YASKAWA SGM series Installation instructions

Rotary Servomotor
AC Servo Drive
Safety Precautions
MANUAL NO.TOEP C230260 00A
Type SGM-
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end
user receives this manual.

Copyright © 2014 YASKAWA ELECTRIC CORPORATION
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 written
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
manual is subject to change without notice. Every precaution has been taken in
the preparation of this manual. Nevertheless, Yaskawa assumes no responsibil-
ity for errors or omissions. Neither is any liability assumed for damages result-
ing from the use of the information contained in this publication.

E-1
Before You Use the Product
Product Confirmation
Please check the model number on the nameplate to confirm that you have received the
correct model of Servomotor.
If you have received the wrong model or if the Servomotor is damaged in any way,
please contact your Yaskawa representative.
Part Names
Note: The actual shape of the Servomotor depends on the series and model.
Motor flange
Nameplate
Connector for
Encoder Cable
Encoder
Connector for Servomotor
Main Circuit Cable
Motor shaft
Encoder
connector
Motor
connector
Motor Main Circuit
Cable
Motor flange
Motor shaft
Encoder
Cable
Nameplate
Encoder

E-2
Safety Precautions
• Indicates precautions that, if not heeded, are likely to result in loss of life, seri-
ous injury, or fire.
• Indicates precautions that, if not heeded, could result in loss of life, serious
injury, or fire.
• Indicates precautions that, if not heeded, could result in relatively serious or
minor injury, or in fire.
• Indicates precautions that, if not heeded, could result in property damage.
Safety Information
To prevent personal injury and equipment damage in advance, the following signal
words are used to indicate safety precautions in this document. The signal words are
used to classify the hazards and the degree of damage or injury that may occur if a
product is used incorrectly. Information marked as shown below is important for
safety. Always read this information and heed the precautions that are provided.
DANGER
WARNING
CAUTION
NOTICE

• Read and understand this manual to ensure the safe usage of the product.
• Keep this manual in a safe, convenient place so that it can be referred to when-
ever necessary. Make sure that it is delivered to the final user of the product.
• Do not remove covers, cables, connectors, or optional devices while power is
being supplied to the SERVOPACK.
• Connect the ground terminals on the SERVOPACK and Servomotor to ground
poles according to local electrical codes. (Connect to 100 or less for a
SERVOPACK with a 100-VAC or 200-VAC power supply, and 10 or less for
a SERVOPACK with a 400-VAC power supply.)
• Do not attempt to disassemble, repair, or modify the product.
• The SERVOPACK heat sinks, regenerative resistors, Servomotors, and other
components can be very hot while power is ON or soon after the power is
turned OFF. Implement safety measures, such as installing covers, so that
hands and parts such as cables do not come into contact with hot components.
• Do not damage, pull on, apply excessive force to, place heavy objects on, or
pinch cables.
• Do not use the product in an environment that is subject to water, corrosive
gases, or flammable gases, or near flammable materials.
E-3
Safety Precautions That Must Always Be Observed
General Precautions
DANGER
There is a risk of electric shock, operational failure of the product, or burning.
WARNING
There is a risk of electric shock or fire.
There is a risk of fire or failure.
The warranty is void for the product if you disassemble, repair, or modify it.
CAUTION
There is a risk of burn injury.
There is a risk of failure, damage, or electric shock.
There is a risk of electric shock or fire.

• Do not attempt to use a SERVOPACK or Servomotor that is damaged or that
has missing parts.
• Install external emergency stop circuits that shut OFF the power supply and
stops operation immediately when an error occurs.
• Select the brake power supply for a Servomotor with a Holding Brake accord-
ing to the power supply voltage and capacity required for the Servomotor
model, as given in manuals and catalogs. Also confirm the input voltage to the
holding brake.
• Always install a surge absorber as a protective device between the brake
power supply and Servomotor.
• The time required for a holding brake to operate depends on the types of pro-
tective devices. The time required for a holding brake to operate will also
change if holding brakes are connected in parallel. Always check the time
required for a holding brake to operate on the actual machine before you oper-
ate a Servomotor.
• Always use a Servomotor and SERVOPACKin one of the specified combina-
tions.
• Do not touch a SERVOPACK or Servomotor with wet hands.
• Do not place an excessive load on the product during storage. (Follow all
instructions on the packages.)
E-4
Storage Precautions
NOTICE
There is a risk of damage to the Servomotor.
There is a risk of product failure.
CAUTION
There is a risk of injury or damage.

