Yaskawa SGDH-10DE-OY Servo Drive

Discontinued legacy 400V class 1kW Yaskawa servo, Sigma II series. The suffix OY stands for custom/special specification, mostly OEM dedicated for original machine builders. Hardware-wise, it is identical to standard SGDH-10DE, but firmware and I/O definitions differ. Direct replacement with standard SGDH-10DE may result in abnormal operation.

✅ Modellaufschlüsselung

SGDH: Sigma II SERVOPACK servo amplifier

10: Rated power 1.0kW

D: 3-phase 400V input (380~480VAC)

E: Standardmodell, unterstützt 3 control modes: Position / Geschwindigkeit / Drehmoment

OY: Custom specification code, not standard off-the-shelf version. Features OEM-specific firmware, custom I/O mapping and function masking. Direct swap with non-OY SGDH-10DE carries firmware mismatch risk.

📌 Key Electrical Specifications

Artikel	Spezifikation
Nennausgangsleistung	1kW
Main Circuit Power Supply	3-phase AC380~480V, 50/60Hz
Kontinuierlicher Ausgangsstrom	3.7A (RMS)
Spitzenausgangsstrom	11.2A (3 Sekunden, 300% Überlastfähigkeit)
Built-in Regeneration Capacity	14W; external regenerative resistor required for heavy braking
Steuermodi	Position (Impulsbefehl), Geschwindigkeit (±10V analog), Drehmoment (±10V analog); mode switching available
Pulse Input	Line driver: max 500kpps; Open collector: 200kpps
Speed Loop Bandwidth	400Hz; supports auto-tuning and inertia identification
Kommunikation	RS232C / RS485; SigmaWin commissioning software; compatible with hand-held operator JUSP-OP05A
Betriebsumgebung	0~+55°C, cabinet mounting, no condensation or heavy dust
Abmessungen (B×H×T)	55 × 180 × 170 mm

🔌 Terminals & Schnittstellen

CN1: I/O signals (command pulse, servo enable, Alarm, positioning complete, analog signals etc.)

CN2: Encoder feedback port, connects to Sigma II motor encoder

CN3: Commissioning port for handheld operator or PC communication cable

Hauptstromkreisklemmen: L1, L2, L3 (3-Phaseneingang); U/V/W to Servomotor; B1/B2/B3 for regenerative resistor

🧩 Compatible Motors (Sigma II 400V Series)

SGMGH / SGMAH / SGMPH 400V 1kW Sigma II motors. Typisches Modell:

SGMGH-09D… (1kW 400V motor, most common matching unit)

⚠️ OY firmware binding. Use original matched motor as priority. Direct replacement with standard SGDH-10DE may trigger motor identification error or I/O logic mismatch.

🛠 Protective Functions

Überstrom, Überspannung, Unterspannung, Überlast, heatsink overheat, main circuit phase loss, Übergeschwindigkeit, Encoder-Unterbrechung, parameter error, CPU fault, regeneration fault, runaway protection.

⚠ Key Notes for Selection & Ersatz

Produktstatus: Discontinued by Yaskawa. New units only available as leftover stock; most available units on market are used or refurbished second-hand parts.
Ersatzoptionen

Direct same-series replacement: SGDH-10DE-OY mandatory with OY suffix. Hardware same as SGDH-10DE without OY, but firmware/logic differs. Back up parameters and test I/O before commissioning.

Cross-series upgrade: Sigma-V SGDV 400V 1kW (SGDV-5R4D01A); Sigma7 SGD7S. Full rewiring and mechanical re-commissioning required; CN1 logic is completely different, plug-and-play replacement impossible.

Common Repair Faults: Main circuit alarm, encoder cable break, Überspannung (regeneration resistor failure), parameter alarm, aging electrolytic capacitors (high incidence on old units).
Inbetriebnahmesoftware: SigmaWin+ (older version required for Sigma II); handheld operator model: JUSP-OP05A.

