Our service specializes in professional diagnostics and comprehensive repair of high-speed gates.
One of the services we offer is the repair of high-speed gate drives.

We perform repairs for service companies, gate manufacturers’ service departments, and maintenance departments of various end customers such as industrial companies and discount store chains.

Every maintenance manager of an industrial plant who has dealt with a high-speed gate drive failure knows that replacing the drive can cost between approximately 1/3 to 1/2 the value of a new gate.

To meet the needs of our customers, we have developed a drive regeneration department in our service, significantly reducing the cost of one of the most expensive repairs.

Learn more about us on our dedicated websites:

Hundreds of companies worldwide utilize our services. The map above (as of December 2023) displays only the locations of cooperating service firms.

REFERENCES

[ click on the company logo to read the references ]

What devices do we repair?

We repair drives from all gate manufacturers.

We have extensive experience with drives for gates manufactured by:

Examples of drives used by manufacturers of high-speed gates

We also repair other types of equipment not listed above*. We have experience servicing both new and very old devices.

*We do not perform diagnostics or repairs of devices for individual customers.

What types of faults do we identify?

We categorize faults into three groups:

I. Group – Damage caused by using a controller without a frequency converter. Controllers lacking soft start and stop functions can damage motor gearbox mechanisms due to harsh starting and stopping of the drive. Example of such a controller: TST WU.

II. Group – Damage caused by very high gate usage frequency or heavy load on the drive due to large gate size and heavy curtain weight.

III. Group – Damage caused by challenging environmental conditions such as high humidity, salinity, and low operating temperatures.

Lack of maintenance of high-speed gates leading to increased forces required to drive the shaft -> also accelerates drive wear and shortens its lifespan.

FAQ – Frequently Asked Questions:

1) What does the repair process involve?

• First, we verify the condition of the drive upon its arrival to us.
• We perform photographic documentation of any mechanical damages.

• We check the functionality of the encoder, electromagnetic brake of the motor, and the brake rectifier.
• We perform impedance measurements of windings and verify if there are any leakage paths from windings to ground.
• Using a crank handle, we check if the drive moves freely or if it locks at any point.
• We disassemble the motor and check if gearbox oil has entered the rotor chamber.
• We remove one of the seals and inspect the oil condition – verifying the presence and extent of metal shavings from worn bearings and gears.

• We dismantle the drive into its components and clean all mechanical parts thoroughly.

• We inspect the condition of all safety-related components of the drive to decide if regeneration is feasible and if we can restore the device to full operational capability.
• We verify and eliminate any sealing grooves.
• If necessary, we repair or manufacture components using CNC technology.
• With all components ready for reassembly, using high-quality new bearings (preferably SNR, NTN, and FAG) and new seals, we assemble the drive and fill it with appropriately selected gearbox oil.

• The final stage involves cyclic tests post-repair using a suitable frequency converter controller to ensure smooth operation of the drive.

2) Is the drive tested in any way after repair?

YES – each drive undergoes cyclic tests using the appropriate, parameterized frequency converter controller designed for it. We have also built a special test bench where we simulate a load similar to the actual load on the device. During testing, the drive performs from several hundred up to even 2,000 cycles. Providing a warranty on our services requires us to ensure with 100% certainty that repaired devices are fully functional.

3) Can you predict a breakdown before the gate completely stops?

YES – but regular maintenance (e.g., once a year) is necessary, during which your service provider will notice symptoms of damage.

What to look out for? -> Strange metallic noises, “grinding” in the gearbox, and gearbox oil leaks.

From our experience in regenerating hundreds of controllers and drives, we estimate that drives operating without a counterbalance system typically begin to fail after exceeding 400,000 cycles. Our service strongly recommends refurbishing high-speed gate drives within the range of 400,000 to 500,000 cycles.

For very large gates or those operating in harsh environmental conditions, the lifespan of such drives will be shorter. However, gates equipped with a counterbalance system can often achieve up to 1.5 million cycles and remain in good condition. It’s important to note that these values should not be taken as absolute certainty, as several factors can affect statistical reliability. These factors include:

• improper installation of the drive,
• incorrect parameterization,
• non-compliance with manufacturer’s recommendations for the drive,
• or improperly conducted or lacking gate maintenance.

4) Can drive failures be prevented?

It depends on which group the damage belongs to and how advanced it is.

I group
(damage caused by using a controller without a frequency converter)

• There is always the option to replace the controller with a more advanced one that includes a soft start function (with a frequency converter).
• We offer refurbished, fully functional controllers with a one-year warranty and free support for startup and fault diagnostics during operation.

The gallery below shows examples of damage to drive components that operated with relay controllers using a start <-> stop mode (without soft start/frequency converter).