• Do not install or store the product in any of the following locations.
• Although machined surfaces are covered with an anticorrosive coating, rust
can develop due to storage conditions or the length of storage.
If you store the product for more than six months, reapply an anticorrosive
coating to machined surfaces, particularly the motor shaft.
• Consult with your Yaskawa representative if you have stored products for an
extended period of time.
• Transport the product in a way that is suitable to the mass of the product.
• Do not hold onto the cables or motor shaft when you move a Servomotor.
• Do not use the eyebolts on a SERVOPACK or Servomotor to move the
machine.
• When you handle a SERVOPACK or Servomotor, be careful of sharp parts,
such as the corners.
• Do not place an excessive load on the product during transportation. (Follow
all instructions on the packages.)
E-5
Transportation Precautions
NOTICE
• Locations that are subject to direct sunlight
• Locations that are subject to ambient temperatures that exceed product spec-
ifications
• Locations that are subject to relative humidities that exceed product specifi-
cations
• Locations that are subject to condensation as the result of extreme changes
in temperature
• Locations that are subject to corrosive or flammable gases
• Locations that are near flammable materials
• Locations that are subject to dust, salts, or iron powder
• Locations that are subject to water, oil, or chemicals
• Locations that are subject to vibration or shock that exceeds product specifi-
cations
• Locations that are subject to radiation
If you store or install the product in any of the above locations, the product
may fail or be damaged.
CAUTION
There is a risk of disconnection, damage, or injury.
There is a risk of damage or injury.
There is a risk of injury.
There is a risk of injury or damage.

• A SERVOPACK or Servomotor is a precision device. Do not drop it or subject
it to strong shock.
• Do not subject connectors to shock.
• If disinfectants or insecticides must be used to treat packing materials such as
wooden frames, plywood, or pallets, the packing materials must be treated
before the product is packaged, and methods other than fumigation must be
used.
Example: Heat treatment, where materials are kiln-dried to a core temperature
of 56C for 30 minutes or more.
• Do not overtighten the eyebolts on a SERVOPACK or Servomotor.
E-6
Installation Precautions
NOTICE
There is a risk of failure or damage.
There is a risk of faulty connections or damage.
If the electronic products, which include stand-alone products and products
installed in machines, are packed with fumigated wooden materials, the elec-
trical components may be greatly damaged by the gases or fumes resulting
from the fumigation process. In particular, disinfectants containing halogen,
which includes chlorine, fluorine, bromine, or iodine can contribute to the ero-
sion of the capacitors.
If you use a tool to overtighten the eyebolts, the tapped holes may be damaged.
CAUTION
• Do not touch the key slot with your bare hands on the shaft end on a Servomo-
tor with a Key Slot.
There is a risk of injury.
• Securely mount the Servomotor to the machine.
If the Servomotor is not mounted securely, it may come off the machine during
operation.
• Install the Servomotor or SERVOPACK in a way that will support the mass
given in technical documents.
• Install SERVOPACKs, Servomotors, and regenerative resistors on nonflam-
mable materials.
Installation directly onto or near flammable materials may result in fire.
Continued on next page.

