Yaskawa ∑ - V Servo Drive Debugging Guide

Yaskawa ∑ - V Series SGDV Servo Drive: A Comprehensive Practical Manual from Selection to Maintenance

In the field of precision positioning and high-speed machining, the performance of servo systems directly determines the production efficiency and machining accuracy of equipment. Yaskawa ∑ - V series servo drives (SGDV), combined with SGMJV/SGMAV/SGMPS/SGMGV/SGMSV/SGMCS series rotary motors, have become the core driving components of many automation equipment due to their high response, high-resolution encoders (up to 20 absolute values), and flexible command option expansion capabilities. This article is based on the original factory technical manual and provides a complete technical guide for on-site engineers, system integrators, and maintenance personnel, covering hardware selection, system configuration, digital operator operation, parameter adjustment, and fault diagnosis.

Chapter 1: Interpretation of Product Series and Models

1.1 Voltage level and power range

The ∑ - V series SGDV servo drives are divided into three categories according to the main power supply voltage:

Voltage level, model suffix, power supply specification, continuous output current range

Single phase 100V FE1A 100~115VAC 0.66~2.8 Arms

Single phase 200V AE1A 220~230VAC 11.6 Arms (specific model)

Three phase 200V AE1A 200~230VAC 0.66~78.0 Arms

Three phase 400V DE1A 380~480VAC 1.9~37.2 Arms

Control the power supply to be the same source as the main power supply (200V/100V series) or independent 24VDC (400V series). Attention: Some models of three-phase 200V drivers can be powered by single-phase 200V, please refer to the manual for details.

1.2 Model Naming Rules (Taking SGDV-120AE1A08000 as an Example)

SGDV: ∑ - V series servo amplifier

120: Continuous output current (12.0 Arms)

A: Voltage level (A=200V, D=400V, F=100V)

E1: Design sequence

A: Functional specifications (A=standard, no special)

008000: Additional specification code

When selecting, the servo motor and driver combination table recommended by Yaskawa must be followed and cannot be randomly matched.

1.3 Basic Specifications Highlights

Control mode: IGBT-PWM sine wave drive

Feedback encoder: Serial encoder, supporting 13 bit increment, 17 bit increment/absolute value, 20 bit increment/absolute value

Speed control range: 1:5000

Speed accuracy: ± 0.01% when the load fluctuates from 0 to 100%; 0% when voltage fluctuation is within ± 10%; ± 0.1% when the temperature fluctuates by ± 25 ℃

Repetitive accuracy of torque control: ± 1%

Protection level: IP10, pollution level 2, altitude below 1000 meters

Applicable standards: UL508C, EN50178, EN55011 Class A, EN61800-3, EN61800-5-1, EN954-1, IEC61508, etc

Safety function: Hard wired base block (HWBB), input/HWBB1,/HWBB2, output EDM1 for monitoring internal safety circuit status

1.4 Environmental and Installation Requirements

Environmental temperature: 0~55 ℃; Storage temperature: -20~85 ℃

Humidity: ≤ 90% RH (no condensation)

Anti vibration: 4.9 m/s ²; Impact resistance: 19.6 m/s ²

No corrosive/explosive gases, no oil mist, no iron powder, no strong electromagnetic field

Chapter 2: System Configuration and Main Circuit Wiring

2.1 Typical System Configuration (Three phase 200V Example)

The main circuit wiring of SGDV driver includes:

Main power input: L1, L2, L3 (three-phase) or L1, L2 (single-phase)

Control power input: also connected to L1, L2 (200V series) or separately 24VDC (400V series)

Motor output: U, V, W

Regenerative resistors: B1, B2 (models with built-in regenerative resistors can be externally connected with higher power resistors)

Grounding: The grounding terminal must be reliably grounded (≤ 100 Ω)

2.2 Precautions for single-phase 200V power supply

Some three-phase 200V drivers allow single-phase 200V power supply, but the maximum output current will decrease at this time. Please refer to the manual of the specific model for confirmation.

2.3 Control I/O signal (CN1)

SGDV provides rich assignable I/O:

Input signal (7 channels): assignable functions include forward rotation prohibition (P-OT), reverse rotation prohibition (N-OT), forward external torque limit (P-CL), reverse external torque limit (N-CL), universal input (SI0~SI6), etc. The signal polarity (normally open/normally closed) and terminal allocation can be modified through parameters.

Output signal (3-channel): assignable functions include positioning completion (COIN), speed consistency (V-CMP), rotation detection (TGON), servo readiness (S-RDY), torque limit detection (CLT), speed limit detection (VLT), brake output (BK), warning (Warning), approach (NEAR), etc.

Fixed output: servo alarm (ALM)

2.4 Encoder Interface (CN2)

Connect the serial encoder and support incremental or absolute value encoders. The absolute value encoder requires an external battery (3.6V) to maintain multi cycle data.

