YASKAWA Sigma II Series User manual

Sigma II Series Servo System
User’s Manual

Safety Information
The following conventions are used to indicate precautions in this manual. Failure to heed
precautions provided in this manual can result in serious or possibly even fatal injury or
damage to the products or to related equipment and systems.
•WARNING: Indicates precautions that, if not heeded, could possibly result in loss of life or serious injury.
•CAUTION: Indicates precautions that, if not heeded, could result in relatively serious or minor injury,
damage to the product, or faulty operation.
•
•PROHIBITED: Indicates actions that must never be taken.
WARNING
!
CAUTION
!
PROHIBITED
©Yaskawa,1999
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior permission
of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because Yaskawa is constantly striving to improve its high-quality products, the information contained in this man-
ual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Never-
theless, Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages
resulting from the use of the information contained in this publication.

Sigma II User’s Manual Chapter 2: Installation
i
Overview....................................................................................................................... viii
Using This Manual.......................................................................................................... ix
Safety Precautions.............................................................................................................x
1: Checking Product and Part Names ...................................................................... 1-1
1.1 Checking the Sigma II Series Products on Deliver.............................................. 1-2
1.1.1 Servomotors................................................................................................ 1-2
1.1.2 Servo Amplifiers......................................................................................... 1-4
1.2 Product Part Names ............................................................................................. 1-5
1.2.1 Servomotors................................................................................................ 1-5
1.2.2 Servo Amplifiers......................................................................................... 1-6
2 Installation ........................................................................................................... 2-1
2.1 Servomotors......................................................................................................... 2-2
2.1.1 Storage Temperature................................................................................... 2-2
2.1.2 Installation Site ........................................................................................... 2-2
2.1.3 Alignment ................................................................................................... 2-3
2.1.4 Orientation .................................................................................................. 2-3
2.1.5 Allowable Shaft Loads................................................................................ 2-4
2.1.6 Handling Oil and Water .............................................................................. 2-5
2.1.7 Cable Stress................................................................................................. 2-5
2.2 Servo Amplifiers.................................................................................................. 2-6
2.2.1 Storage Conditions...................................................................................... 2-6
2.2.2 Installation Site ........................................................................................... 2-6
2.2.3 Orientation .................................................................................................. 2-7
2.2.4 Installation .................................................................................................. 2-7
3Wiring .................................................................................................................. 3-1
3.1 Connecting to Peripheral Devices....................................................................... 3-2
3.1.1 Single-Phase (100V or 200V) Main Circuit Specifications....................... 3-3
3.1.2 Three-Phase (200V) Main Circuit Specifications....................................... 3-4
3.2 Servo Amplifier Internal Block Diagrams.......................................................... 3-5
3.2.1 30 to 400W 200V and 30 to 200W 100V Models...................................... 3-5
3.2.2 0.5kW to 1.5kW 200V Models................................................................... 3-6
3.2.3 2.0kW and 3.0kW 200V Models ................................................................ 3-6

