YASKAWA FSP Series How to use

FSP Amplifier
(FSP-) SERIES
AC SERVO DRIVE Safety Precautions
Short Form Installation Guide

FSP Amplifier Short Form Installation Guide Introduction
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FSP Amplifier Short Form Installation Guide Introduction
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FSP Amplifier Short Form Installation Guide Introduction
Copyright ©2006 by Yaskawa Electric America, Inc.
FSP Amp lifier Safety Precautions, Installation Guide (Short Form)
YEA-SIA-FSP-2 Rev. C
December, 2006
All rights reserved. No part of this publication may be stored in a retrieval system, or
reproduced in any way , including but not limited to photocop y, p hotograp hy , magnetic or
other recording, without the prior agreement and written permission of the publisher.
Program listings may be entered, stored and executed in a computer system, but not
reproduced for publication.
This guide is designed to provide information about the FSP Amplifier hardware.
Every effort has been made to make this guide complete and as accurate as possible.
However, no warranty of suitability , purp ose or fitness is made or imp lied.
Yaskawa Electric America, Inc. (YEA) is not liable or responsible to any person or entity
for loss or damage in connection with or stemming from the use of the FSP Amplifier
and/or the information contained in this publication
YEA bears no responsibility for errors, which may ap pear in this publication and retains
the right to make changes to the products and the guide without prior notice.
Yaskawa Electric America,Inc.
2121 Norman Drive South
Waukegan,IL 60085
United States
Tel: [phone]
Fax:[phone]
[e-mail]
For more information refer to our web site: www.yaskawa.com
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FSP Amplifier Short Form Installation Guide Introduction
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FSP Amplifier Short Form Installation Guide Introduction
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T1. Introduction..........................................................................................................8
T
1.1. Safety Precautions..........................................................................................9
1.2. Notes for Safe Operation..............................................................................10
1.3. Warning Label..............................................................................................16
1.4. Parts..............................................................................................................17
2. Checking Products On Delivery .......................................................................18
3. Appearance and Nameplate..............................................................................19
3.1. Type Designation .........................................................................................20
4. Installation..........................................................................................................21
4.1. Operating Conditions ...................................................................................21
4.2. Installation Sites...........................................................................................21
4.3. Orientation ...................................................................................................22
4.4. M ultip le FSP Amplifier Installation ............................................................23
4.4.1 Where Mounted Side by Side ..............................................................23
4.4.2 Environment Inside Control Box.........................................................23
5. Wi ri ng .................................................................................................................24
5.1. M olded-case Circuit Breaker and Fuse Cap acity.........................................24
5.2. Main Circuit Wiring.....................................................................................24
5.3. Main Circuit Wire Size ................................................................................25
5.4. Typical M ain Circuit Wirin g Examples .......................................................29
5.4.1. Single-phase 100 V/200 V M ain Circuit..............................................29
5.4.2. Single-phase 200 V 0.8 kW and 1.5 kW Main Circuit ........................30
5.4.3. Three-phase 200 V Main Circuit .........................................................31
5.4.4. Three-phase 400 V Main Circuit .........................................................32
5.5. Main Circuit Wiring Graphic Diagrams ......................................................33
5.5.1. Single-phase 100 V/200 V M ain Circuit..............................................33
5.5.2. Single-phase 200 V 0.8 kW and 1.5 kW Main Circuit .......................34
5.5.3. Three-phase 200 V Main Circuit .........................................................35
5.5.4. Three-phase 400 V Main Circuit .........................................................36
5.6. AC Power Source Supply ............................................................................38
5.7. DC Power Source Supply ............................................................................38
5.8. Noise Control...............................................................................................38
6. Operation............................................................................................................39
6.1. Precautions at Test Run................................................................................39
6.2. Conducting Test Run for Servomotor Without Load...................................39
6.3. Conducting Test Run with Servomotor Connected to M achine ..................39
6.4. Precautions During Operation......................................................................40
7. Inspection and Maintenance .............................................................................41
7.1. FSP Amp lifier Inspection.............................................................................41
7.2. Part Rep lacement Period..............................................................................42
7.3. Replacin g the Battery for an Absolute Encoder...........................................42
7.3.1. Recommended Battery.........................................................................42
7.3.2. Replacin g the Battery...........................................................................43
8. Installation Conditions of EMC Directive.......................................................44
8.1. EMC Installation Conditions .......................................................................44
8.1.1. Installation: Single & Three-phase 100/200 V FSP Amplifier (PC) ...44
8.1.2. Installation: Single & Three-phase 100/200 V FSP Amplifier (PLC) .45
8.1.3. Installation: Three-phase 400 V FSP Amplifier ..................................46