E-7
• Do not step on or place a heavy object on the product.
There is a risk of failure, damage, or injury.
• Do not allow any foreign matter to enter the SERVOPACK or Servomotor.
There is a risk of failure or fire.
• Implement safety measures, such as installing a cover so that the rotating part
of the Servomotor cannot be touched accidentally during operation.
NOTICE
• Do not install or store the product in any of the following locations.
• Locations that are subject to direct sunlight
• Locations that are subject to ambient temperatures that exceed product spec-
ifications
• Locations that are subject to relative humidities that exceed product specifi-
cations
• Locations that are subject to condensation as the result of extreme changes
in temperature
• Locations that are subject to corrosive or flammable gases
• Locations that are near flammable materials
• Locations that are subject to dust, salts, or iron powder
• Locations that are subject to water, oil, or chemicals
• Locations that are subject to vibration or shock that exceeds product specifi-
cations
• Locations that are subject to radiation
If you store or install the product in any of the above locations, the product
may fail or be damaged.
• Use the product in an environment that is appropriate for the product specifi-
cations.
If you use the product in an environment that exceeds product specifications,
the product may fail or be damaged.
• A SERVOPACK or Servomotor is a precision device. Do not drop it or subject
it to strong shock.
There is a risk of failure or damage.
Continued on next page.
Continued from previous page.
CAUTION

E-8
• A Servomotor is a precision device. Do not subject the output shaft or the
main body of the Servomotor to strong shock.
• Design the machine so that the thrust and radial loads on the motor shaft
during operation do not exceed the allowable values given in the catalog.
• When you attach the key to the motor shaft, do not subject the key slot to
direct shock.
• Do not allow any foreign matter to enter a SERVOPACK or a Servomotor with
a Cooling Fan and do not cover the outlet from the Servomotor’s cooling fan.
There is a risk of failure.
• If you use oil as the gear lubricant, always inject the specified oil before start-
ing operation.
• You can install the Servomotor either horizontally or vertically. However, if
you install a Servomotor with an Oil Seal with the output shaft facing upward,
oil may enter the Servomotor depending on the operating conditions. Confirm
the operating conditions sufficiently if you install a Servomotor with the out-
put shaft facing upward. Some Servomotors with Gears have restrictions on
the installation orientation. Refer to the relevant technical documents.
• If an installation orientation is specified for a Servomotor with a Gear, install
the Servomotor in the specified orientation.
There is a risk of failure due to oil leakage.
• For a Servomotor with an Oil Seal, use the Servomotor with the oil seal in a
lubricated condition with only splashing of oil.
If the Servomotor is used with the oil seal under the surface of the oil, oil may
enter the Servomotor, possibly resulting in failure.
• The shaft opening of a Servomotor is not waterproof or oilproof. Implement
measures in the machine to prevent water or cutting oil from entering the Ser-
vomotor.
There is a risk of failure.
Continued on next page.
• In an application where the Servomotor would be subjected to large quantities
of water or oil, implement measures to protect the Servomotor from large
quantities of liquid, such as installing covers to protect against water and oil.
• In an environment with high humidity or oil mist, face Servomotor lead wires
and connectors downward and provide cable traps.
There is a risk of failure or fire due to insulation failure or accidents from
short circuits.
Continued from previous page.
NOTICE

• Do not change any wiring while power is being supplied.
• Wiring and inspections must be performed only by qualified engineers.
• Check all wiring and power supplies carefully.
E-9
Wiring Precautions
DANGER
There is a risk of electric shock or injury.
WARNING
There is a risk of electric shock or product failure.
Incorrect wiring or incorrect voltage application to the output circuits may
cause short-circuit failures. If a short-circuit failure occurs as a result of any of
these causes, the holding brake will not work. This could damage the machine
or cause an accident that may result in death or injury.
CAUTION
• Observe the precautions and instructions for wiring and trial operation pre-
cisely as described in this document.
Failures caused by incorrect wiring or incorrect voltage application in the
brake circuit may cause the SERVOPACK to fail, damage the equipment, or
cause an accident resulting in death or injury.
Continued on next page.