Sigma II User’s Manual Chapter 2: Installation
ii
3.3 Main Circuit Wiring............................................................................................. 3-7
3.3.1 Names and Descriptions of Main Circuit Terminals................................... 3-8
3.3.2 Typical Main Circuit Wiring Example........................................................3-9
3.3.3 Cable Specifications and Peripheral Devices ............................................. 3-9
3.3.4 Servo Amplifier Power Losses ................................................................. 3-10
3.3.5 Wiring Main Circuit Terminal Blocks ...................................................... 3-11
3.4 I/O Signals ......................................................................................................... 3-12
3.4.1 Examples of I/O Signal Connections........................................................3-13
3.4.2 List of CN1 Terminals .............................................................................. 3-14
3.4.3 I/O Signal Names and Functions .............................................................. 3-15
3.4.4 Interface Circuits....................................................................................... 3-17
3.5 Wiring Encoders ................................................................................................ 3-20
3.5.1 Connecting an Encoder (CN2) and Output Signals from the
Servo Amplifier (CN1)............................................................................. 3-20
3.5.2 CN2 Encoder Connector Terminal Layout and Types.............................. 3-21
3.6 Examples of Standard Connections.................................................................. 3-22
3.6.1 Single-Phase Power Supply Specifications .............................................. 3-23
3.6.2 Three-Phase Power Supply Specifications ............................................... 3-24
3.6.3 Position Control Mode.............................................................................. 3-25
3.6.4 Speed Control Mode................................................................................. 3-26
3.6.5 Torque Control Mode................................................................................ 3-27
4Trial Operation..................................................................................................... 4-1
4.1 Two-Step Trial Operation .................................................................................... 4-2
4.1.1 Step 1: Trial Operation for Servomotor without Load................................ 4-3
4.1.2 Step 2: Trial Operation with the Servomotor Connected to the Machine.. 4-9
4.2 Supplementary Information on Trial Operation................................................ 4-10
4.2.1 Servomotors with Brakes.......................................................................... 4-10
4.2.2 Position Control by Host Controller......................................................... 4-11
4.3 Minimum Parameters and Input Signals........................................................... 4-11
4.3.1 Parameters................................................................................................. 4-11
4.3.2 Input Signals ............................................................................................. 4-12

Sigma II User’s Manual Chapter 2: Installation
iii
5: Parameter Settings and Functions........................................................................ 5-1
5.1 Settings According to Device Characteristics .................................................... 5-4
5.1.1 Switching Servomotor Rotation Direction ................................................. 5-4
5.1.2 Setting the Overtravel Limit Function........................................................ 5-5
5.1.3 Limiting Torques......................................................................................... 5-9
5.2 Settings According to Host Controller.............................................................. 5-14
5.2.1 Speed Reference ....................................................................................... 5-14
5.2.2 Position Reference.................................................................................... 5-16
5.2.3 Using the Encoder Signal Output .............................................................5-22
5.2.4 Sequence I/O Signals................................................................................ 5-25
5.2.5 Using the Electronic Gear Function..........................................................5-28
5.2.6 Contact Input Speed Control..................................................................... 5-32
5.2.7 Using Torque Control ............................................................................... 5-38
5.2.8 Torque Feed–forward Function................................................................. 5-44
5.2.9 Torque Limiting by Analog Voltage Reference........................................ 5-46
5.2.10 Reference Pulse Inhibit Function (INHIBIT)........................................... 5-48
5.3 Setting Up the Servo Amplifier ......................................................................... 5-49
5.3.1 Parameters................................................................................................. 5-49
5.3.2 JOG Speed ................................................................................................ 5-49
5.3.3 Input Circuit Signal Allocation................................................................. 5-50
5.3.4 Output Circuit Signal Allocation.............................................................. 5-54
5.3.5 Control Mode Selection............................................................................ 5-57
5.4 Setting Stop Functions....................................................................................... 5-60
5.4.1 Adjusting Offset........................................................................................ 5-60
5.4.2 Using the Dynamic Brake......................................................................... 5-61
5.4.3 Using the Zero Clamp Function................................................................ 5-62
5.4.4 Using the Holding Brake .......................................................................... 5-64
5.5 Forming a Protective Sequence ........................................................................ 5-69
5.5.1 Using Servo Alarm and Alarm Code Outputs .......................................... 5-69
5.5.2 Using the Servo ON Input Signal .............................................................5-71
5.5.3 Using the Positioning Completed Output Signal...................................... 5-72