FSP Amplifier Short Form Installation Guide Introduction
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8.2. Cable Core and Cable Clamp.......................................................................47
8.2.1. Cable Core............................................................................................47
8.2.2. Cable Clamp.........................................................................................47
9. Peripheral Devices..............................................................................................48
9.1. Peripheral Device Ty p es and Cap acities......................................................48
9.2. Noise Filter for Brake Power Sup p ly ...........................................................48
9.3. Cable Specifications.....................................................................................50
9.4. Recommended Ferrite Cores........................................................................50
9.5. Shield Box....................................................................................................50
10. Overload Characteristics...............................................................................51
11. Appe ndi x A .....................................................................................................52
11.1. I/O Signals Connector CN1 .....................................................................52
11.2. Encoder Connector CN2..........................................................................53
11.3. Serial Communication Connector CN3 ...................................................54
11.4. Analog M onitor Connector CN5..............................................................54
11.5. Connecting NON-Yaskawa Motor with A/B Encoder ............................55
11.6. Connecting Pulse A/B Encoder without C Pulse (Index Pulse)...............56

FSP Amplifier Short Form Installation Guide Introduction
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1. Introduction
This guide describes the FSP- series AC servo drive (FSP Amplifier) that controls
Yaskawa Sigma II series or any compatible AC servomotor.
This product conforms to the following standards:
• EN61000-6-2: 1999
• EN55011: 1998, Group 1 Class A
However, because this p roduct is a built-in type, reconfirmation of the above
standards is required after being installed in the final product.
Upon receipt of the p roduct and prior to installing the p roduct, read these
instructions carefully and retain for future reference. This will enable you to
properly use the FSP Amplifier and carry out periodic inspection, maintenance, etc.
Related documents:
Title Catalog No.
Sigma FSP Servo System User’s Manual YEA-SIA-FSP-3
AC Servo Motor Instructions for Yaskawa
Sigma II series motors or documentation for
other compatible motors
TOE-C231-2 (for Sigma II)
Manufacturer’s motor specification
FlexWorks User's Manual YEA-SIA-FSP-4
This guide and other related documents can be downloaded from our website:
www.yaskawa.com
Note: YEA is not responsible for accidents or damages resulting from p roduct
modifications made by the user.