E-10
• Check the wiring to be sure it has been performed correctly.
Connectors and pin layouts are sometimes different for different models.
Always confirm the pin layouts in technical documents for your model before
operation.
There is a risk of failure or malfunction.
• Connect wires to power supply terminals and motor connection terminals
securely with the specified methods and tightening torque.
Insufficient tightening may cause wires and terminal blocks to generate heat
due to faulty contact, possibly resulting in fire.
• Use shielded twisted-pair cables or screened unshielded multi-twisted-pair
cables for I/O Signal Cables and Encoder Cables.
• Observe the following precautions when wiring the SERVOPACK’s main cir-
cuit terminals.
• Whenever possible, use the Cables specified by Yaskawa.
If you use any other cables, confirm the rated current and application environ-
ment of your model and use the wiring materials specified by Yaskawa or
equivalent materials.
• Securely tighten cable connector screws and lock mechanisms.
• Do not bundle power lines (e.g., the Main Circuit Cable) and low-current lines
(e.g., the I/O Signal Cables or Encoder Cables) together or run them through
the same duct. If you do not place power lines and low-current lines in sepa-
rate ducts, separate them by at least 30 cm.
• For a motor with a cooling fan, check the rotation direction of the cooling fan
after you wire the fan.
• Install a battery at either the host controller or on the Encoder Cable.
• When connecting a battery, connect the polarity correctly.
• Turn ON the power supply to the SERVOPACK only after all wiring, includ-
ing the main circuit terminals, has been completed.
• If a connector is used for the main circuit terminals, remove the main circuit
connector from the SERVOPACK before you wire it.
• Insert only one wire per insertion hole in the main circuit terminals.
• When you insert a wire, make sure that the conductor wire (e.g., whiskers)
does not come into contact with adjacent wires.
NOTICE
Insufficient tightening may result in cable connectors falling off during opera-
tion.
If the cables are too close to each other, malfunctions may occur due to noise
affecting the low-current lines.
If you install batteries both at the host controller and on the Encoder Cable at
the same time, you will create a loop circuit between the batteries, resulting in
a risk of damage or burning.
There is a risk of battery rupture or encoder failure.
Continued from previous page.
CAUTION

• Before starting operation with a machine connected, change the settings of the
switches and parameters to match the machine.
• Do not radically change the settings of the parameters.
• Install limit switches or stoppers at the ends of the moving parts of the
machine to prevent unexpected accidents.
• For trial operation, securely mount the Servomotor and disconnect it from the
machine.
• Forcing the motor to stop for overtravel is disabled when the Jog (Fn002), Ori-
gin Search (Fn003), or Easy FFT (Fn206) utility function is executed. Take
necessary precautions.
• When an alarm occurs, the motor will coast to a stop or stop with the dynamic
brake according to a setting in the SERVOPACK. The coasting distance will
change with the moment of inertia of the load. Check the coasting distance
during trial operation and implement suitable safety measures on the machine.
• Do not enter the machine’s range of motion during operation.
• Do not touch the moving parts of the Servomotor or machine during operation.
E-11
Operation Precautions
WARNING
Unexpected machine operation, failure, or personal injury may occur if opera-
tion is started before appropriate settings are made.
There is a risk of unstable operation, machine damage, or injury.
There is a risk of machine damage or injury.
There is a risk of injury.
There is a risk of machine damage or injury.
There is a risk of injury.
There is a risk of injury.
CAUTION
• Do not use the holding brake built into a Servomotor to stop the Servomotor.
The holding brake is designed to hold the motor shaft. It is not designed as a
stopping device to ensure machine safety. Provide an appropriate stopping
device on the machine to ensure safety.
There is a risk of brake failure due to wear, damage to the machine, or injury.
• Before you operate a Servomotor, supply power to the holding brake to release
the holding brake. Refer to the timing charts in your Servomotor manual for
details.
• During trial operation, confirm that the holding brake works correctly.
Continued on next page.

E-12
Maintenance and Inspection Precautions
• When overtravel occurs, the power supply to the motor is turned OFF and the
brake is released. If you use the Servomotor to drive a vertical load, set the
Servomotor to enter a zero-clamped state after the Servomotor stops. Also,
install safety devices (such as an external brake or counterweight) to prevent
the moving parts of the machine from falling.
• Always turn OFF the servo before you turn OFF the power supply. If you turn
OFF the main circuit power supply or control power supply during operation
before you turn OFF the servo, the Servomotor will stop as follows:
• Always measure the vibration of the Servomotor with the Servomotor
mounted to the machine and confirm that the vibration is within the allowable
value.
• When you adjust the gain during system commissioning, use a measuring
instrument to monitor the torque waveform and speed waveform and confirm
that there is no vibration.
• An alarm or warning may occur if communications are performed with the
host controller while the SigmaWin+ or Digital Operator is operating.
• Do not change any wiring while power is being supplied.
• If you turn OFF the main circuit power supply during operation without
turning OFF the servo, the Servomotor will stop abruptly with the dynamic
brake.
• If you turn OFF the control power supply without turning OFF the servo, the
stopping method that is used by the Servomotor depends on the model of the
SERVOPACK. For details, refer to the manual for the SERVOPACK.
NOTICE
If the vibration is too large, the Servomotor will be damage quickly and bolts
may become loose.
If a high gain causes vibration, the Servomotor will be damaged quickly.
If an alarm or warning occurs, it may interrupt the current process and stop the
system.
DANGER
There is a risk of electric shock or injury.
Continued from previous page.
CAUTION