II group
(damage caused by very high gate usage frequency or heavy load on the drive)

• It is necessary to dismantle the gate drive and send it to us for comprehensive refurbishment.
• Most often, we perform such refurbishments during scheduled production downtime at the plant, as the repair process itself takes several days.

III group
(damage caused by challenging environmental conditions)

• The effects of the environment in which the gate operates can often be remedied on-site, preparing the drive to operate for another year. We recommend that such maintenance tasks be performed during the annual gate servicing.

Regardless of the type of failure your high-speed gate drive experiences, remember that if your facility has several similar high-speed gates with the same type of drive, we can offer refurbished drive units for sale. By having one spare unit on hand, you can swap out a drive from one gate and send the removed unit to us for refurbishment. This allows you to initiate a smooth process of regular device renewal. If you have any technical doubts, please contact us for professional assistance.

5) What are the symptoms of drive issues?

Issues that we can observe include:

• The gate decelerates intermittently during opening; for instance, it smoothly opens 100cm, slows down over a 20cm stretch, and then resumes its previous speed.
• The drive has oil leaks.

Issues that we can hear include:

• irregular metallic sound (sometimes squealing) coming from the drive during the gate’s operation cycles
• loud clunk during the gate’s opening start, please do not confuse this with the sound of the electromagnetic brake of the drive, which also makes a noise when the drive starts

Issues that we can feel include:

• excessive engine temperature
• Around 80 degrees Celsius is already concerning (we recommend measuring with a thermal imaging camera).

Advanced issues include:

• The gate stops at unspecified moments, and on controllers like:
• Hörmann BK 150 FU E H / Efaflex EFACON / TST FUS / TST FUE / TST FUE2 / FUE3, and similar ones, error messages appear:
  F030 – drawing error
  F410, F440, F510 – Motor overload,
  F519 – Startup issues, motor overload,
• Powering on the controller triggers the circuit breaker in the electrical panel (you are dealing with a drive damage issue that subsequently damaged the controller; in this case, send the drive with the controller to us).

6) How long does the drive repair take?

The repair of most drives takes about five working days. Depending on the type and extent of the damage, this time frame can vary, either shortening or extending accordingly.

7) Is the repair worth it?

YES – otherwise, this subpage wouldn’t be on our website.
The cost of refurbishment is typically 2-3 times lower than the cost of a new drive. We provide a quotation via email upon receiving an inquiry.

8) Can all failures be rectified?

• NO – if despite clear signs of malfunction, the drive has been in use for many months, it may be beyond repair. In such cases, we do not charge for workshop diagnostics.

• We do not perform repairs that could in any way compromise safety. You can be assured that the drive refurbished by us is fully functional and can operate without issues for years to come.

9) Do you repair only high-speed gate drives?

95% of the drives we repair are devices that have operated in high-speed gates with soft start controllers (frequency converters / inverters).

If you have a faulty drive from a large industrial roller gate or an integrated drive with a sectional door controller like the Hörmann WA400FU, we can also comprehensively assist in repairing these devices.

Due to the significant amount of labor involved in these repairs, we do not offer refurbishment services for simple, inexpensive gate devices that operated on relay controllers (start <-> stop).

10) How can I be sure that the drive won’t malfunction again after refurbishment?

We provide a warranty on our services. If during the repairs our technicians observe that the longevity of the drive, despite refurbishment, may not compare to a new drive, we consult on whether to proceed with the refurbishment. Our goal is to restore the drive to a technical condition comparable to factory-new standards.

11) Error F519 appeared on the controller, what does it mean?

This message indicates that the drive is demanding significantly more current from the controller than usual (working hard). It’s possible that the controller is damaged. In such cases, we recommend sending both the controller and the drive for diagnostics and functional testing after the drive repair.

12) If you are interested in repair and want to know its cost, what should you do??

Please send an email to our team at: support@bramy-serwis.pl

The minimal information we need for a quote includes: photos of the nameplates on the drive and gate, a description of the issue (a video recording is also acceptable). Later on, after cost approval, we may also require photos of the entire gate.

You can also give us a call at:

13) Once you have accepted the repair cost, what happens next?

Pack the drive securely, preferably on a pallet. Ensure it is well protected to prevent mechanical damage during shipping by the courier company. Include the quote you received from us (printed out) along with the repair order form containing your contact details (name, surname, email address, and phone number).

Please send the package to the following address:

BRAMY – SERWIS
Popowo 57
64-510 Wronki
Poland

As soon as we receive the drive, you will be notified. We will keep you updated on the progress of diagnostics/repair through our proprietary service system.

14) How long does the repair take? When can I expect to receive the drive back?

The estimated repair time, from the receipt of the package to the issuance of the repair invoice, is several business days. After receiving confirmation of payment, we arrange for a courier to collect the repaired drive.

If after reading the above FAQ you have any additional questions, please feel free to contact us.