Sigma II User’s Manual Chapter 2: Installation
iv
5.5.4 Speed Coincidence Output........................................................................ 5-74
5.5.5 Using the Running Output Signal.............................................................5-75
5.5.6 Using the Servo Ready Output Signal...................................................... 5-76
5.5.7 Using the Warning Output Signal.............................................................5-77
5.5.8 Using the Near Output Signal................................................................... 5-79
5.5.9 Handling Power Loss................................................................................ 5-80
5.6 Selecting a Regenerative Resistor..................................................................... 5-82
5.6.1 External Regenerative Resistor................................................................. 5-84
5.6.2 Calculating the Required Capacity of Regenerative Resistors................. 5-86
5.7 Absolute Encoders............................................................................................. 5-90
5.7.1 Interface Circuit........................................................................................ 5-90
5.7.2 Selecting an Absolute Encoder................................................................. 5-91
5.7.3 Handling Batteries .................................................................................... 5-92
5.7.4 Absolute Encoder Setup............................................................................ 5-93
5.7.5 Absolute Encoder Reception Sequence.................................................... 5-97
5.8 Special Wiring.................................................................................................. 5-102
5.8.1 Wiring Precautions.................................................................................. 5-102
5.8.2 Wiring for Noise Control........................................................................ 5-104
5.8.3 Using More Than One Servodrive..........................................................5-109
5.8.4 Extending Encoder Cables...................................................................... 5-110
5.8.5 400V Power Supply Voltage................................................................... 5-112
5.8.6 Reactor for Harmonic Suppression......................................................... 5-113
5.9 Reserved Parameters........................................................................................ 5-114
6Servo Adjustment ................................................................................................ 6-1
6.1 Smooth Operation................................................................................................ 6-2
6.1.1 Using the Soft Start Function...................................................................... 6-2
6.1.2 Smoothing................................................................................................... 6-3
6.1.3 Adjusting Gain............................................................................................ 6-4
6.1.4 Adjusting Offset.......................................................................................... 6-5
6.1.5 Setting the Torque Reference Filter Time Constant.................................... 6-5
6.1.6 Notch Filter................................................................................................. 6-6

Sigma II User’s Manual Chapter 2: Installation
v
6.2 High-speed Positioning........................................................................................ 6-7
6.2.1 Setting Servo Gain...................................................................................... 6-7
6.2.2 Using Feed-Forward Control...................................................................... 6-9
6.2.3 Using Proportional Control......................................................................... 6-9
6.2.4 Setting Speed Bias .................................................................................... 6-10
6.2.5 Using Mode Switch .................................................................................. 6-11
6.2.6 Speed Feedback Compensation ................................................................ 6-14
6.3 Auto-Tuning....................................................................................................... 6-17
6.3.1 Online Auto-Tuning.................................................................................. 6-17
6.3.2 Mechanical Rigidity Settings for Online Auto-Tuning............................. 6-20
6.3.3 Saving Results of Online Auto-Tuning.....................................................6-22
6.3.4 Parameters Related to Online Auto-Tuning.............................................. 6-24
6.4 Servo Gain Adjustments.................................................................................... 6-26
6.4.1 Servo Gain Parameters.............................................................................. 6-26
6.4.2 Basic Rules of Gain Adjustment............................................................... 6-26
6.4.3 Making Manual Adjustments.................................................................... 6-28
6.4.4 Gain Setting Reference Values ................................................................. 6-33
6.5 Analog Monitor.................................................................................................. 6-35
7. Using the Digital Operator................................................................................... 7-1
7.1 Basic Operation.................................................................................................... 7-2
7.1.1 Connecting the Digital Operator................................................................. 7-2
7.1.2 Functions..................................................................................................... 7-3
7.1.3 Resetting Servo Alarms .............................................................................. 7-4
7.1.4 Basic Mode Selection ................................................................................. 7-5
7.1.5 Status Display Mode................................................................................... 7-5
7.1.6 Operation in Parameter Setting Mode ........................................................7-8
7.1.7 Operation in Monitor Mode...................................................................... 7-16
7.2 Applied Operation.............................................................................................. 7-21
7.2.1 Operation in Alarm Traceback Mode .......................................................7-22
7.2.2 Operation Using the Digital Operator....................................................... 7-23
7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset.......... 7-26