• Wiring and inspections must be performed only by qualified engineers
• If you replace a Servomotor with a Holding Brake, secure the machine before
you replace the Servomotor.
• Wait for six minutes after turning OFF the power supply and then make sure
that the CHARGE indicator is not lit before starting wiring or inspection work.
Do not touch the power supply terminals while the CHARGE lamp is lit after
turning OFF the power supply because high voltage may still remain in the
SERVOPACK.
• Replace the Battery according to the correct procedure.
• The product may suddenly start to operate when the power supply is recovered
after a momentary power interruption. Design the machine to ensure human
safety when operation restarts.
• When an alarm occurs, remove the cause of the alarm and ensure safety. Then
reset the alarm or turn the power supply OFF and ON again to restart opera-
tion.
• If the Servo ON signal is input to the SERVOPACK and an alarm is reset, the
Servomotor may suddenly restart operation. Confirm that the servo is OFF and
ensure safety before you reset an alarm.
• The holding brake on a Servomotor will not ensure safety if there is the possi-
bility that an external force (including gravity) may move the current position
and create a hazardous situation when power is interrupted or an error occurs.
If an external force may cause movement, install an external braking mecha-
nism that ensures safety.
E-13
Troubleshooting Precautions
WARNING
There is a risk of electric shock or product failure.
There is a risk of injury or equipment damage if the equipment falls.
CAUTION
There is a risk of electric shock.
If you remove the Battery or disconnect the Encoder Cable while the control
power supply to the SERVOPACK is OFF, the absolute encoder data will be
lost and position deviation may occur.
WARNING
There is a risk of injury.
CAUTION
There is a risk of injury or machine damage.
There is a risk of injury or machine damage.

• When disposing of the product, treat it as ordinary industrial waste.
However, local ordinances and national laws must be observed. Implement all
labeling and warnings as a final product as required.
• Figures provided in this document are typical examples or conceptual repre-
sentations. There may be differences between them and actual wiring, circuits,
and products.
• The products shown in illustrations in this document are sometimes shown
without covers or protective guards. Always replace all covers and protective
guards before you use the product.
• If you need a new copy of this document because it has been lost or damaged,
contact your nearest Yaskawa representative or one of the offices listed on the
back of this document.
• This document is subject to change without notice for product improvements,
specifications changes, and improvements to the manual itself.
We will update the document number of the document and issue revisions
when changes are made.
• Any and all quality guarantees provided by Yaskawa are null and void if the
customer modifies the product in any way. Yaskawa disavows any responsibil-
ity for damages or losses that are caused by modified products.
E-14
Disposal Precautions
General Precautions
Warranty
Details of Warranty
Warranty P eriod
The warranty period for a product that was purchased (hereinafter called the “delivered
product”) is one year from the time of delivery to the location specified by the cus-
tomer or 18 months from the time of shipment from the Yaskawa factory, whichever is
sooner.
Warranty Scope
Yaskawa shall replace or repair a defective product free of charge if a defect attribut-
able to Yaskawa occurs during the above warranty period.
This warranty does not cover defects caused by the delivered product reaching the end
of its service life and replacement of parts that require replacement or that have a lim-
ited service life.
This warranty does not cover failures that result from any of the following causes.
• Improper handling, abuse, or use in unsuitable conditions or in environments not
described in product catalogs or manuals, or in any separately agreed-upon specifi-
cations
• Causes not attributable to the delivered product itself
• Modifications or repairs not performed by Yaskawa
• Use of the delivered product in a manner in which it was not originally intended