📦 Typical Applications

Machine tool feed axes, Verpackungsmaschinen, Textilausrüstung, Halbleiterausrüstung, handling manipulators. Many legacy machines (Drucken / forming machines) use this OY custom version as OEM standard.

❓ Supplementary Remarks

This is a 400V high-voltage servo. NEVER connect to 220V single/3-phase supply, otherwise power module will be destroyed instantly.

For second-hand units received, perform insulation test and static IGBT measurement before power-on test without load, then connect motor.

HS Code reference: 85011010 (servo drive classification, Nur zur Zollanmeldung, subject to customs broker confirmation).

Yaskawa Sigma II SGDH Alarm Code List (Compatible with SGDH-10DE-OY. Alarm definitions identical for OY custom version; only I/O mapping may differ.)

Notiz: A.xx = drive alarm, power stage cut off after trigger; some alarms require power cycle reset. bb is NOT an alarm, it means servo standby with Servo OFF.

Alarmcode	Alarm Name	Ursache & Fehlerbehebung
A.02	Parameter Corruption	EEPROM parameter damage; abnormal power down, backup battery failure. Abhilfe: restore factory parameters, rewrite parameters. If alarm persists, main board faulty.
A.03	Main Circuit Encoder Fault	Encoder cable broken / shorted, encoder hardware damage; not supported on high-power models.
A.04	Parameter Setting Error	Parameter out of valid range; parameter mismatch after drive replacement (high risk for OY version). Abhilfe: verify Pn parameters, reset factory default then reconfigure.
A.05	Motor Combination Error	Mismatch between drive and motor model; wrong encoder type setting. ⚠️OY custom firmware, easy to trigger after motor replacement.
A.10	Überstrom / Heatsink Overheat	IGBT-Ausfall, motor winding short, power cable earth fault; fan locked, heatsink dust buildup. Most common hardware failure alarm.
A.30	Regeneration Fault	Broken regenerative resistor, loose B1/B2 terminals; damaged regeneration transistor. Frequently seen on 400V models with frequent emergency stop.
A.32	Regeneration Overload	Excessive braking energy; built-in regeneration capacity insufficient. External regenerative resistor required.
A.33	Main Circuit Power Wiring Error	3-phase input phase loss, wrong L1/L2/L3 wiring, Schlechter Kontakt des Schützes.
A.40	Überspannung	Input voltage too high; regenerative energy during deceleration, failed regeneration circuit; aged main circuit capacitors.
A.41	Unterspannung	Insufficient 3-phase supply, contactor not closed; missing 24V control supply, Interne Sicherung durchgebrannt.
A.51	Overspeed	Motor actual speed far exceeds command; Geberfehler, excessive speed loop gain, wiring interference.
A.71	Continuous Overload (High Load)	Mechanischer Stau, bearing damage, übermäßige Belastung; wrong inertia / reduction ratio, Dauervolllast.
A.72	Continuous Overload (Low Load)	Overload under light load; degraded motor insulation, mechanical binding.
A.73	Dynamic Brake Overload	Frequent emergency stop causes dynamic brake circuit overheat; not monitored by SGDH-10DE (1kW).
A.74	Motorwärmeschutz	Motor built-in thermistor triggered, motor overheated.
A.7A	Encoder Communication Abnormality	Poor shielding of encoder cable, long cable interference, oxidiert / loose connector.
A.81	Encoder A/B Phase Error	Loss of encoder A/B signals, Phasenfolgefehler, beschädigtes Kabel.
A.82	Encoder C-phase (Z-Phase) Fehler	Home Z-phase wire break, Geberfehler.
A.83	Encoder Battery Alarm (Absolute Motor)	Low backup battery voltage for encoder, home position lost.
A.84	Encoder Data Error	Data corruption inside absolute encoder.
A.85	Encoder Disconnection	CN2 encoder cable cut, bent / retracted pins in connector.
A.86	Encoder Power Supply Fault	Abnormal 5V output from CN2 port, shorted cable pulls down 5V supply.
A.b1	Main Circuit Detection Fault	Fault in main circuit sampling circuit, power board failure.
A.b2	CPU Fault	Damaged main control board, program runaway.
A.bF	Operator Communication Fault	Broken / loose cable for CN3 handheld operator / commissioning line.
A.C1	Safety Circuit / HWBB Hardware Base Block	Hardware safety circuit open, normally closed emergency stop loop broken.
A.C8	Full-closed External Encoder Fault	Abnormal signal from external linear scale (only with full-closed option card).
A.CA	External Encoder A/B Phase Error	Fault in A/B phase signal of full-closed linear scale.
A.Cb	External Encoder Z-phase Error	Fault on home Z-phase signal of linear scale.
A.CC	Full-closed Position Deviation Excess	Full closed loop mode; large deviation between linear scale position and motor encoder.
A.d0	Position Deviation Excess	Position error exceeds Pn setting before positioning complete; mechanischer Stau, missing pulse command.
A.E7	RS485 Communication Fault	Broken communication cable with host controller, mismatched communication parameters.