2.5 Communication Interface

CN3 (RS-422A): Connected to a digital operator (JUSP-OP05A-1-E) or a personal computer (SigmaWin+), supports 1: N communication (up to 15 stations), and the axis address is set through parameters.

CN7 (USB): Connect to a personal computer (SigmaWin+) for easy debugging and parameter reading and writing.

CN5 (Analog Monitor): 2 channels, ± 10V output (linear effective range ± 8V), 16 bit resolution, accuracy ± 20mV (typical value), maximum output current ± 10mA, setup time 1.2ms.

2.6 Regeneration treatment

Low power driver with built-in regenerative resistor; High power drivers require an external regenerative resistor unit. Fault in the regeneration transistor or broken resistor can cause an A.30 alarm.

Chapter 3: Digital Operators and Panel Display

3.1 Panel LED Display

The front panel of SGDV has a 7-segment LED digital tube (1 digit), paired with status indicator lights:

Rotation detection (TGON): lights up when the motor speed exceeds the set value of Pn502

Base blockade (BB): The base blockade state lights up

Reference input: Illuminates when there is a reference command input

Command option module communication status: Illuminates when communication with option module is normal

3.2 Alarm and Warning Display

When an alarm occurs, the digital display will cyclically show "A." followed by the alarm number (such as A.E60). The warning display is similar but will not cause the servo to stop. When the hard wire base is blocked (HWBB), it displays "Hbb". Display "P-OT" or "N-OT" during overtravel.

3.3 Digital Operator Operation Mode

The digital manipulator (JUSP-OP05A-1-E) supports three main modes:

Practical Function Mode (Fn □□□): Perform auxiliary functions such as origin search, JOG operation, parameter initialization, alarm history clearing, etc.

Parameter setting mode (Pn □□□□): Read and modify servo parameters.

Monitoring mode (Un □□□□): Real time monitoring of motor speed, torque, I/O status, position deviation, etc.

3.4 Example of Parameter Setting Method

Taking the modification of Pn304 (JOG speed) to 1000 min ⁻¹ as an example:

Press the MODE/SET key to enter parameter/monitoring mode.

Use the arrow keys to change 'Un' to 'Pn'.

Move to the right of the cursor and use the up and down keys to call up "Pn304".

Move the cursor to the hundredth position and press the up key to change it to "1000".

Press the DATA key to write.

The modification method for selecting parameters (such as Pn001) is similar, by modifying the digits to achieve function selection (such as changing the stop mode from using DB to not using DB).

3.5 Practical Function Example - Origin Search (Fn003)

Perform origin search through a digital manipulator without the need for instructions from the upper computer. Operation steps:

Enter the main menu of practical functions and select Fn003.

Press the DATA key to enter the execution screen (if "NO-OP" is displayed, check the write protection setting or ensure the servo is OFF).

Press the SVON key to enable the servo (display "RUN").

Press the UP key to rotate forward and the DOWN key to rotate backward, and the motor will search for the origin position (the origin search parameters need to be pre-set).

After completion, press the MODE/SET key to exit.

3.6 Monitoring Mode (Un □□□□)

The parameters that can be monitored include:

Actual speed and commanded speed of the motor

Internal torque command

Input/output signal status

encoder position

Cumulative load rate, regenerative load rate, etc

Chapter 4: Interpretation of Key Parameters

4.1 Basic Parameters

Parameter Name Description

Pn000 Function Selection Basic Switch Rotation Direction Selection and Control Mode (Position/Speed/Torque)

Pn001 function selection application switch 1 servo OFF or alarm stop mode (dynamic braking/free running), overtravel stop mode

Pn002 function selection application switch 2 absolute value encoder usage mode (absolute/incremental), etc

When the Pn00B parameter display selection is set to 1, the tuning parameters are displayed (usually users do not need to set them)

4.2 Gain and tuning parameters

Pn100: Speed loop gain

Pn101: Integral time constant of velocity loop

Pn102: Position loop gain

Pn103: Inertia ratio (load inertia/motor rotor inertia x 100%)

Pn401: Time constant of torque reference filter

4.3 Speed/Position Related Parameters

Pn300: Speed reference input gain

Pn302: Speed 1 (for internal speed control)

Pn304: JOG speed

Pn305: Soft start acceleration time

Pn306: Soft start deceleration time

Pn502: Rotation detection output level (TGON)

4.4 Input/output allocation parameters

Pn50A~Pn50D: Input signal allocation (SI0~SI6)

Pn50E~Pn510: Output signal allocation (SO1~SO3)

Can set signal terminal mapping and logic (positive/negative logic)

4.5 Origin search related parameters

Pn500~Pn508: Origin search method, speed, acceleration and deceleration time, proximity signal logic, etc

Before using Fn003 to perform origin search, these parameters need to be configured correctly

Chapter 5: Fault Diagnosis and Alarm Handling

5.1 Common Alarm Codes

Display alarm name, possible reasons, and handling measures

A. 10. Check U/V/W insulation for overcurrent or overheating of radiator motor wires, grounding, excessive load, and fan faults; Reduce load; Clean the heat sink

