HESSLER Repair Services India
Hessler is a specialist German manufacturer of industrial drives, motor control systems, and automation components for demanding manufacturing environments. Known for robust servo drives and frequency converters, Hessler equipment is widely deployed across Indian textile mills, paper plants, steel foundries, and chemical processing facilities. Their products are engineered for high reliability in harsh industrial conditions with minimal downtime.
Hessler is a specialist German manufacturer of industrial drives, motor control systems, and automation components for demanding manufacturing environments. Known for robust servo drives and frequency converters, Hessler equipment is widely deployed across Indian textile mills, paper plants, steel foundries, and chemical processing facilities. Their products are engineered for high reliability in harsh industrial conditions with minimal downtime.
Synchronics has deep expertise repairing Hessler servo drives, frequency inverters, and control modules used across Indian manufacturing. Our 180+ engineers have extensive experience diagnosing Hessler drive faults, capacitor bank failures, and firmware issues. We maintain calibrated test benches for Hessler servo systems and stock genuine replacement components, ensuring rapid turnaround for critical production equipment.
Hessler servo drive and frequency converter specialists across India.
HESSLER Product Lines We Repair
Our engineers are trained on the full HESSLER product range. Below are the major product families we service.
Hessler Servo Drives
High-performance brushless servo drives for precision motion control in textile machinery, packaging lines, and machine tool spindles. Common issues include encoder feedback faults, thermal shutdown during sustained high-torque operation, and phase loss detection failures.
Hessler Frequency Converters
Variable frequency drives for AC motor speed control in pumps, fans, and compressors. Repair involves DC bus faults, IGBT module failures, and brake resistor burnout common in dynamic braking applications.
Hessler Control Modules
Standalone and modular logic controllers for mill drives and process automation. Prone to relay chatter, analogue input card degradation, and firmware corruption under voltage spikes.
Hessler Brake Control Units
Electromagnetic brake and holding system controllers for vertical lift machines and heavy-load handling. Common faults include solenoid coil open circuits, spring wear, and capacitor bank leakage in humid mill environments.
Hessler Power Supply Modules
Regulated DC power units for servo and control electronics in industrial automation systems. Failures often stem from bulk capacitor aging, transformer winding faults, and rectifier bridge degradation.
Why Choose Synchronics for HESSLER Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on HESSLER equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common HESSLER Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in HESSLER equipment arriving at our workshop.
- ✓Encoder feedback loss on Hessler servo drives — Cable shielding degradation or connector corrosion in high-vibration textile loom and paper mill environments. Intermittent breaks cause the drive to fault with E-01 or E-02 error codes and loss of commutation lock.
- ✓DC bus overvoltage shutdown in frequency converters — Regenerative braking energy during rapid deceleration overwhelms the brake resistor, causing bus voltage spikes above 800V threshold. Common in conveyor and hoist applications where load inertia is high.
- ✓Thermal shutdown and restart cycling in Hessler drives — Heatsink fin clogging by mill dust and cotton fibres restricts airflow. Drive temperature sensors trigger shutdown at 80°C before stable load current is reached, causing erratic cycling.
- ✓IGBT module gate drive failure in power stages — Voltage spikes from motor cables and switching transients damage gate driver ICs (often HIP4081 or IR2104 chipsets). Manifests as phase loss, cross-conduction current, and catastrophic module failure.
- ✓Analogue input signal noise and scaling errors — Inadequate shielding on 4-20mA sensor lines in steel foundries and chemical plants introduces 50Hz mains coupling noise. Control module misinterprets signal causing incorrect ramp rates or setpoint errors.
- ✓Capacitor bank leakage and ESR degradation — Bulk electrolytic capacitors (often 4700µF, 450V units) deteriorate in high-temperature foundry and furnace control environments. Increasing ESR causes voltage ripple and eventual capacitor rupture with explosive venting.
How We Repair Your HESSLER Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using HESSLER Equipment
We serve plant maintenance teams across all major industries where HESSLER automation is deployed.
Frequently Asked Questions — HESSLER Repairs
Do you repair Hessler equipment anywhere in India?+
Yes. Synchronics repairs the full Hessler product range — servo drives, frequency converters, control modules, brake units, and power supplies. We offer PAN India door pickup from Mumbai, Delhi, Pune, Chennai, Hyderabad, Ahmedabad, Nagpur, Surat, Jaipur, and all other major cities. Repairs are completed at our fully equipped facility in Vadodara, Gujarat, with 24-48 hour turnaround for most faults.
What is the typical repair cost for a Hessler HSV servo drive?+
Repair cost depends on fault type and component replacement requirements. Encoder or cable repairs typically cost INR 8,000-15,000. IGBT module or gate driver replacement averages INR 18,000-28,000. Full recalibration and firmware reload add INR 5,000. We provide free initial diagnostics and a fixed quotation before proceeding. Genuine Hessler spare parts are stocked in-house to avoid extended lead times.
How long does Hessler drive repair typically take at Synchronics?+
Standard servo drive and frequency converter repairs take 24-48 hours from receipt. Complex multi-fault repairs or firmware issues may require 3-5 days. We offer rush service (same-day diagnostics) for critical production equipment. All repairs include full functional testing on our calibrated load banks and burn-in cycles to ensure reliability before shipment.
Do you repair Hessler drives that have been damaged by power surges or lightning?+
Yes. Synchronics specializes in surge damage repair for Hessler servo and frequency converter modules. We replace blown IGBT power stages, gate driver ICs, and input protection circuits. We also retrofit surge suppression (varistors, transient suppressors, and LC filters) to prevent future damage. Many textile mills and steel plants in India rely on our surge recovery service to avoid equipment replacement costs.
Can Synchronics recalibrate Hessler control modules after component replacement?+
Yes. Our engineers have full expertise in Hessler control module firmware and parameter configuration. After component replacement, we perform sensor calibration (encoder offset, current feedback zero-point), motor characterization (back-EMF, pole detection), and acceleration/deceleration ramp tuning. All calibration is documented and returned with your repaired module, ensuring seamless restart in production.
How do I send my HESSLER unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a HESSLER drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on HESSLER repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your HESSLER unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
HESSLER Repair Catalog
No products found for HESSLER
Don't See Your HESSLER Model Listed?
We repair the full range of HESSLER industrial electronics — even if the specific model is not yet in our catalog. Send us the unit details and we'll confirm repairability within 24 hours.
Free evaluation • 6-month warranty • PAN India pickup
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Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service