. MKD motors come in various frame sizes and lengths – for example, MKD025, 041, 071, 090, up to the largest MKD112 – to accommodate different power and torque requirements. These rugged motors were engineered for high dynamics and reliability. Thanks to their lifetime-lubricated bearings and brushless design, MKD motors are essentially maintenance-free in normal operation. They sport a fully sealed housing with IP65 protection against dust and coolant ingress, making them suitable for adverse environments. Features like integrated thermal monitoring (KTY temperature sensors) protect the motor from overheating, and many MKD models offer optional holding brakes and high-resolution resolver or encoder feedback for precise motion control. In terms of performance, MKD motors deliver impressive speeds and torque for their size – smaller MKD motors can reach up to 6000–9000 RPM, while larger units produce continuous stall torques on the order of 10–48 Nm or more with peak torques several times higher, often exceeding 100 Nm in short bursts. This combination of high torque-to-inertia ratio and overload capacity gives MKD motors excellent dynamic response for applications like packaging machines, machine tools, printing presses, and robotics.

Even the best-built motors like the MKD series can develop faults over time. After years of heavy use, mechanical wear is a primary concern – the motor’s rotor bearings can wear out or lose lubrication, leading to excess vibration, noise, or rotor misalignment. Worn bearings or mechanical misalignment will not only degrade performance but can also cause the motor to run hot or even trigger drive faults. For instance, a dragging bearing can overheat the motor and lead the drive to throw an F219 Motor Overtemp error to shut it down. Electrical issues can occur as well: insulation breakdown in the windings may cause phase-to-phase shorting, and a demagnetized or weakened magnet can reduce torque output. Another common problem is feedback failure – MKD motors typically use resolver feedback and if the resolver or encoder malfunctions, the drive may register positioning errors or feedback faults. For example, a faulty resolver cable or sensor might result in unstable operation or errors like the aforementioned F229 encoder fault on the drive. Additionally, accidents or mishandling can damage the motor’s internal components.

Indramat MSK Servo Motor Repair (IndraDyn S Series)

The Indramat MSK series (marketed as IndraDyn S by Bosch Rexroth) represents a newer generation of high-performance synchronous servo motors. These motors are known for their high torque density and precision, enabling extremely accurate motion in modern machines. MSK servos are commonly deployed in food processing and packaging equipment, metal forming machines, printing presses, and other applications that demand both power and precision. A hallmark of the MSK design is its advanced feedback technology – MSK motors were among the first industrial servos to incorporate high-resolution optical encoder systems for feedback. This allows them to achieve exceptional positioning accuracy and smooth speed control. The MSK product range covers a wide spectrum of sizes and thus a wide range of performance. In fact, the largest MSK motors can deliver up to ~495 Nm of torque, yet the series can also reach very high speeds up to 9000 RPM in smaller models – an impressive combination made possible by their cutting-edge design. Like the MKDs, MSK motors feature robust IP65 enclosures and offer options like integrated holding brakes and different cooling configurations.

Because MSK motors often serve as critical components in state-of-the-art systems, any downtime or fault can be costly. These motors are complex pieces of technology – they contain not only the electromagnetic core and mechanical components but also onboard memory and electronics One of the most frequent issues encountered with MSK servo motors is related to the encoder/feedback. If an MSK motor’s encoder signal is lost or inconsistent, the drive will typically register an error. For example, F229 “Feedback Quadrature Error” on a Rexroth drive indicates the motor’s encoder feedback is not making sense to the drive. This could result from a damaged encoder cable, loose connector, or a faulty optical encoder in the motor. In practice, simply replacing a worn encoder cable or re-seating the connectors can resolve many F229 errors. In more severe cases, the encoder unit itself might need repair or replacement – something that requires specialized tools and software, since the new encoder must be aligned and its data memory properly initialized.

Why Choose Wake Industrial for Indramat Repairs

Choosing a repair partner for sophisticated industrial hardware isn’t a decision to take lightly. To get in touch with a Wake Industrial representative, contact 1-919-443-0207 or use the quote form embedded on this page to receive a quote within 15 minutes during business hours. Wake Industrial strives to be your go-to source for Indramat/Bosch Rexroth repairs by offering a combination of technical expertise, quality service, and customer support that is second to none. Here are some key reasons clients trust us with their critical automation components:

• Proven Repair Process & Genuine Parts: We follow a systematic repair process for every unit. Only high-quality and genuine components are used to replace faulty parts, ensuring the longevity of the repair.
• Quick Turnaround and Responsive Service: We know downtime is costly. Wake Industrial offers fast turnaround times, including expedited repair services for emergencies at no extra cost. We pride ourselves on a quick response – often within 15 minutes during business hours.
• Global Support & Logistics: No matter where you are, we can serve you. Wake Industrial provides worldwide shipping via FedEx, UPS, and DHL for repaired units, and can handle everything from small electronic modules to large motors (200 lb+ machinery parts) with ease. We make the logistics of sending in your equipment straightforward, and return shipping is fast.
• Quality Assurance & Warranty: We stand behind our work. All Indramat repairs come with a 1-Year Wake Industrial Warranty. This warranty gives you confidence that if an issue related to our repair arises, it will be rectified at no cost.
• Cost Savings and Value: Repairing your Indramat drives and motors is typically far more cost-effective than buying new replacements. On average, professional repair costs 50–70% less than a new unit, yet you still restore your equipment to its original performance. We also help extend the life of older “obsolete” models – avoiding the need for expensive system upgrades. Simply put, Wake Industrial helps you maximize the ROI on your existing industrial assets.

Ready to get your Indramat equipment back to peak condition? Reach out to Wake Industrial today for a consultation or request a fast repair quote. Our knowledgeable team will guide you through the next steps to ship your unit to our facility and will promptly diagnose and fix the problem. With our expertise and dedication on your side, you can quickly overcome drive and motor failures and keep your production lines moving. Don’t let a drive fault or motor issue bring your operations to a standstill – contact Wake Industrial for trusted Indramat repair and refurbishment services and get your automation systems up and running with confidence.

Common Faults, Causes, and Actions