Sigma II User’s Manual Chapter 2: Installation
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7.2.4 Manual Adjustment of the Speed and Torque Reference Offset .............. 7-29
7.2.5 Clearing Alarm Traceback Data ............................................................... 7-34
7.2.6 Checking the Motor Model....................................................................... 7-36
7.2.7 Checking the Software Version................................................................. 7-39
7.2.8 Origin Search Mode.................................................................................. 7-40
7.2.9 Initializing Parameter Settings.................................................................. 7-42
7.2.10 Manual Zero Adjustment and Gain Adjustment of
Analog Monitor Output ............................................................................ 7-44
7.2.11 Adjusting the Motor Current Detection Offset......................................... 7-49
7.2.12 Write Protected Setting)............................................................................ 7-53
8Ratings and Characteristics.................................................................................. 8-1
8.1 Servomotors......................................................................................................... 8-2
8.1.1 Ratings, Specifications, and Dimensional Drawings.................................. 8-2
8.2 Servo Amplifiers................................................................................................ 8-17
8.2.1 Combined Specifications.......................................................................... 8-17
8.2.2 Ratings and Specifications........................................................................ 8-21
8.2.3 Dimensional Drawings ............................................................................. 8-24
9: Inspection, Maintenance, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Servodrive Inspection and Maintenance............................................................. 9-2
9.1.1 Servomotor Inspection................................................................................ 9-2
9.1.2 Servo Amplifier Inspection......................................................................... 9-3
9.1.3 Replacing Battery for Absolute Encoder.................................................... 9-4
9.2 Troubleshooting................................................................................................... 9-5
9.2.1 Troubleshooting Problems with Alarm Displays........................................ 9-5
9.2.2 Troubleshooting Problems with No Alarm Display ................................. 9-35
9.2.3 Alarm Display Table................................................................................. 9-37
9.2.4 Warning Displays...................................................................................... 9-39
A: Host Controller Connection Examples ............................................................... A-1
A.1 Connecting the GL-series MC20 Motion Module.............................................. A-2
A.2 Connecting the CP-9200SH Servo Controller Module (SVA) ........................... A-3
A.3 Connecting the GL-series B2813 Positioning Module...................................... A-4
A.4 Connecting OMRON's C500-NC221 Position Control Unit.............................. A-5

Sigma II User’s Manual Chapter 2: Installation
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A.5 Connecting OMRON's C500-NC112 Position Control Unit.............................. A-6
A.6 Connecting MITSUBISHI's AD72 Positioning Unit.......................................... A-7
A.7 Connecting MITSUBISHI's AD75 Positioning Unit.......................................... A-8
B: List of Parameters................................................................................................B-1
B.1 Parameters............................................................................................................B-2
B.2 Switches...............................................................................................................B-5
B.3 Input Signal Selections ........................................................................................B-9
B.4 Output Signal Selections....................................................................................B-11
B.6 Monitor Modes ..................................................................................................B-12

Sigma II User’s Manual Chapter 2: Installation
viii
Overview
nManual Outline
This manual provides the following information for the Sigma II Series SGMoH/SGDH
servodrives.
•Procedures for installing and wiring the servomotor and servo amplifier.
•Procedures for trial operation of the servodrive.
•Procedures for using functions and adjusting the servodrives.
•Procedures for using the built-in panel operator and the hand-held digital operator.
•Ratings and specifications for standard models.
•Procedures for maintenance and inspection.
nRelated Manuals
Refer to the following manuals as required.
Read this manual carefully to ensure the proper use of Sigma II Series servodrives. Also,
keep this manual in a safe place so that it can be referred to whenever necessary.
Manual Name Manual Number Contents
Sigma II Series Servo System
Catalog Supplement
Servo Selection and Data
Sheets
G-MIAZ#99001 Describes the procedure used to select Sigma II Series servodrives and capaci-
ties.
Sigma Win Software
Operation Manual SIA–S800–1.0 Describesthe applications andoperation
of software for the Sigma servodrive
monitoring devices for use on personal
computers.
Sigma II Series SGMoH/
SGDH
Digital Operator
Operation Manual
TOE–S800–34 Provides detailed information on the
operation of the JUSP–OP02A–1
digital operator, which is an optional
product.