Standby display bb: Not fault, Servo OFF, waiting for /S-ON enable signal.

SGDH CN1 (50-pin I/O Connector, Standard Factory Assignment. ⚠️OY custom version pin functions may be redefined by machine OEM!)

Stecker: 50Pin D-Sub. Separate external DC24V required for I/O circuit; input signals active low (NPN).

🔹 Input Signals (Opto-isolated Input)

CN1 Pin No.	Signal ID	Signal Name	Beschreibung
40	/S-ON	Servo ON	Servofreigabe, ON = motor excitation
41	/P-CON	Proportional Control Switch / Mode Switch	Valid under position mode; switch PI / P control, also usable for home latch
42	P-OT	Positive Over-travel Inhibit	Normalerweise geschlossen; open circuit disables forward movement (hard limit)
43	N-OT	Negative Over-travel Inhibit	Normalerweise geschlossen; open circuit disables reverse movement (hard limit)
44	/ALM-RST	Alarm Reset	Falling edge clears servo alarm
45	/P-CL	Positive Torque Limit	Enable forward torque limiting
46	/N-CL	Negative Torque Limit	Enable reverse torque limiting
47	+24VIN	External 24V Positive	+24V supply for I/O
48	SG	Signal-GND	0V reference for I/O 24V

🔹 Output Signals (Open Collector / Relay Isolated)

CN1 Pin No.	Signal ID	Signal Name	Beschreibung
31 / 32	ALM+ / ALM-	Servo Alarm Output	Conducts under normal condition; opens when alarm triggered (Relaiskontakt)
29 / 30	/S-RDY+ / /S-RDY-	Servobereit	Conducts when no alarm and main power ready
27 / 28	/TGON+ / /TGON-	Motor Rotation Detection	Conducts when motor speed exceeds threshold
33 / 34	PAO / /PAO	Encoder A Differential Output	Encoder A phase, can feedback position to host PLC
35 / 36	PBO / /PBO	Encoder B Differential Output	Encoder B phase
19 / 20	PCO / /PCO	Encoder Z Differential Output	Home Z pulse
37,38,39	ALO1,ALO2,ALO3	Alarm Code Binary Output	3-bit binary alarm code for PLC reading
21 / 22	/COIN+ / /COIN-	Positioning Complete	Conducts under position mode when position error is within window
23 / 24	/V-CMP+ / /V-CMP-	Speed Match Detection	Conducts under speed mode when motor speed reaches command speed
25 / 26	/BK+ / /BK-	Brake Control Output	External motor brake relay control; output after servo excitation

🔹 Pulse Command Related (Position Mode)

CN1 Pin No.	Signal ID	Signal Name
1-2	PULS / /PULS	Pulse Command (Differential Line Driver)
3-4	SIGN / /SIGN	Direction Command (Differential Line Driver)
5-6	PULS-O / SIGN-O	Open Collector Pulse / Richtung (Single-ended command)