E-15
• Causes that were not foreseeable with the scientific and technological understand-
ing at the time of shipment from Yaskawa
• Events for which Yaskawa is not responsible, such as natural or human-made disas-
ters
Limitations of Liability
• Yaskawa shall in no event be responsible for any damage or loss of opportunity to
the customer that arises due to failure of the delivered product.
• Yaskawa shall not be responsible for any programs (including parameter settings) or
the results of program execution of the programs provided by the user or by a third
party for use with programmable Yaskawa products.
• The information described in product catalogs or manuals is provided for the pur-
pose of the customer purchasing the appropriate product for the intended applica-
tion. The use thereof does not guarantee that there are no infringements of
intellectual property rights or other proprietary rights of Yaskawa or third parties,
nor does it construe a license.
• Yaskawa shall not be responsible for any damage arising from infringements of
intellectual property rights or other proprietary rights of third parties as a result of
using the information described in catalogs or manuals.

E-16
Suitability for Use
• It is the customer’s responsibility to confirm conformity with any standards, codes,
or regulations that apply if the Yaskawa product is used in combination with any
other products.
• The customer must confirm that the Yaskawa product is suitable for the systems,
machines, and equipment used by the customer.
• Consult with Yaskawa to determine whether use in the following applications is
acceptable. If use in the application is acceptable, use the product with extra allow-
ance in ratings and specifications, and provide safety measures to minimize hazards
in the event of failure.
• Outdoor use, use involving potential chemical contamination or electrical
interference, or use in conditions or environments not described in product
catalogs or manuals
• Nuclear energy control systems, combustion systems, railroad systems, avia-
tion systems, vehicle systems, medical equipment, amusement machines, and
installations subject to separate industry or government regulations
• Systems, machines, and equipment that may present a risk to life or property
• Systems that require a high degree of reliability, such as systems that supply
gas, water, or electricity, or systems that operate continuously 24 hours a day
• Other systems that require a similar high degree of safety
• Never use the product for an application involving serious risk to life or property
without first ensuring that the system is designed to secure the required level of
safety with risk warnings and redundancy, and that the Yaskawa product is properly
rated and installed.
• The circuit examples and other application examples described in product catalogs
and manuals are for reference. Check the functionality and safety of the actual
devices and equipment to be used before using the product.
• Read and understand all use prohibitions and precautions, and operate the Yaskawa
product correctly to prevent accidental harm to third parties.
Specifications Change
The names, specifications, appearance, and accessories of products in product catalogs
and manuals may be changed at any time based on improvements and other reasons.
The next editions of the revised catalogs or manuals will be published with updated
code numbers. Consult with your Yaskawa representative to confirm the actual specifi-
cations before purchasing a product.

1 Product Handling Precautions
E-17
1 Product Handling Precautions
Handling Servomotors
Observe the following precautions when you handle Servomotors.
• Do not subject the Servomotor to shock.
• Do not hold onto the motor shaft or cables when you move the Servomotor.
Servomotor Installation Environment
Install the Servomotor in the following environments.
If you use a Servomotor in an inappropriate environment, the Servomotor or
encoder may be damaged.
• Confirm the ambient operating temperature for your Servomotor in the
product specifications in the Servomotor catalog or other product
documentation.
OK
°C

1 Product Handling Precautions
E-18
• The surrounding air humidity is 20% to 80% relative humidity (with no
condensation).
• The vibration resistance (vibration acceleration rate) of the Servomotor is
based on the flange surface of the Servomotor. The vibration resistance
depends on the model. Confirm the vibration resistance in the product specifi-
cations in the product catalog or other product documentation.
• If you reduce the thickness of the mounting section (i.e., the heat sink) of the
Servomotor, the rigidity will be reduced, which could increase vibration.
• Do not subject a Servomotor to shock. The shock resistance of a Servomotor
(impact acceleration rate × the number of impacts) is 490 m/s2× 2 impacts at
the flange surface of the Servomotor.
Flange surface