FSP Amplifier Short Form Installation Guide Introduction
1.1. Safety Precautions
In this guide, safety p recautions are classified as WARNING or CAUTION. It is
extremely imp ortant that y ou p ay close attention to these p recautions.
The following symbols are used:
WARNING
Indicates a potentially hazardous situation,
which, if not avoided, could result in death or serious personal injury.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or moderate personal injury and/or
damage to the equipment. In some instances, items described in CAUTION
could also result in a serious accident.
Read the following safety precautions thoroughly before installation, operation,
maintenance or inspection of the FSP Amplifier.
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FSP Amplifier Short Form Installation Guide Introduction
1.2. Notes for Safe Operation
WARNING
• Never touch any rotating motor parts while the motor is running.
Failure to observe this warning may result in injury.
• Before starting operation with a machine connected, make sure that an
emergency stop can be applied at any time.
Failure to observe this warning may result in injury.
• Never touch the inside of the FSP Amplifier.
Failure to observe this warning may result in electric shock.
• Do not remove the terminal cover while the power is ON.
Failure to observe this warning may result in electric shock.
• Do not touch terminals for five minutes after the power is turned OFF.
Residual voltage may cause electric shock.
• Do not touch terminals for five minutes after voltage resistance test.
Residual voltage may cause electric shock.
• Follow the procedures and instructions for trial operation precisely as notedin
the relevant User's Manual.
Malfunctions that occur after the servomotor is connected to the equipment not only damage the
equipment, but may also cause an accident resulting in death or injury.
• The multi-turn limit value must be changed only for special applications.
Changing it inappropriately or unintentionally can be dangerous.
• If the Multi-turn Limit Disagreement alarm occurs, check the setting of
parameter Pn205 in the FSP Amplifier to be sure that it is correct.
If Fn013 is executed when an incorrect value is set in Pn205, an incorrect value will be set in the
encoder. The alarm will disappear even if an incorrect value is set, but incorrect positions will be
detected, resulting in a dangerous situation where the machine will move to unexpected positions.
• Do not remove the terminal cover, cables, connectors, or optional items while
the power is ON.
Failure to observe this warning may result in electric shock.
• Connect the ground terminal to electrical codes (ground resistance: 100 Ωor
less).
Improper grounding may result in electric shock or fire.
• Only authorized personnel must perform installation, disassembly, or repair.
Failure to observe this warning may result in electric shock or injury.
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FSP Amplifier Short Form Installation Guide Introduction
WARNING
• Do not damage, press and exert excessive force or place heavy objects on the
cables.
Failure to observe this warning may result in electric shock, stoppage of operation, or burning.
• Do not modify the product.
Failure to observe this warning may result in injury or damage to the product.
• Provide an appropriate stopping device on the machine side to ensure safety.
A holding brake for a servomotor with brake is not a stopping device for
ensuring safety.
Failure to observe this warning may result in injury.
• Do not come close to the machine immediately after resetting momentary
power loss to avoid an unexpected restart. Take appropriate measures to
ensure safety against an unexpected restart.
Failure to observe this warning may result in injury.
 Checking on Delivery
CAUTION
• Always use the servomotor and the FS P Amplifier in one of the specified
combinations.
Failure to observe this caution may result in fire or malfunction.
 Storage and Transportation
CAUTION
• Do not store or install the product in the following locations.
 Locations subject to direct sunlight.
 Locations subject to temperatures outside the range specified in the
storage/installation temperature conditions.
 Locations subject to humidity outside the range specified in the
storage/installation humidity conditions.
 Locations subject to condensation as the result of extreme changes in
temperature.
 Locations subject to corrosive or flammable gases.
 Locations subject to dust, salts or iron dust.
 Locations subject to exposure to water, oil or chemicals.
 Locations subject to shock or vibration.
Failure to observe this caution may result in fire, electric shock, or damage to the product.
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FSP Amplifier Short Form Installation Guide Introduction
• Do not hold the product by the cables or motor shaft while transporting it.
Failure to observe this caution may result in injury or malfunction.
• Do not place any load exceeding the limit specified on the packing box.
Failure to observe this caution may result in injury or malfunction.
• Do not hold the product by the eyebolt of motor while transporting it.
Failure to observe this caution may result in injury or malfunction.
 Installation
CAUTION
• Never use the products in an environment subject to water, corrosive gases,
inflammable gases, or combustibles.
Failure to observe this caution may result in electric shock or fire.
• Do not step on or place a heavy object on the product.
Failure to observe this caution may result in injury.
• Do not cover the inlet or outlet ports and prevent any foreign objects from
entering the product.
Failure to observe this caution may cause internal elements to deteriorate resulting in malfunction or
fi re.
• Be sure to install the product in the correct direction.
Failure to observe this caution may result in malfunction.
• Provide the specified clearance between the FSP Amplifier and the control
panel or other device.
Failure to observe this caution may result in fire or malfunction.
• Do not apply any strong impact.
Failure to observe this caution may result in malfunction.
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FSP Amplifier Short Form Installation Guide Introduction
 Wiring
CAUTION
• Do not connect a three-phase power supply to the U, V, or W output terminals.
Failure to observe this caution may result in injury or fire.
• S ecurely connect the power supply terminal screws and motor output terminal
screws.
Failure to observe this caution may result in fire.
• Do not bundle or run power and signal lines together in the same duct. Keep
power and signal lines separated by at least 30 cm (11.81 in).
Failure to observe this caution may result in fire.
• Use twisted-pair shielded wires or multi-core twisted pair shielded wires for
signal and encoder (PG) feedback lines.
The maximum length is 3 m (118. 11 in) for reference input lines and is 20 m (787.40 in) for PG
feedback lines. If feedback lines are longer than 20 m (787.40 in), use the 50 m (1968.50 in) cable.
• Do not touch the power terminals for 5 minutes after turning power OFF
because high voltage may still remain in the FSP Amplifier.
Make sure the charge indicator is out first before starting an inspection.
• Avoid frequently turning power ON and OFF. Do not turn power ON or OFF
more than once per minute.
Since the FSP Amplifier has a capacitor in the power supply, a high charging current flows for 0.2
seconds when power is turned ON. Frequently turning power ON and OFF causes main power
devices like capacitors and fuses to deteriorate, resulting in unexpected problems.
• Observe the following precautions when wiring main circuit terminal blocks.
Failure to observe this caution may result in injury, fire, or malfunction.
 Remove the terminal block from the FSP Amplifier prior to wiring.
 Insert only one wire per terminal on the terminal block.

Make sure that the core wire is not electrically shorted to adjacent core wires.

The leakage from the power lines may be extremely large for 400 V FSP Amplifier. Be sure to
secure the wiring of the power lines.
• Do not connect the FSP Amplifier for 100 V and 200 V directly to a voltage of
400 V.
The FSP Amplifier will be destroyed.
• Be sure to wire correctly and securely.
Failure to observe this caution may result in motor overrun, injury, or malfunction.
• Always use the specified power supply voltage.
An incorrect voltage may result in burning.
• Take appropriate measures to ensure that the input power supply is supplied
within the specified voltage fluctuation range. Be particularly careful in places
where the power supply is unstable.
An incorrect power supply may result in damage to the product.
• Install external breakers or other safety devices against short-circuiting in
external wiring.
Failure to observe this caution may result in fire.
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FSP Amplifier Short Form Installation Guide Introduction
CAUTION
• Take appropriate and sufficient countermeasures for each when installing
systems in the following locations.
Failure to observe this caution may result in damage to the product.
 Locations subject to static electricity or other forms of noise.