⚠ Important Remarks (SGDH-10DE-OY Specific)

OY suffix custom drive: CN1 I/O pin functions may differ from above table. OEM modified signal mapping in firmware. Direct replacement with standard SGDH-10DE will cause PLC logic mismatch: servo fails to enable, false limit trigger.
Use differential line driver pulse wiring for better noise immunity; single-ended pulse is prone to pulse loss for long cables with poor shielding.
Factory default P-OT/N-OT hard limits are normally closed loop. Be careful when shorting for commissioning; many machine faults originate from broken limit wiring.
ALM alarm output is passive relay contact. Do NOT connect 24V directly; series into PLC input circuit.

Supplementary Core Parameters (Sigma II SGDH)

Pn000: Auswahl des Steuermodus (Position / Geschwindigkeit / Drehmoment)

Pn100: Position loop gain

Pn101: Position loop integral time

Pn102: Speed loop gain

Pn103: Speed loop integral time

Pn50A / Pn50B: CN1 I/O assignment (Locked on OY version, modified by OEM)

Repair Guide for Yaskawa SGDH-10DE-OY (Sigma II 400V 1kW)

⚠ Safety Precaution: 400V high voltage servo. DC bus capacitors retain high voltage after power off. Fully discharge before maintenance. Disconnect L1/L2/L3 and 24V control supply before repair. OY is OEM custom firmware. Parameters and I/O mapping differ from standard SGDH-10DE. Always back up original parameters before repair.

Common aging issue: Lange Lebensdauer. Degraded electrolytic capacitors are the top hidden failure root cause for intermittent alarms.

Standard Troubleshooting Workflow (External first, isolate drive/motor fault)
Read alarm code: Via JUSP-OP05A hand operator or SigmaWin+, record alarm history.
External isolation test (Kritischer Schritt)

Disconnect U/V/W motor power cables, keep CN1 24V control power and CN2 encoder cable, power on without load.

Alarm still present at no load: Fault inside servo drive hardware.

No alarm at no load, alarm appears after connecting motor: Fault on motor, power cable or mechanical load.

Power-off static measurement (Diode mode on multimeter)

IGBT test: Measure U/V/W against DC bus P and N. Normal reading shows stable diode voltage drop. Direct short on any phase = IGBT breakdown.

Measure main fuse, charging resistor, Gleichrichterbrücke.

Inspect CN1/CN2 connectors for corrosion, bent pins and oxidation.

Disassemble inspection: Check capacitors for bulging / electrolyte leakage, PCB carbonization, burnt components, seized fan.
Component replacement → repair → parameter restore → no-load test → loaded commissioning

Critical note for OY version: Do NOT load standard SGDH factory default parameters, OEM custom I/O logic will be lost and machine stops working.

High-Frequency Fault & Repair Solutions
A.10 Overcurrent / Heatsink Overheat (Am häufigsten)

Symptom: Alarm immediately after power-up or several seconds after servo enable

Alarm immediately on power up: IGBT-Ausfall, damaged drive optocoupler, faulty current detection circuit (7860 current sensor IC is a known SGDH series defect).

Repair: Replace IGBT module, inspect drive optocoupler and gate resistors, replace faulty sampling resistors / detection IC.

No alarm at no load, alarm occurs after connecting motor: Motor inter-turn short, power cable earth fault, mechanischer Stau, Lager festgefressen.

Repair: Megger test motor insulation, replace damaged cable, fix mechanical binding.

Alarm appears after running for a period: Dust buildup on heatsink, aging / stalled cooling fan and overheat protection.

Repair: Clean heatsink dust, Kühlgebläse austauschen.

A.40 Overvoltage

Symptom: Alarm triggered during deceleration or shutdown

Grundursache: Broken regenerative resistor, loose B1/B2 terminals; insufficient built-in regeneration capacity; aged DC bus capacitors; too short deceleration time.