A. 30 regeneration abnormal regeneration transistor fault, regeneration resistor disconnection inspection external regeneration resistor; Replace SERVOPACK

A. 32 regeneration overload regeneration energy exceeds the capacity of the resistor, external larger power regeneration resistor is connected

A. Check the input voltage for overvoltage, high power supply voltage, and rapid deceleration in the 40 main circuit; Extend deceleration time; Install regenerative resistor

A. 41 main circuit undervoltage power supply voltage too low, phase loss check power supply and wiring

A. Check the U/V/W wiring for phase sequence error and excessive reference input of the 51 overspeed motor line; Reduce reference value

A. 71/72 overload load is too large, and the motor line is broken to reduce the load; Check the motor power line

A. Backup error of 81 absolute value encoder battery voltage depleted, replace battery in powered on state, execute Fn008 initialization

A. 83 Absolute Value Encoder Battery Error Battery voltage<2.7V Power on Replace battery

A. The d0 position error pulse overflow position gain is too low, and the load inertia increases significantly by Pn102; Adjust electronic gear

A. F1 power supply phase loss inspection, main power supply phase loss inspection, L1/L2/L3 wiring and MCCB

A. E60 option module communication error option module not connected or faulty check option module installation and communication settings

5.2 Alarm reset method

Press the DATA key through the numeric operator (to be confirmed according to the operation manual, usually a combination key)

Reset through CN1 input signal (/ALM-RST)

Power off and restart

Partial alarms (such as A.81, A.82) need to be cleared through Fn008

5.3 Hardwire Base Block (HWBB)

When both/HWBB1 and/HWBB2 are at low levels, the servo output base is blocked and the motor stops freely. The panel displays "Hbb". This is part of the safety function, used for emergency stop.

5.4 Overtravel Display

P-OT signal ON: forward rotation prohibited, displaying "P-OT"

N-OT signal ON: Reverse prohibited, displaying "N-OT"

Simultaneous ON of both: display alternates

Chapter 6: Maintenance and upkeep

6.1 Regular inspection items

Check the frequency and content of the inspection site

Appearance: Dust and oil stains are cleaned with compressed air every year

Every year, if the screws of the terminal block and connector become loose, they need to be tightened again

Cooling fan replacement in 4-5 years (under standard operating conditions)

Smooth capacitor replacement within 7-8 years

Circuit board electrolytic capacitor replacement within 5 years

Check the contacts of the relay as needed and replace them if necessary

Fuse replacement within 10 years

6.2 Precautions for Replacement

Before replacement, the main power and control power must be cut off, and wait for at least 5 minutes after the CHARGE light goes out.

After replacement, the parameters need to be reset (it is recommended to use SigmaWin+backup/restore).

Pay attention to the direction of airflow when replacing the fan.

6.3 Absolute value encoder battery replacement

Battery model: ER6VC3 (Toshiba) or JZSP-BA01. When replacing, it is necessary to keep the SERVOPACK control power on, otherwise multiple cycles of data will be lost. After replacement, execute Fn008 to reset multiple cycles of data.

6.4 Long term storage

If stored for more than 6 months, it is recommended to power on every six months to prevent the degradation of electrolytic capacitors.

Chapter 7: Practical Debugging Techniques

7.1 Inertia identification and automatic tuning

By using SigmaWin+software or the tuning function of digital operators (such as Fn200), the load inertia ratio can be automatically measured and the speed loop gain can be set. The correct setting of the inertia ratio (Pn103) directly affects the speed loop response.

7.2 JOG Operation Inspection

Select Fn002 in practical function mode to perform jog operation, quickly verifying the motor rotation direction, encoder feedback, and load connection status.

7.3 Input signal monitoring

By monitoring the input signal status in monitoring mode (Un005), it can be confirmed whether external switches, limit switches, emergency stops, and other signals are properly connected. The status is displayed as bit data, with the upper LED on indicating high level and the lower LED on indicating low level.

7.4 Output signal verification

Monitor the output signals (such as ALM, BK, TGON, etc.) through Un006 to confirm if the servo status feedback is normal.

7.5 Parameter Backup and Recovery

SigmaWin+allows for easy parameter backup, comparison, and batch copying. When replacing the drive, first backup the original parameters, and then restore the new drive to quickly put it into operation.

Chapter 8: Safety Precautions

The output terminals U, V, and W of the servo drive must not be connected to the power supply, otherwise the drive will be burned.

After power failure, wait for at least 5 minutes to confirm that the CHARGE light is off before touching the interior.

The grounding resistance must be ≤ 100 Ω and cannot be shared with high current equipment such as welding machines.

External emergency stop circuit and overtravel limit switch must be configured, and cannot rely solely on the stop function of servo software.

Dynamic braking (DB) is only used for emergency stop and cannot replace normal start stop with frequent start stop servo ON signals.

When using the safety function (HWBB), independent mechanical safety measures still need to be provided externally.