Locations subject to strong electromagnetic fields and magnetic fields.

Locations subject to possible exposure to radioactivity.
 Locations close to power supplies.
• Do not reverse the polarity of the battery when connecting it.
Failure to observe this caution may damage the battery or cause it to explode.
 Operation
CAUTION
• Conduct trial operation on the servomotor alone with the motor shaft
disconnected from machine to avoid any unexpected accidents.
Failure to observe this caution may result in injury.
• Before starting operation with a machine connected, change the settings to
match the parameters of the machine.
Starting operation without matching the proper settings may cause the machine to run out of control or
malfunction.
• Forward run prohibited (P-OT) and reverse run prohibited (N-OT) signals are
not effective during zero point search mode using parameter Fn003.
Failure to observe this caution may result in injury.
• When using the servomotor for a vertical axis, install the safety devices to
prevent workpieces to fall off due to occurrence of alarm or overtravel. Set the
servomotor so that it will stop in the zero clamp state at occurrence of
overtravel.
Failure to observe this caution may cause workpieces to fall off due to overtravel.
• When not using the online autotuning set to the correct moment of inertia ratio.
Setting to an incorrect moment of inertia ratio may cause vibration.
• Do not touch the FSP Amplifier’s heat sink, regenerative resistor, or servomotor
while power is ON or soon after the power is turned OFF.
Failure to observe this caution may result in burns due to high temperatures.
• Do not make any extreme adjustments or setting changes of parameters.
Failure to observe this caution may result in injury due to unstable operation.
• When an alarm occurs, remove the cause, reset the alarm after confirming
safety, and then resume operation.
Failure to observe this caution may result in injury.
• Do not use the servo brake of the servomotor for ordinary braking.
Failure to observe this caution may result in malfunction.
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FSP Amplifier Short Form Installation Guide Introduction
 M ainte nance and Ins pe ction
CAUTION
• Do not disassemble the FSP Amplifier.
Failure to observe this caution may result in electric shock or injury.
• Do not attempt to change wiring while the power is ON.
Failure to observe this caution may result in electric shock or injury.
• When replacing the FS P Amplifier, resume operation only after transferring
the previous FSP Amplifier parameters to the new FSP Amplifier.
Failure to observe this caution may result in damage to the product.
 Disposal
CAUTION
• When disposing of the products, treat them as ordinary industrial waste.
Failure to observe this caution may result in injury.
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FSP Amplifier Short Form Installation Guide Introduction
1.3. Warning Label
The following illustration shows an examp le of the FSP Amp lifier’s warning
label.
The mounting position of the label differs depending on the model and capacity
of the FSP Amp lifier.
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FSP Amplifier Short Form Installation Guide Introduction
1.4. Parts
The part names of the FSP Amplifier are shown in the following diagram:
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FSP Amplifier Short Form Installation Guide Checking Products On Delivery
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2. Checking Products On Delivery
The following procedure is used to check FSP- series products upon delivery.
Check Item Comments
Are the delivered
products the ones
you ordered?
Check the model numbers marked on the nameplates of
the FSP Amplifier.
Is there any
visible damage?
Check the overall appearance and check for damage or
scratches that may have occurred during transportation.
Are there any
loose screws? Tighten any loose screws with a screwdriver.
If any of the above items are faulty or incorrect, contact your local sales
representative or the dealer from whom you purchased the product(s).

FSP Amplifier Short Form Installation Guide Appearance and Nameplate
3. Appearance and Nameplate
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FSP Amplifier Short Form Installation Guide Appearance and Nameplate
3.1. Type Designation
FSP - 05 D - MC
Flexible ServoPack
Max. Appli cable
ServomotorPower
(see table below)
InputVoltage
B - 100VAC , or
A - 200VAC , or
D - 400VAC
Control Method
MC - Serial
MH - A-B quadrature
Options
- No options
C - Pre-loaded ECAM
S - Single-phase amplifier
(08 and 15 only)
Output Capacity
Code
Max. Applicable S ervomotor
Power (kW)
A3 0.03
A5 0.05
01 0.10
02 0.20
04 0.40
05 0.50
08 0.75
10 1.00
15 1.50
20 2.00
30 3.00
50 5.00
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