Repair:

Measure resistance of B1-B2 regenerative resistor; replace if open or resistance drift.
Test main electrolytic capacitors; replace units with excessive ESR.
Verzögerungszeit verlängern; install external regenerative resistor for frequent braking applications, modify Pn600/Pn603 parameters.
A.41 Undervoltage

Symptom: No display on panel or undervoltage alarm after power on

Grundursache: 3-phase supply phase loss, poor contactor contact; burnt charging resistor; blown main fuse; aged bus capacitors; failed auxiliary switching power supply.

Repair:

Measure 3-phase input voltage.
Disassemble and inspect charging resistor (prone to open circuit on old units), main circuit fuse.
Test bus capacitor capacity and replace degraded capacitors.
Repair auxiliary power supply: replace damaged PWM IC and regulator circuit.
A.30 Regeneration Fault

Symptom: Brake circuit detection error

Grundursache: Damaged regeneration transistor, loose B1/B2 terminals, faulty 358 op-amp (regeneration detection), damaged optocoupler.

Repair: Replace faulty op-amp and optocoupler, inspect brake IGBT, tighten B1/B2 terminals.

A.81/A.82/A.85/A.86 Encoder Alarms

Symptom: Encoder alarm immediately after enable or intermittent random alarm

Grundursache: Oxidiert / bent pins on CN2 encoder connector; broken / poorly shielded encoder cable; short circuit pulling down 5V encoder supply; Encoder-Hardwarefehler.

Repair:

Replace shielded encoder cable and re-crimp CN2 connector.
Measure 5V output at CN2. If voltage low, repair on-board 5V supply of drive.
Repair or replace motor encoder if encoder itself is damaged.
A.02 Parameter Corruption

Symptom: A.02 alarm right after power on

Grundursache: Damaged mainboard EEPROM; abnormal power-off causes parameter loss; failed backup battery on mainboard.

Repair: Replace EEPROM chip, write original OY version parameters. ⚠️ Do NOT load standard SGDH parameters, I/O logic mismatch will occur.

Keine Anzeige nach dem Einschalten, panel dark

Grundursache: Blown control circuit fuse, damaged auxiliary switching power supply, open startup resistor.

Repair: Repair auxiliary power board, replace fuse, startup resistor and PWM power chip.

A.71/A.72 Continuous Overload

Symptom: Overload alarm after running for a period

Grundursache: Übermäßige mechanische Belastung, bearing binding; degraded motor insulation; wrong inertia parameter; excessive gain setting.

Repair: Fix mechanical issues; test motor insulation; run inertia identification again and reduce position / speed loop gain.

Unique Repair Notes for SGDH-10DE-OY
Firmware Lock: OY suffix uses OEM custom firmware with modified CN1 I/O mapping. After replacing main control board, OY custom firmware must be flashed. Standard SGDH mainboard directly fitted will cause I/O logic failure and machine malfunction.
Parameter Backup First: Before repair, use SigmaWin+ to online read and fully backup all parameters. This is critical for post-recovery commissioning.
Motor Matching Restriction: A.05 motor combination error easily occurs after drive or motor replacement. OY firmware binds matched motor model; random Sigma II motor replacement is not allowed.
Capacitor Replacement Recommendation: This model is very old. Full replacement of main circuit electrolytic capacitors is recommended as preventive maintenance, eliminates intermittent voltage-related alarms.
Post-repair Test Procedure
Leerlauftest: Disconnect U/V/W, Einschalten. Panel shows bb with no alarm. Enable servo and verify S-RDY ready output works correctly.
Reconnect wiring: Reconnect encoder cable and motor power cable, jog at low speed and check for vibration or abnormal noise.
Belastungstest: After passing no-load test, Belastung nach und nach aufbringen, monitor bus voltage and current to confirm no alarms.
Restore backed-up parameters, verify limit, Alarmausgang, positioning complete and other I/O signals.
Repair Cost Reference