Yaskawa SGDH‑04AE‑OY Ver.55942 Sigma II 200V 400W Servo Driver

The Yaskawa SGDH‑04AE‑OY Ver.55942 is a high‑performance AC servo amplifier from the Sigma II series, rated for 400 W (0.4 kW) continuous output at 200 V AC input. This driver is engineered to control Yaskawa’s Sigma II series servomotors (such as SGMAH, SGMGH, or SGMPS) with exceptional precision in position, speed, and torque. The firmware version 55942 represents a mature revision that includes enhanced auto‑tuning algorithms, improved vibration suppression, and expanded communication options. This unit is widely deployed in industrial automation for applications requiring reliable, maintenance‑free motion control.

Electrical Ratings and Power Section

The SGDH‑04AE‑OY accepts either single‑phase or three‑phase 200‑230 V AC ±10% at 50/60 Hz. In single‑phase operation, the rated input current is 2.6 A; in three‑phase, it is 1.8 A. The amplifier delivers a continuous output current of 2.0 A RMS and a maximum peak current of 8.8 A for up to 3 seconds, enabling high torque bursts. The PWM switching frequency is factory set to 12 kHz, striking a balance between low audible noise and power efficiency. A built‑in regenerative circuit handles deceleration energy; for most applications with inertia ratios up to 10 times the motor inertia, no external regenerative resistor is required. The main circuit uses IGBTs (insulated gate bipolar transistors) with built‑in overcurrent protection. The control power is derived from the main input, simplifying installation.

Control Modes and Performance

The driver supports three primary operating modes: position control (pulse‑train input), speed control (analog voltage), and torque control (analog voltage). In position mode, it accepts line driver differential signals up to 500 kpps or open‑collector signals up to 200 kpps. Electronic gearing allows arbitrary numerator/denominator ratios (1/10 to 10 times). The speed control range is 1:5000 with a stability of ±0.01% of rated speed under constant load. Torque control accuracy is ±2% of rated torque. The velocity frequency response is 400 Hz, which permits high loop gains and stiff mechanical behavior. The driver also offers a “gain switching” function, allowing different PID gains during acceleration, constant speed, and settling phases to optimise settling time and minimise overshoot.

Auto‑Tuning and Vibration Suppression

One of the standout features of the SGDH‑04AE‑OY Ver.55942 is its real‑time auto‑tuning. Upon initial setup, the driver performs a test motion to measure the load inertia ratio (up to 30 times the motor rotor inertia). It then automatically calculates position loop gain (Kp), speed loop gain (Kv), and speed loop integral time constant (Ti). During normal operation, adaptive tuning continuously adjusts these parameters as the load changes. The driver includes four notch filters (adjustable from 50 Hz to 2 kHz) to suppress mechanical resonance, and a vibration suppression filter that reduces settling vibration at the end of positioning moves. A friction compensation function further improves low‑speed following accuracy.

I/O and Communication Interfaces

The SGDH‑04AE‑OY provides a comprehensive set of control signals. Digital inputs (6 points, 24 V DC, sinking/sourcing selectable) include: servo ON, alarm reset, gain select, forward run inhibit, reverse run inhibit, and pulse input enable. Digital outputs (4 points, open collector) include: servo ready, alarm, positioning completion (speed coincidence), and torque limit detection. Analog inputs: two ±10 V channels (one for speed/torque reference, one for torque limit). Analog outputs: two channels (0‑10 V) for monitoring motor speed, torque, or current. Communication is via RS‑232C or RS‑422 (dedicated to the host controller) using Yaskawa’s protocol. An optional fieldbus module (MECHATROLINK, DeviceNet, Profibus, or EtherCAT) can be installed in the CN6 expansion slot. The driver also includes a pulse output (encoder follower) that mirrors the motor encoder signals for external counting.

Encoder Interface and Feedback

The driver is compatible with Yaskawa’s 13‑bit incremental encoder (2048 P/R, quadruple) and 16‑bit absolute encoder (optional). The encoder signals are received via a dedicated 10‑pin connector with differential line receivers for noise immunity over cable lengths up to 20 metres. The driver supplies 5 V DC power to the encoder (300 mA max). It also supports serial communication with the encoder for reading alarm history and motor temperature. For absolute encoder versions, the driver maintains multi‑turn position data via a battery backup (CR2032 lithium cell) mounted on the driver’s front panel.

Protection, Diagnostics, and Environmental Specifications

The SGDH‑04AE‑OY includes extensive protective functions: overcurrent, overvoltage, undervoltage, overload (electronic thermal), regenerative overload, encoder error, overspeed, overtravel (forward/reverse limit), and CPU error. A built‑in dynamic brake engages automatically when the servo is turned off or an alarm occurs. The front panel features a 5‑digit seven‑segment LED display that shows status, alarm codes (e.g., A.02 for overcurrent), and parameter setting mode. Diagnostic information can also be read via SigmaWin+ software on a PC connected through the RS‑232 port. Operating ambient temperature: 0 to 55 °C (derate above 45 °C). Storage: -20 to 85 °C. Humidity: 90% max non‑condensing. Vibration resistance: 5 G (10‑500 Hz). The enclosure is rated IP20 (finger‑safe) and is designed for mounting inside a control cabinet. Dimensions (W×H×D): 68 mm × 130 mm × 150 mm; weight approximately 1.2 kg.

Application Examples

The SGDH‑04AE‑OY is ideal for small to medium‑duty automation tasks such as: pick‑and‑place robots (400 W is sufficient for light grippers), conveyor indexing drives, automatic tool changers on CNC routers, medical infusion pump mechanisms, and laboratory liquid handling systems. Its 200 V AC input makes it suitable for regions with standard industrial voltage, and the availability of multiple control modes allows it to replace both stepper drives (in position mode) and simple variable frequency drives (in speed mode). When paired with a compatible Yaskawa servomotor, the system achieves an overall positioning accuracy of ±0.02° for rotary axes or ±0.01 mm for linear positioning (with a 5 mm pitch ballscrew). The Ver.55942 firmware also improves the driver’s response to pulse train input jitter, making it more robust in noisy industrial environments.

Installation and Wiring Notes

The driver is designed for DIN rail (35 mm) or panel mounting. Adequate cooling clearance: 40 mm above and below. Power terminals (L1, L2, L3 for mains, U, V, W for motor) accept wire sizes up to 1.5 mm² (AWG 16). Control I/O uses spring‑clamp or screw terminals (depending on revision). It is recommended to use shielded cable for encoder and analog signals, with the shield connected to the driver’s ground terminal. The driver complies with UL 508C, CSA C22.2 No. 14, EN 61800‑3, and EN 61800‑5‑1, and carries CE marking.